Attachment-T - General C&I Technical Requirement Requirements For Packaged System

EMPLOYER CONSULTANT
JSC "TOSHKENT ISSIQLIKELEKTRMARKAZI
CONTRACTOR
ÇALIK ENERJİ SAN.VE TİC. A. Ş
PROJECT
Construction of Two Gas Turbine Units (GTU) with a capacity of 32 MW each

at Tashkent HPP
REVISION HISTORY
A 25.02. 2022 For Review APM RAM AKC
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
DOCUMENT TITLE/SUBJECT:
GENERAL C&I TECHNICAL REQUIREMENTS FOR PACKAGED SYSTEM
PROJECT DOCUMENT NO:

Type
Doc.
Disc
Project Unit System Orig. Serial No Rev. A

Detailed Information
THPE 00 VC YI TCE 001 Size A-4
VENDOR DOCUMENT NO: ** if applicable

Lang. Eng.
Total
82
Sheet
This document is the property of ÇALIK Enerji Sanayi ve Ticaret A.Ş and may not be copied, used, reprinted or distributed by others.
GENERAL C&I TECHNICAL Doc. No. : THPE-00-VC-YI-TCE-001
Page : 2 OF 85
REQUIREMENTS FOR Date : 25.02. 2022
PACKAGED SYSTEM Revision :A
INDEX:
1. GENERAL.......................................................................................................................................................
1.1. PROJECT BACKGROUND............................................................................................................................

1.2. INTENT OF SPECIFICATION........................................................................................................................
2. CODES AND STANDARD............................................................................................................................
3. PROTECTION CLASSES...........................................................................................................................12
4. IDENTIFICATION.......................................................................................................................................14
5. FIELD INSTRUMENTS..............................................................................................................................14
5.1. GENERAL REQUIREMENTS..........................................................................................................................14

5.2. TECHNICAL DATASHEETS...........................................................................................................................17
 Pressure Gauge / Differential Pressure Gauge...........................................................................................17
 Pressure / Differential Pressure Switch.....................................................................................................18
 Temperature Gauge..................................................................................................................................20
 Pressure / Differential Pressure / Flow / Level Transmitter.......................................................................21
 Thermocouple..........................................................................................................................................22
 Resistance Temperature Detector (RTD)..................................................................................................23
 Thermowell..............................................................................................................................................24
 Temperature Transmitter..........................................................................................................................24
 Conductivity Type Level Switch..............................................................................................................26
 Level Switch (Side Mounted External Cage Type)...................................................................................26
 Float / Displacer Type Level Switch (Top Mounted)................................................................................27
 Level Gauge (Tubular Type)....................................................................................................................27
 Level Gauge(Float & Tape Type).............................................................................................................28
 Radar Type Level Transmitter..................................................................................................................29
 Displacer Type Level Transmitter............................................................................................................29
 Hydrostatic Type Level Transmitter.........................................................................................................30
 Coriolis Flow meter..................................................................................................................................31
 Ultrasonic Flow Meter..............................................................................................................................32
 Flow Nozzle.............................................................................................................................................33
 Orifice Flow Element...............................................................................................................................33
 Vibration Monitor....................................................................................................................................34
This document is the property of ÇALIK Enerji Sanayi ve Ticaret A.Ş and may not be copied, used, reprinted or distributed by others
Page : 3 OF 85
 Thrust Position Monitor...........................................................................................................................34

 Case Expansion Monitor..........................................................................................................................34
 Tachometer/RPM Monitor.......................................................................................................................35
 Eccentricity/Key phasor Monitor..............................................................................................................35
 Temperature Monitor...............................................................................................................................35
 Gas Chromatograph.................................................................................................................................36
 Gas Detector............................................................................................................................................36
 Gas Flow computer..................................................................................................................................37
 Conductivity Analyzer.............................................................................................................................38
 pH and ORP Analyzer..............................................................................................................................39
 Silica Analyser.........................................................................................................................................39
 Density indicator......................................................................................................................................40
 Turbidity analyser....................................................................................................................................40
 Rotameter.................................................................................................................................................41
6. PROGRAMMABLE LOGIC CONTROLLER (PLC)...............................................................................42
6.1. GENERAL REQUIREMENTS..........................................................................................................................42

6.2. TECHNICAL REQUIREMENTS.......................................................................................................................43
 Input / Output (I/O) Subsystem.................................................................................................................43
 Processor Subsystem................................................................................................................................44
 Communication Subsystem......................................................................................................................45
 System Power Supplies............................................................................................................................45
 PLC Console............................................................................................................................................45
 Displays...................................................................................................................................................45
 LED/TFT Alarm monitoring....................................................................................................................46
 System Software......................................................................................................................................46
 Peripherals...............................................................................................................................................47
 Training...................................................................................................................................................47
 Inspection & Testing................................................................................................................................47
 Interface with Main Plant DCS.................................................................................................................48
7. PANELS AND DESKS.................................................................................................................................49
7.1. CONSTRUCTIONAL FEATURES OF PANELS, CUBICLES & ENCLOSURES..........................................................49

7.2. TERMINAL BLOCK AND CUBICLE WIRING....................................................................................................51
7.3. EARTHING.................................................................................................................................................53
7.4. NAME PLATE.............................................................................................................................................54
Page : 4 OF 85
7.5. WITHSTAND CAPABILITY OF EQUIPMENT.....................................................................................................55
8. PANEL MOUNTED DEVICES...................................................................................................................55
9. INSTRUMENT INSTALLATION AND ERECTION HARDWARE.......................................................58
9.1. GENERAL...................................................................................................................................................58
9.2. LOCAL MEASURING & CONTROL ELEMENTS...............................................................................................59
9.3. HAZARDOUS AREAS....................................................................................................................................59
9.4. PRIMARY ISOLATION AND INSTRUMENT VALVES...........................................................................................60
9.5. INSTRUMENT TUBING AND PIPING..............................................................................................................60
9.6. PNEUMATIC PIPE WORK............................................................................................................................61
9.7. INSTRUMENT MOUNTING............................................................................................................................62
9.8. LOCAL INSTRUMENT ENCLOSURE AND RACKS.............................................................................................62
9.9. CLIMATIC PROTECTION, SEALING AND PURGING.........................................................................................64
9.10. HEAT TRACING SYSTEM..........................................................................................................................65
10. C&I CABLES.............................................................................................................................................65
10.1. TECHNICAL REQUIREMENTS...................................................................................................................65

10.2. CABLE INSTALLATION.............................................................................................................................66
 Separation................................................................................................................................................66
 Segregation..............................................................................................................................................67
 Laying and Terminating...........................................................................................................................67
 Identification............................................................................................................................................67
 Cable Screens and Armouring..................................................................................................................67
10.3. CABLE AND INDIVIDUAL CORE LABELLING..............................................................................................67
 Cable numbers.........................................................................................................................................67
 Cable designation.....................................................................................................................................68
 Cable labelling.........................................................................................................................................68
11. CONTROL VALVES................................................................................................................................68
11.1. GENERAL REQUIREMENTS......................................................................................................................68

11.2. CONTROL VALVE SIZING.........................................................................................................................68
11.3. VALVE CONSTRUCTION...........................................................................................................................69
11.4. END PREPARATION................................................................................................................................69
11.5. VALVE MATERIALS.................................................................................................................................70
11.6. VALVE POSITIONERS..............................................................................................................................70
11.7. VALVE ACTUATOR..................................................................................................................................71
11.8. LIMIT SWITCHES....................................................................................................................................71
Page : 5 OF 85
11.9. SOLENOID VALVE.................................................................................................................................71

11.10. CONTROL VALVE ACCESSORY DEVICES...................................................................................................71
12. MOTOR OPERATED VALVES (MOV).................................................................................................72
13. SOLENOID VALVE.................................................................................................................................72
14. DRIVE CONTROL PHILOSOPHY........................................................................................................72
15. QUALITY ASSURANCE AND INSPECTION.......................................................................................72
16. TESTING...................................................................................................................................................72
16.1. TESTING & INSPECTION.........................................................................................................................73
17. DOCUMENTATION.................................................................................................................................84
Page : 6 OF 85
DOCUMENT REVISION HISTORY SHEET
REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS
A IFR 25.02.2022 Issued for Review
Page : 7 OF 85
ACRONYMS
C&I : Control & Instrumentation
CCPP : Combined Cycle Power plant
CCR : Central Control Room
DCS : Distributed Control System
EER : Electronic Equipment Room
EWS : Engineering Work Station
FOC : Fiber Optic Cable
GT : Gas Turbine
GTG : Gas Turbine Generator
GPS : Global Positioning System
I/O : Input / Output
IRIG : Inter-Range Instrumentation Group
LCD/LED : Liquid Crystal Display/Light Emitting Diodes
LCP : Local Control Panel
LCR : Local Control Room
MOV : Motor Operated Valve
NTP : Network Time Protocol
OWS : Operator Work Station
PLC : Programmable Control System
TCP/IP : Transfer Control Protocol/Internet Protocol
TFT : Thin Film Transistor
TSI : Turbine Supervisory Instrumentation
TMR : Triple Modular Redundancy
XLPE : Cross Linked Poly Ethylene
UPS : Uninterrupted Power Supply
EPB : Emergency Push Button
ESD : Emergency Shut Down
LIE : Local Instrument Enclosure
LIR : Local Instrument Rack
Page : 8 OF 85
1. GENERAL
1.1. Project background
The Government of the Republic of Uzbekistan (here after shall be referred as

“EMPLOYER”) planned extension of the Tashkent Heat Power Plant (THPP) to
increase the heat and power generation capacity through the Construction of two Gas
Turbine Units (GTU) with the capacity of with approx. gross capacity of 32 MW each.
The THPP is located about 4.5km to the south-west from city centre and about 1.5km to
the north-west from the Tashkent International airport in residential area of Yaskkasaray
district, Republic of Uzbekistan.
Calik Enerji (CE) (here after shall be referred as “CONTRACTOR”) has received the
orders to provide Engineering, Procurement, Construction and Commissioning (EPC)
services for the completion of the proposed 2x32 MW gas turbine units (GTU) along
with Heat Recovery Steam Generator (HRSG) at existing Tashkent Heat Power Plant
(THPP) in Tashkent, Uzbekistan. The works comprise of the detailed design, supply of
material and equipment, the erection/execution of the proposed works and equipment,
the commissioning, testing, trial run, reliability tests, performance tests and warranty
support as well as training of the local plant personnel of a gas turbine power station
with steam generation. TATA Consulting Engineers Limited, Bengaluru (here after
shall be referred as “CONSULTANT”) is engaged by Contractor as the design
engineering consultant (DEC) for the project.
The proposed power block shall consist of 2 GTU, 2 HRSG and along with associated
balance of plant equipment’s. The steam produced in the HRSG shall be supplied to
existing steam turbine and for district heating through existing steam header via
pressure reducing station. The main fuel for the power plant shall be natural gas.
1.2. Intent of specification

This specification covers the general Instrumentation and Control system guidelines to
be considered for Mechanical Technical Specifications.
The Instrumentation and Control System envisaged shall be complete in all respect
and adequate for safe, reliable, efficient and commercial operation of the plant under
Page : 9 OF 85
normal and worst service and environmental conditions. The scope of work shall
include detailed design, supply, supervision of erection, testing and commissioning of
all C&I equipment. The design of C&I system shall be such that isolation of any piece
of defective equipment would be possible without shutting down the main equipment
or disturbing the operation of associated instrument and accessories.
Bidder shall also refer Attachment G - Employer's Technical requirement -
Instrumentation for C&I requirements and any deviation between this document and
Employer's Technical requirement shall be brought to Contractor’s notice and final
decision will be as per Contractor’s decision.
All bidder documents shall be in English and Russian Language.
2. CODES AND STANDARD
The latest edition and addenda of the following publications are applicable to the
extent indicated by the specific reference.
All equipment furnished and work performed under this design base document shall
comply with the approved standards, specifications and regulations, codes and tests of
the following, but not limited to:
S.N Parameter Unit
1 ASME American society for Mechanical Engineers
PTC 19.2 Instrument and apparatus for pressure

measurement
PTC 19.3, Temperature Measurement
PTC 19.5, Flow Measurement
PTC 19.11 Water and Steam in power cycle

MFC3M Measurement of Fluid Flow in Pipes Using
Orifice, Venturi & Nozzles
2 ANSI American National Standards Institute
ANSI/FCI 70-2, Control Valve Seat Leakage

Classifications
Page : 10 OF 85
S.N Parameter Unit
ANSI B16.34, Valves – Flanged and Butt Welding

End
ANSI MC 96.1 Temperature Measurement
Thermocouples
ANSI/ISA S84.01, Application of Safety
Instrumented System
3 IEC International Electrochemical Commission
61131-3 Real Time Automation

61508:1999, Part 1-7, Functional Safety of
Electrical/Electronic/Programmable Electronic
Safety Related (As Certified by TUV)

60529 :Protection Class for Enclosure, Cabinets,
Control Panels and Desks
60584 Part 1: Reference tables;
60584 Part 2: Tolerances;
60584 Part 3: Extension and compensating cables
751, Thermometer-element-platinum resistance
60770 Part 1: Methods of evaluating performance

60770 Part 2: Guidance for inspection and routine
testing
61151 – Functional safety – Safety Instrumented
systems for processor sector
60534, Control Valve Noise calculation
4 DIN Deutsche Industries Norman
Page : 11 OF 85
S.N Parameter Unit
DINVVDE 19250 –Functional Safety And

Explosion Protection
DIN V VDE 0801 mel. Amendment AI, Principles
for computers in safety-related systems
DIN VDE 0110, Insulation Co-ordination for low
voltage electrical equipment
DIN "TIE 0116, Electrical Equipment for furnaces
DIN "TIE 0160 incl. Amendment Al ; Electrical
equipment for use in power installation
DIN EN 54-2 , Fire detection and alarm system –
Part 2 – Control and Indicating equipment
DIN VDE 0883-1 , Opto Electronic interface
elements
DIN IEC 68 Environmental Testing

Instrumentation Systems and Automation
5 ISA
Society
ISA S84.01, Application of Safety Instrumented
System
6 ISO International Standard Organization
JEC Japan Electro technical Committee

7
JIS Japan Industrial Standards (JIS)

8
7 UL Underwriters Laboratories
UL 508 For Industrial Control Equipment

UL 991 Standard for Test of Safety Related Controls
Employing Solid State Devices
Page : 12 OF 85
S.N Parameter Unit
UL 1998 Standard for Safety of Software in

Programmable Component
8 NFPA National Fire Protection Association
NFPA-72 National Fire Alarm Code
9 FM Factory Mutual
FM 3611 for the entire FSC -System with non-

incendive field wiring circuit’s for selected Modules
10 CE Conformité Européenne
CE directives 89/336/EEC (Electromagnetic

Compatibility directives) and 73/23/EEC (Low
Voltage).
11 BS British Standard
3. PROTECTION CLASSES
Instruments, devices and equipment for location in outdoor/indoor/air-conditioned

areas shall be designed to suit the environmental conditions indicated below and shall
be suitable for continuous operation in the operating environment of a Combined
Cycle Power Plant and also during periods of air conditioning failure without any loss
of function.
Ambient Required
Temperature Relative Protection class of
Pressure Atmosphere
(outside Humidity Panels /cabinets
temperature) /desks
Outdoor Location
47 DegC max Atmosphere 100%Max Air (dirty) IP 67 (IP 68 for
Page : 13 OF 85
Ambient Required
Temperature Relative Protection class of
Pressure Atmosphere
(outside Humidity Panels /cabinets
temperature) /desks
electrical actuators) ^^^
-29.5 DegC Atmosphere 67 (IP 68 for electrical

5% Min Air (dirty)
min actuators) ^^^
Indoor Location
47 DegC max Atmosphere 95% Max Air IP 54
-29.5 DegC
Atmosphere 5% Min Air IP 54
min
Air-conditioned Area
24 +/- 2DegC
Atmosphere 95% Max Air IP 41
normal
50 DegC
Atmosphere 5 % Min Air IP 41
Max. ^
^ During Air Conditioning failure
^^^ With suitable canopy for protection from rain water and direct sunlight.
1. For hazardous areas the protection class shall be in accordance with the
requirements of the relevant ATEX, IEC, NEC, JIS or equivalent code for the
location.
Page : 14 OF 85
4. IDENTIFICATION
Each item of equipment shall be durably and legibly labeled, indicating the purpose,
plant identification number (generally KKS shall be followed) and where necessary
any operating position functions. Labels shall be break-proof, UV-resistant design.
Labels shall be provided on front and rear access doors of all cubicles. Labels shall be
provided inside cubicles to assist the identification of apparatus and terminals.
Instruments, valves, actuators and all other field mounted equipment shall similarly be
identified with suitable labels with following information:
1. Instrument KKS tag
2. Service description.
3. Machine readable symbols encoding KKS, clear text and specific information
easing operation and maintenance.
The material of all labels and the dimensions, legend and method of printing shall
subject to approval. Surfaces of labels for cubicles and control equipment shall have a
matt or satin finish to avoid dazzle. Colors shall be permanent and free from fading.
Labels shall be fixed using stainless steel screws. Any alternative method of fixing
shall be to approval. Danger labels shall have red lettering on a white background.
All Tag Plate shall be provided in English and Russian Language.
All warning,instruction notices shall be in English, Russian and Uzbek Language.
5. FIELD INSTRUMENTS
5.1. General Requirements

