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LIST OF FUNCTIONAL SPECIFICATIONS – INSTRUMENTATION
(As applicable for Sagar Laxmi Modification Project)
Page 2 of 2
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 2 OF 11
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 3 OF 11
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 4 OF 11
4.1.2.5 All flanges on the level instrument pressure retaining parts shall be of the same
type and rating as the process flanges, and shall be in accordance with the vessel
trim specification.
4.1.2.6 Float type level gauges shall comprise of a simple float magnetically coupled
with the indicator assembly.
4.1.2.7 The drain valve from all level instruments shall be piped / tubed into the platform
drains system. All level instruments in toxic and hydrocarbon service shall have
blow down connections to closed drain / safe venting place.
4.1.2.8 Each Level gauge shall be hydro tested to a pressure of 1.5 times the design/max/
process pressure. The manufacturer before shipment shall perform calibration and
alignment of all instruments.
4.1.3 Gauge Glasses
4.1.3.1 Gauge Glasses shall be provided on all vessels except product storage tanks, to
cover the complete operating range of level including the spans of level
transmitters and level alarm switches.
4.1.3.2 Reflex gauge glasses of the high-pressure type shall be used for gas-liquid
interfaces where the liquid is clean and colorless.
4.1.3.3 Transparent or thru vision gauges shall be used for liquid-liquid interfaces,
distillates heavier than 250 API gravity, all-crude and residues. Interface gauges
shall be connected directly to the vessel without gauge columns. Transparent
gauge glasses shall be back-lighted with gauge illuminators. Each Illuminator
shall have power isolation switch.
4.1.3.4 Gauge glasses shall have one or more sections of approximately 302 mm (11-
7/8") visible length with top and bottom connection. A maximum of five sections
shall be used for a single gauge. Where more than one gauge is required, they
shall overlap a minimum of 25 mm (1") of visible length.
4.1.3.5 Standard velocity check gauge-cocks shall be furnished with all gauge glasses.
They shall be the offset type with bolted bonnet, ¾” male unions at valve seat-and
gauge connections. Stem shall have hand wheels and quick closing thread with
double seated plunger to permit repacking cock in service and with tip on plunger
to unseat ball check before cock is closed.
4.1.3.6 Gauge glass assemblies shall be chosen for the design pressure and temperature
of the respective vessel.
4.1.3.7 Multiple gauge glasses installation may be mounted on a single pipe column with
block valves at the vessel. Multiple gauge glasses installations shall be
adequately supported so as to prevent strain on gauge valves and nozzles.
4.1.3.8 A block valves shall be installed between the gauge valve and source of fluid to
permit removal of the gauge glass.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 5 OF 11
4.2 Material:
4.2.1 The material requirements for Level Gauge shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided in
Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.2.3Body and cover plate shall be SS316. Bolts and nuts shall be SS316. The glass shall
be toughened borosilicate (Klinger or equivalent) which is resistant to thermal and
mechanical shocks. Ball checks plunger seat and valve stem shall be type SS 316.
Drain connection shall be ½” NPT and shall be provided with a SS 316 drain valve.
Wherever necessary, higher-grade material suitable to the process conditions shall be
used. Vent connection shall be ½” NPT on top of each gauge glass. Vent valve with
blind flange shall be provided with top connection. Drain connections shall be piped to
drip pans or deck drains.
4.3 Resolution: “Resolution of the markings on the gage shall be ±2mm.
4.4 Reading Scales: Units for level indicating scales shall be 0-100 percent. (For tanks,
it can be the measure of the height of the tank in the resolution desired) suitable least
count
4.5 Enclosure Class: The level gauge shall be weather proof to IP 65 for electrical
enclosure.
4.6 Miscellaneous:
Nameplate: In addition to the requirements mentioned in the Instrument Design
Criteria 3.6.6.1, the level gauge shall have “stamped” on its SS name plate the
following details:
• Tag Number
• Manufacturer’s Name and Trade Mark
• Gauge type and Model Number
• Material of construction and Pressure Rating
• C/C distance / Measuring range.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 6 OF 11
ANNEXURE – I
CHAMBER
COCK COCK
S. No. Piping Class &HAND
BODY TRIM
WHEEL.
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1,
PE1, PXF1, PF1, A2, B2, D2, E2, XG1, A1H,
1 A3, B3, A8 SS316 SS316 SS316
A1N, B1N, D1N, E1N, F1N, XF1N, PA1N, SS316L SS316L SS316L
5
PB1N, PD1N, PF1N, XG1N (NACE) (NACE) (NACE)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 7 OF 11
ANNEXURE – II
HOOK UP DRAWING
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 8 OF 11
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 9 OF 11
LIST OF ITEMS.
