Integrated Field Plan Execution Services In Satellite Fields In RJ-ON 90/1 Block Instrumentation & Control Design Basis

Doc No.
S340HAL-SRX-IC-BD-0001
Integrated Field Plan Execution Services In Satellite Fields In RJ-ON 90/1 Block
Revision A3
INSTRUMENTATION & CONTROL DESIGN BASIS
TABLE OF CONTENTS
1. INTRODUCTION....................................................................................................... 5
1.1. Project Background ................................................................................................... 5
1.2. Scope of Document................................................................................................... 5
1.3. Codes and Standards ............................................................................................... 6
2. DEFINITION............................................................................................................ 11
3. REFERENCES ....................................................................................................... 12
4. METEOROLOGICAL DESIGN DATA...................................................................... 13
5. ABBREVIATIONS ................................................................................................... 13
6. ORDER OF PRECEDENCE ................................................................................... 15
7. UNITS OF MEASUREMENTS ................................................................................ 15
8. PLANT UTILITIES ................................................................................................... 16
8.1. Instrument Air Supply .............................................................................................. 16
8.2. Nitrogen Supply ...................................................................................................... 16
8.3. Power Supply .......................................................................................................... 17
9. EQUIPMENT PROTECTION PHILOSOPHY........................................................... 17
9.1. General ................................................................................................................... 17
9.2. Ingress Protection ................................................................................................... 18
9.3. Electrical Area Classification ................................................................................... 18
10. PLANT LIFE ............................................................................................................ 18
11. INSTRUMENTATION AND CONTROL SYSTEM.................................................... 18
MAIN CONTRACTOR SUB-CONTRACTOR ENGG CONSULTANT
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11.1. Scope of Work ........................................................................................................ 18
11.2. General ................................................................................................................... 19
11.3. Control Room .......................................................................................................... 21
11.4. Process Control System .......................................................................................... 22
11.5. Emergency Shutdown System ................................................................................ 23
11.6. Plant Fire and Gas Detection System...................................................................... 24
11.7. Hardwired Console & Annunciator Panel ................................................................ 24
11.8. Interposing Relay .................................................................................................... 25
11.9. Building Fire Alarm System (BFAS)......................................................................... 25
11.10. Package Control System ................................................................................. 26
11.11. Interface to Existing System ............................................................................ 27
12. FIELD INSTRUMENTATION, CABLES AND INSTALLATION REQUIREMENTS ... 27
12.1. General ................................................................................................................... 27
12.2. Flow Measurement.................................................................................................. 28
12.3. Level Measurement................................................................................................. 29
12.4. Pressure Measurement ........................................................................................... 30
12.5. Temperature Measurement ..................................................................................... 31
12.6. Control Valves ......................................................................................................... 32
12.7. Safety Relief Valves ................................................................................................ 33
12.8. Pressure Vacuum Relief Valves .............................................................................. 33
12.9. Shutdown Valves .................................................................................................... 33
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12.10. Self-acting Regulators ..................................................................................... 34
12.11. Pig Detector ..................................................................................................... 34
12.12. BS&W Analyzer ............................................................................................... 34
12.13. Impulse Tubing ................................................................................................ 34
12.14. Cable ............................................................................................................... 35
12.15. Signal Grouping ............................................................................................... 35
12.16. Instrument & Electrical Interface ...................................................................... 36
12.17. Cable Glands ................................................................................................... 37
12.18. Junction Box .................................................................................................... 37
12.19. Cable Tray ....................................................................................................... 38
12.20. Earthing Philosophy ......................................................................................... 38
13. SPARES ................................................................................................................. 39
13.1. PCS/ESD System Spares ....................................................................................... 39
13.2. Start-up and Commissioning Spares ....................................................................... 39
13.3. Spare Parts for Two Years Operation...................................................................... 39
13.4. Documentation ........................................................................................................ 39
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1. INTRODUCTION
1.1. Project Background
Cairn Oil & Gas (Vedanta Limited) is India’s largest private upstream O&G company with
operating interests in several producing fields in India contributing ~27% of India’s domestic
crude production. Cairn Oil and Gas (Vedanta Limited) is the operator of the onshore RJ-
ON-90/1 block, on behalf of itself and its Joint Venture (JV) partners Cairn Energy
Hydrocarbons Limited (CEHL) and Oil and Natural Gas Corporation Limited (ONGC),
located in Barmer district, in the state of Rajasthan, India. Cairn Oil & Gas (Vedanta Limited)
holds 70% participating interest in the block which contains 38 major oil and gas
discoveries, with significant gas potential in the southern area and oil in the northern area
of the Barmer Basin. Apart from 4 major discoveries in the basin, viz. MBA (Mangala,
Bhagyam & Aishwariya) & RDG (Raageshwari Deep Gas), remaining 34 discoveries are
relatively marginal in nature, and are geographically widespread across the basin and are
under various stages of execution.
Cairn Oil and Gas (Vedanta Limited) intends to fast track the execution of 14 identified fields
in RJ-ON-90/1 block in order to maximize the resource monetization with cost optimization.
To achieve these objectives, Cairn Oil and Gas (Vedanta Limited) intends to partner with
global Oil & Gas Service/EPC companies and/or consortiums, with capabilities for end to
end Integrated Oil well construction (including but not limited to drilling, completion,
fracturing and associated well services) and development of surface facilities (including but
not limited to well pad, intra-field network and evacuation facilities / pipeline to designated
hook-up point).
Halliburton Offshore Services Inc. (HOSI) has been awarded the Engineering, Procurement
and Construction (EPC) contract for Integrated Field Plan Execution Services in the
identified 14 fields in RJ-ON-90/1 block in Barmer District of Rajasthan, India. Sparklet
Engineers Private Limited (SEPL) is the subcontractor to Halliburton Offshore Services Inc.
for the development of surface facilities in these fields and Petrocil Engineers and
Consultants is the selected engineering partner of SEPL. Accordingly PETROCIL will carry
out the Basic and Detailed Design & Engineering services including interfacing of all vendor
packages along with procurement support services like RFQ preparation, Technical Bid
Evaluation and Vendor Document Review of identified packages.
1.2. Scope of Document
This document describes basis of design and provides instrumentation design data and
criteria including the instrumentation design codes and standards that will be used for the
design & engineering of various equipment, systems, lines etc. This document is prepared
as a common document for all locations in “Satellite Field Integrated Project” in the RJ field.
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1.3. Codes and Standards
The Instrument Measurement and Control system shall be designed to standard

engineering practices and shall generally conform to the latest editions of the following
international Standards and Codes as applicable.
American Gas Association (AGA) Reports
AGA Report No.3 Orifice Metering
AGA Report No.8 For Super Compressibility Factor Computation
American National Standards Institute (ANSI)
ANSI/FCI-70-2 Control Valve Seat Leakage

Electromagnetic Compatibility Limits - Recommended
ANSI/IEEE C63.12
Practices
Part 1 & II: Performance Requirements for Combustible Gas
ANSI/ISA 12.13.01
Detectors
ANSI/ISA 51.1 Process Instrumentation Terminology
ANSI/ISA 75.01.01 Flow Equations for Sizing Control Valves

Face-to-Face Dimensions for Integral Flanged Globe-Style
ANSI/ISA 75.08.01
Control Valve Bodies (Classes 125, 150, 250, 300, and 600)
Face-to-Face Dimensions for Flangeless Control Valves
ANSI/ISA 75.08.02
(Classes 150,300, and 600)
Face-to-Face Dimensions for Flanged Globe-Style Control
ANSI/ISA 75.08.06
Valve Bodies (Classes 900, 1500, and 2500)
American Petroleum Institute (API)
Sizing, Selection and Installation of Pressure - Relieving

API RP 520
Devices in Refineries
API STD 521 Pressure Relieving and Depressurising Systems
API STD 526 Flanged Steel Safety Relief Valves

Commercial Seat Tightness of Safety Relief Valves with Metal
API STD 527
to Metal Seats
API RP 551 Process Measurement Instrumentation
Instrumentation and Control Systems for Fired Heaters and
API RP 556
Steam Generators (Boilers)
API STD 607 Fire Test for Soft-Seated Quarter Turn Valves
API STD 670 Machinery Protection Systems
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Guide for Venting Atmospheric and Low Pressure Storage

API STD 2000
Tanks
American Society of Mechanical Engineers (ASME)
ASME B16.05 Pipe Flanges and Flanged Fittings

Face to Face and End to End Dimensions of Valves (also
ASME B16.10
shown as ANSI/ASME B16.10)
ASME B16.36 Orifice Flanges
ASME PTC 19.3 Pressure Gauges and Gauge Attachments

Measurement of Fluid Flow in Pipes using Orifice, Nozzle and
ASME MFC-3M
Venturi
ATEX
Equipment intended for use in Potentially Explosive

ATEX 94/9/EC
Atmospheres
British Standards Institute (BSI)
Instrumentation Cables - Specification for PVC Insulated