Field instruments/equipment and subsystems offered by the Bidder shall be from
reputed experienced manufacturers of specified type and range of equipment, whose
guaranteed and trouble free operation has been proven. Further, all instruments shall
be of proven reliability, accuracy, and repeatability requiring a minimum of
maintenance and shall comply with the acceptable international standards and shall be
subject to Owner's approval. All transmitters shall be SMART Type with HART
compatible and minimum SIL2. Exact SIL rating shall be defined as after SIL study.
All instrumentation shall be installed in compliance with the latest edition of BS 6739
or international equivalent standard and the recommendations of the manufacturer.
Only one instrument shall be fitted to each tapping point. Separate instruments shall
be provided for control/indication and protection systems.
Instrumentation loops for control and protection purpose shall be separated. However,
for flow measurements one common primary element (e.g. orifice plate, orifice nozzle
or other inline devices to be installed into a pipe) can be used. At least triple redundant
Page : 15 OF 85
measuring and control loops shall be used for protection and dual redundant
measuring loops for modulating control functions.
Where triple redundant measuring loops are applied, the resultant signals may be
commonly used for protection and modulating control.
Additionally, it shall be considered, that all field devices (e. g. transmitters, binary
sensors (e. g. level switch)) which might affect the availability of the main process in
case of malfunction shall be designed in a redundant configuration.
Please check clause 5.3.4 of Attachment - G-Employer's Technical Requirement-

Instrumentation for Redundancy requirements.
All instrument connections required for overall plant performance testing in
accordance with ASME PTC 46 shall be installed.
Connections to instruments after the primary isolating valve shall be made using steel
or a material corresponding to the piping class of the line to which it is connected.
Stainless steel (316) shall be used in certain atmospheres to prevent erosion or
corrosion problems. Instrument isolating valves, vent/test valves and instrument
manifolds shall be provided for all devices where appropriate. Instrument vent and
drain points shall be routed to a safe position away from site personnel.
Isolation/root valves should have seating arrangement in full open position so that no
leakage takes place through the gland when fully open.
In applications where process pressure surges and/or pulsating pressures are likely, the
instrument shall be protected by suitable pressure dampening devices. The type of
pressure damper shall be to the approval of the Contractor.
Where viscous or corrosive process liquids are measured, the instrument shall be
protected by a diaphragm, purging system or similar form of protection. The type of
protective system shall be to the approval of the Contractor.
All indicating instruments and controls shall be readable and accessible from floor
level or permanent platforms. Local gauge glasses shall be visible from any control
valve that controls the vessel level. Instruments shall be selected such that the
operating point falls between 1/3 and 2/3 of the full scale range.
Temperature sensor, neck pipe, thermowell, measuring head and head mounted
transmitter shall always be sourced from one manufacturer as a complete unit.
All thermocouples and RTDs shall be provided duplex at each position with one
element connected to the transmitter and one element kept as installed spare. For
motor windings, bearings, and other applications with limited space, single sensors
may be used. In this case, transmitters may be not head mounted as well.
RTD shall be used up to 500ºC. Thermocouple shall be used for measurement
temperature above 500ºC.
Span and zero of the instruments should be independently adjustable and accessible
in situ without interference to the installation of the instrument.
Page : 16 OF 85
Post or bracket mounts for instruments shall not be attached to pipe work, removable
flooring, and handrails or be directly affixed to machinery and equipment subject to
vibration.
The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds and all the other accessories required for mounting/erection of these local
instruments shall be furnished, even if not specifically asked for, on as required basis.
The contacts of equipment mounted instruments, sensors; switches etc. for external
connection including spare contacts shall be wired out in flexible/rigid conduits,
independently to suitably located common junction boxes. The proposal shall include
the necessary cables, flexible conduits, junction boxes and accessories for the above
purpose. Double root valves shall be provided for all pressure tapping where the
pressure exceeds 40 Kg./sq.cm. Root. Size of root valve shall not be smaller than 25
NB.
Tags on orifice plates shall be stamped with the basic design information (i.e. flow
rate, pressure and temperature of the passing fluid, the orifice diameter and the
pressure differential generated).
In general, orifice plates shall be designed for flange taps. However, approved taps
may be substituted when applicable for good engineering practice. Primary elements
located in steam or high pressure feed water pipes shall be of weld-in type. The final
installation of the orifices shall be welded in / mounted not before purging of the
piping.
In general, the concentric type orifice shall be used. Eccentric or segmental types shall
be used for measurement of dirty gases or fluids carrying suspended matter that might
tend to cause build-up. Venturi tubes shall only be considered when operating
economy requires low permanent pressure losses.
For level and volume measurements, the following measuring principles are
permissible:
a) Differential pressure measurement (for measuring levels in boilers and vessels
filled with homogeneous liquids without solids content)
b) Hydrostatic measurement (for measuring levels in unpressurized boilers,
vessels, tanks and silos containing homogeneous liquids)
c) Capacitive measurement (for measuring levels of liquids with or without solids
content as well as bulk materials in storage tanks and silos up to a measuring
range of 2000 mm; the limits of application due to the medium parameters of
the measuring circuits planned on a case-by-case basis shall be observed)
d) Ultrasonic and microwave measurement (for measuring levels of liquids with
or without solids content but without foaming as well as bulk materials in
storage tanks and silos as long as the cone formed by material deposition is
negligible, with a measuring range of over 2000 mm
e) Microwave measurement (for measuring levels of liquids with or without
Page : 17 OF 85
foaming
f) Weighing measurement (for measuring levels of bulk materials by means of
weighing measuring chambers containing unchanging homogeneous liquids
and bulk materials in silos and tanks as well as proportioning containers)
g) Measurement by sounding line (for measuring levels of bulk materials in silos
and tanks that only change slowly, i.e. <2% of the total volume between
measurements)
Use of other type of Level Instruments shall be treated as deviation and subject
to Owner’s approval.
Individual components of measuring circuits may not exceed the following
measurement tolerances:
Pressure: <0.1%
Differential pressure: <0.1%
Temperature (Pt100) <0.15°C
Temperature (ThCpl) <0.30°C
Flow measurement (Coriolis): <0.5%
Flow measurement (MID) <0.5%
Flow measurement (ultrasonic):<0.5%
Electrical (current, voltage etc.): <0.25%
Analog sensors are to be preferred for taking measurements, as these allow more
differentiated and flexible monitoring possibilities. Binary signals for further
processing, for triggering of commands etc. shall be derived out of analogue signals
inside PLC modules or DCS. Binary sensors are only permissible for:
 limit switches at equipment assemblies
 safety-relevant monitors and limiters
 flow measurements for which pulse outputs are merely counted
 level limit transmitters in bunkers, silos etc.
Integrated limit switches of pressure gauges or thermometers or not allowed.
5.2. Technical Datasheets

 Pressure Gauge / Differential Pressure Gauge
Sl. No. Features Minimum Requirements

01. Type Bourdon / Bellows / Diaphragm
02. Sensing Element Material ANSI SS 316
03. Movement Materials AISI 304 SS
Page : 18 OF 85
04. Case Material / Protection Epoxy coated Die Cast Aluminum / IP 65 as per
Class IEC 60529
05. Dial Size 150 mm
06. Scale Black lettering on white background in 270 C arc
07. Range Selection Normally operate at 60% of its maximum pressure
range.
Instrument installed for measurement of steady
pressure at varying pressures shall operate in a band
centered on 60% of its maximum range.
08. Over range Protection 1.15 times the maximum range
09. Adjustment External Micrometer screw for zero adjustment.
Internal micrometer screw for range adjustment.
10. Stop at Max. Reading Shall be provided
11. Element Connection Argon welding
12. Process Connection M20 X 1.5 bottom connection for local mounting,
back connection for panel mounting
13. Accuracy ±1% of span or better
14. Safety Feature Neoprene Safety Diaphragm (Blowout disc) at the
back
15. Feature Shatter-proof glass
16. Chemical Seal Unit SS 316 Flange and Diaphragm, PTFE coated /
block, Silicon Oil filling fluid
17. Applicable Standard BS EN 837
18. Accessories Snubbers for pulsating fluid applications / 2-valve
manifold / Pigtail / Siphon for steam service /
Gauge Saver, if maximum or Design Pressure is
very high than the Operating Pressure / Counter
Flanges / Bolts, Nuts, Gaskets / SS Tag Plate
 Pressure / Differential Pressure Switch

01. Type Bourdon / DP Cell
02. Sensing Element material AISI 316 SS
Page : 19 OF 85
03. Wetted Parts material SS 316

04. Case Material Epoxy coated Die Cast Aluminum
05. Setter Scale Black graduation on white linear scale. Graduation 0
– 100% with red pointer for set points.
06. Over range for Pressure / Maximum line (or static) pressure on either side
Vacuum Switch without permanent deformation or loss of accuracy,
1.30 times maximum range continuously, without
affecting the calibration.
07. Set Point Adjustable in switch operating range.
08. Static Pressure for Maximum Line Pressure or Static Pressure on either
Differential Pressure Switch side without permanent deformation or loss of
accuracy.
09. Adjustments Internal – set point
10. Process Connection M20 X 1.5 bottom connected for local mounting,
back connection for panel mounting
11. Switch Configuration 2 SPDT/ 1 DPDT
12. Switch Rating 5A, 230 V AC / 2A, 24 V DC
13. Switch Type Snap acting, shock and vibration-proof
14. Terminal Block Suitable for full ring lugs for 0.5 to 1.5 Sq.mm. cable
connection
15. Cable Connection M26 x 1.5
16. Enclosure Class IP-65 as per IEC 60529
17. Performance a) Accuracy of setting : 1% of span
b) Repeatability : 1% of span
18. Accessories a) Snubbers for pulsating fluid application.
b) Tag Number, service engraved in SS tag
plate
c) Teflon back-up sheath protection, as
required.
d) i) Remote diaphragm seal with SS 316
armored capillary for typical application.
MOC (Material Of Construction) of seal
material shall be as per process fluid
requirement.
Page : 20 OF 85
ii) Silver coated diaphragm for corrosive

services like chlorinated water.
iii) Syphons for steam and hot water
services.
e) Retention ring and screws for surface
mounting.
f) 2-valve manifold / 5-Valve Manifold (SS
316) for DPS.
(h) Mounting bracket / Clamp for 2 ‘’ pipe,
bolt & nut.
 Temperature Gauge

01. Type Filled system and Bimetallic type dial thermometer
as appropriate
02. Stem SS 316
03. Movement Materials AISI 304 SS / Direct Bourdon tip connection to
pointer spindle
04. Case Material/Protection Epoxy coated Die Cast Aluminum/ IP65 as per IEC
class 60529
05. Dial Size 150 mm
06. Scale Black lettering on white background in 270 C arc
07. Adjustment Micrometer screw for zero adjustment. Internal
micrometer screw for range adjustment.
08. Pointer Externally Adjustable
09. Range Selection Normal Process Temperature – approximately two
third of Temperature range.
10. Stop at Max. Reading Shall be provided
11. Over range Protection 130% of FSD
12. Instrument Connection Bottom connection for local mounting, back
connection for panel mounting.
13. Process Connection M20 X 1.5 with Thermowell
14. Performance :-
Page : 21 OF 85
a) Accuracy ±1.0% of full scale deflection or better

b) Repeatability Less than 0.5% of full range
15. Accessories Counter Flanges / Bolts, Nuts, Gaskets / SS Tag
plate, SS Thermowell etc.
16. Feature All angle type, Safety Glass
 Pressure / Differential Pressure / Flow / Level Transmitter

01. Type 2-Wire, Smart
02. Output Signal 4-20 mA
03. Signal Processing Unit Microprocessor based, HART
Measuring transmitters and processing modules shall
be provided with an integrated signal interface for
remote parameterization and diagnosis under HART
protocol.
04. Static Pressure / Overload Maximum line (or static) pressure on either side
Pressure for DPT, Static without permanent deformation or loss of accuracy,
Pressure / Overload Pressure 130 percent of maximum span continuously, without
for PT affecting the calibration.
05. Turn-down Ratio 50:1 for other applications.
100:1 for flow applications.
06. Span and Zero Continuously adjustable, non-interacting & both
local & remote calibration facility.
08. Zero Suppression/ Elevation At least 100% of span
09. Local Indicator To be provided
10. Display Digital LCD Integral Display (minimum 5 digit)
Engineering Unit
11. Body and its rating
a) Stainless Steel/ 1.5 times the maximum fluid
pressure for DPT.
b) Forged Carbon Steel Rating : 1:5 times the
maximum fluid pressure (minimum) for PT.
Page : 22 OF 85
12. MOC of Electrical Housing Aluminum Alloy or better

13. Operating Voltage 16 – 48 Volts DC
14. Load 600 Ohms (minimum) at 24 Volts DC
15. Accuracy ± 0.1% of span or better
16. Sealing / Isolation i) Extended diaphragm with 5 mtrs. SS armored
capillary for corrosive, viscous and dirty fluid
applications. Material for separator diaphragm,
depending on application.
ii) Silver/ Teflon coated diaphragm for corrosive
services.
17. Accessories a) Universal mounting bracket suitable for 2
inch pipe and wall mounting.
b) High tensile carbon steel U-bolts.
c) Installation accessories as per relevant
installation drawing.
d) Snubbers for pulsating pressure, syphons for
steam and hot water services.
e) 5-valves SS 316 manifold for DPT / 2-valves
SS 316 manifold for PT/ 3-valves SS 316
manifold whenever DPT are used for
pressure measurement, oval flange
connection to transmitter body, constructed
from barstock. Manifold shall be non-integral
type. Manifold process side and instrument
side connection shall be M20 x 1.5
f) Companion flange with nuts, bolts and
gaskets.
g) Brass, Double compression cable gland with
each instrument.
 Thermocouple

01. Type of Thermocouple. 16 AWG wire of Nickel-Chromium/Constantan
(Type E), ungrounded
Page : 23 OF 85
02. No. of element Duplex

03. Housing/Head IP-65/ Diecast Aluminium.
Plug in connectors are to be provided for external
signal cable connection
DIN EN 50446 BUZ form with hinged-cap and
quick-locking mechanism, (or) BUZHD form with
additional integrated field display with sensors
with head-mounted transmitter
04. Sheathing of Thermocouple Swaged type magnesium oxide insulation.
05. Calibration and accuracy As per ANSI-C-96.1(special class) for T/C AND
IEC 60584 Class 1
06. Characteristic Linear with respect to temp, within ±½ percent of
top range value
07. Accessories Medium resistant thermowell of heat-resistant steel
and/ or ceramic
08. Standard IEC-60584 for Thermocouple and
ASME PTC-19.3 for Thermo-well.
09. Application Measurement above 500 deg C)
 Resistance Temperature Detector (RTD)

01. Type 3 / 4 wire , Pt-100 (100 ohm at 0 deg C)
02. No. of Element Duplex
03. Housing/Head IP-65/ Diecast Aluminium.
Plug in connectors are to be provided for external
signal cable connection
DIN EN 50446 BUZ form with hinged-cap and
quick-locking mechanism, (or) BUZHD form with
additional integrated field display with sensors with
head-mounted transmitter
04. Sheathing of RTD Metal sheathed , ceramic packed
05. Calibration and accuracy As per IEC 60751 Class-A for RTD
06. Characteristic Linear with respect to temp, within ±1/2percent of
top range value
Page : 24 OF 85
07. Applicable Standards As per IEC-60751 for RTD & ASME PTC-19.3 for
Thermowell
08. Accessories a) Adjustable Nipple-Union-Nipple with thermo
well connection / plug in connectors
b) Compression fittings / unions
c) Flanges etc.
d) Thermowell as per requirement
09. Standard IEC-60751 for TRD and
ASME PTC-19.3 for Thermowell.
10. Application Measurement below 500 deg C
 Thermowell

01. Material AISI 316 SS
02. Process connection Threaded/Flanged/Welded
03. Max Internal bored dia Shall match with temp. Element
04. Bore Connection 5% wall thickness
05. Identification Mark Tab Number punched on head
06. Surface Treatment Polish after machining
07. Element Connection M20 X 1.5
08. Applicable Standard ASME PTC-19.3
09. Accessories Plug and chain for test thermo wells.
 Temperature Transmitter

01. Working Principle SMART
02. Type Two wire, HART
Page : 25 OF 85
03. Input Thermocouple and RTD-3/4 wire

04. Output Signal 4-20 mA.
05. Signal Processing Solid-state electronic circuitry
Measuring transmitters and processing modules
shall be provided with an integrated signal interface
for remote parameterization and diagnosis under
HART protocol.
06. Span and Zero Continuously adjustable, non-interacting & both
local & remote calibration facility.
08. Output Indicator LCD type
09. Nameplate Tag number and service engraved in stainless steel
tag plate
10. Body Die Cast aluminium
11. Operating Voltage 16 – 48 V DC
12. Load 600 ohms at 24 V DC
13. Performance
i) Accuracy +/- 0.1% of span
ii) Repeatability +/- 0.05% of span
iii) Cold Junction Compensation Built-in
14. Mounting a) Head Mounting as long as the ambient
temperature at the measuring head is always
<55°C and the measuring point is accessible
b) If there are no means to fulfill these
conditions appropriate separate transmitter
shall be used as field device with integrated
local display, for DIN-rail mounting in
control box with local display or, if the
distance between sensor and assigned control
panel is <15 m, as DIN-rail mounted
transmitter for cabinet installation with
separate field display.
15. Accessories a) Universal mounting bracket suitable for pipe and
surface mounting. (for field mounting)
b) Hi-tensile carbon steel U-bolts. (for field
mounting)
Page : 26 OF 85
c ) M26 x 1.5 cable gland.
 Conductivity Type Level Switch

