SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

CONTENTS

1.

GENERAL

2.

CONTROL SYSTEM SPECIFICATIONS

3.

VENDOR LIST

4.

SCOPE OF WORK

5. SCOPE OF SUPPLY

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 1 of 18

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 2 of 18

1.0 GENERAL
1.1 Introduction
This document describes the Project Specific scope of work / supply to be carried out
by Package vendor for Package Boiler plant for DHT/HGU/SRU Process facilities of
HPCL Visakha Refinery, at Vishakhapatanam (AP) - India.
The package vendors scope includes Design, Engineering, procurement, supply,
Fabrication, Inspection, Transportation, Storage, shop testing, site installation, site
supervision, commissioning & Documentation .
1.2

Definitions:
a)
b)

Owner : HPCL
PMC \ EPCM : TEIL

1.3

This document identifies the specific job requirements / specifications pertaining to the
scope of package vendor. This document shall be read in conjunction with the latest
revision of Package specification no. 6261-KA-102, MMS specification 6261-KA-303,
UPS specification no. 6261-N-137 (attached under electrical section of the
Enquiry) ,Interface Block diagram IST-403, standards / documents / drawings and
other documents attached else where in the bid document. The requirements, which
have not been specifically identified in Scope of Work & Scope of Supply but required
for completion of package or referred elsewhere in these documents, are in package
vendors scope.

1.4

In the event of any conflict between this document and any other document attached
to package enquiry , the package vendor shall follow the following documents in order
of their priority.
a) Statutory requirements and codes & standards.
b) Specific Job requirement for instrumentation in Package Boiler.(This Document)
c) Engineering Specification for control and instrumentation in package units
( 6261-KA-102)
In case of contradiction among documents, package vendor shall refer to EPCM
(Toyo) for clarification. However most stringent specification / latest proven
technology / owners specific requirements shall be followed with EPCM / Owners
approval . Owners / EPCM decision shall be considered as final.

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 3 of 18

1.5

Package Boiler A & B shall be controlled from a remote control room(MOI CR). A
Package vendor to provide BMS PLC (as per details below) for Burner management
and Yokogawa CS3000 DCS for Boiler & balance of plant. The BMS PLC & CS 3000
DCS (Cabinets) shall be installed in Boiler Rack Room(BRR) located near the Boiler
Area (as indicated in Plot Plan). A common UPS for Package Boilers shall be provided
by package vendor & same shall be installed in BRR. Also an Engineering station with
SOE for Burner management shall be provided & installed in BRR. The Operating
work stations ( OWS ) and the Auxiliary Console with Annunciator shall be installed in
MOI control room located remotely from BRR. The SWAS and Stack Analyzer
cabinet / container with AC Unit shall be installed in field.
The Interface cabinets for interfacing MCC signals shall be installed in Substation. All
required construction material i.e signal & power cables, cable glands , cable duct /
tray, cable duct / tray supports, junction boxes, Instrument air manifolds / header etc.
for Boiler & for all equipments supplied along with Boiler to BRR Substation, between
BRR & substation, between DM Plant-II CR to BRR & between BRR to MOI CR shall
be in package vendors scope. The MCT blocks, MCT Frames, GI cable tray inside
Boiler Rack Room, inside substation(MCC), inside MOI control room. UPS for
Yokogawa CS3000 DCS , BMS PLC, MMS & Instruments in package vendors battery
limit shall be supplied by Package vendor. All necessary interconnecting power,
signal, system cabling inside Boiler rack room between package vendor supplied
Yokogawa CS3000 Control System, BMS PLC & MMS cabinets & from/to operator
work station(s) & Engineering station shall be in package vendors scope of design,
supply, installation.
Refer Boiler Plot Plan attached in the Tender for location of mentioned Control
room/Rack Room & substation.

1.6

Henceforth for this specification, unless otherwise mentioned:

DCS shall mean the Yokogawa CS 3000 system
PLC shall mean BMS PLC
Vendor shall mean Package vendor.

1.7

A common dedicated PLC for Burner Management System (BMS) to be

provided .And a common DCS for Boiler & balance of plant items shall be
provided .The PLC shall be TMR ( TRIPLE MODULAR REDUDANT) OR alternatively
QMR , with TUV AK5 ,SIL3 certification. The PLC shall have redundant processors ,
redundant power supply, redundant Input/Output cards & redundant communication
cards. The total scan time of PLC shall not be more than 300msec. The DCS shall be
designed as per clause no. 2.0 as a minimum. All the signals from PLC shall be
available in DCS on serial link. All the machine & motor vibration & temperature
signals shall be wired to MMS. If vendor is supplying multiple MMS racks ,then all
Racks shall be supplied as fully interconnected & ready for connecting to DCS through
serial link. Common Alarm/Trip signals shall be hardwired from MMS to DCS/PLC. All
the signals from MMS shall be available in DCS on serial link. All the signals from
Analyzer control cabin / container shall be available in DCS on serial link.