BS 5308 Part II
Cables
Specification for Differential Pressure Transmitters with
BS 6174
Electrical Output
Specification for Performance Requirements for Cables to
BS 6387
Maintain Circuit Integrity under Fire Conditions
Fire Detection and Fire Alarm Systems - Part 14: Guidelines for
BS DD CEN/TS 54-14 planning, design, installation, commissioning, use and
maintenance
EN 10204 Metallic Products –Types of Inspection Documents
Electromagnetic Compatibility. Requirements for household
BS EN 55014-1
appliances, electric tools, and similar apparatus. Emission
Measurement of Fluid Flow by Means of Pressure Differential
BS EN ISO 5167-1 Devices Inserted in Cross-Section Conduits Running Full. Part
1: General Principles and Requirements
Electronic Industries Alliance (EIA)
Interface Between Data Terminal Equipment and Data Circuit

EIA RS232-C –Terminating equipment employing Serial Binary Data
Interchange
Electrical Characteristics of Generators and Receivers for use
EIA RS485
in Balance Digital Multipoint Systems
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International Electro-Technical Commission (IEC)
IEC 60079 Electrical Apparatus for Explosive Atmosphere

Polyvinyl Chloride Insulated Cables of Rated Voltages up to
IEC 60227
and Including 450/750 V
IEC 60331 Fire Resisting Characteristics of Electric Cables
IEC 60332 Test on Electric Cables under Fire Conditions
IEC 60478 Stabilized Power Supplies DC Output

Classification of Degrees of protection Provided by Enclosures
IEC 60529
(IP Code)
IEC 60534 - Parts
Industrial - Process Control Valves
1,2,3,4,5 and 8
Test Method for Insulation and Sheaths of Electrical Cables
IEC 60540
and Cords
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
IEC 60793-1 Optical fibres, Part 1, Generic Specification
IEC 60794 Optical Fibre Cables, Part 1, Generic Specification
Electromagnetic compatibility for industrial process
IEC 60801
measurement and control equipment
Common test methods for insulated and sheathing materials of
IEC 60811
electrical and optic cables
IEC 61000 Electromagnetic compatibility
Electromagnetic Compatibility for Industrial Process
IEC 61000-2/3/4
Measurement and Control Equipment
IEC 61131 Programmable Controllers
Digital Data Communication for Measurement and Control -
IEC 61158-SER
Fieldbus for Use in Industrial Control Systems
Function Blocks for Industrial Process Measurement and
IEC 61499
Control systems (Feras)
Functional Safety of Electrical/Electronic/Programmable
IEC 61508
Electronic Safety Related Systems
Functional Safety - Safety Instrumented Systems for the
IEC 61511
Process Industry Sector
Metal Thermowells for Thermometer Sensors - Functional
IEC 61520
Dimensions
IEC/ITS 61423 Heating Cables for Industrial Applications
Institute of Electrical and Electronics Engineers (IEEE)
Standard for Digital Interface for Programmable

IEEE 488
Instrumentation
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Standard for Higher Performance Protocol for the Standard

IEEE 488.1
Digital Interface Programmable Instrumentation
Standard Codes, Formats, Protocols and Commands for use
IEEE 488.2
with IEEE 488.1
IEEE 730 Software Quality Assurance Plans
Information Technology - Telecommunication and Information
IEEE 802.3 Exchange Between Systems - Local and Metropolitan Area
Networks - Specific Requirements
IEEE 802.4 Information Processing System, Local Area Network
IEEE 828 Software Configuration Management Plans
IEEE 829 Software Test Documentation

Recommended Practice for Software Requirements
IEEE 830
Specifications
Surge Withstand Capabilities (SWC) Tests for Relays and
IEEE C37.90.1
Relay Systems Associated with Electric Power Apparatus
Standard for Withstand Capability of Relay Systems to
IEEE C37.90.2
Radiated Electromagnetic Interface from Transceivers
Indian Codes, Standards and Regulations (IS)
IS 736 Codes and Practice for Electrical Wiring Installations
IS 1554 PCV Insulated (Heavy-Duty) Electric Cables

Electrical Apparatus for Explosive Gas Atmospheres –
IS 2148
Flameproof Enclosures ‘d’
IS 3624 Specification for Pressure and Vacuum Gauges
IBR Indian Boiler Regulation
SMPV Rules Static and Mobile Pressure Vessel Rules 1981

DGMS Directorate General of Mines Safety Norms
Directorate General of Civil Aviation Rules and Aircraft Act
DGCA
1934, Rule 30, 37
Petroleum Explosives Safety Organizer / Chief Controller of
PESO / CCE
Explosives, Nagpur
Indian Electricity Rules 1956-2004
Indian Explosive Act 1881
International Society of Automation (ISA)
ISA 5.1 Instrumentation Symbols and Identification
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ISA 5.2 Binary Logic Diagrams for Process Operations

Graphic Symbols for Distributed Control/Shared Display
ISA 5.3
Instrumentation, Logic and Computer Systems
Terminology, dimensions and Safety practices for Indicating
ISA 16.1/16.2/16.3 Variable Area Meters: Rotameters, Glass Tube, Metal Tube,
Extension Type Glass Tube
ISA FCI-70.2 Leak Testing of Control Valves
Face-to-Face Dimensions for Integral Flanged Globe-Style
ANSI/ISA 75.08.01
Control Valve Bodies (Classes 125, 150, 250, 300, and 600)
Face-to-Face Dimensions for Flangeless Control Valves
ANSI/ISA 75.08.02
(Classes 150, 300, and 600)
Face-to-Face Dimensions for Flanged Globe-Style Control
ANSI/ISA 75.08.06
Valve Bodies (Classes 900, 1500, and 2500)
Face-to-Face Dimensions for Sliding Stem Flangeless Control
ISA-75.08.09
Valves (Classes 150, 300, and 600)
ISA MC 96.1 Temperature Measurement Thermocouples
ISA RP 55.1 Hardware Testing of Digital Processing Computer
International Organization for Standardization (ISO)
ISO 04126: 1991 Safety Valves
ISO 00031, Parts 1-13 Quantities and Units

SI Units and Recommendations for the Use of their Multiples
ISO 01000
and of certain other units
Measurement of Fluid Flow by Means of Pressure Differential
BS EN ISO 5167-1 Devices Inserted in Circular Cross-Section Conduits Running
Full
ISO/TR 5168 Measurement of Fluid Flow – Evaluation of Uncertainties
Measurement of Fluid Flow in Closed Conduits, Guidance to
the
ISO 10790
Selection, Installation and Use of Coriolis Meters (Mass Flow,
Density, and Volume Flow Measurements)
ISO 3170 Petroleum Liquids - Manual Sampling
Petroleum liquids and gases; Fidelity and security of dynamic
ISO 6551 measurement; Cabled transmission of electric and/or electronic
pulsed data
ISO 9001 Quality Management and Quality System Elements
Quality Management Systems - Guidelines for performance
ISO 9004
improvements
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Measurement of Fluid Flow in Closed Conduits, Guidance to

ISO 10790 the Selection, Installation and Use of Coriolis Meters (Mass
Flow, Density, and Volume Flow Measurements)
National Fire Protection Association (NFPA)
NFPA 20 Standard for Installation of Centrifugal Fire Pumps

NFPA 70 National Electrical Code (NEC)
NFPA 72 National Fire Alarm Code
NFPA 72E Automatic Fire Detectors
Oil Industry Safety Directorate (OISD)
OISD STD 137 Inspection of electrical equipment.

OISD STD 147 Inspection & safe practice during electrical installations.
OISD STD 149 Design aspects for safety in electrical systems.
Safety instrumentation for process system in hydrocarbon
OISD STD 152
industry.
Maintenance & inspection of safety instrument in hydrocarbon
OISD STD 153
industry.
OISD STD 163 Process Control Room Safety
OISD STD 174 Well Control
OISD STD 180 Lightning Protection.
Underwriters Laboratory (UL)
UL 2250 Standard for Instrumentation Tray Cable

UL 508 Industrial Control Equipment
2. DEFINITION
Nomenclature Description
Cairn Oil and Gas (Vedanta Limited) or its authorized
Company
representative (CAIRN)
Main Contractor Halliburton Offshore Services Inc. (HOSI)
Sub-contractor Sparklet Engineers Pvt Ltd (SEPL)
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Engineering Consultant Petrocil Engineers & Consultants (PETROCIL)

Shall mean the party, who manufactures or supplies the
Vendor
equipment and services specified
Integrated Field Plan Execution Services In Satellite Fields In
Project
RJ-ON 90/1 Block-Surface Facilities (Satellite Project)
3. REFERENCES
Doc. No. Description

Integrated Field Plan Execution Services in Satellite
SOS
Fields in RJ-ON-90/1 Block- Scope of services
Raag-Oil-Stage-II Scope of Services RJ-ON-90/1 Block
Chapter 1
Rajasthan
Guda Oil Field Scope of Services RJ-ON-90/1 Block
Chapter 2
Rajasthan
Tukaram Scope of Services RJ-ON-90/1 Block
Chapter 3
Rajasthan
Chapter 4 NL Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 5 KW-6 Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 6 KW-3 Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 7 GSV Scope of Services RJ-ON-90/1 Block Rajasthan
Raag-South Scope of Services RJ-ON-90/1 Block
Chapter 8
Rajasthan
Chapter 9 Shakti Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 10 SL-1 Scope of Services RJ-ON-90/1 Block Rajasthan
Saraswati SW-1 Scope of Services RJ-ON-90/1 Block
Chapter 11
Rajasthan
Guda South 7 Scope of Services RJ-ON-90/1 Block
Chapter 12
Rajasthan
Chapter 13 NP Scope of Services RJ-ON-90/1 Block Rajasthan
Kaam 1 Scope of Services RJ-ON-90/1 Block
Chapter 14
Rajasthan
Appendix 1 Scope of Services for Quick Production Facility (QPF)
Appendix Telecom scope for satellite fields – R2
Cairn Standards
CAIRN-TSG-IC-SP- Specification for Instruments