01. Sensing elements Conductivity type
02. Material SS 316
03. Repeatability  1 % of full range or better
04. Accuracy  1 % of full scale or better
05. Probe length As per requirement
06. End connection Manufacturer standard
07. Over-range proof 130% of max. design pressure
08. No. of contact 2SPDT/ 1 DPDT, snap action type dry contact
09. Rating of contacts 5A, 230 V AC / 2A, 24 V DC / 0.25 A
10. Enclosure IP 65 as per IEC 60529
11. Housing Cast aluminum epoxy coated weather proof
12. Electrical Connection M26 x 1.5
13. Set point Adjustable in switch operating range.
14. Accessories All mounting accessories
 Level Switch (Side Mounted External Cage Type)

01. Type External cage float operated. Magnetically coupled.
02. Float Material AISI- 316 stainless steel or better
03. Other wetted parts AISI- 316 stainless steel or better
05. External Cage Carbon Steel/stainless steel or better as per process
requirements, welded type / flanged construction.
Cage pressure rating shall equal or exceed the rating
of the main vessel.
Page : 27 OF 85
06. External Cage Mounting Side-Side

07. External Cage Connection 25NB Socket Welded
08. Switch Housing Epoxy coated die-cast aluminum alloy with neoprene
gasket conforming to IP-65.
09. Type of Switch 2 SPDT/ 1 DPDT
Configuration
10. Contact Rating 5A, 230 V AC / 2A, 24 V DC / 0.25 A
12. Enclosure IP 65 as per IEC 60529
13. Mounting On standpipe
 Float / Displacer Type Level Switch (Top Mounted)

01. Type Float / displacer Type
02. Float/Stem/ Displacer SS 316
Material
03. Repeatability  1 % of full range or better
05. Process Connection As per requirement
06. No. of contact 2 SPDT/ 1 DPDT
07. Rating of contacts 5A, 230 V AC / 2A, 24 V DC / 0.25 A
09. Hydro Test Chamber – 100% at 1.5 times rated pressure or as per
ANSI flange rating
Float – 1.1 times of operating pressure
10. Mounting Top
 Level Gauge (Tubular Type)
Page : 28 OF 85
01. Sensing Element & material Tempered toughened Borosilicate gauge glass steel
Armored reflex or transparent type
02. Body Material Forged carbon steel / 304 SS
03. End Connection Process connection as per ASME PTC and drain / vent
15 NB
04. Accuracy +/- 2 %
05. Scale Linear vertical
06. Range Selection Cover 125 % of max. of scale
07. Over Range Test Test pressure for the assembly shall be 1.5 to the
Maximum design pressure at 38 degree C
08. Housing CS / 304 SS leak – proof
09. Zero / Span adjustment To be provided
11. Identification Engraved with service legend or
or laminated phenolic Name plate
12. Packing PTFE Teflon
13. Illumination 230 V AC, 50 Hz, 25 / 40 Watts either
with deflector or diffuser (for
transparent type level gauge) / 230V AC,
50 Hz, 25 /40 Watts with red and
green filter
14. Accessories Gasket for all KEL – F shield for transparent type vent
and drain valves of CS / SS as per requirement
15. Others Anti – Frost extension for low temperature service.
Heating / cooling arrangement
 Level Gauge(Float & Tape Type)

01. Type Float and Tape
02. Float & Tape Material AISI 316
Page : 29 OF 85
03. Pulley Material Aluminium

04. Guide Wire SS 316 Stainless Steel
05. Accuracy ± 1% of span
07. Indication On circular or vertical dial
08. Rating Twice the design pressure
09. Packing PTFE Teflon
10. Accessories 2 wire transmitter / limit switch assembly , liquid
seal assembly
 Radar Type Level Transmitter

01. Type Guided wave radar
02. Principle TDR (Time domain reflectometry)
03. Probe Type Coaxial, SS 316 / 316 L Material
If required, probe shall be suitable for over-fill
prevention.
04. Signal O/P 4 – 20 mA DC with signal suitable for over-fill
prevention.
05. Display Integral
06. Power Supply 24V DC
07. Accuracy +/- 3mm
09. Mounting Top mounted
10. Accessories Mounting Accessories, Cable Glands (Ex-proof) Of
Nickel Coated Brass Per BS 6121, Name Plate,
Integral Indicator, Process Connections Flanges And
Counter Flanges With Nuts, Bolts And Gaskets
 Displacer Type Level Transmitter
01. Type SMART
Page : 30 OF 85
02. Stage of operation Continuous

03. Material
i) Displacer AISI 316 SS
ii) Suspension Wire AISI 316 SS
iii) Torque tube housing Carbon steel or SS as per application
iv) Torque tube Inconel/ SS
v) Displacer Chamber Carbon steel or SS as per process application
vi) Transmitter Housing Die cast aluminium or better
04. Operating Voltage 16 – 48 V DC
05. Transmission 2-wire

06. Output Signal 4-20 mA signals superimposed with signal.
07. Signal Processing Solid-state electronic circuitry
08. Static / overload pressure Maximum static pressure without permanent
deformation or loss of accuracy
09. Turn-down ratio 10:1 or better
10. Zero & Span Easily accessible (local zero & span adjustment and
non-interactive type)
11. Enclosure class IP-65 as per IEC 60529
12. Output Indicator LCD type
13. Nameplate Tag number and service engraved in stainless steel
tag plate
14. Load Impedance 600 ohms at 24 V DC
15. Accuracy +/-0.5% span or better
16. Process Connection 2” Companion Flange with nuts, bolts and gaskets
17. Accessories a) Counter Flange, nuts, bolts, gaskets etc.
b) Weight for 5 point calibration of Instruments
c) Vent and drain plugs
d) M26 x 1.5 cable gland
18. Preferred Features a) Test plug connection and cutout terminals

physically separated from other electronics.
b) Electronic damping facility (adjustable)
 Hydrostatic Type Level Transmitter
Page : 31 OF 85
01. Sensor Type Submersible Pressure Transmitter with ceramic cell
02. Transmitter Type 2-Wire, SMART
03. Output Signal 4-20 mA
04. Accuracy +/- 0.1% OF CALIBRATED SPAN
05. Signal Processing Unit Microprocessor based
06. Static Pressure / Overload Maximum line (or static) pressure on either side
Pressure without permanent deformation or loss of accuracy,
1.50 times maximum range continuously, without
affecting the calibration.
07. Span and Zero Adjustment Required
09. Local Indication Required
10. Display Digital LCD External Display (minimum 5 digit)

Engineering Unit
11. Case Material Die Cast Aluminium
12. Power Supply 24 Volts DC loop powered
13. Electrical Connection M26 x 1.5
Nameplate Tag number and service engraved in stainless steel

14. tag plate
15. Mounting Type 3” FLANGED
16. Instrument Connection Size 2" YOKE FOR WALL OR PIPE MOUNTING
17. Accessories a) Manifolds, Pulsation dampeners for pulsating

fluid applications
b) All mounting accessories

 Coriolis Flow meter
Page : 32 OF 85

01. Primary Element Flow tube of SS316 or better
02. Heating arrangement Integral with flow element
03. Temperature control To be provided
04. Allowable pressure drop <0.5 Kg/Sq. cm.
05. End Connection type/size Flanged WNRF to ANSI 300
06. Cable entry M26 x 1.5
07. Accuracy +/- 0.25% of Flow rate or better
08. Power supply 230 V AC, 50 Hz
09. Drain Self draining facility
10. Enclosure SS 316
11. Display LCD display
12. Output 2 nos. isolated output of 4-20 mA.
14. Turn down Ratio 100:1
15. Housing IP 65 as per IEC 60529
Counter flanges, Nuts, Bolts, Gaskets, U clamps,
16. Accessories
prefab cables etc.
 Ultrasonic Flow Meter

01. Type Ultrasonic
02. End connection Flanged WNRF to ANSI 300
03. Cable entry M26 x 1.5
04. Accuracy +/- 0.5% of flow rate or better
05. Repeatability +/- 0.3% of reading
06. Power supply 230 V AC, 50 Hz
07. Enclosure SS 316
08. Display LCD
Page : 33 OF 85

09. Output 2 nos. Isolated output of 4 – 20 mA
10. Turn Down Ratio 100:1
11. Housing IP 65 as per IEC 60529
12. Accessories Counter flanges, Nuts, Bolts, Gaskets, etc.
 Flow Nozzle

01. Application High fluid velocity flow measurement
02. Design Standard BS EN ISO 5167
03. Number of Tappings As required plus one additional pair of taps
04. Diameter ratio 0.4 and 0.7
05. Thickness Suitable for application
06. Meter run pipe Same as pipe material
07. Accessories Meter run pipe, nipples and root valve
 Orifice Flow Element

a) Design Standard ISO 5167
b) Material SS 316
3 mm for main pipe diameter up to 300 mm and 6
c) Thickness
mm for main pipe diameter above 300 mm.
d) Beta ratio 0.2 – 0.70
Flanged weld neck 3 pairs of tappings.
e) Tapping’s However, approved taps may be substituted when
applicable for good engineering practice.
f) Material of Branch Pipe Same as main pipe
g) Root Valve type Globe
h) Root Valve material SS 316
i) Instrument Connection size M20X1.5
Page : 34 OF 85
 Vibration Monitor
S.No Features Minimum Requirements

1 Sensitivity 100 mv/mil
2 Accuracy +/- 0.5% of full scale
3 Frequency Range User programmable
4 Transducer Supply +/- 24 V DC
Digitally adjustable over full scale
5 Alarm Adjustment
to alert danger set-points
 Thrust Position Monitor

5 Alarm Adjustment
6 Repeatability ±0.5% or Better.
 Case Expansion Monitor
S.No. Features Minimum Requirements

5 Alarm Adjustment
Page : 35 OF 85

6 Repeatability ±0.5% or Better.
 Tachometer/RPM Monitor

±1 RPM for speed output and within ±20
2 Accuracy RPM/min for rotor acceleration

output

Over speed and under speed set
5 Alarm set points
points.
6 Alarm Adjustment
7 RPM Range 1 to 99,999 rpm
8 Resolution +/- 1 RPM

 Eccentricity/Key phasor Monitor

Two proximity probes, one for
1 Input signal
eccentricity and one for key-phasor.
2 Accuracy ±0.5% of full scale.
3 Frequency Response 0 -10 Hz
 Temperature Monitor

1 Input signal Thermocouple/RTD multichannel
2 Accuracy ±10 C at Ambient

Digitally adjustable within 0.10 C
3 Alarm Adjustment
Resolution
Page : 36 OF 85
 Gas Chromatograph
S.No. Feature Minimum Requirements

1. Principle Component separation- Elution
Analyzer – TCD, FID , FPD
2. Number of stream 1
3. Detector 1 ppm to 100%
4. BTU Calculation As per ISO standards
5. Analysis Period 8 minutes per stream
7. Sensitivity +/- 0.5% of FS
8. Repeatability +/- 1% of FS
9. Accuracy Less than +/- 1% of FS
10. Linearity +/- 2% of FS
11. Area Classification Class 1 div 2 Y purge – T3
12. Construction Drip Proof and dust proof construction
13. Display LCD
14. Column Packed
15. Gas requirement He and burner air
16. Calibration Automatic / manual user selectable
17. Sampling System 1
18. Installation Floor mount
20. Sample Probe 1
21. Power supply 230 VAC, 50 Hz
22. Communication MODBUS RTU
 Gas Detector

1. Sensor type Infra-red diffusion type
Die cast Aluminium/SS304 (Suitable for
2. Housing/Sensor enclosure
Hazardous classification)
3. Detection gas Combustible gas
4. Concentration 300-10000 ppm
Page : 37 OF 85
5. Loop voltage Vc <24 V DC

6. Range 0 - 100% LEL
7. Output 4-20mA
8. Heater voltage Vh 5.0 V ± 0.2 V AC or DC
9. Alarm settings Local visual and audible alarm
10. Rain cover Required
11. Installation 2” pipe or wall
12. Load Resistance RL Adjustable
13. Heater resistance RH 31Ω ± 3 Ω
15. Heater Consumption PH ≤900 mW
16. Sensing resistance RS 2KΩ - 20 KΩ (in 5000 ppm CH4)
17. Sensitivity S RS (in air) / RS (5000 ppm CH4) ≥ 5
18. Slope ≤ 0.6
19. Temperature Humidity 20 ˚C ±2˚C
20. Pre heat time Over 48 hrs
21. IP rating IP 65 as per IEC 60529
 Gas Flow computer

1. Fluid Fuel gas
2. Accuracy of static pressure ± 0.075%
3. Temperature element RTD (PT-100 Ohm)
4. Security switch On/Off dual level on board
5. Scan Rate All inputs sampled at 1kHz
7. Time Base Stability ± 7.5 ppm
8. Weather proof IP 66
9. Explosion proof Required
10. Resolution 24 Bit(0.0012% FS)
11. Stability of static pressure ± 0.1% of URL (for 12 months)
12. Lithium data battery backup To be provided by supplier
13. Display 4x16 LCD
Page : 38 OF 85
Required to store windows OS, application

14. 64mb Flash memory
programs, configuration files
15. Software To be provided by supplier
18. Installation Pipe mount
21. Power supply 24Vdc
22. Signal output 4-20mA , Ethernet TCP/IP, RS-485
 Conductivity Analyzer
Sensor - Two electrode conductivity sensor

01. Type
Transmitter - Microprocessor based 2-wire
02. Measurement Type Flow through type measuring Specific Conductivity
03. Accuracy ±1 % of span
04. Measurement Range 0 - 50 µS/cm
05. Temperature Compensation Required

Temperature compensating
06. PT100
element
07. Repeatability ± 1% FSD

Quantity of flow through
08. Adjustable through needle valve
cell
Auto calibration & zero
09. Required
check: provided
11. Display Digital LCD Integral Display

12. Power Supply 24 V DC loop powered
13. Output 4 - 20 mA
14. Enclosure Protection IP 65

Tag number and service engraved in stainless steel
16. Nameplate
tag plate
 pH and ORP Analyzer
Page : 39 OF 85
Sensor - Glass, ORP or antimony electrodes

01. Type
02. Accuracy ±0.2 % of span
03. Repeatability: ± 1% FSD

pH electrode, reference electrode & temp.
04. Electrode
compensator assy.
0 - 14 for pH
05. Measurement Range
1500 to 1500 mV for ORP
Manual calibration & zero
06. Required
check:

Temperature compensating
08. PT100
element

11. Power Supply 24 V DC loop powered

15. Nameplate
tag plate
 Silica Analyser
Photometric SilicoMolybdate Blue Color

01. Type
02. Measurement Range 0-5000 PPB freely programmable
03. Calibration Range 0-10 PPB
Page : 40 OF 85
Manual calibration & zero

04. Required
check:

Single beam infrared led at 820 nm and reference
06. Light source
beam

09. Power Supply 230 V AC, 50HZ

13. Nameplate
tag plate
 Density indicator
01. Principle Measuring Principle Hydrometer

02. Type Indicating
03. MOC of Outer Body PP
04. MOC of Hydrometer Borosilicate Glass
05. Accuracy ± 1 % of Span
06. MOC of Rod PVC Sleeved
07. Isolation Valve PVC Valve Provided
 Turbidity analyser
01. Type On-line

02. Operating principle Alternate Light source
03. Electrode holder – type Flow through
04. Analyzer output 4 to 20 mA DC
Page : 41 OF 85
05. Power supply 230V AC, 50 Hz

06. Accuracy + 1% of span
07. Repeatability + 2% of full scale
08. Type of contacts Snap action micro-switch
09. No. of contacts 1 SPDT
10. Rating of contacts 5A 230V AC, 0.2 Amp 220V DC

Automatic temperature Required with PT 100 element
13.
compensation
 Rotameter
S.No Feature Minimum Requirement
1 Type Variable area Linear scale
2 Fluid media Water
3 Float Material SS 316
4 Accuracy  2 % of full scale or better
5 Process connection As per requirement
6 Over-range proof 150% of max. design pressure
7 Enclosure Transparent toughened glass/IP 65
8 Accessories Flange, orifice in case of bypass Rotameter
6. PROGRAMMABLE LOGIC CONTROLLER (PLC)