39 GLOBE VALVE ½” SW 01 No
46 FLANGE ¾” TH 04 Nos
For ¾”FL
62 GASKET 02 Nos
½”
51 CAP TH 02 Nos
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 10 OF 11
LIST OF ITEMS.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 11 OF 11
4 UPPER FLUID
5 LOWER FLUID
SERVICE COND 6 PRESS - OPER / MAX
7 TEMP - OPER / MAX
8 TYPE
9 VISIBLE LENGTH mm
10 NOS. OF SECTIONS
11 CENTRE TO CENTRE DISTANCE mm
LEVEL GAUGE 12 CONNECTION SIZE & RATING
13 CONNECTION LOCATION
14 BODY MATERIAL
15 CHAMBER BODY MATERIAL
16 GLASS TYPE
17 BODY MATERIAL
18 TRIM MATERIAL
19 VESSEL CONN & TYPE
20 GAUGE CONN & TYPE
21 TYPE
22 BALL CHECK
GAUGE COCK
23 RENEWABLE SEATS
24 BONNET
25 SCREW - INSIDE / OUTSIDE
26 CLOSING - PLAIN / QUICK
27 MINIMUM RATING
28 ILLUMINATORS
29 ILLUMINATOR D ETAILS
30 MICA SHIELD
31 HEATING CHAMBER
ACCESS-ORIES 32 COOLING CHAMBER
33 NON-FROSTING TYPE
34 CALIBRATED SCALE
35 GAUGE - VENT
36 GAUGE - DRAIN
37 IBR CERTIFICATION
MISC. 38 MODEL NUMBER
39 MANUFACTURER
Notes :
□ DEVIATION □ NO DEVIATION
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 1 of 8
FUNCTIONAL SPECIFICATION
(PNEUMATIC)
TOTAL
REVIEWED APPROVED
PREPARED No. OF DATE REV. No.
BY BY
PAGES
VS RS GRP 8 18.02.2008 3
ET RS GRP 12 28.03.2007 2
ET MC RK 12 23.06.2005 1
AK MC AC 12 17.04.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 2 of 8
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 3 of 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 4 of 8
4.1.1.9 Connection for air or gas supply, transmission and control signals shall normally
be internally threaded ¼” NPT.
4.1.1.10 Level switches, float or displacer-operated, shall be actuated mechanically for
switch operation. Head or pressure operated level switches shall be calibrated as
required. Each switch shall be hydro tested to a pressure of 1.5 times the max
process pressure. The manufacturer before shipment shall perform calibration
and alignment of all instruments.
4.1.1.11 External Cage Type Instruments:
4.1.1.11.1 External cage level instruments shall have pressure ratings equal to or greater
than the relevant piping classification for flanged valves.
4.1.1.11.2 Connection for external cages shall be minimum DN50 flanged.
4.1.1.11.3 A positive seal shall be used in transferring float / displacer motion to the
external mechanism where a float or displacer element is employed.
4.1.1.11.4 All external cage instruments shall be designed to permit rotation of the head,
torque tube and transmitter or switch case in relation to the cage / well portion.
4.1.1.11.5 The standard configuration for external cages shall be side and side.
4.1.1.11.6 All external cages shall be fitted with vent and drain and test connections
normally of ¾” NPTF.
4.1.1.12 Displacement Type Instruments:
4.1.1.12.1 Displacement type level instruments shall be of the externally mounted type.
4.1.1.12.2 Displacer chambers for external displacers shall have minimum DN50 ANSI
300 RF flanged vessel connections.
4.1.1.12.3 ‘Side and Bottom’ connections shall be used with ring type joints or similar
connections. Side and top connections shall be used only in cases where this
would avoid a pocket in the connecting piping (on small vessels).
4.1.1.12.4 Connection for internal displacer shall be DN 100 flanged, unless otherwise
specified and approved by the Company.
4.2 Material:
4.2.1 The material requirements for Level switch shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided
in Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.3 Enclosure Class: The Level switch shall be weather proof to IP 65 or better.
4.4 Miscellaneous: For Level Instruments, especially Switches, the bottom connection
shall not be located at the bottom of the vessel, on or near the exit / drain of the
vessel / equipment, as it may cause erroneous signals of “LSLL/LSL” on account
of the velocity of the draining liquid.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 5 of 8
ANNEXURE – I
Material Selection Chart for level switch
4 A5 MONEL MONEL
5 A7 CS SOLID TEFLON
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 6 of 8
ANNEXURE – II
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 7 of 8
ANNEXURE – II
(Hook Up Drawing)
ANNEXURE – II (Contd.)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 8 of 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 1 of 8
FUNCTIONAL SPECIFICATION
FOR
LEVEL SWITCH
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
VS RS GRP 9 18.02.2008 3
ET RS GRP 12 28.03.2007 2
ET MC RK 12 23.06.2005 1
AK MC AC 12 17.04.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 2 of 8
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 3 of 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 4 of 8
4.1.2.6 The switch element shall be selected in such a way that it can withstand an over-range
pressure of 1.5 times maximum range without loss of calibration.