0001 and Controls
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CAIRN-TSG-IC-SP- Specification of Instrumentation for Packaged

0007 Equipment
CAIRN-TSG-IC-SP-
Specification for Process Control System
0008
CAIRN-TSG-IC-SP- Specification for Actuated Valves (Control Valves and
00011 ESD Valve)
CAIRN-TSG-IC-SP-
Specification for Machinery Protection System
00013
CAIRN-TSG-IC-SP-
Specification for Remote Terminal Unit (RTU)
00014
CAIRN-TSG-IC-SP-
Specification for Pressure Relief Valves
00015
CAIRN-TSG-Q-GUI-
Guideline for Inspection Test Plan
0004
DECO-RX-FG-SP-2004 Specification for Fire & Gas System
DECO-RX-FG-SP-4001 Specification for Fire Detection & Alarm System
DECO-RX-J-PRO-2001 Equipment Numbering System
CAIRN-TSG-IC-DWG-
Typical Instrumentation Installation Standard
0001-01
CAIRN-TSG-IC-DWG-
Typical Electrical & Instrument Interface Drawings
0002-01
CAIRN-TSG-CN-LSP-
Approved Vendor List
0001
CAIRN-TSG-R-SP-
Specification for Fire & Gas Detection Philosophy
0008
4. METEOROLOGICAL DESIGN DATA

For this section, refer Process Design Basis S340HAL-SRX-P-BD-0004 Section 6.
5. ABBREVIATIONS
ABBREVIATIONS DESCRIPTION
AC Alternating Current
BS&W Basic Sediment & Water
CCTV Closed Circuit Television
CPF Central Processing Facility
CPU Central Processing Unit
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DC Direct Current
ESD Emergency Shutdown
FGS Fire & Gas System
FOC Fibre Optic Cable
FRP Fibre Reinforced Plastic
GSM Global System for Mobile Communication
HART Highway Addressable Remote Transducer Protocol
H2 Hydrogen
HD High Definition
HDPE High Density Poly Ethylene
HMI Human Machine Interface
H2S Hydrogen Sulphide
IO Input/output
IP Ingress Protection
IR Infra-Red
IS Intrinsic Safe
LCP Local Control Panel
LED Light Emitting Diode
LSOH Low Smoke Zero Halogen
MCC Motor Control Centre
MGL Mean Ground Level
MSL Mean Sea Level
OWS Operator Work Station
PA Public Addressing
PCS Process Control System
PLC Programmable Logic Controller
PoE Power Over Ethernet
PTZ Pan-Tilt-Zoom
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PVC Poly Vinyl Chloride

QPF Quick Production Facility
SIL Safety Integrity Level
SOV Solenoid Operated Valve
SOW Scope of Work
UHF Ultra High Frequency
UPS Uninterrupted Power Supply
VHF Very High Frequency
VOIP Voice Over Internet Protocol
6. ORDER OF PRECEDENCE
Normally the project specific documentation (specifications, drawings and datasheets) are
in compliance with the regulations, standards and codes. In the event there is conflict, the
following order of precedence shall apply from highest Importance as mentioned below:
1. Government Regulations and Statutory Requirements
2. Project specifications and data sheets
3. Design Basis
4. Indian and International codes and standards
5. Company Standards/Specifications /drawings
7. UNITS OF MEASUREMENTS
Quantity or Variable Metric Units Imperial / Field Units

Capacity m3 BBL
Liquid Flow by Volume m3/hr or L/H BOPD/BLPD
Gas Flow by Volume kgmol/h or Nm3/h MMSCFD
Liquid / Gas Flow by Weight kg/h or kg/s
Length mm or m
Pipe Diameter mm N.B.
Surface Area m2
Volume m3 BBL
Pressure kPa, bara or mmWG
Design Pressure kPa, barg or mmWG
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Quantity or Variable Metric Units Imperial / Field Units

Differential Pressure kPa, bar or mmWG
Pressure Losses kPa/km or bar/km
Power kW
Heat Duty 106 kcal/h or kJ/h
Temperature oC , oK
Viscosity Pa.s (Pascal-second)
8. PLANT UTILITIES
8.1. Instrument Air Supply
The instrument air supply shall be taken from the instrument air package units, which shall
maintain uninterrupted supply of air. The operating pressure of the instrument air system
shall not be less than the following
a. Minimum Operating 6.0 kg/cm2g

b. Normal Operating 6.5 kg/cm2g
c. Maximum Operating 10.5 kg/cm2g
The dew point of the air anywhere in the system is considered to be at least -40°C @
atmospheric pressure.
Sizing of instruments shall be done on a minimum instrument air pressure of 5 kg/cm2g.
Pneumatic control should be limited to local control. Pneumatic control air pressure shall
normally be 0.2 kg/cm2g to 1 kg/cm2g (3 to 15 psi). Control valve actuators may be 0.4
kg/cm2g to 2 kg/cm2g (6 to 30 psi).
8.2. Nitrogen Supply
The nitrogen supply shall be taken from the nitrogen bottles, which shall maintain
uninterrupted supply of nitrogen. Nitrogen shall be supplied at the required pressure using
PCVs, since the pressure in the nitrogen bottles is high. The design / operating pressure of
the nitrogen system shall not be less than the following.
a. Minimum Operating 6.0 kg/cm2g
b. Normal Operating 6.5 kg/cm2g
c. Maximum Operating 10.5 kg/cm2g
The dew point of the Nitrogen anywhere in the system is considered to be at least -100°C
@ atmospheric pressure.
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Sizing of instruments shall be done on a minimum pressure of 5 kg/cm 2g. Pneumatic control
nitrogen pressure shall normally be 0.2 kg/cm2g to 1 kg/cm2g (3 to 14.2 psi). Control valve
actuators may be 0.4 kg/cm2g to 2 kg/cm2g (6 to 28.4 psi).
8.3. Power Supply
Various instrumentation panels and field mounted instruments as applicable shall be

powered from UPS for ensuring system availability.
The output voltage of UPS system shall be as indicated below:
230 V AC +/-1%, 50Hz, 1 phase.
PCS/ESD/FGS, Package Control System, Building Fire and Gas detection system, CCTV,
PA system and communication system etc. shall be powered from UPS.
However all systems powered from UPS shall be suitable for operation at 230 V AC -15%
and +10% single-phase, 50 ± 1% Hz.
The UPS shall provide a 30 minute battery back-up.
The electronic field instruments, devices and circuits shall be powered (24 VDC) by the
respective control systems (PCS, ESD, FGS, Package Control System).
The 230 V AC, 50 Hz UPS power supply feeders (redundant) shall be made available by
Electrical at respective control room at each facility.
Any other voltage other than 230 V AC required shall be derived with internal power supply
unit installed inside the panel.
Utility power for the panels like lighting, socket etc. shall be from non UPS 230V AC feeders.
Wherever redundant power supplies are provided it shall be possible to isolate, disconnect,
remove and replace faulty power supplies without loss of operation. Failure of a single
power supply unit shall not interrupt system operation.
9. EQUIPMENT PROTECTION PHILOSOPHY
9.1. General
Field mounted instruments and auxiliary devices shall be suitable for operation in a wet,
hot, dusty, corrosive, and dessert environment. Instruments and auxiliary devices mounted
inside enclosed buildings shall be suitable for operation in ambient temperatures between
0°C & 50°C, and with a relative humidity of 80%. All the Instruments, outdoor sheltered
control cabinet or equipment installed in field shall withstand black body temperature of
80°C.
All essential Test Reports and Certificates shall be provided to the CONTRACTOR/
COMPANY. All the certificates shall be in English language.
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9.2. Ingress Protection
Field mounted instruments shall be weatherproof to IP65 in accordance with IEC 60529 as
a minimum. Instruments if any installed below ground level shall be IP67 as a minimum.
Instruments, Equipment and Panels to be installed inside Building enclosures shall have
an ingress protection of minimum IP 42 as per IEC 60529.
9.3. Electrical Area Classification
All Instruments shall conform to the electrical area classification in which they are installed.
For each zone, safety certificates shall be available for the installed electrical apparatus.
Explosion proof method is preferred one. Where ever Explosion proof is not possible /
available intrinsic safety method shall be utilized and shall have COMPANY’s prior
approval. Active barriers (Galvanic Isolator) shall be used for IS circuits and installed in safe
area.
All Instrumentation equipment’s, materials and installation methods shall comply and fully
satisfy the requirements for the area classification identified on the project Hazardous Area
Drawings. All electronic equipment which may be used in potentially explosive atmospheres
(Flammable gases, vapors or dusts) shall comply with ATEX directive 94/9/EC and IS 2148
requirements incorporating applicable certification to IEC 60079.
Electrical & Electronic instruments shall be provided with hazardous area approval
certificates from an internationally recognized certifying agency such as BASEEFA, FM,
UL, CENELEC or equivalent. It shall also have approval from local bodies like PESO
(Petroleum Explosives Safety Organizer), CCE (Chief Controller of Explosives), DGMS
(Directorate General of Mines Safety) Nagpur.
All electronic field Instrumentation shall be suitable for use in given Hazardous Area
Classification. As a minimum, all electronic field instrumentation shall be certified for use in
Zone 2, Gas Group IIA/IIB, Temp 3 Hazardous areas to IEC 60079. In addition to that,
battery room located instruments shall be suitable for Gas Group IIC.
10. PLANT LIFE
The plant life for the surface facilities at all locations shall be 10 years.
11. INSTRUMENTATION AND CONTROL SYSTEM
11.1. Scope of Work
Project scope consists of following instrumentation and control systems & sub-systems at
various Fields.
 Integrated PLC System consisting of Process Control system (PCS),