Programmable Logic Controller (PLC) shall be microprocessor-based system. The
PLC shall be versatile, expandable, user friendly and latest state of art technology. The
system shall be envisaged for the purpose of sequential operation, protection and
Page : 42 OF 85
interlock, data acquisition system, alarm functions, closed loop control and data
archiving for fully automatic operation.
The hardware and software shall be the latest available at the time of system Factory
Acceptance Test (FAT). The latest system software version shall be made available for
all units prior to the completion of warranty period so as to have an identical and latest
software version for all systems of the plant.
The PLCs shall have on-line diagnostic feature and on-line maintenance facility. PLC
shall be supplied with its programming, commissioning, maintenance and diagnostic
tools (at least two sets for PLC). PLC backup software shall be presented to the Client
after commissioning of the PLC system.
Binary signals shall be exchanged via potential free signals. Analogue signals (4-20
mA) to be exchanged must be galvanically isolated.
The functions realized in the PLC shall be implemented graphically with IEC 61131-3
languages and / or Continuous Function Chart. The programs shall be graphically
represented using nonproprietary, commonly understandable block diagrams for
sequential and continuous programs.
The system shall be modular in construction and expandable in future by adding
additional electronic modules, which shall be easily accessible for maintenance and
repair. The modules shall preferably be suitable for inserting in 19” rack. The types of
modules shall be kept to minimum possible in order to have interchangeability and
spares inventory.
The system shall have extensive self-diagnostic hardware and software features for
easy and fast maintenance of the PLC. Safety barriers shall be provided for
intrinsically safe input / output circuits.
The PLC shall have very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and
electromagnetic disturbances expected in a plant. The system shall be programmed as
per the logic requirements required for the functioning of the systems and equipment.
Bidder shall prepare their own logic / ladder diagrams depending upon the capability
of the programmable logic controller offered by them.
Operation of the PLC shall be completely unaffected by a momentary power loss of
the order of 20 milliseconds. On-line replacement of any module shall be possible in
such a way that the removal and addition of the module shall be possible without de-
energizing the system or causing any interruption in the system while replacing a
faulty module except for the inputs /outputs which are being handled by that module.
However, in case of redundant PLC configurations, there shall not be any process
upset while replacement.
Spare capacity after completion of commissioning:
Page : 43 OF 85
20% spare I/O points per total points of each type of I/O shall be provided by bidder
after final commissioning for future modification..
On completion of hand-over the cubicles must provide at least 20% of fully fitted
spare capacity for wiring, terminals, I/O cards and power supplies and in addition
another 20% for future built-ins. Related software licensing shall have already
provisions to extend the built-in equipment for another 20% in future. All these spares
percentages shall be achieved after successful commissioning and start-up of all the
equipment.
Each module shall be sized such that no more than 60% of its installed capacity is
utilized during normal operation and shall not exceed 80% even under extreme load
condition.
The system shall be provided with programming and diagnostic facility. The system
shall have extensive self-diagnostic feature to monitor completely the software and
hardware faults in the system. Hardware diagnostics up to card level shall be provided.
Binary field signals shall be time stamped at the PLC input module. In order to
facilitate a chronological history of all input signals for the event loggers, sequence of
event recorders (SOE), alarm and fault analysis systems the time resolution shall not
exceed 10 ms. The chronological history, created inside the PLC, shall be streamed to
the DCS’s SOE.
6.2. Technical Requirements

 Input / Output (I/O) Subsystem
I/O subsystem shall be suitable for accepting discrete inputs, BCD inputs and analog
inputs. The I/O modules shall be mounted in the I/O racks. Each I/O shall be
electrically isolated from external control circuit by suitable means. Each I/O shall be
provided with galvanic isolation. The minimum isolation level between I/O and logic
circuit shall be 1000 V DC. Each module shall have LED for each I/O channel to
indicate the status of each input / output. Redundancy in I/O level shall be maintained
as per the process requirement.
PLC inputs shall be provided with potential free dry contacts. All the inputs shall be
double ended i.e., two wires per input and not common return for all inputs. The
contact interrogation voltage for input contacts shall be 24V DC minimum. Each input
channel shall be protected by separate fuse. Output contacts from the PLC shall be
potential free dry contacts. Each output shall be short-circuit proof and protected by
fuse. Visual indication of fuse blown must be provided for each input and output
channel and should be alarmed.
Page : 44 OF 85
All analogue inputs shall have up to four associated alarm levels. Alarm level dead
bands shall be adjustable between 1 percent and 10 percent for each alarm level. Dead
bands shall be set to 2 per cent unless otherwise indicated.
Each alarm level shall be configurable to be true either above or below the set point.
Alarm senses for each point shall be assumed as high-high, high, low and low-low
unless otherwise indicated.
Any analogue data that is beyond its expected range shall be considered as bad data.
An alarm shall be generated when this occurs and the value that is shown on the
PLC/DCS shall be shown as bad data.
 Processor Subsystem
The processor sub system shall include CPU, memory, power supply, communication
interface etc. Dedicated PLCs shall be envisaged for each Auxiliary plant. The
processor shall have capability to implement all the control functions required. The
processor shall have sufficient memory for storage of the program instructions as
applicable to the logic requirements.
The PLC shall be provided with non-volatile, erasable, programmable memory as a
backup for volatile memory. The PLC shall boot from the non-volatile memory on a
processor fault. A battery for backup shall be provided with the processor However, in
case volatile memory is provided, battery backup shall be provided for a minimum of
three months to keep the stored program intact. A battery drain indication shall be
provided at least one week before the battery gets drained.
The PLC main memory shall be adequate for all designed tasks plus a reserve of 25
percent and shall be capable of future expansion. Memory shall be provided with
adequate capacity with 30% spare capacity under worst loading condition and at least
50 per cent spare duty cycle under normal loading conditions.
The PLC shall have the capability of being modified on-line and off-line with the use
of a bidder furnished programming equipment (hardware and software).
The healthiness of processor hardware and software shall be continuously monitored
by watchdog timer. PLCs shall be provided as a minimum with redundant processor
subsystem including CPU, memory and power supply. Redundancy shall be provided
such that, in case of failure of the main processor, the standby processor shall take
over automatically and vice - versa. The changeover shall be bumpless and shall not
result any process or system upset. In case of failure of complete processor system i.e.,
both processors, outputs shall take fail safe state automatically. The scan time of
programmable controller shall be of the order of 100 milliseconds or better. Scan time
of PLC is defined as the cycle time taken by the system to read input, process input
executing logic and update control output for all the logics configured within the
system. Other activities like diagnostic routines, output / dump of data to peripherals,
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or any other activity which consume processor time shall also be accounted while
computing scan time.
 Communication Subsystem
The communication subsystem shall provide reliable and high speed data transfer
between the processor subsystem, I/O subsystem, PLC console and other devices
connected to the system. Redundancy in communication subsystem shall be provided,
such that on the failure of the active device, communication link or bus, the redundant
device communication link or bus shall take-over automatically without interrupting
the system operation. The communication bus shall be of coaxial / fibre optics type.
Information about the failed device shall be displayed locally as well as on the PLC
console. It shall be possible to manually switch-over the communication from main
bus device to redundant bus device without interrupting the PLC functions. The
offered PLC shall have provisions of communication interface facility with Main Plant
DCS system in order to make the entire system operational from central control room.
The interface with DCS shall be via redundant OPC link. All the required redundant
Fibre Optic Cable Interface Modules on PLC side are included in the Bidder’s scope.
These interface modules shall match the Contractor’s Fibre Optic Cable specification
to be furnished during detailed engineering.
 System Power Supplies
Programmable logic controller shall operate on Uninterrupted Power Supply system
supplied by others. Each I/O rack shall be provided with separate power supply feeder
and power supply module. For the Operator Stations and Engineering Station the
power supply shall be from the UPS system.
 PLC Console
PLC Console shall be provided as operator Interface station for control and monitoring
of the plant. This shall be done through dynamic mimic displays and control displays.
PLC console shall also be used for program storage, display, fault diagnostic and
alarm monitoring. It shall be possible to modify, add or delete the application program
on-line without affecting the outputs. It should be possible to modify or create new
displays from PLC Console.
Isolation shall be provided between programming terminal and related subsystems, if
there is any possibility of high voltage from LED/TFT being transmitted to other
subsystems.
Bidder shall provide necessary desk and furniture for installation of Operator Station /
Engineering Station in the local control room.
 Displays
The system shall be capable of reading the status of equipment, acquiring the analog
signals, displaying the status in the form of mimic diagram, video trend, bar graph,
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periodic display, alarm display, alarm overview display, logs such as hourly/shift/daily
logs, alarm logs etc.
 LED/TFT Alarm monitoring
The system shall display history of alarms in chronological order of occurrence on the
Operator Station LED/TFT. At least three (3) levels of alarm priority shall be available
which shall be displayed in different colour. It should be possible to display and print
alarms. System shall have all alarm related functional keys like acknowledge, reset
etc. Other design features like set point / dead band adjustment, alarm priority, manual
and automatic inhibition based on predefined logic etc. shall be provided, which shall
be as finalized during detail engineering. The alarm display shall be built bottom up
with the most recent alarm at the top of the list. When a point returns to normal, the
associated alarm line shall change colour suitably and on acknowledgement, the line
shall be blanked out. The alarms below the blank lines shall move upward to fill the
empty lines. If the capacity of the LED/TFT display page is exceeded, alarm history
shall be stored in memory to accept the over- flow. This alarm history shall be
displayed upon operator demand. The format and details of alarm displays shall be
finalized during detail engineering. When a point goes into an alarm state and appears
on the alarm screen, the time of alarm shall flash until acknowledged by the operator.
Acknowledgement by the operator shall cause the time to stop flashing. All alarm
initiations and return to normal, shall be logged on a printer.
The functions realized in the PLC shall be implemented graphically with IEC 61131-3
languages and / or Continuous Function Chart. The programs shall be graphically
represented using nonproprietary, commonly understandable block diagrams for
sequential and continuous programs. Additionally, a verbal, extensive, description
of the program shall always be supplied. The software programing and Graphics shall
have the English and Russian languages available, either to be at the same time, or to
be switchable between the two languages. The same to be available in DCS and all
workstations for Operation and Engineering.
 System Software
Complete licensed software for PLC based system including the communication
software system shall be supplied and implemented to meet completely the
specification requirements. Application software shall be built based on approved
logic diagram, graphics etc. and shall include controls, graphics, logs, trends,
historian, report generation etc. The system software shall include all programs for the
PLC and PLC console which are required to perform all the PLC functions including
communication and self-diagnostics. Diagnostic software shall have the capability to
provide information about the failed module / system either in the form of a system
configuration display or provide information in the form of a statement. The Bidder
shall provide software license for all the software provided for the project and shall
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not be machine specific. All software licenses shall be valid for the continuous service
life of the plant and equipment. Password security shall be provided in order to ensure
security level to the plant operation. 2 sets of all software have to be supplied on non-
erasable media as backup.
 Peripherals
All peripherals shall conform to the minimum requirements indicated in the
specification, the exact make and model number shall be as approved by the
Contractor during detailed engineering stage.
LCD/LED shall be multi-sync, 32” of IPS (In Plane switching) technology with
intelligent terminal and key board. LCD/LED shall be provided with graphic and
mimic capabilities with minimum 64 distinct colors. The graphic resolution shall be
1920x1200 dots minimum with 0.25 mm dot pixel and refresh rate shall be 85 Hz or
better and of non glare type. Suitable optical filter for minimum secondary glare shall
be provided.
The colour printer shall be automatic duplex printing. Printing speed shall be
minimum 6ppm for colour and 24 ppm for black and white. The printer shall be
heavy-duty type with minimum 50,000 pages/month printing capability, 600 dpi
resolution, 128 MB memory and 3000 sheet input capability. However the size and
type of all printers shall be finalized during detail engineering and subject to the
owners approval.
 Training
Bidder's experienced personnel/engineers shall provide training courses on offered
PLC system to Owner's engineers in the following areas:
(a) Operator training
(b) Hardware Maintenance training
(c) Software training
(d) Any other specialized training as required for system operation and maintenance.
The maintenance training shall include lectures and hands on experience on similar
type of equipment / system at manufacturer works and recently commissioned
operating plant and / or training simulator. The details of hardware and software
training shall be finalized during detailed engineering and shall be subject to
Contractor's approval.
 Inspection & Testing
The Bidder shall furnish the complete FAT procedure to Contractor for approval
during detail engineering and shall inform Owner the schedule of FAT to enable
Owner to witness the same.
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All tests required by prevailing IEC and safety standards, particularly IEC 62381 shall
be conducted and the results recorded, with test records and certificates to be handed
over to the Client.
Three copies of the testing and installation certification shall be presented to the Client
prior to commissioning. An analysis of the heat balance in the switchgear cubicles
shall be provided. An Analysis of the selectivity of the completed installation shall be
provided.
The following tests shall be performed as a minimum:
 System pre-test: physical check of all modules, racks, Cabinets etc.
 System power-up test: functionally test of all hardware and software.
 Functional testing which shall include the following as a minimum.
 Complete system configuration function check and loading.
 Demonstration of all PLC system functions.
 100% checking of logics configured in the PLC.
 Checking of scan time.
 Checking of all PLC console functions and operation in association with
peripherals.
 System redundancy checks including correct changeover of the backup unit in
case of failure of main unit and vice versa.
 System diagnostic checking for all subsystems, including checking of the
testing software for I/O modules signal conditioning modules, CPU, Memory
etc.
 Checking of output status on processor failure.
 Simulation of power failure and system restart.
 Auto boot up of system configuration and program after power restoration.
The PLC system shall be tested at site after installation and commissioning with all
inputs and output connected.
 Interface with Main Plant DCS.
The PLC shall be interfaced with main plant DCS for signal exchange. Bidder shall
provide redundant interface through redundant OPC link (OPC UA ) with Main Plant
DCS. Also Bidder to provide all the relevant software & hardware for communication
with the equipment/systems.
Data exchange with Main plant DCS for control, interlock & protection shall be
through hardwired input/output in the form of galvanically isolated 4 - 20 mA signal
and potential free contact input, output.
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7. PANELS AND DESKS
7.1. Constructional Features of Panels, Cubicles & Enclosures

All panels, cubicles, consoles and enclosures furnished as per this specification shall
be of free standing type and shall be constructed of specified gauge of steel plates.
The panel sheet thickness shall be 2 mm CRCA. Enclosures with fixed, integral
switchgear and apparatus as self-standing enclosures of floor mounted type shall be
provided.
All electrical plant equipment and devices and especially the control panels, cabinets
and junction boxes, shall be fully feasible to operate with its individual nominal load
under the site ambient conditions.
Cabinet dimensions: Maximum dimensions of control enclosures in mm (height x
width x depth) 2200x1200x800. Panels and cabinets lined up in a row may not be
staggered arranged, thus only cubicles with the same size in depth shall be put side-by-
side.
Junction boxes indoor: housing and door shall be of carbon steel or stainless steel
1.4301 (AISI 304) , all-round foamed-in PU seal; IP 55, with door and mounting
plate.
Junction boxes outdoor: housing for wall or pole mounting applicable; min IP66;
material shall be of Stainless steel 1.4301 (AISI 304) with door and mounting plate.
All junction boxes in outside locations shall be equipped with a rain roof of stainless
steel. Rain roof color according “Painting and Finishing”
Neoprene Gasket, Exhaust Fans with louvers & filters shall be provided in all consoles
and panels.
All cable entries shall be from the bottom side through PVC or metallic cable glands,
providing strain relief function each. Cable glands mounted in bottom plate providing
panel or cabinet ingress protection min. IP4x (acc. IEC 60529).
Plan box for technical documents inside the cubicle, size min. A3 shall be provided.
All equipment with identical ratings and of identical design shall be interchangeable.
The spectrum of types shall be limited in order to reduce variety of spare parts.
Power interruptions: Voltage drops and power supply interruptions at the power
interface terminals shall not lead to dangerous conditions of the system and its
components, incl. hazardous conditions to operators and environment.
Panels, cabinets or junction boxes which are erected in areas where the ambient
temperature can easily drop below 15°C shall be equipped with an anti-condensation
heater. The installed heating power shall be assessed by calculation.
All panels shall be mounted on vibration dampers, which are secured to channels
mounted on the floor. Panels are mounted on false floor suitable support frames from
sub-floor level shall be provided. If the panels are not mounted on false floor, they
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shall have a pedestal of a uniform height of at least 200 mm. All panels shall have auto
on/off switch for internal lighting. Control panels, cabinets and junction boxes shall be
designed and adequately fastened to conform to Seismic Zone 4.
An individual calculation about the heat dissipation of every single panel, cabinet or
junction box to verify the correct dimensioning of the engineered cabinet ventilation
and/or anti condensation heater, has to be provided prior construction. Panels, cabinets
or junction boxes, which are erected in areas where the ambient temperature can easily
drop below 15°C shall be equipped with an anti-condensation heater. The installed
heating power shall be assessed by calculation.
The finish colours for exterior and interior surfaces shall conform to RAL 7035.
The enclosures shall boast the best possible surface protection and corrosion
resistance.
Special performance shall be provided by multi-layer treatment e.g.:
 Dip coat priming treatment to achieve long-term device protection (Nano coating)
 heavy metal-, chromate- and silicone-free polyester resin to create even layer
structures on the surfaces, edges and hollow spaces and ensuring a complete seal
 Electrostatic, heavy metal-, chromate- and silicone-free powder-coating on a
polyester resin basis with a perfect mechanical resistance; thickness min. 80 μm
 2-component paint to achieve the highest resistance to organic and inorganic
substances.
For the internal cubicle frame hot dip galvanized material without paint is acceptable.
All panels and cabinets shall be provided with a continuous bare copper ground bus.
The ground bus shall be bolted to the panel structure and effectively ground the entire
structure.
Nameplates of adequate size shall be provided for each panel on front and rear of the
panel.
As for free space of the PLC & other cabinets the bidder to provide 20% spare
terminals, I/O module & relay module.
At least 20% free space shall be available in all cubicles, junction boxes and
marshalling racks after final commissioning for future ad-on items. This free space
shall be distributed inside the cubicles in such a way that additional terminals,
equipment or modules may be added to any group of controls. At least 20% spare
cores shall be provided in each control and monitoring cable. All spare cores shall be
terminated.
The spare capacity as specified above shall be uniformly distributed throughout all
controller systems. The system design shall ensure that above-mentioned additions
shall not require any additional controller/processor/Peripheral drivers in the system
delivered at site. Further, these additions shall not deteriorate the system response
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time/ duty cycle, etc. from those stipulated under this specification and shall meet
other redundancy / functional requirement.
Unless otherwise stated all apparatus shall be accommodated in cubicles. All the
apparatus of solid-state type shall be mounted on plug-in cards in racks. Similar racks
or cubicles shall, as far as possible, be employed for all apparatus. Cubicles, cabinets,
racks and control panels shall all conform to applicable IEC 60297 Standards.
They shall be of the free standing type, fabricated steel construction, and provided
with suitable equipment mounting fittings. Neither racks nor cubicles shall, unless
otherwise approved, exceed 2200 mm in height. The methods used for cubicle
mounting, including the provision of anti-vibration mounts, shall be to approval.
Support steelwork shall be suitably sized for the equipment weight with facilities for
ensuring that the cubicles etc. are level.
Doors must open in the direction of escape with an opening angle min. 170°. Doors
shall provide high resistance to torsional stiffness and its individual width shall not
exceed 600mm.
Door lock for enclosure doors h>800mm: foldable handle (no swing) for lock inserts.
Door lock for enclosure doors h≤ 800mm: T-handle prepared for lock inserts. One
door per enclosure equipped with wiring plan pocket, size min. A3.
Only LED-type indicator shall be used on the front panel of cubicles, feeders and
motor-supply outlets, thus any accommodating panel or cabinet shall have on its front
side a separate push button for the lamp test function.
Earthing of each door by use of flexible tin-plated copper, min. 200/16 (l / mm²),
Openings and covers shall not reduce the enclosure IP-class.
Ventilation covers shall protect against intrusion of insects and vermin.
Cooling fans shall be installed inside of the door and shall consist of outside the door
mounted filter grids that allow tool less filter exchange. The maximum noise level of a
single ventilation fan shall not exceed 45dB(A) and the cumulated noise level of all
fans in one room shall not exceed 55dB(A).
All panels shall be adequately and evenly illuminated internally using universal
fluorescent light with integral motion detector. It shall be connected via suitable fuses
to a separate incoming 230V AC power supply from a lighting cabinet. The light
fixtures shall have a degree of protection against electrical shock of Class I or Class II
according to IEC 598-1. Class I fixtures shall be grounded.
The lighting circuit shall not be routed via the cabinet main switch, to ensure lighting
function and socket supply during maintenance works. 230 V AC two-pole plug
receptacles with side earthing contacts shall be furnished inside each panel. Minimum
number of receptacles shall be two.
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7.2. Terminal Block and Cubicle Wiring