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 4 of 18

The DCS, PLC & MMS cabinet shall be in vendors scope of design, supply &
installation and commissioning . DCS , PLC & MMS rack shall be installed in separate
cabinets. All interconnecting cables & cabling between all the vendor supplied
cabinets shall be in the vendor scope of design, supply ,installation & commissioning.
The DCS as well as PLC & MMS chassis / rack shall be separate for each Boiler.
Grouping of signals from two Boilers in the same chassis is not acceptable. (E.g If
there are three chassis for Boiler A then Boiler B shall have identical three chassis.)
A common Engineering PC for PLC (server grade) of latest configuration with SOE &
color printer shall be provided & installed in BRR and one Operator work station PC
for each Boiler (total 2 nos) with one Aux. console . MOI control room as a minimum.
Additional requirement of OWS and Aux. Consoles shall be decided by vendor &
brought to EPCMs /Owners notice.
1.8

Loop philosophy

1.8.1 Sensor / transmitter for shutdown purpose shall be separate from that of control.
Two out of three (2oo3) voting shall be considered for critical signals (i.e shutdown).
1.8.2 The shutdown valve needs to be separate from control valve. If Manual Reset on
Solenoid valve is required then vendor to provide separate field station for
the same.
1.9

MCC Interface.

1.9.1 MCC shall also be in the vendors scope of supply, for more details refer electrical
section of this enquiry.
1.9.2 Start/Stop for all drives with RUN indication & Auto / Manual switch shall be provided
on LCP.
1.9.3 All MCC related cables (status & commands) shall be wired to interface cabinet . The
interface cabinet shall be provided by vendor & shall be installed in Substation(MCC
Room).
1.9.4 Vendor to provide Motor RUN indication & Motor Trip Alarm indication for all
drives(HT & LT). Two separate contacts shall be provided for each drive. One set of
contact will be wired to purchasers DCS / ESD by others & another set of contact shall
be wired to Vendor DCS & any signals required for Interlock purpose shall be wired
directly to PLC by vendor. If these status indications are also required on LCP then
vendor to multiply the contacts in the DCS/PLC cabinet.
1

1.9.5 Following Relay contact rating shall be followed,

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 5 of 18

1) All status indications shall be hardwired for all LT & HT drives. The Pot free contact
shall be provided in MCC. The 24V DC contact voltage shall be provided from
DCS/PLC.
2) Commands to MCC- LT Drives (below 55 KW) :
All commands to MCC shall be hardwired. The pot free contact shall be provided from
DCS/PLC. The relay contact shall be suitable for 240 V AC.
3) Commands to MCC- For Drives(above 55 KW):
All commands to MCC shall be hardwired. The pot free contact shall be provided from
DCS/PLC. The relay contact shall be suitable for 110V DC.
1.9.6 Vendor to study the Interface Block Diagram Package Boiler IST-403 attached with
the specification and provide full compliance to the same.
1.9.7 Relay based logic in any of the package vendor supplied control panels shall not be
acceptable.
1.9.8 Along with technical offer, Vendor shall provide the total quantity of cabinets with
dimensions for following.
a) DCS ; b) PLC ; c) UPS ; d) Battery Rack
2.0

Control System Specifications

2.1 General :
The Boiler & balance of plant Distributed Control System (DCS) shall be designed for
reliable, effective and optimum control and monitoring of a process plant. The DCS
system shall be minimum fault tolerant. The DCS, by employing distributed
intelligence and database techniques, shall provide highly secure, safe, reliable,
maintainable, effective process/ safety monitoring and control of the production/
ancillary facilities from existing MOI Control Room .
This section defines the minimum requirements of system design including hardware
& software, configuration, manufacture, engineering, programming, of Distributed
control system (DCS). The scope shall include as a minimum
- Manufacture, procurement , supply, testing, installation, handling and
commissioning of all equipment, System Cables and accessories.
- Building of all operator interface, screen displays, database and reports.
- System Hardware & Software configuration. 1
- FAT of all hardware / software and system integration testing under simulated
conditions.
- Supply, install, test and commission marshalling racks, system cabinets and
consoles /printers. Including cables, terminals, IS barriers, power supplies and
cubicle internal mountings.
- Supply of all system as well as control room furniture and Buyer requirements.
- Proving of DCS system functionality as per requirements.