Emergency Shutdown System (ESD) and Fire & Gas System (FGS)
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 Push Button console (Not provided in QPFs)

 Plant Fire and Gas devices
 Building Fire alarm system
 Control panels supplied by package vendors
 Field instrumentation
 Telecom systems
In QPF fields, a combined PLC based control system, for process control, emergency
shutdown and F&G monitoring, is considered taking into consideration the lesser number
of I/O’s. Further details will be available in the Architecture Diagram of respective well pads.
11.2. General
The Well Pads/QPF/CPF shall be monitored and controlled from the Control System
located in the Control Room in the respective area. Where ever new system is considered
for the existing field modification, the same shall be capable of being interfaced with the
existing control system. In existing fields if a new system is considered the SIL rating of
new system shall match SIL rating of the existing system.
For new fields, Emergency Shutdown System and Fire & Gas System shall be SIL 3
certified. The combined PLC in QPF field shall also be SIL 3 certified. In existing fields if a
new system is considered, then also the Emergency Shutdown System and Fire & Gas
System shall be SIL 3 certified.
An engineering/operator workstation shall be provided to monitor and control the facility as

indicated in respective architectural diagram. The workstation shall also be used for
program modifications.
Each of the integrated PLC system shall be interfaced with the Cairn communication back
bone via fibre optic/GSM/ Microwave communication. The facility parameters will be made
available to the Cairn main control centre.
Control systems involving electrical start-up/shutdown systems shall be energized for

normal operation and de-energized for shutdown. All control systems shall be engineered
and designed for safe failure positions in the event of a complete loss of electrical power,
instrument air and/or nitrogen systems.
Instrumentation shall not be effected by the operation of a two way radio (UHF or VHF) or
electromagnetic interference. Electromagnetic Compatibility of Instruments, Instrument
Systems and Instrument installations shall be in accordance with IEC 61000.
The Instrumentation system shall conform to applicable International codes and practices.
Initiators and final control element used in Safety applications (ESD and FGS) shall be SIL-
2 certified as a minimum and shall be certified by certifying agencies like TUV/ Exida or
equivalent.
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Flying leads for instruments including SOV & Limit Switches are not acceptable and shall
otherwise be provided with an area certified Junction Box/Terminal box to terminate the
flying leads.
Electronic instrument signal shall generally be of two wire 4-20mA with HART protocol.
Field Limit Switches wherever used shall be proximity type with Single Pole Double Throw
(SPDT) configuration. It shall be potential free contact with a rating of 2A at 24V DC.
Individual field instruments shall be connected to local field junction boxes. A minimum
unobstructed space of 0.9 m shall be maintained between the bottom of the box and the
nearest objects to permit cable entry.
Instrument signal wiring junction boxes shall not be used for electrical cables. PCS and
Safety Instrument System signals shall be segregated into separate junction boxes. Further
signal segregation is mentioned in the Signal Grouping Section.
Field Junction boxes shall be Ex‘d’ certified for use in Zone 1 and Ex‘e’ certified for use in
Zone 2, Gr. II A&B, Temperature classification T3. Ex‘d’ junction boxes shall be made of
Die cast Aluminium and Ex‘e’ junction boxes shall be made of SS 316 with 2mm thickness
as minimum.
Multi-pair cable entries and individual field instrument cables entries shall be from bottom.
Main Cables shall be directly buried in trench and branch cables shall be laid on tray or
buried up to the junction boxes.
All instruments shall be installed as per the project specific Hook up diagram.
Local control panel, which comes as part of the skid system, shall comply to Cairn
specification for package PLC.
PLC based Local Control Panel/Burner Management System shall be provided for Heater
Treater with all instruments and accessories supplied as part of Heater Treater Package.
Local Control Panel, which comply to Cairn specification, shall be provided for Instrument
Air package with all instruments and accessories supplied as part of IA Package.
Flame Front Generator package shall be supplied by the Flare stack vendor with all required
instrumentation complying area classification.
Fire and Gas Devices comprise of Flame Detectors, Combustible Gas Detectors, Manual
Alarm Call Stations, Beacons and Hooters. The type of detectors used shall be decided in
mapping study.
Instrument housing material for transmitters, limit switches etc. shall be low copper Di cast
aluminum with epoxy coating.
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Instrument vent/drains and valve manifolds shall be suitable for the stated service. Wetted
parts for instruments shall be selected to suit the process requirement and the same shall
be mentioned in the respective data sheet. However, SS316 shall be considered as a
minimum.
Casing material for pressure and temperature gauges shall be SS316.
FRP Canopy shall be provided for all field mounted electronic instruments and junction
boxes. Pre-fabricated canopies shall be provided for field installed LCP system. All
instruments shall be provided with stainless steel tag plates.
All instruments that need tuning and maintenance shall be accessible from the ground
platforms or fixed ladders.
11.3. Control Room
The Well pad/CPF shall be monitored and controlled by an Integrated Control System
located in the Porta cabin based Control Room. The type of construction of Control room
shall be performed as per Annexure – 1 in OISD-STD-163.
The following equipment in general shall be located in the Control Room:
 PLC Control panel

 Operator Work Station/Engineering Workstations
 Operator Push-button Console
 Printers
 Building Fire Alarm Panel inclusive of Smoke Detection Panel
 Telecom Panels
The new integrated PLC system comprises of Process Control System (PCS), Emergency
Shutdown System (ESD), Fire & Gas System (FGS), Operator / Engineering Workstations
with consoles, hardwired & annunciation consoles shall be located in control room.
For QPF, a combined (PCS, ESD & FGS) SIL 3 certified PLC system with a panel mounted
HMI will be provided. Same shall be located in control room.
Cable entry into the control room/panels shall be from the bottom. In control panel field
cables shall be terminated on Knife-edge, SAKR Type (or equal) disconnects terminals.
In brown fields, the existing and new systems shall be integrated via Ethernet / RS-485
Modbus communication for monitoring and shall be hardwired for ESD signals. Depending
upon the spare availability at each existing well pads on a case to case basis the interface
requirements will be defined. The integration of the new system with the existing shall be
carried out without any disturbance to the existing system wherever possible.
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Building Fire Alarm System consisting of Smoke, Heat, H2 detectors, Manual Alarm Call
points, Sirens and Strobe lights shall be provided. The Fire Alarm system shall be
interfaced with building fire extinguishing system as applicable.
The wellhead parameters shall be made available to the Cairn main Control system (by
others) through communication network. As per the Telecom scope, provision to hook up
the fiber optic cable will be available in the existing facility.
The panels for CCTV and other telecom systems shall also be located in control room.
11.4. Process Control System
PLC based Process Control System shall be provided for control and monitoring of the
facility. For brown fields, new PLC based system shall be provided for new facility I/O’s and
interfaced with the existing system.
The Process Control functions shall be performed by a PLC based Process Control System
(PCS) located in the respective control Rooms. The Control System shall provide the basic
monitoring, regulatory control, sequencing, alarm functions and all non-ESD functionality
of the process and utility system, also other package PLC shall be interfaced with PCS
through redundant communication for monitoring. The PCS shall display control loop status
including process input, controller set-point and controller output etc.
Operator / Engineering work station shall be provided as indicated in architecture diagram

for monitoring and control of the facility.
The controller shall be sized to meet the requirements with 50% spare capacity for memory
as well as CPU loading.
The Control System shall be able to accept an increase of 20% in the number of software
points without any hardware modification after plant commissioning. This 20% spare
capacity shall be usable without modification of the system.
 Redundancy shall be provided for the following
 Power supply
 CPU
 Communication (Except Fire Alarm Panel and Existing Systems)
 Redundancy is not envisaged for PCS IO cards