Separate terminal blocks shall be provided for the different voltage levels and
functional systems, in each case with 20 % spare terminals or at least 5 spare terminals
(the highest figure of both shall be valid).
Terminals for voltages above 60 VAC resp. 125 VDC shall be protected against
contact and labeled accordingly (BGV A3) if they are close to LV equipment on a
lower voltage level.
Infeed terminals shall be provided with Plexiglas cover.
Screw terminals shall be attached to terminal blocks with cable connections and
outgoing feeders (as from 60V) in accordance with (IEC 60947-7)
Spring-loaded terminals shall be attached to terminal blocks with cable connections
below 60 V, as per thelatest version of IEC standards related.
Terminal mounting rails shall be of 35x15 mm DIN-rail in accordance with DIN EN
60715; each rail shall provide min. 25% spare place for future extensions.
Terminal blocks below 50cm from access level shall be installed on angled upwards
mounted rails.
One wire per connection is mandatory. Mechanical jumpers may be used for the
multiple wire connections.Double wire connection is not acceptable.
All terminals and terminal blocks shall be consecutively numbered according to the
associated wiring diagram, using standardized labeling material
For each terminal type, matching accessories and corresponding protection and
neutral conductor terminals shall be used.
The available free space in front of a single terminal shall not exceed 4cm.
Adequate ducts, trays or supports shall be provided for the field cabling within the
enclosures. Wires must be numbered according to a numbering system approved by
Client at each end with special tabs so that change by mistake is impossible.
Designation and coding of insulated and bare conductors shall be in accordance with
IEC 60445 and should conform to the technical specifications in the associated wiring
diagram.
Shielding terminals shall be provided for the termination of individual screens
(shields) of analogue signals. Wiring and isolation inside enclosures shall conform to
the requirements defined in IEC 60204-1, IEC 61439-1. The color coding of the
insulation shall be according to IEC 60757 or due to client’s specification.
Only plastic-insulated, stranded conductors of type H 07 V-K with a minimum cross-
section of 1.5 mm2 Cu shall be used. Wiring connections to printed circuit boards or
similar electronic modules might differ.
Conductor ends shall be provided with crimp lugs, crimp pins or end ferrules with
plastic protective shrouds.
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Filling degree of a cable duct inside an enclosure shall not exceed 70%. Conductors of
power and control circuits shall be laid separately.
Crossovers from doors and swiveling frames shall be run in flexible tubing with door
lead-out clamps, and without restricting access to other equipment and components.
N and PE potential must be kept strictly separated from each other and shall be
provided with dedicated connection terminals next to the main infeed of an enclosure.
Potential distribution might be done by individual conductors or by looping. Looping
shall be done by use of twin ferrules. Wiring and installations of electrical circuits
exposed to explosive atmospheres or environments shall fully comply with the
requirements of IEC 60079.
Every single core shall be connected to a dedicated and documented terminal,
including spare cores. Bidder has to obtain a confirmation in writing of the client since
core colors and minimum cross-sections shall be consistent throughout the whole
power plant.
Cubicle wiring shall be of the flame-retardant/fire resistant. Wires shall not be joined
or teed between terminal points. Bus wires shall be fully insulated and run separately
from one another along the top or bottom of the cubicle. Fuses and links shall be
provided to enable all circuits in a cubicle, except lighting or heating circuit, to be
isolated from the bus wires.
All wiring shall be terminated with approved crimped terminations. Other methods of
wiring termination shall be to the Contractor’s approval. Terminal blocks shall have
separate terminals for incoming and outgoing connections and no more than two
connections shall be permitted on any one terminal. Terminal blocks that rely on
springs only for retaining the terminations, and those which employ a pinch screw
terminal are not acceptable.
It shall be possible to work on small wiring for maintenance or test purposes without
making the cubicle dead. Circuits working at different voltages shall be adequately
segregated and labelled.
Power supply bus bars in cubicles shall be carefully routed and each bus bar shall be
shrouded. It shall not be possible to inadvertently short bus bars either between
themselves or to earth.
7.3. Earthing
Earthing of electronic equipment is required to reduce the effects of electrical
interference and for the safety of operation and maintenance staff. Where there is a
conflict between the two, personal safety shall always take precedence.
The PLC systems shall have a separate IS electrical (chassis) earth and isolated clean
instrument earth system shall be utilized. All non-current carrying metallic parts of
equipment and enclosures shall be bonded to a single earth point within each item of
equipment via flexible, green-yellow coded cabling, minimum section 6 mm2. The
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screened conductors shall be grounded at one end at individual, central points.

Terminals allocated for analogue screen (shield) connections shall be connected to the
instrument earth bar.
After completion of the erection work and before starting the commissioning of the
particular control systems, the earthing and grounding system shall successfully
perform the related standardized test according IEC 60204-1.
Bidder has to prove the conformity of the required resistance value according to IEC
60204-1 and to certify this measurement and the individual measuring values prior the
energization of the equipment.
Low impedance earthing of the reference conductor (M) and screening systems must
be provided in addition to the measures described above, in order to reduce over
voltages and other types of electrical interference caused by lightning. Bidder has to
ensure that no impermissible potential differences can occur in the building area in the
event of lightning or an earth fault in the power system.
Earthing should be generally in accordance with BS 6739, BS 7671 and BS 7430 or
equivalent international standards unless otherwise approved.
Protective screens around insulated cables shall be insulated from field instruments,
connected through any field junction boxes, and be continuous up to the earthing point
in the destination cubicle or panel.
Cubicles, desks etc. shall be equipped with a "clean" instrument earth comprising an
insulated copper earth bar for the connection of cable screens. All "clean" instrument
earth bars shall be clearly labeled as such. Connection of the instrument earth to the
site earth shall be by separate conductor to the equipment safety earth.
All non-current carrying metallic parts of plant, equipment, components, enclosures,
racks etc, shall be earthed by connection to the main plant earth bar in an approved
manner and all earthing terminals and connections shall be of adequate dimensions.
For all panel, cubicle doors or swinging frames, flexible cable or braid shall be used
for earthing these items; the door hinges shall not be accepted as a means of earthing
this part of the equipment.
The design of equipment shall be such that cable screens and cable armouring are kept
electrically separate throughout the equipment installation so as to avoid the
introduction of earth loops and minimize interference pickup.
7.4. Name Plate

Bidder shall supply all labels, nameplates, instruction and warning plates necessary for
the identification and safe operation of the I&C equipment of the power plant. All
instructions shall be in both English and Russian and the size of the lettering shall be
to the approval of the client.
The inscriptions on all plates, except warning plates, shall be engraved with black
filled lettering shall be provided. Warning plates shall be manufactured from stainless
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steel with a matt or satin finish, engraved with red lettering on white background, and
located in a position which shall afford maximum personnel safety.
Inscriptions shall be to the approval of the client and shall basically follow the power
plant KKS nomenclature in conjunction with IEC 81346 for labelling.
Stainless steel shall be used on outdoor equipment.
All labels, nameplates, instruction and warning plates shall be securely fixed at I&C
items or in direct vicinity to it with stainless steel rivets, suitably plated self-tapping
screws or pendant type tags will be used if it is difficult to fix labels, tag plates directly
on instrument. The use of adhesives shall not be permitted.
All equipment within panels and desks shall be individually identified by satin or matt
finish stainless steel labels or laminated plastic labels where approved.
Each item mounted on mounting plates in panels, control cabinets, junction boxes and
the like shall have an individual label mounted on the front of the item and on the
mounting plate where the item is located. Every single panel, control cabinet and
junction box shall have an individual label on the upper side of its front panel
providing due to its size a visibility of not less than 4m.
Every control cabinet, junction box or other I&C enclosure shall be equipped with an
individual nameplate giving the following information and shall be attached outside
the single enclosure adjacent to each incoming supply
- Name or trade mark of supplier;
- Certification mark, when required;
- Serial number, where applicable;
- KKS tag number and description
- rated voltage, number of phases and frequency (if a.c.), and full-load current for each
supply;
- short-circuit rating of the equipment;
- Main document number (see IEC 62023).
The details for junction boxes and marshalling cabinets might be customized.
7.5. Withstand Capability of Equipment

Power supplies to PLC/PC equipment shall be equipped with surge protection and all
other power conditioning requirements.
The control equipment shall be capable of operating continuously during voltage
excursions without damage or malfunction. Additionally the system shall continue to
operate and maintain its integrity during short time voltage drops of up to 25 per cent
of rated voltage as may be caused by fault conditions.
The equipment shall be designed for operation in the presence of transient interference
and shall be capable of withstanding randomly phased transient over-voltages of either
polarity without producing erroneous indications or outputs. Selective protection
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equipment shall isolate faults in any one control loop to prevent disturbance in any
other loops. Such faults will include over-current, under-voltage, and overvoltage
8. PANEL MOUNTED DEVICES
Devices shall be mounted with adequate spacing allowed for wiring and/or piping
connection so that instrument removal, replacement and servicing may be
accomplished without interruption of services to adjacent devices or without unduly
disturbing other wiring and/or piping connections. All devices shall be so located that
terminals and adjustment devices are readily accessible without use of special tools
and with terminal marking clearly visible.
Front-of-panel mounted devices shall not be located lower than 760 mm or higher than
1700mm above the floor level (with the exception of annunciators) without prior
approval by the Employer.
Devices inside the panel shall not be located lower than 500mm or higher than
1700mm above the floor level without prior approval by the Employer.
Instrument devices exerting strong cantilever forces on the panel steel shall be
adequately supported to remain plumb and true within 1.5mm of the desired vertical
and horizontal alignment.
Annunciators, control switches, push buttons, instruments and alarm/indicating lamps
shall be located on the front of the panels. Relays and amplifiers etc. shall be located
within the panels.
System cabinets containing programmable controllers/PLCs may have built in
industrial PC’s with color TFT touch screens mounted on the panel doors of such
cabinets (the screen being on the external side of the door with PC being on the inside
of the cabinet). The purpose of such screens enables not only control of the local
process/system, but provides status indication, alarm messaging of the system under
local as well as remote control (if required). The PC shall be connected to the PLC via
plugged leads and the serial interface of the PLC.
Enclosures located outside or in areas where increased dirt, dust or humidity can be
expected the panel mounted devices shall be protected by a system window concealing
the displays, operating instruments or cut-outs against these influence as well as
against unauthorized access. Material of this system window: Extruded aluminum
section with die-cast zinc corner pieces and single-pane safety glass, providing IP54.
Emergency switches shall not be covered by this window.
b) Annunciators
Alarm functions shall be indicated on internally illuminated annunciator units.
Each annunciator shall have at least 20% spare ways for possible future alarms and
shall be as compact as possible without unnecessary decorative trim.
The alarm indications on each annunciator shall be logically arranged in a format
which is agreed by client. The alarm lights shall have secret legends which are
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invisible until illuminated. The legends area of each indication shall not be more than
30 mm high and 60 mm wide.
The wording of all legends shall be approved by the client before manufacture.
“Alarm accept", "Reset" and "Lamp test" pushbuttons shall be provided in the middle
of the panel.
A buzzer and a siren of approved make approximately 80 decibels at 3 meter sand of
not less than 30 minute rating shall be mounted within the panel together with muting
switches mounted inside for use during commissioning and testing.
Audible devices in the same room or area shall have distinguishable sounds and
adjustable sound levels.
Panel alarm annunciators and audible alarm shall operate as follows:
- When an alarm condition occurs, a light behind the appropriate legend shall flash on
and off intermittently and the audible alarm shall sound. The flashing rate shall not be
less than 2 Hz and shall not exceed 5 Hz;
- On pressing the "Alarm accept" push-button, the audible alarm shall be silenced and
the flashing light shall become steady;
- The alarm indication shall remain illuminated whether or not the alarm condition has
returned to normal until the 'alarm reset pushbutton has been operated whereupon the
light shall be extinguished if the fault condition no longer exists;
- Operation of the "lamp test" pushbutton shall cause all the alarm lamps to be
illuminated simultaneously and the audible alarm to be sounded;
- The alarm system shall respond to any new condition that might arise while an
existing condition is being indicated, whether accepted or not, and to any that might
occur during a "lamp test" operation.
The operation / acceptance of one alarm shall not inhibit the operation of the
appropriate audible device or the flashing of the appropriate alarm indicator if a
further alarm condition occurs. Alarms operated on two or more annunciators shall
require acceptance at each annunciator. Alarms shall be accepted automatically and
the appropriate audible device silenced after an adjustable period of 1 to 5 minutes.
Alarms shall be initiated by opening or closing of volt-free contacts which shall
remain unchanged throughout the periods in which the alarm conditions exist.
Alarm circuitry, shall be arranged so that spurious or transient alarm states persisting
for less than 0.5 seconds do not initiate any action. However, the suppression circuitry
shall be such that repeated spurious or transient status for the same alarm occurring in
a five second period shall initiate the appropriate
action. The alarm system shall operate on a 24 V DC supply and be designed on the
'fail safe' principle so that a fault in any circuit component causes an alarm.
All accessories such as LED indication lamps, LED lamp extractor, pushbuttons etc.
as required shall be provided.
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c) Supply indicators
Ammeters are to be provided on the cubicle front panel for the cubicle feeders and the
supply outlets for motors higher than 55 kW or motors of lower rating, but particularly
important for the process.
A single voltmeter with 4-position voltmeter changeover switch must be provided for
measurements of bus bar voltage between each phase and neutral. Measuring
instruments should, in general, be square in shape.
d) Mimic presentation
For easy monitoring and a rapid grasp of the operational state, Video Display Units (if
the ambient conditions are suitable) or colored mimic diagrams with the required
switch position indicators, apparatus symbols and pilot lamps must be provided in
every case on cubicles for packaged control systems. Lamp test facilities for all
indicating lamps connected shall be provided. All indicating lamps shall be of LED
type.
For other Panel requiremnts like interior lighting, service socket,