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 6 of 18

-Training of Buyers personnel at factory and at site on functional, operational and

maintenance aspects of the system.
-Supply of complete technical and as built documentation in electronic form as well
as hardcopy.
- Supply of all software on CDs along with required software licenses.
- Preparation (with Contractors inputs) of a FDS (Functional Design Specification)
2.2

Design & Construction

This system shall be designed fault avoidant as a minimum by selecting high grade
components of proven quality and proper design of system electronics. Redundancy
shall be provided, as a minimum, as specified below, to improve the system
availability and reliability. Due considerations shall be given to the environmental
conditions also.
The system shall be able to operate satisfactorily in the climatic conditions as
specified in tender. Wherever required, the components shall be tropicalised to suit
site conditions.
The system shall be of modular construction and expandable in future by adding
modules. The type of modules shall be kept to the minimum possible in order to have
interchangeability and low inventory.
The system software shall be governed by the operating system running in a real time
mode and shall be able to meet all specified functional requirements as a minimum.
Any other standard / special software package, if available shall also be offered
describing the full capabilities.
All system software including operating system software, network software and any
other proprietary software supplied shall be with suitable number of Licenses.
On-line replacement of any module shall be possible in such a way that removal and
addition of a module shall be possible without de-energising the system. Furthermore,
there should not be any interruption of the system while replacing a faulty module
wherever redundant modules are provided.
The system shall be upward compatible i.e. new enhancements can be incorporated
in the system for future up gradation
The complete monitoring & control of Package Boiler shall be from MOI Control Room
(However, the I/O Subsystem shall be segregated Boiler wise i.e. separate I/O cards
with separate chassis shall be considered for each Boiler. Mixing of I / O counts in
same card or same chassis shall not be acceptable. The same shall be located in
remote Rack Room termed as BRR further .(i.e Boiler Rack Room).
Throughout Boiler-wise segregation shall be followed for the Controller Sub-system,
I/O sub-system, Relay ,Barrier & Marshalling Cabinets etc.
The MOI Control Room shall house the vendor supplied Workstations, printer and Aux
consoles. The control system cabinets containing the field I/O cards, controllers,
gateways and all equipment shall be installed by vendor in BRR .Communication
between BRR & MOI CR shall be through existing redundant data highway . The
existing data highway cable is already available from existing Yokogawa CS 3000
system cabinets in DM -II CR. (refer to the plot plan attached with tender where DM- II
CR & MOI control Room locations are indicated).

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 7 of 18

All equipment shall be placed in HVAC (Heating, Ventilation and Air Conditioning)
controlled rooms.
The redundancy requirement for various system components shall be as follows:
Controller system 1 : 1 redundant
Input / output system
For closed loops and critical I/Os 1 : 1 redundant
For open loops and non critical I/Os Non-redundant
1
Communication system 1:1 redundant
Power supply 1:1 redundant
2.3

Spares :
Systems shall be designed with 15% installed pre-wired spares with all required
hardware such as relays, barriers, terminals etc. In addition, 15% spare space shall be
available throughout the system for allowing future expansion including system
cabinets, Marshalling cabinets.
Communication networks & controllers shall not be loaded more than 60% as a
minimum. Wherever possible, all equipment shall be standardized to ensure
commonality of spares, minimal training and greater economies as far as
maintenance and additional procurement is concerned
Mandatory spare module of 10% or one module of each type, whichever is higher
must be supplied for each type of modules being used including in consoles. This shall
include spare modules for hardwired instruments, relays, barriers, assignable
recorders, personal computers, programmable logic controllers etc.