 The Control System shall have interface with the Safety Systems (ESD and Fire and
Gas Detection System),
 Alarm handling of all instrument system shall be performed by the Control System
and functions shall include tag number alarm, identification of alarm priority level,
annunciation of alarms, alarm acknowledgement and alarm resetting.
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 The system shall include the monitoring of process variables from field instruments,
position indicating proximity switches for ESD valves etc.
 Necessary provision shall be made for Control and monitoring of pumps from PCS
as per requirement. Auto/Manual and Duty /Standby selection of pumps shall be
implemented in the PCS system. No hardwired interface is considered for
Auto/Manual and Duty/Standby selection.
 The system shall have a user-friendly system for generation of databases,
configuration, graphics etc.
 The graphics shall be of the interactive type through which it shall be possible to
control the process.
 Facility shall be available for historical trend recording.
 230V, 50Hz, 1phase AC power shall be made available from a UPS.
 Refer architectural diagram for respective Well Pad for additional details.
11.5. Emergency Shutdown System
The ESD system shall be provided to continuously monitor the Safety parameters of the plant
and to take Actions to maintain the Safety of the plants on demand.
The system shall be PLC based with SIL 3 certification. ESD system shall share the
Operating and Engineering workstation with PCS.
 The Safety System shall be able to receive 4-20 mA DC signal from both 2 wire, 3
wire and 4 wire field transmitters.
 ESD & F&G loops shall be of minimum SIL 2 rated and shall be independent to
process control loops.
 Redundancy shall be provided for the following.
 Power Supply
 CPU
 Communication
 IO modules
 The system shall provide the wetting voltage for digital inputs, which are connected
to switches, which have voltage free contacts. (e.g., reset and ESD switches)
 The digital output signal shall be provided for solenoid valves, interface relays,
sirens and strobe light of the fire detection system, and/or local panel alarm lights.
The signal shall be powered 24V DC.
 The software spare capacity for the Safety system and for serial communication
connection to Control System shall be 50%. The controller shall be sized to meet
the requirements with 50% spare capacity for memory as well as CPU loading.
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 The Safety System shall communicate with Control System on a redundant serial
link for transfer of essential parameters.
 230V, 50Hz, 1phase AC power shall be made available from UPS.
11.6. Plant Fire and Gas Detection System
The Fire and Gas detection system shall be a part of plant ESD system. The detectors shall
be integrated into the safety shutdown system.The I/O card segregation is considered for
F&G signals from process ESD signals.
The new facilities shall be covered with adequate Fire and Gas detectors and Manual Call
Points according to mapping study. Hooters & Beacons are provided for audible and visual
alarms. Status alarm and confirmed fire detection alarm shall be transferred to the Process
Control System. The logic shall be implemented as per FGS Cause & effect Diagram.
Detector status matrix shall be configured as a graphic in the Process Control System.
Types of detectors used are as follows;
 Flame detector – Triple IR type
 Flammable Gas Detector – IR Point type
Output signal of Fire & Gas Detectors shall be 4 – 20 mA SMART with HART protocol or
digital, potential free contact. Open path gas detectors shall be considered as per HSE
requirement.
Upon confirmed fire detection at the well pad/QPF/CPF, the facility shall be isolated by
closing the shutdown valves on well heads or vessel inlet/outlet.
Upon Fire or Gas detection, necessary shutdown action shall be initiated and alarms
generated as per cause & effect diagram.
Emergency Shutdown Push buttons shall be provided at strategic locations that shall be
easily accessible to personnel for operation. Audio Visual facility using colored beacons for
both fire & gas separately and sirens shall be provided at appropriate locations that are
easily visible to the operators.
11.7. Hardwired Console & Annunciator Panel
The safety system shall include an operator push button console located in the control
room. The manual shut down switch for tripping shall be provided in the hardwired console.
Necessary indicating lamps shall be provided for critical alarms.
Hardwired console requirement will be in indicated in the respective Cause and Effect
diagram for respective well pad for additional details.
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11.8. Interposing Relay
The Interposing relays shall be provided as an interface between PCS / ESD system and
Switchgear / MCC panels / Third party package PLC’s. Interposing relays shall be provided
for all digital output signals from PCS/ESD systems to MCC. Interposing relays are not
envisaged for status feedback signals from MCC. Potential free contacts shall be wired
from MCC to PCS/ESD system for status feed backs. Electrical drive trip commands from
the safety system to the MCC shall be transferred through SIL 3 rated relays. For all other
signals, non SIL rated relays shall be used. The Interposing relay shall be located in
respective MCC by electrical.
For digital output signals to package PLCs interposing relays shall be provided in Package
PLC panel.
11.9. Building Fire Alarm System (BFAS)
Building Fire Alarm System (BFAS) shall be provided for all rooms and areas in the control
building and other buildings as applicable.
All Detectors associated with Fire Alarm Panel shall be addressable type. The Fire Alarm
System shall be designed as per the NFPA 72. A dedicated Fire Alarm Panel shall be
located in the control room. The Fire Alarm Panel shall be interfaced with PCS through
communication. The interface with ESD/FGS shall be through hardwired interface for
shutdown action. Building Fire Alarm Panel shall be provided with an integral Mimic Panel.
The following types of F & G detectors shall be utilized
 Manual Call point (MCP) – Dual Action type (Break Glass with lift flap)
 Smoke detector (SD) – Addressable type (Optical Type)
 Heat Detector (HD) - Addressable type
 Hydrogen Detector (H2) - Electrochemical type
 Beacon – Red
 Hooter
In addition to the above mentioned detectors, executive action on Clean Agent System /
Fire Extinguisher shall be provided based on HSE Philosophy.
230V, 50Hz, 1phase AC power shall be made available from a UPS for powering of the
panel.
Battery Room shall be provided with Hydrogen Detector. Devices in battery room shall be
flame proof type and shall be suitable for Gas Group IIC (Hydrogen). Arrangement to
automatically trip exhaust fan in case of FGS activation shall be provided.
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11.10. Package Control System
Some of the equipment for the facility are considered to be provided as packages. Same is
considered to be fabricated in the form of skid and provided to site.
In general, such packages can be categorized into the following types based on the location
of control system:
TYPE-1 Package: This type shall be applicable for the process packages, where the
package equipment monitoring and control is implemented in the plant control system.
Package operation, monitoring and control shall be done from the OWS of plant control
system. The instruments and valves in the package shall be wired up to junction box
installed at skid boundary and interfaced with plant control system through multi-pair
cables.
TYPE-2 Package: Supplied with its own instrumentation and PLC based control system
with redundant serial communication to PCS for the operation, control and monitoring. All
signals for shutdown shall be interfaced with facility ESD system through hardwired
interface. Package PLC system shall be located in the control room and the PLC panel
shall be provided with panel mount HMI. All critical and control signals shall be hardwired
for control. Modbus shall be used only for monitoring purpose.
Type-3 Package: Supplied with its own instrumentation and PLC based control system with
redundant serial interface RS-485 to PCS for the operation, control and monitoring. All
signals for shutdown shall be interfaced with facility ESD system through hardwired
interface. Package PLC system shall be located at package skid. The Local Control Panel
for PLC shall meet the hazardous area requirement where it is installed.
Wherever package PLC is provided, same shall be responsible for the control and safe
shutdown of the package. This shall control all auxiliaries of the main equipment’s within
the package including start/stop/trip and sequencing. Facility PCS/ESD will perform
monitoring of the package and trip in case of emergency.
Control panels that are supplied, as part of the vendor packages shall be located in the
field, provided the panel design is suitable for hazardous area classification and
environmental conditions prevailing stated in this document. Otherwise, these shall be
located in a control room. All control panel indications as applicable shall be provided with
high intensity multi-LED lamps and an extended sunshade for clear visibility during day
time.
Vendor supplied panels shall be interfaced with the facility real time process control and
monitoring system for transfer of all essential data. List of signals transferred shall be
developed during the detailed engineering. Interface of package control panels to PCS
system shall be through redundant serial communication.
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Package PLC shall be with redundant processor, communication and power supply.
Redundancy shall also be provided for I/O modules of critical signals (shutdown signals), if
any. All sub-systems or system components installed outdoor shall have corrosive
environmental protection coating meeting the G3 classification as per ISA S71.04.
11.11. Interface to Existing System
The new integrated control system in brown field shall be interfaced with the existing well
pad control system over redundant Serial Link in case of PCS and hard wire interface for
ESD, for transfer of process parameters / ESD signals.
ESD action is required from GUDA-7 to SDV at AGI-6 (as per C&E requirement). The new
Integrated PLC at GUDA-7 shall communicate with PLC at AGI-6. A new SIL 3 based ESD
system is envisaged in AGA 6 to interface signals like shutdown valve and transmitters.
The ESD action from GUDA-7 to AGI-6 and vice versa shall also be implemented using this
PLC. This ESD PLC shall communicate with GUDA-7 & RTU at AGI-6.
Shutdown interface between well pads which are connected via pipeline is implemented
via non redundant FOC, this will not be SIL rated.
12. FIELD INSTRUMENTATION, CABLES AND INSTALLATION REQUIREMENTS
12.1. General
Electronic instrumentation shall be used. All field transmitters shall be provided with integral
digital LCD indicators configured in engineering units. Loop powered remote indicators shall
be provided wherever required as per plant operational philosophy.
All field transmitters shall work on two wire 4-20mA analog mode with superimposed HART.
All instruments shall be Ex’d’ type.
All transmitters shall be factory calibrated to the ranges mentioned in the data sheets.
Mounting shall be on 2” pipe using standard SS316 brackets supplied by the vendor for
non-line mounted instruments. Mounting structure for field instruments and junction boxes
shall be duly painted as per Project painting specification. Due care shall be taken to
insulate different materials while mounting. All electronic instruments shall work on 24V DC
power.
Pneumatic control should be limited to local control. Pneumatic control air pressure shall
normally be 0.2 kg/cm2g to 1 kg/cm2g (3 to 15 psi).
Diaphragm seals shall be selected in case of the following applications
 As an alternative to impulse line purging

 For corrosive service as applicable.
 In applications that require flushing in viscous, waxy, sticky, or plugging services.
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 In applications where pressure rating is higher than or equal to 600#.
Bleed/Flushing ring shall be considered. MOC of wetted part material shall be mentioned
in respective data sheet for instruments.
For critical applications, gauges should be installed as backup to the transmitter.