Grounding,Ventilation fans,Anti condensation heaters,Mimic Bus
presentation,Piping,tuing and penumatic connections etc. refer 5.3.8 clause of
Attachment - G-Employer's Technical Requirement-Instrumentation
9. INSTRUMENT INSTALLATION AND ERECTION HARDWARE
9.1. General
All the instrumentation shall be installed so that it complies with latest edition of BS
6739 or equivalent international standard and the recommendations of the
manufacturer. Only one instrument shall be fitted to each tapping point.
All pressure instruments shall be provided with root isolation, instrument isolation and
drain/ vent valves. All differential pressure instruments shall be provided with root
isolation, instrument isolation manifold and individual leg drain/ vent valve with caps.
Level instruments shall have tank isolation valve, drain and vent valves. Control
valves shall have inlet/ outlet isolation valve, bypass valve and upstream/ downstream
drain valves.
Instruments shall be mounted on a height of 0,80 m up to 1,65 m above operating floor
level and centralized together as appropriate on racks. Particular attention shall be paid
to easy access to the devices, including all operating equipment, like test valves, valve
manifolds, drains, vents etc., as well as ease of readability of measuring instruments.
Sufficient open work space shall be provided without obstacles in a radius of 0,6 m.
All open air mounted field instruments shall be grouped on transmitter racks and
enclosed by transmitter protection boxes. Temperature sensors shall be provided at
Page : 59 OF 85
least with a suitable shade to protect them from direct sunlight. A weatherproof design
with type of protection IP 67 IEC 529 shall be provided. Instruments in water services
or where water can accumulate in the impulse lines shall be trace heated where the
ambient temperature can fall below 5°C. Wind chill factor shall also be taken into
account in such cases, which might require trace heating at a higher temperature.
All instruments shall be installed as per standard / good engineering practice.
Wherever instruments are mounted on open racks, canopies shall be provided for
weather, dust, humidity and sun rays’ protection. Instrument impulse tubing, piping &
fitting shall be done as per standard / good engineering practice. All impulse tubes /
fitting shall be SS316. All fittings shall be of minimum 3000# rating.
C&I erection materials shall be as per ASME codes. For instrument end connection
metric thread (ex. M20, M22, etc.) shall be followed.
Junction boxes shall be provided in the field to run Multi-pair cables. Junction boxes
(JBs) shall be of Aluminum LM6 material. Explosion proof JBs shall be provided in
hazardous area. JBs shall have bottom entry and bottom exit wherever applicable.
Separate junction boxes shall be provided for analogue, digital, power, RTD, cables.
Perforated GI trays of minimum 3mm thickness / ladder trays shall be provided for
laying instrument cables. Separate dedicated trays shall be provided for analogue,
digital and power cables. All cables shall be tied and identified with Aluminum tags.
Each core/ pair of cable shall be identified with cross and direct ferrules. All cable
glands shall be Nickel plated brass and double compression type.
For instrument air GI pipes with GI fittings of minimum 3000# rating shall be
provided from instrument air receiver or battery limit up to air manifold. Air manifold
shall be of GI with drain valve and needle valve. From air manifold to individual
control valves, PVC coated copper tube shall be used. All internal tubing of control
valve shall be of SS.
9.2. Local Measuring & Control Elements

Sensing elements shall be suitable for service fluid, temperature and pressure.
For sea water or brine service the wetted parts shall be Hast alloy C or Monel.
The body, Flanges, bolts and housing shall be stainless steel 304, 316L to suit the
application at the discretion of the Engineer.
Field instruments shall be located away from equipment/location where
severe/continuous vibrations or shocks occur or are expected.
Temperature and pressure compensation shall be provided, especially for
steam/variable specific gravity applications.
Page : 60 OF 85
9.3. Hazardous Areas

All C&I equipment shall be suitable for the specific area in which it is located. This
shall take into account the presence of any potentially hazardous conditions or
substances.
If equipment is expected to operate in the presence of flammable or explosive
materials explosion proof construction is the preferred method of protection. All
equipment offered for use in such areas shall have the necessary certification by the
appropriate Certification Bureau and its proposed application shall fully comply with
all conditions of the certificate.
The design and installation of the equipment shall take into account fully the
appropriate sections and requirements of BS EN 50014/BS EN 60079.
9.4. Primary Isolation and Instrument Valves

All primary isolating and blow down valves shall be capable of being locked in the
open or shut positions. The direction of rotation shall be clearly marked on the hand-
wheel.
Instruments used in high-pressure process applications (media above 40 bar) shall be
provided with a double primary isolating valve at the pressure source and this valve
shall not be smaller than 25 mm.
The primary isolation valve shall have butt-welded ends on both sides, screwed
fittings are not permitted. All primary isolating valves and valves used for protection
purposes shall be capable of being locked in the "OPEN" or "SHUT" position. Fittings
associated with locking of valves shall be securely attached to the valve body.
Padlocks for locking the valves shall be supplied if necessary by safety reasons.
The primary isolating valve shall be located at the tapping point, be of the parallel or
globe type and rated for the temperature and pressure of the main line. The primary
isolation valve shall be compatible with the system material to which it is connected.
Instrument isolating, equalizing and vent valves shall preferably be incorporated in a
single manifold, i.e. two/three way manifolds for pressure measurements and five way
manifolds for differential measurements. The instrument manifolds/valves shall be
manufactured in stainless steel unless the process conditions require different
materials. Valve seating and seals shall be suitable for the process conditions.
Locking facilities for primary isolation valves and instrument valves/manifolds shall
be provided for C&I, related to safety/reliability of Unit/Plant.
9.5. Instrument Tubing and Piping

Instrument sensing line piping, valves, tubing, manifolds, fittings, etc. shall conform to
the requirements of ANSI/ASME-B31.1, “Power Piping,” section 122.3, where
applicable. The fitting at the root valve and downstream through the tubing, valve
manifolds, etc., to the instruments are covered by this design criteria.
Page : 61 OF 85
Stainless steel instrument tubing shall be connected by suitable compression fittings.

Tubing shall be routed to ensure all compression fittings are accessible and comply
with the manufacturer’s instructions.
All process tubing shall be ½ inch minimum, 0.065” wall thickness, ASTM A213
TP316 annealed, seamless, drawn tubing..
All joints from the root valves, down to the local instrument installation, shall use
socket weld fittings. All connections at the instrument shall be compression swage
fittings.
All instrument installations shall include instrument shutoff and drain valves at the
instrument. All pressure transmitters shall include a 2-valve manifold, and all
differential pressure transmitters shall include a 5-valve manifold; all manifolds shall
include plugged calibration test ports. Manifolds shall be direct-connect type (pipe-to-
flange), and shall be mounted to the instrument enclosure, pedestal or instrument rack.
The transmitters shall then be bolted directly to the manifolds. All installations shall
be designed such that instruments, valves, and manifolds can be physically removed
without disturbing any other installations.
Instrument piping shall be provided with suitable heat tracing provision for ambient
temperatures below 0˚c in order to avoid freezing of process medium. Instrument
primary piping and tubing shall generally be kept to a maximum of 50 feet in order to
minimize response time.
Horizontal runs shall have a slope of not less than one (1) inch per foot and must be
adequately supported to maintain a constant slope. Provisions for venting of the air in
the high point of the line shall be provided. Vacuum sensing lines such as low
pressure steam extraction pressure sensing lines shall always slope up to the
instrument.
Instrument primary piping for steam flow, liquid flow, and manometer level
measurement systems shall slope downward from the primary element connections to
the instrument. Instrument primary piping for flue gas and airflow measurement
systems shall slope upward from the primary element connections to the instrument.
If these requirements cannot be met, special venting and drain provisions shall be
required.
Primary piping instrument taps shall not be located on the bottom of the pipeline.
Transmitters used for tripping shall be separate. No transmitters shall be shared
between control , monitoring and tripping purpose. Three transmitters can share the
same equilibrium containers and tapping point.
Instrument primary piping and tubing shall be supported in accordance with support
requirements for process piping. Tubing and primary piping ¾ inch O.D. and smaller
shall have support spacing every five (5) feet. Continuous support for tubing shall
normally be provided in tubing tray.
Compression type tubing joints shall be used up to a temperature of 800 F. Above
800 F socket weld tubing joints shall be used.
Page : 62 OF 85
Tubing using compression type joints shall be continuously supported using tubing
tray. Tubing using socket weld type joints can be non-continuously supported with
spacing every five (5) feet.
All instrument vent/drain points shall be directed to a safe position away from site
personnel.
The primary instrument piping shall be 12 mm NB stainless steel piping. For
applications up to 40 barg pressure, schedule 40 shall be used. For pressures above 40
barg, schedule 80 shall be used.
9.6. Pneumatic Pipe Work

Each individual air user shall be provided with an air filter regulator set with a
lubricator to the approval of the Contractor. A line size lockable isolating valve shall
be provided immediately upstream of the filter regulator.
The connection to the air user at the air supply manifold shall be supplied with an
isolation valve that shall have a locking facility. 20% spare connections, with isolating
valves, shall be supplied at each manifold.
The air supply pipe work and tubing shall be suitably sized to ensure that there is
negligible pressure drop during peak consumption of instrument air.
9.7. Instrument Mounting

All indicating instruments and controls shall be grouped together, where possible, in
suitable housings and gauges shall be installed. They shall be readable and accessible
from floor level or permanent platforms. Gauge glasses shall be visible from any
control valve that controls the vessel level. Where gauge racks are used to suitable
sunshades shall be provided.
Transmitters and process switches shall be located in instrument housings containing
up to six instruments. Clearance shall be allowed for servicing and access to all items.
Instrument housings shall be provided with internal illumination, heaters, and a
maintenance power socket with an RCD and a communications jack socket.
Instruments, housings and gauge racks shall be positioned so that exits are not
obstructed. For installation, it shall be ensured that field devices shall be provided with
an anti-vibration mount with corresponding fixations and fastened to the building’s
steelwork or concrete structure, for example by means of instrument brackets to DIN
16281, instrument racks, valve manifolds with appropriate attachment means etc. The
fixations shall be executed to allow secure mounting of the field devices.
Post or bracket mounts for instruments shall not be attached to pipework, removable
flooring, handrails, or be directly affixed to machinery and equipment subject to
vibration.
Page : 63 OF 85
9.8. Local Instrument Enclosure And Racks

Transmitters and switches, devices, etc. (mounted in the field shall be suitably grouped
together and mounted (i) local instruments enclosure (conforming to IEC 60529) in
case of outdoor open areas of the plant (ii) Heated instrument enclosure in case
process is prone to freezing (iii) In local instrument pedestals / racks in case of
covered/indoor areas. The exact grouping of instruments in a particular instrument
enclosure/instrument rack shall be as finalized during detailed engineering stage
subject to Contractor's approval. LIEs/LIRs dimensions and number of instruments
mounted on it shall be finalized during detailed engineering stage.
All open air mounted field instruments shall be grouped on transmitter racks and
enclosed by transmitter protection boxes. Temperature sensors shall be provided at
least with a suitable shade to protect them from direct sunlight. A weatherproof design
with type of protection IP 67 IEC 529 shall be provided.
The internal layout shall be such that the impulse piping/ blow down lines are
accessible from back side of the enclosure / rack and the transmitters etc. are
accessible from front side for easy maintenance. Bulkheads, especially designed to
provide isolation from process line vibration shall be installed on instrument
enclosures/racks to meet the process sensing line connection requirement. Vibration
dampeners shall be installed for each enclosure / rack.
The enclosures shall be constructed of 3 mm sheet plate and shall be of modular
construction with one or more modules and two end assemblies bolted together to
form an enclosure. Double inter locking doors shall be provided. The doors shall be
the three-point locking type constructed of not less than 1.6 mm thick steel. Doors
shall have concealed quick removal type pinned hinges and locking handles. Door
locks shall accept the same key. Gaskets shall be used between all mating sections.
The instrument racks shall be free standing type constructed of suitable 5 mm thick
channel frame of steel and shall be provided with a canopy to protect the equipment
mounted in racks from falling objects, water etc. The canopy shall not be less than 3
mm thick steel, and extended beyond the ends of the rack. Bulk heads, especially
designed to provide isolation from process line vibration shall be provided. Exact
fabrication details shall be as finalized during detailed engineering stage.
Enclosures/racks shall be reinforced as required to ensure true surface and to provide
adequate support for instruments and equipment mounted therein. Centre posts or any
member which would reduce access shall not be provided.
The enclosures shall be made in GRP (Glass Reinforced Polyester) with stainless steel
hardware, closed cell neoprene gasket, viewing window and where needed, with
heater/thermostat. Furthermore the enclosure shall be light grey coloured, waterproof
constructed, antistatic, fire retardant and self-extinguishing, UV resistant and non-
absorption of hydrocarbons
Page : 64 OF 85
The Bidder shall prepare the piping drawings and the general arrangement layout
drawings for each of the enclosures and racks. Special attention shall be given in the
piping layout to avoid air traps in liquid filled piping or water pockets in piping
intended to be dry. Drawings shall indicate the arrangement of all equipment, piping,
valves and fittings within, the enclosure/racks and shall be subject to Contractor's
approval.
All liquid filled blow down lines, except those measuring vacuum shall be connected
to a two inch header which is extended through one end of the enclosure and turned
downward for directing the blow down into a drain. The material of the blow down
header shall be carbon steel as per ASTM A 106 Gr. C.
All items of the plant shall be equipped with suitable locally mounted directly
connected locally indicating measuring equipment, particularly pressure, level, flow,
electrical and temperature gauges sufficient for commissioning or general maintenance
purposes.
All locally mounted instruments shall be located in readily viewable and accessible
positions.
The scope of local measuring instrumentation shall at least be as follows:
Pressure gauges shall be provided on the suction and discharge side of all pumps, on
the gas side of all diaphragm pulsation damper units, on all pressurized vessels; on all
main distribution header sections. Differential pressure gauges shall be provided on all
strainers, and filters of all types.
Temperature indicators shall be provided on the inlet and outlet of all coolers/heaters
on the cooling side and on heating side, and on all lube oil return lines and all lube oil
tanks. :level indicators shall be provided on all vessels, typically but not necessarily
limited to storage and buffer tanks of all types, liquid/gas or air separators, knock-out
vessels and header tanks.
Graduated level indications shall be provided on all reagent tanks for prevision
reading. Flow indicators or tell-tales shall be provided on all cooling water lines and
bearing lubrication lines, for both water and oil lubricated bearings. Flow graduated
indicators shall be provided on all sample lines.
9.9. Climatic Protection, Sealing and Purging

In general, equipment supplied shall conform to the environmental classes defined in
IEC 60654. Instruments and their associated pipe work shall be mounted in heated or
protected locations wherever possible in order to minimize the effects of ambient
weather conditions. Were this is not possible a suitable means of ensuring and/or
minimizing such effects shall be applied. All open air mounted field instruments shall
be grouped on transmitter racks and enclosed by transmitter protection boxes.
Page : 65 OF 85
In operation, during installation and maintenance, and during transit, the equipment
may be subjected to continuous vibration and shock loads. The mechanical design
shall take account of these conditions to minimize the risk of failure.
Instruments shall be mounted in heated or protected locations wherever possible in
order to minimize the effects of ambient weather conditions.
All field mounted instruments shall be weatherproof to IP65 as per IEC 60529 or
equivalent and suitable for the local operating conditions. Field mounted instruments
shall be provided with a suitable shade to protect them from direct sunlight. All
instruments, instrument tapping points and controls shall be accessible from floor level
or permanent platforms.
Instruments in water services or where water can accumulate in the impulse lines shall
be trace heated where the ambient temperature can fall below 0°C. Wind chill factor
shall be considered.
Instruments in liquid services, which solidify at ambient temperature, shall be
provided with diaphragm seals.
Seal chambers or diaphragm seals shall be used where fluid services are corrosive,
viscous, congealing, deposit forming, or dangerous. Seals shall be located as close as
possible to the primary isolating valve.
9.10. Heat Tracing System

An Electrical Heat Tracing system shall be provided in order to achieve the smooth
operation of plant during the winter season or other when the ambient temperature is
too low. All necessary hardware, processing equipment, local cubicles, and cabling
and calibration tools/equipment shall be provided.
The term heat-tracing refers to the continuous or intermittent application of heat on the
piping, equipment, and instrumentation where fluid (water or other product) may be
exposed to low temperature/freezing conditions. Whenever the contents of a pipe or
vessel are maintained at temperatures exceeding the ambient temperature, there shall
be a flow of heat from the product to the external air. Insulation shall slow the heat
loss, but shall not prevent it. Heat tracing is a method to provide the supplemental heat
just enough to compensate for the heat loss due to lower ambient temperature.
The heat tracing system shall designed of series panels with temperature control and
monitoring units for heat tracing used in freeze protection and process temperature
control applications.
This series of panels shall be configured for ambient or line sensing control. The
system shall implement a scale able design such that they can be configured with or
without communications, ground fault monitoring or enclosure heater.
Page : 66 OF 85
10. C&I CABLES
10.1. Technical Requirements