2.4

System Component / Instrument Enclosures

All the equipment covered in this specification shall be located in general purpose
non hazardous area, in control room/rack room. All control room/rack room mounted
equipment shall be weather proof to IP-43.
Hazardous protection philosophy of field instruments is generally by EExia
instruments for which intrinsic safe barriers shall be considered .Explosion proof
(EExd) instruments suitable to area class may be used in case IS instrument is not
available with EPCM/Owners approval.
The Main UPS (redundant) is under Package vendor scope of supply. Package
Vendor to decide the UPS capacity as per the plant load .
As UPS is in the Package Vendor scope, power distribution for complete system also
shall be in the scope of Package vendor. Each consumer shall be provided with a
separate MCB of proper rating for isolation and protection of the system. On event of
any of the following conditions , system shall go to fail-safe mode:
Power Failure
1
Frequency Variation

2.5

Heat load calculations

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 8 of 18

The control system vendor shall provide Heat load calculations for the total system ,
considering the installed spares as well as components which would be installed in
space reserved for future expansion.
As the BRR i.e Boiler rack room is in scope of vendor , Package vendor to consider
The load of the system ,marshalling cabinets, UPS & any other accessories required
to be installed in BRR for sizing the HVAC.
2.6

System Furniture
All system furniture required for mounting and operation of the system including
mounting of table top equipments shall be supplied.
The system shall consist of the following major sub-systems :
a. I/O system
b. Processor system
c. Communication system
d. Operator interface system
e. Foreign device interface (if any)
f. Hardwired instrumentation

2.7

Functional requirements
The system as a minimum, shall meet the following requirements :
a. Control
b. Data acquisition and monitoring
c. Alarming
d. Logging and report generation
e. Historical data storage
f. Trending
g. System shall have free memory space available for the user, and CPU shall have
additional capability to perform advanced control functions, process optimization
Programs or generate management reports.
h. Communication with third party and/or higher level automation systems via the
Open Control Systems Network.
The DCS operator interface shall be the primary integrated window for operation of
the control and safeguarding systems and shall provide access to:
i. Process control.
1
j. Sequence control status.
k. Equipment status.
l. Alarm overview.
m. Trip status overview.
n. Override status.
o. Real time trending.
p. Historical data trending.
q. Fire and gas detection status.
r. Machine Monitoring.

2.8

Processor system

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 9 of 18

The control function of the system shall be executed by microprocessor based

multi-loop controller consisting of I/O ports and a set of algorithms which are easily
configurable. This system shall be capable of executing following control functions
and set of algorithms as a minimum :
a. General : Monitoring and alarms
b. Control : P, PI, PID, adaptive gain, ratio, cascade, feed forward, etc
c. Arithmetic : Addition, subtraction, multiplication, division, averaging, square root,
ramp,rate of rise / fall, etc.
d. Linearization :Flow pressure / temperature compensation, linearization,
polynominal etc.
e. Dynamic : Lead / Lag, dead time, timer, etc.
f. Modes : Auto , Manual , Cascade or Computer.
g. Limiter : Low Limiter, High Limiter, set point.
h. Comparator : Less than, greater than etc.
i. Selector : Low, High, etc.
j. Logic : AND, OR, NOR, NOT, XOR, Start / Stop, etc.
k. Miscellaneous :Bumpless transfers, direct / reverse output , Anti-reset windup , slow
fast ramping of setpoint & output etc.
The processor scan time shall be 1 second, with ability to select faster scan times upto
250 msec.
The controller shall be able to operate in either manual, auto, cascade or computer
mode. Mode change-over in either direction shall be bumpless. It shall be possible to
change set-point, tuning ,constant, operating mode, control loop configuration from
the central level i.e. operators interface keyboard and engineers interface keyboard.
In computer mode, controller shall be able to track computer generated set point and
shall hold the last generated value in case of computer failure. In such case, controller
shall fall back on auto mode and continue to operate at the last received set point, in
general. Other options like predefined set point operation and fail safe condition shall
also be possible. On the resumption of computer set point again, the controller shall
not return to the computer mode automatically,
Any addition/deletion of tag number should be possible without booting of the system
or plant shutdown.
Any changes in any portion of the database during running of the plant should be
possible.
Downloading of the changed software to the respective sub system should be
possible in running condition of the plant. Saving, updating and taking back up of the
database with respect to the latest changes made should be automatic and without
affecting the plant running.
The size of the memory shall be sufficient for storage of the program instruction
required by the control schemes. Control system vendor Offer shall indicate the
amount of memory occupied by the actual program and spare capacity available for
later program modifications or additions. A minimum of 40% spare memory space
shall be provided at the time of handing over of the system to Owner.
Memory shall be non-volatile. However, in case volatile memory is provided, battery
backup shall be provided for a minimum of one year to keep the stored program intact.
A battery drain indication shall be provided at least one week before the battery gets