Transmitters shall be mandatory for trip application. Shutdown initiating devices shall be
direct mounted with tapping points being independent of the normal process control
devices.
Instruments that fall under SIL loop shall specify the SIL level requirement in the respective
data sheet.
All instruments that need tuning and maintenance shall be accessible from the ground,
platforms or fixed ladders.
All instruments and all F&G devices shall be procured from Cairn approved Vendor list
except for Tubes and fittings. For Tubes and Fittings, approved Vendor ASTEC – TUBES
AND FITTINGS shall not be considered due to quality issue observed at site.
All instruments shall have IP65 protection for outdoor installations. Approval agencies
should be UL, FM, CSA, IEC, or equal. All field mounted electronic instruments shall be
provided with canopy.
In general, switches shall not be used for process application, transmitters shall be
considered for the same.
All instruments and equipment shall be numbered as per Cairn Tag Numbering Procedure.
Mounting structure for field instruments and junction boxes shall be duly painted as per
Project painting specification. Due care shall be taken to insulate different materials while
mounting.
12.2. Flow Measurement
Flow measurement shall be done using differential pressure (orifice meter) and Coriolis
type. Orifice plates sizing, design, construction and dimensions shall be as per API MPMS
14.3, ISO 5167 & ISO 5168. The selected DP at meter max shall be 0-100 inches of water
column (25 kPa). Other DP‘s which shall be selected are 10 kPa, 50 kPa or 100 kPa. A DP
value of less than 10 kPa shall not be considered unless it is unavoidable.
Orifices should typically have a beta ratio (ratio of orifice bore diameter to pipe internal
diameter) between 0.2 and 0.75. Orifice flanges shall be DN50 (2”), 300# as a minimum.
Socket welded flange taps shall be used for all orifice meter installations as in-line with the
piping specifications. Orifice plate material shall be SS316 minimum, provided the material
is suitable for service fluid. For pipe sizes less than 2”, Integral Orifice flow meter shall be
provided.
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All orifice type flow transmitters shall be with 5 valve manifold for secondary isolation. Vent
/ Drain hole shall be provided in orifice plates for removal entrapped liquid or gas.
DP type flow transmitters shall be able to withstand differential pressure equal to full line
pressure without zero or calibration change. Full scale flow range shall be selected such
that maximum flow reading is 90- 95 % of full scale and normal flow reading is 70 – 80 %
of full scale. The minimum and maximum flow rate shall be between 20 and 90 %.
Variable area flow meters (Rotameters) shall be the armoured metal tube type except when
flow rates are too low for their use, and then glass tube rota meters may be considered.
The use of glass tube rotameters shall be restricted to purging, injection and sampling
systems with working pressures less than 350kPa (50 psig). They shall not be used in
hydrocarbon gas, liquid service or any other process streams. Rotameter’s instrument
range shall remain 1:10 as minimum. Rotameter normal flow rate shall be between 50%
and 75% of capacity, provided anticipated minimum and maximum flow rates will be
between 10% and 95% of capacity.
Restriction orifice plates shall be similar to flow metering orifice plates in terms of
construction and sizing. The material of construction shall be SS 316 unless special
materials are required, thickness of the plate shall be selected according to pressure drop
across the plate. For higher pressure drop hard facing of the orifice shall be considered.
Coriolis flow meters shall be supplied with an in-line sensor flow tube and a remote mounted
Transmitter, unless otherwise specified. The flow meter shall be properly supported and
Vendor shall provide necessary means for meter support, to ensure vibration free and
stress free installation in the pipe work by others.
12.3. Level Measurement
Level Measurement shall employ any one of the following methods:
 Transparent/Reflex type level gauge for local indication

 Displacer type for vessels and sump pits
 Radar type for tanks
 Differential pressure for ranges not covered by displacer instruments.
When two or more gauge glasses are required to cover the level range, they shall be so
installed that the visible length overlaps by at least 25mm (1").
Magnetic level gauges shall not be used on process vessels containing crude oil.
Displacer type transmitters shall have material to suit the process conditions as mentioned
in the data sheet or shall be SS316 as a minimum. Drain and vent provision with valves
shall be provided. The body of the displacer shall be flanged to permit removal of the
displacer.
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Where both critical and non-critical level transmitters are installed on the same vessel, the
process connections for 0% and 100% shall be at the same elevations. When considering
a range of densities, high level alarms and high trip settings shall be based on the lowest
density of the liquid. Low level alarm and low trip settings should be based on the highest
density of the liquid.
Guided wave radar / Displacer type shall be used in situations where an interface between
two liquids exists.
Connection Connection Connection

Service Remark
Size Type Location
Process Connection of Bridle
Vessels or
3” (DN80) Flanged Crude & Produced Water
Tanks
Vessels or
2” (DN50) Flanged Other Services
Tanks
Differential Pressure Level Instruments

Crude, Produced Water or
Vessels or
4” (DN100) Flanged process fluid that could plug, Upto 1m
Tanks
solidify, congeal or corrosive
Crude, Produced Water or
Vessels or
3” (DN80) Flanged process fluid that could plug, More than 1m
Tanks
Filtered Water or Steam Vessels or
2” (DN50) Flanged
Condensate Tanks
Displacer Level Instruments
Vessels or
Tanks
Guided Wave Radar Level Instruments
Vessels or
Tanks
12.4. Pressure Measurement
Pressure measuring elements shall be provided with diaphragm seal for high viscous or
high pour point liquids. Otherwise, standard instruments without diaphragm seal shall be
provided. Pressure gauges should be selected so that normal operating pressure is
between 50% and 70% of full scale. Pressure gauges shall have a nominal diameter of 150
mm (6 in). Pulsation dampeners shall be used on all pressure instruments in pulsating
service. Pressure gauge shall have blow-out disc and shatter-proof glass. Pressure gauges
for high pressure (above 6000 kPa) application shall be solid front type. Dials shall be white
with black numerals. Accuracy of the measurements shall be ±1% of full-scale range. DP
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Gauges shall be of Diaphragm or Bellows type. Pressure gauges shall have a standard
over range protection of minimum 130% of range.
Bourdon tube pressure gauges shall be of the safety-pattern type in accordance with EN
837-1.
Pressure and DP transmitters shall be SMART with HART protocol. The transmitters shall
have a transmitted accuracy of ±0.075% of span for which they are calibrated.
Capillary material, if used, shall be SS316. Diaphragm seal connection with capillary shall
be provided with bleed rings, along with vent and drain connection, between process
isolation valve and diaphragm connection for flushing and calibration.
Connection Connection
Service Connection Location
Size Type
Pressure Instruments
Crude, Gas, or Produced Water
2” (DN50) Flanged where process fluid that could plug, Diaphragm Seal
1/2” (DN15) NPT Other Services Direct
12.5. Temperature Measurement
The primary element to be used for temperature measuring shall be the Resistance
Temperature Detector (RTD) up to a measurement of 850°C (1562°F) per IEC-60751. All
temperature instruments shall be provided with thermowell.
Thermowells shall have a stand out of 150mm from the pipe/vessel for non-insulated cases
and 225mm standout in case of external insulation, jacketing or heat trace. Thermowell
insertion length shall be selected such that the tip of the temperature element is located
approximately at the centre of the pipe. Material for thermowells shall be ANSI type 316SS
as a minimum, machined from bar stock, generally in a tapered configuration. Process
connections for thermowells shall be 2” flanged.
Thermowell shall be capable of withstanding the maximum design pressure and

temperature of the system where it is installed. Wake frequency calculation for the
thermowells shall be carried out in accordance with ASME PTC 19.3.
Temperature indicator for local indication shall be bi-metallic, every angle type. Dial shall
be of 150 mm with shatter-proof glass. Dial thermometer ranges shall be selected such that
the operating temperature is between 50 to 75 % of scale.
Temperature transmitters shall be provided with 3-wire RTD element. Temperature

transmitters used for all applications shall be remote mounted. Transmitters shall be 2
wired, loop powered, SMART with HART Protocol. The temperature transmitters shall be
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capable of driving a 600 ohm load at 24 VDCThe primary element to be used for
temperature measuring shall be the Resistance Temperature Detector (RTD) up to a
measurement of 850°C (1562°F) per IEC-60751. All temperature instruments shall be
provided with thermowell. . Accuracy of the transmitters shall be ±0.5 %.
Wireless transmitters, if used, shall only be considered for monitoring applications.
12.6. Control Valves
Control valves shall be provided with electro-pneumatic smart positioner, complete with air
filter regulator.
Control valve trim characteristic shall be equal percentage unless 50% or more of the
dynamic pressure drop is allocated to the control valve and pump minimum flows bypass
application, where upon it shall have a linear characteristic. Hardened trim shall be provided
for control valves with flashing, cavitation or for those used at extreme process conditions.
Generally, for liquid level application, linear characteristics shall be used. Quick opening
characteristic shall be used for On/Off control application.
Control valve sizing shall generally be based on ISA 75.01.01. Valve should be sized so
that the flow is controlled between 10 to 80 % of valve travel. The minimum body size shall
be DN25 (1”). Non-standard sizes such as DN32 (1 ¼”), DN65 (2 ½”), DN125 (5”) etc. shall
not be used. For size below DN50 (2”), ball type control valve shall be avoided..
Spring-return pneumatic diaphragm actuators are preferred one. Extension or radiation