For analogue signals, shielded cables shall be provided with non-ferrous metal screens
for each twisted pair as well as an overall screen. For digital signals, cables with an
overall screen shall be used.
All the instrument cables shall utilize stranded copper conductors with twisted and
shielded pairs or triads. The instrument cable shall be suitable for installation indoor or
outdoor, in trays, conduits, and underground ducts per the requirements of the NEC.
UL accepted maximum conductor operating temperature rating of 90°C continuous.
Voltage rating shall be of 300 or 600 Volts.
The minimum conductor size for twisted shielded single and multi-pair cables shall be
1.5sq.mm.
The required compensating wires for temperature measurements must be at least 1.5
mm2.
Multi pair cables shall be employed in analogue circuits up to a maximum of 20 mA,
and digital circuits up to 50 V dc; this shall include solenoids up to 24 V dc.
Multi pair cables shall have twisted pairs of solid or stranded tinned copper conductors
of 1mm2 minimum cross sectional area. These cables shall have MICA tape, and
XLPE or EPR insulation.
The cores of multi pair cables shall be colour coded in accordance with IEC 60189-2.
Individually screened cables shall have a copper backed polyester tape with a stranded
copper drain wire around each pair. Each pair shall be identified by a numbered tape.
The overall screen shall be similar to that of the individual screens.
All multicore control and instrumentation cables shall have a minimum cross sectional
area of 1.5 mm2, have XLPE or EPR insulation with copper wire braid and a halogen
free black outer sheath.
Voltage rating shall be 600 Volts for control cables. Cables shall be Capable of
storage, handling, bending, and installation at ambient temperatures as low as - 10
degrees C without cracking the jacket or insulation. Cables shall be UL listed type
PLTC in accordance with the NEC.
The fiber optic cables (FOC) shall comply with ANSI/FDDI standards and shall be
designed for indoor and outdoor (according to requirements) environments in riser
shafts, metal conduits/raceways above the ceiling and duct banks between buildings.
HDPE sub ducts shall be used to protect FOC in the underground duct bank. The cable
jacket shall be flame retardant as per NFPA rated and water resistant with color coding
to help distinguish fiber media from other premise cables. The cable shall be non-
metallic in construction. The FOC shall be multimode, non-metallic, tight buffer and
graded index type. The maximum attenuation shall be 1 db/km at 1300 nm
Page : 67 OF 85
wavelength. Monomode fiber cables shall consist of always 24 fibers. Fiber - type
9/125 μm, OS-1. 19” patch panels shall be used for termination, connectors shall be
LC-Duplex as standardized by IEC 61076-3-106 var. 4. All fibers shall be terminated /
connected.
Monomode fiber cables shall comply with IEC 24702.
The fibre optic cables shall be complete with non-metallic strain relief elements.
Each fiber shall be color coded accordıng to IEC 60304.
Fibre optic cables that are installed outdoors shall be armored. Cables used indoors
shall be reinforced with a steel wire braid.
10.2. Cable Installation

 Separation
Running C&I cables along the same route as power cables shall be avoided. Where
this is not possible, the cables shall be segregated as fully as possible. It is not
permissible for power and C&I cables to share the same tray/rack/conduit.
C&I cables shall be run on dedicated trays with a minimum separation between the
C&I trays and other trays.
If C&I cable trays are to be installed in the same routes as power cable trays then the
C&I trays are to be installed at a lower level than the power cable trays to ensure that
heat generated by the power cables does not travel through the C&I cables.
A closed conduit C&I cabling system shall be used for individual field devices up to
the local junction box.
 Segregation
All C&I cables from one unit shall be segregated from those for any other unit. The
cables for common or station equipment shall be segregated from any unit cabling.
Cabling for redundant equipment shall be installed over separate routes. Cabling for
redundant instrumentation (e.g. two-out-of-three voted signals) shall be installed over
at least two separate routes.
 Laying and Terminating
C&I cables shall be fully supported either in conduits, on tray, racks or other support
systems subject to the Contractors approval. The cables shall be adequately supported
and clamped to prevent excessive sagging. Cable routes shall be such that the cables
are not exposed to extremes of temperature from the plant processes and prolonged
exposure to direct sunlight without some form of thermal protection.
The installation of the cable cores/pairs within the plant equipment, adaptable boxes,
junction boxes and marshalling boxes shall be such that a core/pair can be moved from
one extreme end of the terminal rail to the other end. In addition the core/pair shall be
capable of being re-terminated a minimum of three times.
Page : 68 OF 85
All spare cores/pairs shall be tied back with a length capable of being terminated as
above.
 Identification
Each cable shall be identified with a cable number approved by the Owner/Engineer.
Each cable core shall be uniquely identified using interlocking ring plastic ferrules or
similar. Clip on or 'c' type ferrules shall not be used. The core identifier shall be to the
approval of the Owner/Engineer.
Where the route of the cable is through junction boxes, marshalling boxes, etc both the
incoming core and the outgoing core shall carry the same unique core identification.
 Cable Screens and Armouring
The design of equipment shall be such that cable screens and cable armouring are kept
electrically separate throughout the equipment installation. This separation shall be
maintained throughout by the installation of a suitable earth system subject to
approval.
10.3. Cable and Individual Core Labelling

 Cable numbers
Cables shall be classified acc. to the voltage levels, e. g.
K0001 ... K0999 HV-power cables AC > 20 kV
K1001 ... K1999 MV- power cables AC ≤ 20 kV, > 1 kV
K2001 ... K2999 LV- power cables AC ≤ 1 kV
K3001 ... K3999 power cables DC 110 V, 220 V
K4001 ... K4999 UPS-cables AC / DC
K5001 ... K5999 control cables AC / DC 24 V, 60 V, 230 V
K6001 ... K6999 signal cables, binary and analogue
K7001 ... K7999 system cables (network cables, serial bus cables, FOC, etc.)
K8001 ... K8999 special cables (e.g. compensation cables for thermocouples, etc.)
K9001 ... K9999 small power lighting cables (non process cables).
 Cable designation
Deviating from the original KKS system the cable numbers shall be used at the
positions AANNN of the equipment unit code break down level.
In this case one alphanumeric digit instead of 2 intended by KKS shall be used. The
system code of the cables destination shall be taken. If the destination is ambiguous,
the system with the lower alphabetical digit shall be the destination. The complete
cable designation will then consist of the system break down level and the cable
number (e. g. 2 LAC11 K6201).
 Cable labelling
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The complete cable label shall consist of the KKS of the starting point of the cable, the
cable designation and the destination’s KKS, separated by dots.
Following example shall illustrate the structure.
0 BJA01 • 2 LAC11 K6201 • 2 LAC11 AP010-M01
Cable labels shall be of durable, break-proof, UV-Resistant design. Labels shall
be attached at the start and end of the cable and at least at each branch of cable
supports (which have different designations).
11. CONTROL VALVES

The control valves and accessories furnished by the Bidder shall be designed
constructed and tested In accordance with the latest applicable requirements of code
for pressure piping ANSI B 31.1, ISA, and other standards specified or acceptable
equal standards.
11.2. Control Valve Sizing

The valve sizing shall be suitable for obtaining maximum flow conditions with valve
opening at approximately 80% of total valve stem travel and minimum flow
conditions with valve stem travel not less than 10% of total valve stem travel. All the
valves shall be capable of handling at least 120% at the required maximum flow.
Seller shall offer the most appropriately sized trim for the service. Reduced trims
should have reduced ports (i.e., not reduced travel). Seller shall size the valve to be 25
percent capacity at the process design condition and/or 90 percent capacity at the
process maximum design condition specified herein. Bidder shall size the valve
actuator based on delivering the required force output when the instrument air header
pressure is at a low of 4.83 bars (70 psig).
Bidder shall furnish the sizing calculations, which shall be subject to Owners’
approval during detailed engineering. The sizing calculation of control valves shall
conform to ISA-S-75.01. The maximum seat leakage shall meet the requirements of
ANSI/FCI 70.2 as applicable for the intended use. Permissible noise level should not
be allowed to exceed 85 dBA at one meter distance from the control valve in any case.
11.3. Valve Construction

1. All valves shall be of globe body design & straightaway pattern with single or
double port. Unless otherwise specified or recommended by the manufacturer to
be of angle body type. Rotary valve may alternatively be offered when pressure
and pressure drops permit.
2. Valves with high lift cage-guided plugs & quick-change trims shall be supplied.
Page : 70 OF 85
3. Bonnet joints for all control valves shall be of the flanged and bolted type or any
other construction acceptable to the Contractor. Bonnet joints of the internal
threaded or union type shall not be acceptable.
4. Plug shall be of one-piece construction, either of cast, forged or machined from
solid bar stock. Plug shall be screwed and pinned to valve stems or shall be
integral with the valve stems.
5. Valve characteristic shall match with the process characteristics.
6. All actuators for ON/OFF and regulating services shall be complete with all
accessories including the following:
 Side mounted Hand wheel with lock
 Positioner for regulating services
 End position (open / close) limit switches.
 Local position indicator and non-contact type position transmitter with 2 wire,
4-20 mA DC output for regulating services. Solid-state integrated circuitry
shall be utilized and shall be intrinsically safe and EMI and RFI immune.
 Junction box near the valve for terminating the limit switch position
transmitter.
11.4. End Preparation

Valve body ends shall be either butt welded/socket welded, flanged or screwed. Steel
valves shall conform to ANSI B16.34. Socket-weld end valves shall conform to MSS
SP-84. Butterfly valves shall conform to MSS SP-67. The welded ends wherever
required shall be butt welded type as per ANSI B 16.25 for control valves sizes 65 mm
and above. For valves sizes 50 mm and below welded ends shall be socket welded as
per ANSI B 16.11. Flanged ends wherever required shall be of ANSI pressure-
temperature class equal to or greater than that of the control valve body. Where valve
body material requires a dissimilar metal field weld, end extensions of metal similar
to the pipe to which they shall be welded shall be installed and stress relieved by the
manufacturer.
11.5. Valve Materials

The control valve body material shall be Alloy steel / Carbon steel / 316 SS as per
process requirement. Bidder shall offer valves with body and trim materials as per
process requirement with relevant comparison of properties including cavitation
resistance, hardness, tensile strength, strain energy, corrosion resistance and erosion
resistance etc. of the offered material and the specified material. Valve body rating
shall meet the process pressure and temperature requirement as per ANSI B16.34.
Page : 71 OF 85
11.6. Valve Positioners

1. Valve positioners shall be furnished on diaphragm or piston actuators for the
following functions:
a) To amplify or convert to a required actuator pressure.
b) To position a spring less piston or diaphragm actuator.
c) To position a valve in which a large unbalanced force exists.
d) Valve in important temperature control loops.
e) Line pressure exceeding 2000 kPa (300 psig).
f) For split range applications or situations with more than one valve operating from single
control signal.
g) Valves size 4” and over.
h) Extension bonnets or bellows seals.
i) Butterfly valves, Saunders patent bodies, or three-way valves.
2. Valve positioners shall be considered on diaphragm or piston actuators under the
following operating conditions:
a) On valves handling sludge, coke or solids in suspension.
b) On pressure control of a low pressure, large volume gas system.
c) On high temperature service (i.e., greater than 220 deg. C (450 deg. F) and low temperature
service (i.e., less than 0 deg. C (32 deg. F).
d) On venture throat valves, three-way valves, characterized ball, butterfly and Saunders
valves.
3. Positioners shall be all digital as specified. Where feasible, digital positioners
shall be equipped with a bypass arrangement by means of which the control
signal may be applied directly to the valve operation. Pressure gauges for signal,
air supply and valve loading pressures are also required.
4. If a control valve is subjects to excessive vibration a pneumatic positioner shall
be used and the converter mounted elsewhere.
11.7. Valve Actuator

All control valves shall be furnished with pneumatic actuators. The Bidder shall be
responsible for proper selection and sizing of valve actuators in accordance with the
pressure drop and maximum shut off pressure and leakage class requirements. The
valve actuators shall be capable of operating at 60 degC continuously. Valve actuators
and stems shall be adequate to handle the unbalanced forces occurring under the
specified flow conditions or the maximum differential pressure specified. An adequate
allowance for stem force, at least 0.15 Kg/sq.cm. per linear millimeter of seating
surface, shall be provided in the selection of the actuator to ensure tight seating unless
otherwise specified. The travel time of the pneumatic actuators shall not exceed 10
seconds.
11.8. Limit Switches

1. Limit switches shall be furnished for the following functions as required:
Page : 72 OF 85
a) For electrically indicating one of two predetermined positions in the stroke of a control
valve.
b) For actuating solenoids, relays, alarms or similar equipment.
2. The switches shall be suitable and rated for hazardous location and shall have
waterproof enclosure.
3. The switches shall be adaptable to operate in response to linear or rotary motion
of the valve, and shall be capable of mounting in any position.
4. Limit switches shall be installed to provide remote indication of the valve
position. (In the CCR via the DCS)
5. The electrical rating shall be 230 VAC, 15A, 24 V DC.
11.9. Solenoid Valve

Enclosures for solenoid valves shall be IPW66 (NEMA 4) for outdoor locations.
Solenoid valves shall be rated for continuous duty at 220VAC or 125VDC or 24VDC
or as specified otherwise. Solenoid coils shall have Class H insulation. Solenoid
valves shall be specified on the Control Valve Data Sheets. All solenoid valves shall
also be provided with manual operators. The valves shall be 3-way or 4-way with
minimum 8mm or 1/4 NPT connection. Solenoid valves shall have body construction,
trim materials and internal arrangement suitable to the application.
For instrument air, solenoid valves shall have brass bodies, composition seats and
universal flow design.
11.10. Control Valve Accessory Devices

All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-
jacks, limit switches, microprocessor based electronic Positioner, diffusers, external
volume chambers, position transmitters (capacitance or resistance type only),
reversible pilot for Positioner, tubing and air sets, solenoid valves and junction boxes
etc. shall be provided as per the requirements.
12. MOTOR OPERATED VALVES (MOV)
Motorized valves shall be used for isolation purposes and shall consist of self-
contained (Integral) actuator units with motor, gearbox, contactor, controls,
limit/torque switches and all auxiliary equipment installed in each actuator housing. A
lockable local/remote selector switch with open/close controls shall be located on the
actuator. The actuator shall be designed such that it may be disengaged from the valve
if a fault has occurred and the valve operated normally by using the hand wheel.
Each end of the actuator travel shall be fitted with suitable limit and torque switches
for preventing over-travel and consequential damage to the actuator. Limit switches
shall be installed also to provide remote indication of the valve position. Local valve
position indication shall be provided on the actuator. The valve position shall be
Page : 73 OF 85
indicated in the control system and the relationship between the command signal and
the actuator position shall be monitored and any discrepancy alarmed in the control
system.
13. SOLENOID VALVE
Solenoid valve coils shall be 230 V AC or 24VDC or 125VDC or as specified, Class

H high temperature construction and shall be designed for continuous duty. Three-way
solenoid valves shall be designed for universal operation so that the supply air may be
connected to any port. Solenoid valves shall have either pigtail wires or screw
terminals for electrical connections. Valves shall be selected to incorporate body
construction, trim materials, and internal arrangements suitable to the application.
Solenoid enclosures shall be IEC 60529 compliant.
14. DRIVE CONTROL PHILOSOPHY
Bidder shall refer Attachment – Drive Control Philosophy to be considered for

supplied drives.
15. QUALITY ASSURANCE AND INSPECTION
Bidder shall refer relevant sections of Attachment – O for Quality assurance and
testing requirements for supplied equipment/ systems.
16. TESTING
The Bidder shall carry out the following tests on the completed equipment in the
manufacturer’s works. The Company/Engineer reserves the right to witness such tests:
a) Visual inspection;
b) Functional tests;
c) Redundancy checks;
d) Control loop testing;
e) Communication test with DCS via OPC
f) Voltage withstand test and insulation test;
g) Control Valve Testing
 Non Destructive Test as per ANSI B-16.34.
 Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat leakage
test.
 Valve closure test and seat leakage test in accordance with ANSI-B 16.34 and
as per the leakage class indicated above.
Page : 74 OF 85
 Functional Test: The fully assembled valves including actuators control

devices and accessories shall be functionally tested to demonstrate times from
open to close position.
 CV Test: Please refer Cl No. 16.1 (a), Sr. no. 21 (Type test requirements),
Control Valves.
Where a number of items of equipment are intended to operate together, the complete
assembly shall be tested to demonstrate that the interconnected items are compatible.
Site acceptance tests shall include, but not be limited to, the following:
i. Demonstration of the correct functioning of hardware and software in connection
with the plant response;
ii. Redundancy tests by actual means;
iii. Commissioning tests including instrument calibration checks, loop tests,
sequence, control and protection logic tests, demonstration of operator displays,
alarm facilities and other functional software packages (eg sequence of events,
data historian, performance monitoring etc);
16.1. Testing & Inspection

1. All equipment furnished under this specification shall be subject to test by
authorized quality assurance personnel of the Bidder, representatives of the
Owner and/or Owner’s Engineer during manufacture, erection and on
completion. Bidder quality assurance personnel for these shop and site tests shall
be identified in advance and shall be acceptable to the Owner. The approval of
the Owner/Owner’s Engineer or passing of such inspection of tests shall not,
however, prejudice the right of the Owner/Owner’s Engineer to reject the
equipment if it does not comply with the specifications when erected or fails to
give complete satisfaction in service.
2. The Bidder shall furnish details of shop and site tests proposed to be conducted
by him at various stages to meet the specification requirements for each type of
instrument/system along with his proposal. Bidder shall also furnish details of
his proposed shop and site quality assurance organization for this package.
3. Bidder shall prepare a detailed shop and site ‘Quality Assurance Program’ to
meet the requirements of these specifications for Owner’s/Owner’s Engineer’s
approval. This document shall also contain the formats for reports and
maintenance of test records specification of test equipment to be used for site
tests.
4. All equipment and systems furnished under this specification shall be subjected
to shop & site tests in accordance with the Quality Assurance Program approved
by the Owner/Owner’s Engineer and shall be adequate to ensure full compliance
with these specification, all applicable codes & standards and detailed
engineering drawings and documents approved by the Owner/Owner’s Engineer.
Page : 75 OF 85
5. The Bidder shall provide all required test equipment and simulation devices for
performing all shop and site tests. All tests equipment shall be of reputed make,
required accuracy class and shall be recently calibrated. The record of calibration
of test equipment shall be made available to the Owner/Owner’s Engineer on
demand.
a) Test & Inspection for Instruments
After Manufacturing, all instruments shall be tested and calibrated at Factory.
Bidder shall be responsible in obtaining test certificates related to calibration of
all the Instruments and submit for Owner/Owner’s Engineers approval. Bidder
shall allow dispatch of these instruments only after passing applicable Factory
Acceptance test and approved by Owner/Owner’s Engineer. The details of the
tests to be carried out for the different instruments / field equipments/ Systems
shall be as indicated in the Table 5.1 and any other tests as required by the
Standards and Codes.
S.N. Instruments/Equipments Test to be conducted