4.1.2.7 Level switches shall be heavy duty, with user adjustable set point . Adjustments shall
be tamper-proof.
4.1.2.8 The Level-sensing element shall be designed to meet a service life of one million
switching cycles.
4.1.2.9 Vendor shall ensure that set point falls between 35% and 70% of adjustable range of
the selected model in general.
4.1.2.10 The primary type of level instrument for level switches shall be float type. Level
displacer and float instruments shall be external chamber type. Solid displacers are
preferred to hollow displacers, especially in high-pressure services.
4.1.2.11 The drain valve from all level instruments shall be piped into the platform drains
system.
4.1.2.12 All flanges on the level instrument pressure retaining parts shall be of the same type
and rating as the process flanges, and shall be in accordance with the vessel trim
specification.
4.1.2.13 The collapse pressure of hollow displacers and floats shall be entered on the
instrument data sheet, and marked on the instrument nameplate.
4.1.2.14 The primary type of level instrument for remote transmission shall be displacer type.
4.1.2.15 All switches shall be Ex d.
4.1.2.16 External Cage Type Instruments:
4.1.2.1.15.1 External cage level instruments shall have pressure ratings equal to or greater than
the relevant piping classification for flanged valves.
4.1.2.1.15.2 Connection for external cages shall be minimum DN50 flanged.
4.1.2.1.15.3 A positive seal shall be used in transferring float / displacer motion to the external
mechanism where a float or displacer element is employed.
4.1.2.1.15.4 All external cage instruments shall be designed to permit rotation of the head, torque
tube and transmitter or switch case in relation to the cage / well portion.
4.1.2.1.15.5 The standard configuration for external cages shall be side and side.
4.1.2.1.15.6 All external cages shall be fitted with vent and drain and test connections normally
of ¾” NPTF.
4.1.2.17 Displacement Type Instruments:
4.1.2.17.1 Displacement type level instruments shall be of the externally mounted type.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 5 of 8
4.1.2.17.2 Displacer chambers for external displacers shall have minimum DN50 ANSI 300
RF flanged vessel connections.
4.1.2.17.3 ‘Side and Bottom’ connections shall be used with ring type joints or similar
connections. Side and top connections shall be used only in cases where this would
avoid a pocket in the connecting piping (on small vessels).
4.1.2.17.4 Connection for internal displacer shall be DN 100 flanged, unless otherwise
specified and approved by the Company.
4.2 Material:
4.2.1 The material requirements for Level switch shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided in
Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed.
4.3 Accuracy: The maximum error shall not exceed 1% of the span. Repeatability shall be
±1%.
4.4 Reading Scales: Units for level switch shall be in mm.
4.5 Enclosure Class: In addition to weatherproof, the switch enclosure shall be explosion-
proof to NEMA-7 and certified by third party agencies like UL/FM/BASEEFA or equal
for use in hazardous area (CL 1,DIV.1, GR.D). A warning label which reads
(EXPLOSION PROOF INSTRUMENT, ISOLATE ELSEWHERE BEFORE
OPENING”, shall be affixed on pressure switches which are certified as explosion
proof.
4.6 Miscellaneous:
The switches shall be provided with SS name plate indicating the following:
• Tag Number
• Manufacturer’s Name and Model Number
• Adjustable range
• Element material
• Enclosure classification.
4.6.1 For Level Instruments, especially Switches, the bottom connection shall not be
located at the bottom of the vessel on or near the exit / drain of the vessel / equipment,
as it may cause erroneous display of level on account of the velocity of the draining
liquid.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 6 of 8
ANNEXURE – I
Level Instrument
S. No. Piping Class
Body Displacer / Float
4 A5 MONEL MONEL
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DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 7 of 8
ANNEXURE – II
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3102
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9000: 2000 (Electrical) Page # 8 of 8
ANNEXURE – III
(TYPICAL DATA SHEET FOR LEVEL SWITCH –Electrical Type)