bonnet shall be provided for valves having high temperature (above 200°C).
For control valves with leakage class IV and below, the actuator shall be sized to provide,
under minimum air supply conditions, 1.3 times the torque required to position and fully
stroke the inner valve against maximum differential pressure that may develop.
For control valves with leakage class V and above, this factor is to be considered as 1.7
Use of elastomer packing such as PTFE or glass filled TFE shall be limited to 230°C (450°F)
service temperature. Above 230°C, graphite compound type packing materials or
manufacturer's recommended packing shall be used. Graphite packing shall not be used
on water services where the possibility of sand exists. Asbestos materials shall not be used.
Leakage rate shall be as per ANSI FCI 70-2, with a minimum leakage rate of Class-IV. Tight
shut-off valve shall have leakage rate of Class-V or better. For steam service, modulating
valves shall be considered with leakage Class V or higher. Control valve noise shall not
exceed 85 dBA at one metre distance under any operating conditions. Pneumatic
connection for the control valve shall be 1/2” NPTF.
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All the valves, which have a size less than or equal to 2”, shall have a minimum ANSI class
rating of 300#. Valves larger than 2” shall be in accordance with piping specification.
12.7. Safety Relief Valves
Safety relief valves shall be conventional or balanced bellows, enclosed spring type
selected as per process requirements. In general, the body material shall be carbon steel
with SS316 trim. Sizing shall be as per API 520. A balanced bellow type relief valve shall
be provided when the discharge is routed into a closed system and the downstream
pressure may exceed 10% of the set pressure. Generally, thermal relief valves connection
size shall be ¾ X 1” or as indicated in the P&ID’s.
12.8. Pressure Vacuum Relief Valves
Direct acting PVRV valves are low pressure devices designed for the protection of fixed
roof atmospheric or low pressure storage tanks. In general, the body material shall be
carbon steel with SS316 trim. Shall be of flanged connection. Overpressure protection shall
be in accordance with API STD 620 (maximum working pressure less than 100 kPag (14.5
psig) and API STD 2000.
12.9. Shutdown Valves
All shutdown valves shall be tight shut-off ball valves with flanged ends and shall be rated
for the relevant pipe class. Shut off for Shutdown valves shall be as per API 598. In general,
the body material shall be carbon steel with SS316 trim.
Shutdown valves shall be provided with spring return pneumatic actuator. Aluminum
actuators shall not be used on valves which form part of the emergency shutdown system
or emergency depressurizing valves.
Solenoid valves mounted on the valve body shall be certified EEx(d) suitable for 24V DC
operation. Solenoid valves shall be 3 ways, continuously energized, low power
consumption and universal type. Solenoid valve coils shall be powered by 24V DC and
shall operate on low pickup voltage.
The maximum process differential pressure for actuator sizing shall be the difference
between atmospheric pressure and the maximum upstream pressure with the valve fully
closed.
For ESD valves, the actuator shall be sized to provide, under minimum air supply
conditions, 2.0 times the torque required to position and fully stroke the inner valve against
maximum differential pressure that may develop.
Critical ESD valves shall incorporate partial stroke (PST) testing depending on the outcome
of the SIL study.
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Doc No.
Revision A3
Aluminium actuators shall not be used on valves which form part of the emergency
shutdown system, or for emergency depressurising valves The body and coil housing
material shall be SS316, with protection class of IP-65. Material for actuator case or housing
shall be steel. Cast iron shall not be used.
Limit switches shall be mounted on the actuator to provide valve open / close status to the
PCS. Pneumatic connection for the shutdown valve shall be 1/2” NPTF.
12.10. Self-acting Regulators
Self-acting regulators may be accepted for some services if it can be shown that the failure
characteristics will not lead to dangerous process situations occurring. Self-actuated valve
shall not be used where its downstream is connected to a pressure system, where the
application requires tight shut off. The pressure containing parts generally include body,
bonnet, flanges, plugs etc and shall be of the same pressure rating as that of the piping
class valves in the same service. In general, the body material shall be carbon steel with
SS316 trim.
12.11. Pig Detector
Pig detectors shall be of bidirectional mechanical trigger type system. Signaller shall be
provided with flag indication and also a Single Pole Double Throw (SPDT) switch for
signalling to control room. The electrical switch shall be with contact rating of 2A at 24V
DC, potential free contact. The electrical switch shall be hermetically sealed and comply
with the electrical area classification in which they are installed.
12.12. BS&W Analyzer
BS & W Analyzer shall be provided to find the water cut in oil. Basic Sediments and Water
Analyzer shall be of RF admittance type or measurement of dielectric through capacitive
measurement principle or other latest and proven technology.
The analyzer shall give analog output of 4-20 mA, 2-wire, loop powered on 24 V DC or 4-
wire type with power supply 110 V AC, 50 Hz. It shall be preferably SMART type with HART
Protocol, wherever available.
The wetted parts of the analyzer shall be SS 316. The analyzers shall be suitable for
outdoor use and shall meet Ingress Protection rating of IP 65. The analyzers enclosure
shall be EEx(d) type suitable for specified hazardous area classification.
The measuring cell shall be connected to a remote mounted control unit providing a 4 -
20mA DC output.
12.13. Impulse Tubing
Impulse tubes and pneumatic tubes shall be ½” OD. All tube fittings shall be double
compression type and in SS316. Tube wall thickness shall be 0.049” minimum. MOC for
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Doc No.
Revision A3
tubing shall be either SS316 or DSS based on process fluid composition and same shall
be reflected in Hook up drawing
12.14. Cable
All multi pair instrument cables from the field junction boxes and local panels to control
room shall be with stranded copper conductors, individual and overall screened with steel
wire armor. The outer and inner sheath of the cables shall be PVC. The cables shall be
Low Smoke Zero Halogen (LSOH) type.
The signal cable size shall be 1 mm2. The outer and inner sheath of the cables shall be
PVC. The cables to the solenoid valves, Hooter, Sounder etc. shall be steel wire armored,
solid copper conductor, and 2.5 mm2 with PVC inner and outer sheath. The cables between
the field instruments and junction boxes shall be single pair or triad as required. These
branch cables shall be 1.5 mm2 stranded copper conductor, screened, steel wire armored
with inner and outer sheath of PVC.
The outer sheath of all instrument and Fire & Gas cables shall be black. While the cables
used in shutdown circuits and fire detection systems shall be fire resistant to IEC 60331,
the others shall be flame retardant to IEC 60332.
The main cables shall be direct buried in trench from JB to control room. Branch cables
shall be directly buried in trench or run on trays from instrument to JB. Depth of cable
trenches near cellar pit and rig movement area will be 1.2m.
The type of Multi-pair/Triad/Core cables shall be standardized to the following
- 5 Pair, 10 Pair, 20 Pair
- 5 Core, 10 Core, 20 Core
- 5 Triad, 10 Triad, 20 Triad
12.15. Signal Grouping
Signals shall be grouped in multi pair cables as indicated below.

 Separate JB/multi-pair cables shall be provided for PCS and ESD/FGS signals
 Analog and Digital signals shall be routed through separate JB / Multi-pair cables.
Further signal segregation shall be done as following:
 24V DC discrete circuits to field instruments (pressure switches, solenoids, etc.)

 4-20 mA DC control wire (transmitters and control valves)
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Doc No.
Revision A3
 Millivolt circuits (thermocouples)

 Digital data bus signals
 Intrinsically safe wiring
12.16. Instrument & Electrical Interface
The signal interface requirement between electrical and instrumentation will be as per the
P&ID. The table below indicate the maximum number of signal interface envisaged for Type
1 motor.
Signal Detail Contact Type Remarks
Start Command from 24V DC pulse shall be extended For all types of Motor
PCS/PLC to MCC (Always to MCC from PCS/PLC to start Feeders
hardwired for all motor the motor. 24V DC Interposing
feeders) relay shall be considered at
MCC.
Stop Command from 24V DC shall be continuously For all types of Motor
PCS/PLC to MCC (Always extended to MCC from Feeders
hardwired for all motor PCS/PLC, which is de-energized
feeders) (negative pulse) to trip the motor.
24V DC Interposing relay shall
be considered at MCC
Start permissive Command 24V DC pulse shall be For all types of Motor
from PCS/PLC to MCC continuously extended to MCC Feeders
(Always hardwired for all from PCS/PLC to give the start
motor feeders) Without this permission, 24V DC Interposing
contact, motor feeder shall not relay shall be considered at
start either from local or from MCC.
remote.
Emergency Trip Command 24V DC continuous (maintained) For all types of Motor
from ESD to MCC (Always shall be normally continuously Feeders
hardwired for all motor extended to MCC from
feeders) PCS/PLC, which is de-energised
to trip the motor. SIL-3 certified
24V DC Interposing relay shall
be considered at MCC.
Running status Indication - Normally Open Dry Contact at For all types of Motor
Feedback from MCC to MCC, which closes (Continuous) Feeders
PCS/PLC (Always hardwired to issue a running Feedback to
for all motor feeders) PCS/PLC
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Doc No.
Revision A3
Motor Available/ Ready to start Normally Open Dry Contact at For all types of Motor
(Always hardwired for all MCC, which closes (Continuous) Feeders
motor feeders) - Feedback to issue Motor Available
from MCC to PCS/PLC. This Feedback to PCS/PLC
signal qualifies that the motor
feeder is electrically ready to
start from PCS/PLC
Motor Electrical Fault (Always Normally Open Dry Contact at For all types of Motor
hardwired for all motor MCC, which closes (Continuous) Feeders
feeders) -Feedback from MCC to issue Motor Electrical fault
to PCS/PLC Feedback to PCS/PLC
Local / Remote (LCS) Dry Close Contact (Continuous) For all types of Motor
Indication - Feedback from from MCC for Remote Mode to Feeders
MCC to PCS/PLC (Always PCS/PLC
hardwired for all motor
feeders)
Speed Feedback from