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 10 of 18

drained. A potential free contact shall be provided for hardwired annunciation in the
control room. Watchdog timer shall be a software device. The healthiness of
processors shall be continuously monitored by watchdog timer. Any hardware or
software problem in the processor system including CPU, memory, power supply,
communication interface etc shall cause the watchdog timer to report
processor failure.
In case Multiprocessor configuration is offered, the processors must be able to
communicate with each other over the interconnecting data link.
Loop integrity shall be maintained in processor system architecture by providing one
to one processor back-up. In case failure is detected in the active processor all the
loops of the failed processor shall be transferred to the back-up processor. The
processor system shall have automatic control transfer switching (HOT Standby).
Design must ensure that data integrity is maintained during switch over and no portion
of data to be transferred is corrupted before and during switch over to the back-up
processor. The indication of the failed processor shall be displayed on the operator
station.
Loop integrity shall also be applicable to I/O system, power supply modules and any
other device associated with the processor system.
While downloading any changes, made to a particular tag, from engineer interface
system to the processor system the controller output shall be maintained at its last
value and should not be driven to zero value even momentarily or even fail safe value.
2.9

I/O System
The I/O system shall be capable of accepting process signals from various process
sensors preferably without requiring external or auxiliary signal conditioning devices.
The system inputs shall include 4-20 mA DC, and discrete
inputs, Pulse/frequency as a minimum. It shall be capable of processing linear and
non-linear analog inputs, providing square root extraction for flow signals,
linearization. The system shall be able to generate 4-20 mA DC current signals for
analog outputs and potential free contacts for the discrete outputs as a minimum apart
from others as specified elsewhere.
No. of inputs per Inputs/output (I/O) module shall be as follows
a. Analog I/O Modules : 16 channels
b. Discrete I/O Modules : 32 channels
1
Essential and continuous control commands and statuses to the MCC shall be
hardwired and be routed via Interposing Relay Cabinets.
Contact voltage of 24 V DC & 110 V DC shall be followed as per details provided in
clause no. 1.9.5 of this document.
Each I/O shall be galvanically isolated from external control circuit by suitable means.
Each I/O shall be protected against the reversal of polarity of the signal. Reversal of
polarity on I/O termination shall be indicated in DCS.
Each digital I/O module shall have a LED per channel to indicate the status of each
Input / output.

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ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 11 of 18

All the inputs shall preferably be double ended i.e. two wires per input and not with
common return for all inputs.
Each output shall be short-circuit proof and protected by fuse. Visual indication of fuse
down must be provided for each output.
All 4-20 mA inputs shall be capable of being software configurable on an individual
channel basis to provide energizing power for a 2-wire transmitter or to receive
powered signal from an external device such as 4-wire transmitter. The 2-wire option
shall be capable of driving the transmitters plus an additional load of 600 ohms such
as that imposed by a local indicator.
4-20 mA signals from Analyzers shall be hardwired to DCS. Analyser alarms, Analyser
house door switch alarm etc. shall also be available via serial link to DCS.
2.10

Cabinets
Following cabinets shall be required in general:
a. Power distribution cabinets (for AC distribution and DC distribution).
b. Processor system cabinets PLC & DCS
c. Interface cabinet ( for MCC interface & powered digital outputs)
d. Marshalling cabinets (DCS / PLC)
The signals shall be segregated in Marshalling cabinets as indicated below :
a. IS Analog 4-20 mA cables (through safety barriers)
b. Non-IS Analog 4-20 mA cables (if any)
c. IS Digital contact / alarm signals (through safety barriers)
d. Non-IS Digital contact / alarm signals) (if any)
e. Power cables
1
f. System communication cables
g. MCC interface signals (Further separate terminal block shall be provided for
commands & feedbacks)
(DCS & PLC marshalling cabinets shall be separate).

2.11

Earthing
A system earth & dirty Earth Pits shall be provided by others near the BRR. Vendor to
provide the common Earth Bus bar in BRR (separate for Signal & Body earth). The
supply & laying of Earthing cable from system / marshalling cabinets to Bus Bar &
from Bus Bar to Earth Pits is under vendor scope.
For OWS in MOI vendor to connect the earthing cable in existing earthing pits
available near MOI CR.

2.12

Functional testing
This shall include the simulation of each input and output to verify proper system
response.