o
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> C
Level/Length-> mm
1. Tag. No.
General 2. Quantity
3. Service
4. Area Classification
5. Internal / external
6. Interface
7. Case Material
8. C/C – Distance
9. Conn. Size & Rating
10. Location Upper
11. Location Lower
Case 12. Case Orientation
13. Rotatable Head
14. Finned Extension
15. Vent Drain Conn. Size
16. Case to head flange size & rating
17. Displacer or Float
18. Diameter Length mm.
19. Insertion Depth mm.
20. Displacer Extension mm
Displacer
Or Float 21. Displacer or Float Material
22. Displacer or Float Stem Material
23. Spring/Torque Tube Material
24. Function
25. Output
26. Control Modes
27. Differential
28. Controller Action
29. Elect. Area Classification
30. Enclosure Material
31. Area Classification
Functional 32. Power Supply
Data 33. Switch Type
34. Qty. Form
35. Contact Rating
36. On Level Inc. O/P
37. On Level Dec. Contact
38. Cable Entry
39. Upper Liquid
40. Lower Liquid
41. Sp. Gr. Upper Lower
Service
42. Press. Nor. Max.
Conditions
43. Viscosity-Upper Lower
44. Temp. C Nor. Max.
45 Model No.
Others 46. P & ID No.
47. IBR Certification
NOTE:-
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FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 2 OF 11
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 3 OF 11
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 4 OF 11
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 5 OF 11
4.5.2 All wetted parts shall be suitable for intended process application.
4.5.3 The cage material shall be compatible with the vessel material, and shall be
Carbon Steel as a minimum. Flange material for external cages shall be Carbon
Steel as a minimum.
4.5.4 All flanges on the level instrument pressure retaining parts shall be of the same
type and rating as the process flanges and shall be in accordance with the vessel
trim specification.
4.5.5 Torque tube when used shall be of Inconel / Monel minimum, with nylon bushing
type bearings. All other wetted parts shall be SS 316 minimum, unless otherwise
specified.
4.6 Accuracy:
4.6.1 For Displacer Type / DP Type Level Transmitter: The maximum error shall not
exceed ±0.5% of the span .
4.6.2 For Radar Type Level Transmitter: ± 3mm(Liquid Level) and ± 10mm(Interface
measurement) or better.
4.7 Output Signal:
4.7.1 Output signal shall be 2 wired 4-20 mA DC, and capable of delivering the rated
current signal into external load of around 600 ohms when powered with nominal
24V DC (negative earthed).
4.7.2 Transmitters shall have HART protocol for communication for remote calibration
and diagnostics from HART maintenance system
4.8 Reading Scales:
Units for level indicating scales shall be 0 – 100 percent.
4.9 Display:
LCD Type, Local/ Integral with the transmitter head or Remote Display. The
Transmitter shall be configurable in engineering units.
4.10 Enclosure Class:
The transmitter shall be weatherproof (IP 65 or better). In addition the LT
enclosure shall be as per Clause no 3.6.4.4.5 of Instrument Design Criteria.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 6 OF 11
ANNEXURE – I
Level Instrument
S. No. Piping Class
Body Displacer / Float
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 CARBON STEEL SS 316
(EXCEPT WAT. INJ. SERVICE)
4 A5 MONEL MONEL
CARBON STEEL
SOLID TEFLON
5 A7 TEFLON LINED
[** All Process wetted parts shall be NACE MR-01-75 (Latest Edition ) as minimum ]
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 7 OF 11
ANNEXURE – II
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 8 OF 11
ANNEXURE – II
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 9 OF 11
NOTES:
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 10 OF 11
ANNEXURE-III ( Page 2)
DISPLACER TYPE LEVEL TRANSMITTER
UNITS: Flow→ Liquid M3/Hr Gas→ M3/Hr Steam → Kg/Hr Pressure → Kg/Cm2 G Temp→ 0C Level / Length→ MM
1. Tag No.
2. Service
General 3. Internal / External
4. Interface
5. Body or Cage Material
6. Flange Material
7. Conn. Size Type & Rating
8. Flange Facing & Finish
9. Location Upper
Body / Cage 10. Location Upper
11. Case Orientation
12. Rotatable Head
13. Finned Extension
14. Vent Drain Conn. Size
15.
16. Displacer or Float
17. Diameter Or Length mm.
18. Insertion Depth mm.
Displacer or 19. Displacer Extension mm.
Float 20. Displacer Or Float Material
21. Spring / Torque Tube Material
22.