4-20mA signal from MCC to Only for VFD fed
MCC to PCS/PLC for VFD PCS/PLC motor feeders
feeders
Speed Reference from

4-20mA signal from PCS/PLC Only for VFD fed
PCS/PLC to MCC for VFD to MCC/VFD motor feeders
Feeders
12.17. Cable Glands
Cable glands shall be of brass material, nickel-plated, EEx(d) Flameproof & EEx(e)
increased safety (dual certified) as applicable. No separate earthing connection to the cable
gland is envisaged. All the electronic instruments shall have ½” NPT cable entries.
12.18. Junction Box
Field Junction boxes shall be Ex‘d’ certified for use in Zone 1 and Ex‘e’ certified for use in
Zone 2, Gr. II A&B, Temperature classification T3. Ex‘d’ junction boxes shall be made of
Die cast Aluminium and Ex‘e’ junction boxes shall be made of SS 316 with 2mm thickness
as minimum. Junction boxes shall be with 2.5 sqmm terminals for signal wiring. Stainless
steel gland plates shall be provided at the bottom. All spare cable entries shall be plugged
with certified metallic plugs. 10% Spare terminals and 10% spare cable entries shall be
provided.
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Doc No.
Revision A3
12.19. Cable Tray
Cable trays shall be of heavy duty, galvanized steel type with suitable thickness. The size
of the cable tray shall be suitable for the number of cables they are intended to carry.
Sufficient spare space shall be provided in the cable tray.
12.20. Earthing Philosophy
The following earth systems shall be provided
 Instrument Earth (Clean Earth)
 Safety Earth
At the instrument end of the cable, the screen tapes shall be cut back from the bedding or
bundles to ensure electrical isolation. The screen shall then be made electrically continuous
through all junction boxes (via isolated screen bars/terminal blocks) to the isolated "panel
reference Instrument earth" bar in the control room (The screen shall be connected to earth
only at one end, which is at Control Room).
All the casings of the instruments, junction boxes, armour of the instrumentation cables,
metallic structures, cable trays, supports of the Junction boxes shall be connected to the
plant’s Safety Earth network.
Panel Vendor documentation shall include comprehensive specification for the overall
grounding arrangements required for panel.
All metal parts (e.g. doors, swing-out racks, etc.), enclosures, etc., shall be earthed to
Safety Earth system. PCS/ESD/FGS cable shielding shall be earthed to the clean
Instrument Earth system.
All metallic equipment within the cabinets shall be connected to a single “common cabinet”
safety earth point. Each cabinet shall be provided with a M10 earthing bolt for connection
to the plant safety earthing system or protective earth.
Shield of cables of analog cables from field transmitters shall be terminated in the junction
box. Shield cables of each pair in multi-pair cable is terminated in shield terminal in
marshalling cabinet. The marshalling terminal blocks are terminated in the common shield
earth bus bars. The shield earth and the system earth shall be isolated inside the cabinets.
Vendor shall provide an earth leakage monitor to monitor earth leakage for the PLC system.
The related alarm shall be taken up in the common cabinet utility alarm.
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Doc No.
Revision A3
13. SPARES
13.1. PCS/ESD System Spares
The system I/O racks shall contain 10 % installed spare I/O channels of each type in use
in the specific I/O cabinet. Other system components to support the spare I/O such as
power supply, terminal blocks, I/O cables, I/O communication etc. shall also be installed
with 10% spare capacity. Spare I/O shall be pre-wired to the terminal blocks. The I/O racks
shall have an additional 10% spare rack space with no modules installed. 20% spare
terminal blocks shall be provided.
13.2. Start-up and Commissioning Spares
Instrumentation Spare Parts required for the startup and successful commissioning of the
various systems shall be procured and made available at the site well before the end of
construction and before start of commissioning.
13.3. Spare Parts for Two Years Operation
Recommended Spare Parts list for Two years operation of the Instrumentation System
shall be obtained from each vendor in SPIR forms and finalized in consultation with the
client. This shall enable the client to raise Purchase Orders for these Spares separately on
the vendors. Vendor shall also provide list of all items that could be replaced in its life of
operation.
13.4. Documentation
In general, the following documentation shall be developed for the project by consultant /
vendor. This shall also be applicable for Skid vendors.
 Architecture Diagram
 Instrument Index
 Data Sheets for Instruments
 Control Room Layouts.
 Cable Schedules
 Inter-connection and Termination Schedules
 Instrument/JB location & Cable Routing Layouts
 Fire & Gas Detector Layouts
 Instrument Loop Diagrams
 Instrument Installation Details
 Hook-up Schemes and Bill of Material
 I/O List and Alarm List
 Cause and Effect Drawings
 Bulk MTO
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Doc No.
Revision A3
 Vendor Documentation as applicable

 As Built Documents.
All documents shall be prepared on Word, Excel or AutoCAD. Any other document required
for the completion of engineering shall be prepared by consultant/contractor / vendor.
Page | 40

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Integrated Field Plan Execution Services In Satellite Fields In RJ-ON 90/1 Block Instrumentation & Control Design Basis

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1.1. Project Background ................................................................................................... 5

1.2. Scope of Document................................................................................................... 5

1.3. Codes and Standards ............................................................................................... 6

4. METEOROLOGICAL DESIGN DATA...................................................................... 13

6. ORDER OF PRECEDENCE ................................................................................... 15

7. UNITS OF MEASUREMENTS ................................................................................ 15

8. PLANT UTILITIES ................................................................................................... 16

8.1. Instrument Air Supply .............................................................................................. 16

8.2. Nitrogen Supply ...................................................................................................... 16

8.3. Power Supply .......................................................................................................... 17

9. EQUIPMENT PROTECTION PHILOSOPHY........................................................... 17

9.1. General ................................................................................................................... 17

9.2. Ingress Protection ................................................................................................... 18

9.3. Electrical Area Classification ................................................................................... 18

10. PLANT LIFE ............................................................................................................ 18

11. INSTRUMENTATION AND CONTROL SYSTEM.................................................... 18

MAIN CONTRACTOR SUB-CONTRACTOR ENGG CONSULTANT

11.1. Scope of Work ........................................................................................................ 18

11.2. General ................................................................................................................... 19

11.3. Control Room .......................................................................................................... 21

11.4. Process Control System .......................................................................................... 22

11.5. Emergency Shutdown System ................................................................................ 23

11.6. Plant Fire and Gas Detection System...................................................................... 24

11.7. Hardwired Console & Annunciator Panel ................................................................ 24

11.8. Interposing Relay .................................................................................................... 25

11.9. Building Fire Alarm System (BFAS)......................................................................... 25

11.10. Package Control System ................................................................................. 26

11.11. Interface to Existing System ............................................................................ 27

12. FIELD INSTRUMENTATION, CABLES AND INSTALLATION REQUIREMENTS ... 27

12.1. General ................................................................................................................... 27

12.2. Flow Measurement.................................................................................................. 28

12.3. Level Measurement................................................................................................. 29

12.4. Pressure Measurement ........................................................................................... 30

12.5. Temperature Measurement ..................................................................................... 31

12.6. Control Valves ......................................................................................................... 32

12.7. Safety Relief Valves ................................................................................................ 33

12.8. Pressure Vacuum Relief Valves .............................................................................. 33

12.9. Shutdown Valves .................................................................................................... 33

MAIN CONTRACTOR SUB-CONTRACTOR ENGG CONSULTANT

12.10. Self-acting Regulators ..................................................................................... 34

12.11. Pig Detector ..................................................................................................... 34

12.12. BS&W Analyzer ............................................................................................... 34

12.13. Impulse Tubing ................................................................................................ 34

12.14. Cable ............................................................................................................... 35

12.15. Signal Grouping ............................................................................................... 35

12.16. Instrument & Electrical Interface ...................................................................... 36

12.17. Cable Glands ................................................................................................... 37

12.18. Junction Box .................................................................................................... 37

12.19. Cable Tray ....................................................................................................... 38

12.20. Earthing Philosophy ......................................................................................... 38

13. SPARES ................................................................................................................. 39

13.1. PCS/ESD System Spares ....................................................................................... 39

13.2. Start-up and Commissioning Spares ....................................................................... 39

13.3. Spare Parts for Two Years Operation...................................................................... 39

13.4. Documentation ........................................................................................................ 39

MAIN CONTRACTOR SUB-CONTRACTOR ENGG CONSULTANT

1.1. Project Background

1.2. Scope of Document

MAIN CONTRACTOR SUB-CONTRACTOR ENGG CONSULTANT

1.3. Codes and Standards

The Instrument Measurement and Control system shall be designed to standard