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DOC NO. : 6261-KA-403
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Testing as a minimum shall include :a. Complete system configuration loading

b. Demonstration of all DCS/PLC system functions.
c. graphics and other views, report generation etc.
d. 100% checking of logics configured in the PLC by connecting switch/ lamp at
input / output.
e. Checking of all DCS console displays, keyboard operation, printer/hard copier
function etc.
f. System redundancy check including correct change over of the backup unit in
case of failure of main unit.
g. System diagnostic checking for all subsystems on local level as well as on
console including checking of the testing software for I/O modules signal
conditioning modules, when specified.
h. Checking of output status on processor failure.
i. Checking of first-out alarm generation.
j. Simulation of power failure and system restart auto boot-up of system configuration
and program after power restoration
3.0

VENDOR LIST
All instruments and instrumentation items shall be procured from project approved
vendors given in a list for this purpose. In case, few of the items are to be supplied
from a vendor other than mentioned in the list, then package vendor to indicate the
same as a deviation.

4.0

SCOPE OF WORK

Design, engineering, sizing & selection(type & material) ,installation &

commissioning etc. of all instrumentation including signal ,power & system cable
(including motor operated valve), cable glands , cable tray(FRP/GRP), cable tray
supports, cable duct(FRP/GRP) , junction boxes, instrument air header
/manifolds, Steam & water analysis system(SWAS), Local control panels, Flue
Gas Analyzers ( STACK ), MCT blocks and MCT Frames, GI cable tray inside
BRR, inside Substation/MCC room and inside MOI control room. DCS for Boiler
& balance of plant, PLC, MMS ,UPS ,UPS PDB,OWS, AUX. Console & Boiler
package Instruments and all necessary cables as per job specification.

The Graphics for full package (including BMS) shall be developed by vendor.
Same shall be provided for EPCM/Owner approval.
Design, engineering, sizing, selection (type &material) ,installation &
commissioning of all field instruments for Deaerator, BFW Pumps, Dosing
system
All dosing calculations shall be executed by vendor in DCS.

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DOC NO. : 6261-KA-403
Sheet 13 of 18

The FD Fan turbine shall be driven by Governor(Woodward make) mounted in

BRR cabinet. And shall be integrated with DCS.
Vendor shall supply Local gauge board ,which shall include Turbine start / stop &
feedbacks as indicated in Interface Block diagram attached with enquiry.
Laying of all signal , power ,control system cables as per job specification.
ll instrument cables shall be laid over the ground.
Laying of earthing cables from system panels to earth pits outside Rack
room/control room.
Laying of earthing cables from field to earth pits.
Lay a redundant DCS link between BRR and existing Yokogawa DCS in DM Plant-II
control room . Install the OWS & Aux console in existing MOI CR, and integrate &
commission it with the existing DCS network between MOI CR & DM Plant-II CR. All
necessary hardware/cabling required for integrating the vendor supplied control system
with existing System in DM Plant-II CR & MOI control room shall be installed by vendor.

All critical signals/shutdown shall be executed in vendor PLC only.

DELETED
Site Installation, site supervision, calibration / testing, & commissioning of
package.
Provide with a Boiler Control philosophy indicating the below requirements as a
minimum.
a. Start permissive conditions which are outside vendors battery limit but
required to be wired to DCS,& PLC to be identified by vendor & brought to
EPCMs notice.
b. Instruments which are outside vendors battery limit but required to
be wired to DCS & PLC to be identified by vendor & brought to
EPCMs notice.
c. DELETED
1
d. DELETED

Vendor to provide the requisite data for

a. Hardwired & Softwired Interface of DCS & PLC with Plant DCS/ESD in the
formats attached.(Refer Attachment-1).
b. DELETED
c. DELETED
Vendor to provide the required information by filling in the details in the above
listed formats after award of contract.
Design the UPS for Package Boiler plant as per UPS specification attached with
Enquiry.
UPS shall be designed with 25% spare capacity.
Design the power distribution system for control system , all Instruments &
panels supplied by vendor.
Vendor to prepare & submit all drawings and documents listed in document
schedule ( Attachment-11) attached with enquiry.

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 14 of 18

Vendor to provide the DCS graphics in[ (*.gif) or (*.bmp) or (*.jpg) ] format to be
further loaded by others on purchasers DCS operating system.
Vendor shall prepare and submit the as built drawings/ documents post commissioning

Any other activity not specifically listed in this document but required as part of
commissioning of the Package unit Instrumentation is also in vendors scope.