Pressure indicators  Calibration test
1
 Hydro test (1.5 times max. Pr.)
 Calibration test
 Hydro test
 Contact rating test
2 Pressure switches  Accuracy test
 Repeatability Test
 Hysteresis test
 Differential test
 Hydro test
Pressure Transmitters  Leak test
3
 Over range test
 Accuracy test
 Repeatability test.
 Hydro test
Differential Pressure
 Leak test
4
Indicators  Over range test
 Accuracy test
5 Differential Pressure  Calibration test
Switches  Hydro test
 Leak test
 Over range test
 Accuracy test
Page : 76 OF 85

 Repeatability test
 Hydro test
Differential Pressure
 Leak test
6
Transmitters  Over range test
 Accuracy test
 Material test
Thermometers  Accuracy test
7
 Bore concentricity
 Hydrostatic test for TW (1.5
times max. pr.).
 Material test
 Accuracy test
8 Temperature switch  Bore concentricity
times max.pr.)
 Calibration
 Material test
 Accuracy test
Resistance temperature
 Bore concentricity test
9
detector assembly  Insulation test (<500 M ohms at
500 V, DC) as per ISA
 Hydro test for TW.
 Accuracy test
 Calibration
 Material test
 Insulation test (<500 at 500 V,
Thermocouple assembly DC) as per ISA
10
 Hydro static test (1.5 times max.
pr.)
 Bore concentricity
 Accuracy test
11 Temperature transmitters  Accuracy test
 Ambient temperature error test
12 Thermowells  Material test
 Bore concentricity : ±1.5% of
wall thick
Page : 77 OF 85

times max.pr)
 Functional test
 Temperature rise test
Interposing relay  High voltage test
13
 Limits of operation test
 Insulation test
 Hydrostatic test
Level gauges  Material test
14
 Seat leakage test
 Ball check test
 Material test
15 Level switches  Hydro test
 Material test
Level Switch (Probe)  Contact rating test
16
 Hydro test
 Material test
Flow switch  Hydro test (1.5 time max. pr)
17
 Functional test
 Material test
18 Flow glasses  Hydro test (1.5 time max. pr)
 Functional test
Variable area flow metes  Material test
19
 Hydrostatic test (1.5 time
max.pr)
Flow element  100% Radiography test
20
 Hydro test / Calibration test
21 Control valves  Hydrostatic test :
MSS-SP-61/ANSI B 16.34
 Seat leakage test : As per ANSI
B 16-104
 CV test : As per ISA procedure
 Magnetic particle test : As per
ANSI B 16.34 Special class
(applicable for pr.> 70 bar &
tem < 400 OC
 Liquid penetration test : As per
ANSI B 16.34 Special class
Page : 78 OF 85

(applicable for pr > 70 bar &
temp < 400 OC
 Calibration
 Hysteresis test
 Calibration
22 Position Transmitters  Hysteresis
 Accuracy test
I/P Converters  Calibration test
23
 Accuracy Test
 Hydro test
Solenoid Valves  Seat leakage test
24
 CV test
 Coil insulation test
Air Filter Regulators  Calibration test
25
 Accuracy test
Junction Boxes  Test for degree of protection
26
 Material test
 Hydro test
 Air leak test for tubing, Piping &
Transmitter Racks/ fittings Verification of degree of
protection
Enclosures/Local
 Test for enclosure type
27
Panels/Marshalling  Type tests & routine tests as per
Cabinets/System Cabinet relevant international standards.
 Electrical tests as detailed under
“Wiring, Terminations &
Accessories”
Wiring Termination and
28
Accessories
 Conductor resistance test (*)
 High voltage test (*)
 Impulse dielectric test
 Insulation test
a Routine test  Humidity test
 Temperature rise tests on power
circuits
 Short time current tests on
power circuits.
b Type test  Annealing test (*)
 Test for insulation and sheath (*)
 Flame retardance test – (a)
Oxygen index, (b) Flammability
 Test for acid gas generation
Page : 79 OF 85

 Test for water absorption (*)
 Wet dielectric test.
Note (*) – As per relevant
International standards
 Test for moulding for flame
resistant
 Non-hygroscopic and
Decarbonized
29 Test for terminal blocks
 Insulation test between terminals
 Insulation between terminal
block and frame
b) Test & Inspection for PLC
Tests for PLC shall include:-
1. Factory Acceptance Test (FAT)

To be carried out at PLC suppliers works & witnessed by Owner/Owner’s
Engineer, successful completion of which shall be the basis for “Authorization
for Shipment to Site”. FAT shall be preceded by Pre-FAT inspection/Test by
Bidder/supplier
i. Pre – Acceptance Test (Pre-FAT)

The authorized quality assurance personnel of Bidder/supplier shall conduct all
tests as per the requirements of approved quality assurance program and fully
satisfy in compliance with specification requirements by all equipment / sub-
systems and the system as a whole before sending notification for Factory
Acceptance Test to Owner / Owner’s Engineer. Bidder/supplier shall maintain
accurate records for all pre-acceptance tests which shall be properly
documented and duly certified documents shall be furnished to Owner /
Owner’s Engineer at least one month prior to Factory Acceptance Test.
 Input-Output Wiring Check

Bidder shall conduct a point by point wiring continuity check to every input
and output and verify that the wiring connections agree with documentation.
The test shall be performed by connecting a controlled signal to each input
Page : 80 OF 85
point in sequence. One point at a time, the wiring of all outputs shall be
checked.
Upon completion of point wiring checkout, Bidder shall conduct a system
operational test employing static signals over the range of input signal.
Appropriate static signals simulating each input shall be applied, scanned,
processed, printed etc. as directed by the program. Signal strength shall be
varied in order to check alarm functions and output fidelity. Simulation shall
include testing of all specified system functions and operation. All calculations
and conversions shall be verified against pre-calculated results.
Calibration of outputs shall be individually tested for the quality and range over
the period of not less than ten days (i.e. 220 hours) after completion of
debugging, in order to confirm system stability and accuracy and to detect
faulty programming, operation and components.
 Burn-in and Elevated Temperature Test

All microprocessor based system / equipment shall be tested as a complete
system/equipment with all devices connected for a minimum of 168 hours
(7days) continuously under energized conditions prior to shipment as per the
following testing cycle:
o Elevated temperature test cycle
During the elevated temperature test which shall be for 48 hours of the
total 168 hours testing, the ambient temperature shall be maintained at 50
deg C. The equipment shall be interconnected with devices which shall
cause it to repeatedly perform all operations it is expected to perform in
actual service with loads on various components being equal to those
which shall be experienced in actual service.
During the elevated temperature test the cabinet doors shall be closed or
shall in the same positions as it is expected in actual service and inside
temperature in the zone of highest heat dissipating components/modules
shall be monitored. The temperature rise shall not exceed by 10 degree C
above the ambient temperature at 50 degree C.
The 48 hours test period shall be continuous but shall be divided into four
12 hours segments. The input voltage during each 12 hours segment shall
Page : 81 OF 85
be nominal voltage for 11 hours; followed by 110 per cent of nominal

voltage for 30 minutes; followed by 90 per cent of nominal voltage for 30
minutes.
o Burn-in test cycle
The 48 hours elevated temperature test shall be followed by 120 hours of
burn-in test as above except that the temperature shall be at normal
operating temperature prevalent at actual service conditions.
During this test, the process I/O & other load on the system shall be
simulated by simulated inputs & in the case of control systems the
process which is to be controlled shall also be simulated.
Microprocessor based systems shall be subject to the elevated
temperature test and burn-in test as complete assemblies. Testing of
individual components or modules shall not be acceptable.
ii. Notification for FAT

Bidder shall give Owner / Owner’s Engineer written notice for the readiness of
control system for testing.
Bidder shall maintain proper records duly signed by authorized quality
assurance personnel regarding all stage inspections, tests on individual
equipment/subsystem/systems which are conducted by Bidder as per his
standard procedure as well as those conducted to meet the requirements of this
specification and Owner/Owner’s Engineer approved "Quality Assurance
Program".
Bidder shall furnish copies of the following as implemented documents prior to
Acceptance Tests.
 System configuration drawings

 Copies of all as-built drawings (GA, IA, Wiring drawings etc)
 Final approved copies of all drawings / documents.
 All off-line diagnostic program listings
 Off-line diagnostic manuals
 Dump of individual and complete data base
 Detailed main and bulk memory maps
 Final Design Specification Volumes
Page : 82 OF 85
 Test data to verify all calculations

 Procedures of generating database, logs, structuring / tuning of
controllers etc.
 Test procedures, copies of approved data sheets and relevant pages of
approved QAP for field instruments & control actuators.
 All test reports for all types of tests carried out by Bidder.
iii. Acceptance Test at Bidders/Suppliers Factory/Shop

The Acceptance Test shall include all reasonable exercises which the
combination of equipment and software can be expected to perform. The test
shall include but not be limited to, the following:
 Demonstration of the proper function of all hardware.

 Demonstration of required spare system capacity and all other
parametric requirements of this specification.
 Demonstration of all man / machine functions.
 Demonstration of the proper functioning of all software.
 Demonstration of all diagnostic features.
 Point by point exercising of each input and output.
 Thorough exercising of each device, including the processor / CPUs,
Peripherals etc.
The Acceptance Tests shall also include the following Tests:
 Simulation of Inputs - to verify conversion accuracies, scan rates,

operator functions, corrections of calculations.
 Operational Tests - to verify that the system performs all required
functions and meets the specification requirements with respect to "free"
processor time, spare memory requirements, loop response time and other
parametric requirements.
 Diagnostics Test - to test working and bulk memory locations, instruction
complements, functioning of outputs and peripheral devices, functioning
of system check modules, etc.
 Power-consumption test - to verify KW consumption.
 Power failure test - to observe the consequences of a total power failure.
 Accuracy and Repeatability Test - accuracy and repeatability for analog
inputs shall be demonstrated by statistical analysis using the point values
read every scan cycle for a consecutive 8 hours period for a total of 10
percent of all analog inputs. The specified noise rejection capabilities shall
be demonstrated using the same test and analysis, by the application of at
least 135 V RMS common mode and 25 V RMS differential mode to the
Page : 83 OF 85
same inputs. The noise rejection test shall be a second 8 hours test. Inputs
to be used shall be randomly selected by Owner / Owner’s Engineer prior
to the test.
 Functions - All system functions shall be tested to demonstrate that they
are in accordance with the specification.
 Calculations - All calculations shall be tested to demonstrate that they are
in accordance with the specification and I/O schedule. Bidder shall prepare
all test cases for calculations (three for each calculation at low, mid and
upper ranges of inputs) and submit them for Owner / Owner’s Engineer's
review in accordance with contract schedule. Test cases shall include
performance calculations, flow and level calculations.
 Demonstration of the manual and auto switch over from main to standby
Bus / Controllers.
The following minimum criteria shall be followed during all tests:
 System shall meet all parametric and functional requirements of contract

specification.
 The Control system shall be able to perform all specified functions without
any interruption and / or degradation.
 Any allowable operator inputs through keyboards shall not result in system
crash or hanging.
 Except for bulk memory failure, the disconnection / failure of any
peripheral device while system is operating shall not lead to system crash.
 Pulling out or insertion of any I/O module from its slot, shall not result in
any system / sub-system failure.
The results of all Acceptance Tests shall be properly documented by Bidder
and submitted to Owner / Owner’s Engineer.
Upon successful completion of Acceptance Test, Owner / Owner’s

Engineer shall provide Bidder with a written authorization for shipment of
the system equipment to the project site.
2. Site Acceptance Test (SAT)

Involves tests for site commissioning; guarantee tests for system performance
& availability; to be conducted in presence of Owner/Owner’s Engineer.
1. On-site test shall include all tests to be carried out by Bidder at site upon
receipt of equipment. These shall include but not be limited to inspection
of equipment, preliminary on-site checks and tests, pre-commissioning
trials, start-up tests, trial operation, performance and guarantee test,
availability test etc.
2. Bidder shall perform the site tests in accordance with the requirements of
Page : 84 OF 85
the specification and Owner / Owner’s Engineer's approved “Quality

Assurance Program".
3. Bidder shall maintain all test records in Owner / Owner’s Engineer’s
approved formats. These shall be countersigned by the authorized quality
assurance personnel of Bidder supervising these works.
a. Preliminary On-Site Inspection and Tests

After field installation and before equipment energisation and connection
of field inputs, Bidder shall inspect all equipment and shall check wiring
and cabling to assure correctness of connections and power equipment
installation. After these checks, Bidder's representative shall power the
system and perform standard diagnostic tests on all system modules and
equipment to assure that the system is working. The field inputs and
outputs shall then be connected by Bidder.
b. Start-up
On completion of erection of the equipment and before start-up, each
item of the equipment shall be thoroughly cleaned and inspected for
correctness and completeness of the installation and acceptability for
start-up, leading to initial pre-commissioning tests at site. The list of pre-
commissioning tests to be performed shall be as Owner / Owner’s
Engineer's approved "Quality Assurance Program".
On completion of inspection, checking and after the pre-commissioning
tests are satisfactorily over, the complete equipment shall be operated
integrally with sub-systems and supporting equipment as a complete
system.
17. DOCUMENTATION
All I&C equipment, metering/measuring devices forming part of the

scope of supply and service shall be completed with all supporting
technical documentation, i.e. certificates from manufacturer and
calibration reports to be registered in the state register of the Republic of
Page : 85 OF 85
Uzbekistan as well as metrological certification to be conducted in

Uzstandart Agency.
A complete set of documentation (including docs on functional
assembles and systems) regarding metering/measuring devices shall be
submitted including:
 Specifications on metering gauges installed on functional assembles
or systems
 Operations manual explicitly describing specifications of metering
gauges.
 Methods to check and calibrate metering gauges
 Metering gauges calibration certificates issued by manufacturing
plant
 Certification of metering/measuring systems and instrument
channels.
 Calibration certificates

Attachment-T - General C&I Technical Requirement Requirements For Packaged System

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EMPLOYER CONSULTANT

JSC "TOSHKENT ISSIQLIKELEKTRMARKAZI

ÇALIK ENERJİ SAN.VE TİC. A. Ş

Construction of Two Gas Turbine Units (GTU) with a capacity of 32 MW each

A 25.02. 2022 For Review APM RAM AKC

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

GENERAL C&I TECHNICAL REQUIREMENTS FOR PACKAGED SYSTEM

PROJECT DOCUMENT NO:

Project Unit System Orig. Serial No Rev. A

THPE 00 VC YI TCE 001 Size A-4

VENDOR DOCUMENT NO: ** if applicable

1.1. PROJECT BACKGROUND............................................................................................................................

2. CODES AND STANDARD............................................................................................................................

5.1. GENERAL REQUIREMENTS..........................................................................................................................14

 Thrust Position Monitor...........................................................................................................................34

6. PROGRAMMABLE LOGIC CONTROLLER (PLC)...............................................................................42

6.1. GENERAL REQUIREMENTS..........................................................................................................................42

7. PANELS AND DESKS.................................................................................................................................49

7.1. CONSTRUCTIONAL FEATURES OF PANELS, CUBICLES & ENCLOSURES..........................................................49

7.5. WITHSTAND CAPABILITY OF EQUIPMENT.....................................................................................................55

8. PANEL MOUNTED DEVICES...................................................................................................................55

9. INSTRUMENT INSTALLATION AND ERECTION HARDWARE.......................................................58

10. C&I CABLES.............................................................................................................................................65

10.1. TECHNICAL REQUIREMENTS...................................................................................................................65

11. CONTROL VALVES................................................................................................................................68

11.1. GENERAL REQUIREMENTS......................................................................................................................68

11.9. SOLENOID VALVE.................................................................................................................................71

12. MOTOR OPERATED VALVES (MOV).................................................................................................72

13. SOLENOID VALVE.................................................................................................................................72

14. DRIVE CONTROL PHILOSOPHY........................................................................................................72

15. QUALITY ASSURANCE AND INSPECTION.......................................................................................72

16.1. TESTING & INSPECTION.........................................................................................................................73

DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS

A IFR 25.02.2022 Issued for Review

1.1. Project background

The Government of the Republic of Uzbekistan (here after shall be referred as

1.2. Intent of specification

2. CODES AND STANDARD

S.N Parameter Unit

1 ASME American society for Mechanical Engineers

PTC 19.2 Instrument and apparatus for pressure

PTC 19.3, Temperature Measurement

PTC 19.5, Flow Measurement

PTC 19.11 Water and Steam in power cycle

2 ANSI American National Standards Institute

ANSI/FCI 70-2, Control Valve Seat Leakage

S.N Parameter Unit

ANSI B16.34, Valves – Flanged and Butt Welding

3 IEC International Electrochemical Commission

61131-3 Real Time Automation

60584 Part 1: Reference tables;

60584 Part 2: Tolerances;

60584 Part 3: Extension and compensating cables

751, Thermometer-element-platinum resistance

60770 Part 1: Methods of evaluating performance

60534, Control Valve Noise calculation

4 DIN Deutsche Industries Norman

S.N Parameter Unit

DINVVDE 19250 –Functional Safety And

DIN IEC 68 Environmental Testing

6 ISO International Standard Organization