Inspection & testing

a) Field Instruments as per doc no.6261-KA-102 attached with tender.
b) Integrated Factory acceptance test (FAT) for vendor DCS ,PLC & MMS shall be
carried out by package vendor at vendors works. EPCM & Owner to witness the
same if required. All data inside vendors battery limit shall be simulated & tested
on HMI during FAT.
5.0

SCOPE OF SUPPLY

All types of instruments including field transmitters and pressure / temperature /

level gauges, thermowells, thermocouples with transmitters, RTDs (To be
supplied with transmitter if not wired to MMS), orifice assemblies, On-off /
shutdown valves with all accessories, control valves with accessories, safety
relief valves, servo gauges( if required ), level / flow / pressure transmitters,
mass flow meters, SWAS, Flue Gas Analyzer and any other special instruments
etc. as required for the package as per job specification.

Vendor shall supply Coriolis mass flow meters on Fuel oil supply and return lines with flow
meter cum totaliser for fuel oil and fuel gas. Vendor shall supply Turbine flow meters for
fuel .Gas The Mass flow meter accuracy shall be 0.2 %FS minimum. The mass flow
meter must have the capability to periodically check the validation of the last calibration
through software without dismantling the meter. Coriolis Mass Flow Meters shall be
calibrated at NABL Accredited Lab like FCRI, Palakkad in India and the calibration of
Mass Flow Meters shall be certified by Third Party Agencies like EIL/Lloyds/BV. However
imported make Coriolis Mass Flow Meters shall be calibrated at the respective foreign
vendors works, duly accredited by the respective countrys well known Accreditation
Authority like PTB, SGS etc and the same shall be certified by well known third party
agencies like SGS, LRIS, DNV etc.

All pressure tappings shall be provided with a root isolation valve.

All types of field instruments for Deaerator ,BFW pumps and Dosing System .
Flow transmitters shall be provided for the air from the FD and ID fans. Straight
duct length for installation of flow transmitter shall be as per good
engineering practice.
Deaerator with level control valve, pressure control valve, HV on steam line,
online oxygen analyzer at outlet of Deaerator.

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

Sheet 15 of 18

UV/IR type flame scanners shall be considered for scanning of flames on continuous
basis. Withdrawal type Ionisation Rod flame detectors can be used for detection of pilot
flames during start up of burners and same is to be withdrawn once the main burner
flame is established. Separate scanner to be provided for ignitor gun and main burner.
Minimum two numbers of scanners shall be provided for each main burner with 2 of 2
voting.

For high-pressure steam drum application conductive type (Hydra step bicolour
type) level instrument shall be provided.

For all the control/shut down valves in steam / BFW application body metallurgy of the
valves shall be WCC or equivalent and trim to be properly stellited. All shutdown valves
shall have Leakage class VI.

Block and bypass valve ( TSO ) to be provided for turbine meters ,vortex meters, PD
meters and mass flow meters.

UPS with half hour battery backup shall be provided.

All accessories & necessary hardware for power distribution
DCS & PLC with barriers ,relays & all necessary hardware mounted in vendors
control panel. PLC shall be used for all the interlock requirements for package
Governor(Woodward make) for Turbine driven pumps
Engineering station & colour printer
Operator Work Stations (OWS) and AUX console in MOI control room
Furniture for mounting Engineering PC & OWS in respective MOI control room /
Rack Room (with chairs).

Machine monitoring system(MMS) -BN 3500 excluding System 1 supply.

Control System The PLC , DCS & Governor shall reside inside BRR. All the
Local Panel Signals shall be hardwired to BRR. Data from MMS rack shall be
available in DCS via serial link. MMS alarms & trips shall be hardwired to
vendors DCS or PLC(as required) . DCS shall have redundant communication
to plant DCS. The DCS shall communicate to plant DCS through redundant
serial Link(RS 485)
Vendor to provide two Separate earthing bus bars( one for Instrument Earth(i.e
signal earth ) & another for dirty earth (body/chasis) ) inside each control panel
and system cabinet.
Vendor to provide two Separate earthing bus bars( one for Instrument Earth(i.e.
signal earth ) & another for dirty earth (body/chasis) inside BRR
Vendor to provide suitable earthing bus bars in field area. For details, refer
electrical section of the Enquiry
Vendor shall design ,supply & install the earthing cables suitably considering the
control system vendors requirement

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 16 of 18

For serial link to plant DCS the package vendor shall consider necessary Fiber
optic hardware in PLC cabinet for Fiber optic link ,i.e Interface unit, patch cords
,media convertor, etc as an option. The Fiber optic cable from BRR to plant DCS
shall be supplied by others
Local control Panels (LCP), switches, lamps & other accessories.(With
Intrinsically safe Annunciator )
a. Soot Blower control panels
b. Local Start-up panels
1) The Local control panels shall be weather proof certified to IP 65. And shall
be purged type .Pressurisation shall be type X (as per NFPA 496 ). And all
internal accessories including switches and indication lamps shall be flame proof
type.
2) LCP terminal blocks shall be supplied with Partition plates for higher electrical
voltages other than 24VDC.
3)Each incoming feeder shall be provided with appropriately sized 2 Pole circuit
breaker.
4) LCP shall be provided with removable gland plate, suitable for accommodating
all the cables.
5) The panel interior shall be designed as such keeping the power & other signals
cables away from each other, preferably on the extreme ends of the panel.
6) DELETED.

Local Control Panel shall have Canopy/ Shed Provision at the top for
Monsoon/Sun Protection and also lighting arrangement outside the Local Control
Panel shall be provided at the top of the Panel in addition to the Lighting
arrangement inside the Local Control Panel.
Automatic sequential soot blowing shall be provided through a PLC and MCC
along with a local start-stop push button for each soot blower.
Local Gauge Board(s) alongwith the required tubing & fittings shall be in
vendors scope of design ,supply , installation & commissioning
Auto start for all BFW Pumps & remote start / stop shall also be provided from DCS
Flue Gas Analyzer for Stack ,with necessary sampling handling & conditioning system
(Flue Gas to be analysed for CO, O2 , SPM(suspended particulate matter), NOx & SOx
)shall be supplied by vendor
Flue Gas analyzer (STACK ) and SWAS shall be located in control cabinet / container
with AC Unit. The SWAS panel shall consist of the following analysers as minimum:

Service
Boiler Feed Water

Analysers
pH
Conductivity
x
x

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

Boiler Water
Main Steam (S/H Out)

x
-

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 17 of 18

x
x

In addition to the above, bidder shall provide analyzers for Dissolved oxygen,
Silica and sodium / ammonia
DELETED
Hot extraction type stack analysers are preferable over the dilution one,
However selection of Hot Extraction or Dilution type shall be decided as per the
process data / conditions
All installation and erection materials such as impulse piping, pipe fittings and
valves, tubing, cable tray and tray support including fire protection ( within
package vendor battery limit ) requirement, all types of consumables and
accessories for mounting all instruments and instrument supports / accessible
platforms.
All type of signal cables such as signal / alarm, control, thermocouple extension
.From field to BRR, BRR to Substation, BRR to DM Plant-II CR,DM Plant-II CR
to MOI CR(if any) & MOI CR to BRR
All interconnecting hardware for DCS /PLC shall be supplied by vendor
All types of system cables and communication cables including redundant DCS
link between BRR and existing Yokogawa DCS in DM Plant-II control room .
Cabling for the supplied OWS & Aux console in existing MOI CR for integrating
with the existing DCS network between MOI CR & DM Plant-II CR. All necessary
system cabling for integrating the vendor supplied control system with existing
System in DM Plant-II CR & MOI control room shall be in vendors scope
All UPS & Non-UPS power supply /distribution cables
Cable ducts & Cable trays(FRP/GRP) from field to BRR , from BRR to MOI
control room and from BRR to Substation(MCC room) &GI cable trays inside
BRR , inside Substation(MCC room) , inside MOI control room & structural
supports,consumable for cable laying and routing
Separate Junction Boxes for different types of signals such as 4-20 mA dc, RTD,
for solenoid valves, switch contacts, alarm, intrinsically safe and non
intrinsically safe instruments(with EPCMs approval) etc.
DELETED
DELETED
DELETED
All instruments, junction boxes ,glands, LCPs etc supplied by vendor shall be
certified for Zone 2 IIC T4
All pipes and pipe fittings for instrument air supply distribution / Air Manifolds
and tubes and tube fittings for instrument air supply / steam tracing / Hook ups
etc.
Earthing strip for earthing of all instrumentation items like local panel, junction
boxes, cable trays / ducts, stanchions etc.
FRP canopies for field instruments
Any other erection material necessary for installation and commissioning of
instruments and special instrument items

SPECIFIC JOB REQUIREMENT

FOR INSTRUMENTATION IN
PACKAGE BOILER
ISSUED : 20.07.2009
Rev 1

JOB NO. : 6261

TOYO ENGINEERING INDIA LTD.

DOC NO. : 6261-KA-403
Sheet 18 of 18

Each of mandatory spares(including 2/3/5 valve manifolds), list of 2-years

operational spares, start-up and commissioning spares for all instruments and
any special instrument items.
DELETED.
DELETED.