23. Function
24. Output
25. Control Modes
26. Differential
27. Controller Action
28. Elec. Area Classification
Trans. / 29. Elec. Power Or Air Supply
Controller / 30. Switch Type
Switch 31. Qty. Form
32. Contact Rating
33. On Level Inc. Contact
34. On Level Dec. Contact
35. Cable Entry Single / Dual
36. Enclosure
37. Intrinsically Safe
38. Filter Regulator with Gauge
39. Jacketing – Medium Conn.
Option 40. -Temp. C Press
41. Torque Tube Flushing Conn.
42. Intrinsically. Safe Weather Pr. / Pmete
43.
44. Upper Liquid
45. Lower Liquid
Service 46. Sp. Gr. Upper Lower
Conditions 47. Press. Nor Max.
48. Temp. C – Nor. Max.
49. Model No.
50.
51. IBR Certification
NOTES:
VENDOR’S SIGNATURE WITH SEAL
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 11 OF 11
ANNEXURE-III (Page 3)
RADAR TYPE LEVEL TRANSMITTER
1. Tag No.
2. Service
GENERAL 3. Line Number/ Equipment No.
4. P&ID No.
5. Area Classification
6. Upper Fluid
7. Lower Fluid
8. Density: (Kg/m3) Upper Lower
9. Pressure: Op. Max.
10. Temperature: Op. Max.
SERVICE COND. 11. Design Pressure
12. Design Temperature
13. Die Electric Constant Upper Lower
14. Type
EQUIPMENT 15. Internal Diameter / Height
16. Type
17. Principle
18. Range
SENSOR 19. Probe Type
20. Probe Length
21. Probe Material
22. Probe Submerging Cond. Fully/ Partially
23. Mounting
24. End Connection: Material
25. Internal/ External
26. Interface
27. Cage Material
28. Center to Center Distance: (mm)
29. End Connection: Size Rating
30. Location: Upper Lower
CAGE 31. Rotatable Head
32. Connection Size & Type: Vent Drain
33. Cage to Head : Flange Size Rating
34. Cable Entry Single / Dual
35. Location:
36. Type
37. Output
38. Accuracy
39. Repeatability
40. Resolution
TRANSMITTER &
INDICATOR 41. Housing Material
42. Enclosure
43. Environmental Protection
44. Galvanic Isolation
45. Power Supply
46. Cable Entry
47. Cable Gland
48. Set Point
49. Approvals/ Certifications
OPTIONS 50. LCD Display Location
51. Make
52. Model No.
NOTES:
VENDOR’S SIGNATURE WITH SEAL
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
Design Division Spec # 3200
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai FLOW SWITCH Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FUNCTIONAL SPECIFICATION
FOR
FLOW SWITCH
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS RS GRP 4 18.02.2008 2
ET RS GRP 6 28.03.2007 1
ET MC AC 6 13.05.2003 0
ISO -FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3200
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai FLOW SWITCH Discipline Instt.
ISO 9001: 2000 Page # 2 of 4
CONTENTS
ISO -FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3200
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai FLOW SWITCH Discipline Instt.
ISO 9001: 2000 Page # 3 of 4
ISO -FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3200
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai FLOW SWITCH Discipline Instt.
ISO 9001: 2000 Page # 4 of 4
ANNEXURE – I
Typical Data Sheet For Flow Switches
FLOW SWTICHES
3 3
UNITS: Flow Liquid – M /HR. Gas – NM /HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Line Number
GENERAL 3 Line Size & Schedule
4 Service
5
6 Switch Type
7
8 End Connection – Size & Rating
9 End Connection – Facing & Finish
10 Material – Body & Flange
11 Material – Element
BODY
12 Range
13
14
15
16
17
18 Type – Electric / Pneumatic
19 Output Type
20 Contact Rating
21 Load Type
22 Enclosure Class
23 Area Class
24 On flow increase – O/p Contact
SWITCH
25 On flow decrease – O/p Contact
26 Accuracy
27 Repeatability
28 Set Point
29 Difference – Fixed / Adjustable
30 Set Point Adjustment – Internal / External
31
32
OPTIONS 33
34
35 Fluid State
36 Flow Min. Maximum
37 Flow Normal
38 Inlet Pressure Operating Maximum
39 Temperature Operating Maximum
SERVICE 40 Sp. Gr. At Oper. Temp.
CONDITIONS 41
42 Molecular Weight
43 Operating Viscosity (Cp)
44 Allowable pressure drop
45 Corrosive Content
46
47 IBR Certification
48 Manufacturer
ITEM DETAILS
49 Model Number
50 Remarks
NOTES:
ISO -FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3201
Offshore Design Section FUNCTIONAL Rev. No. 04 (a)
Engineering Services SPECIFICATION FOR Disciplin
Instrumentation
ISO – 9001:2008 FLOW TOTALIZER e
Page: 2 OF 4
CONTENTS
4.2 Accuracy 4
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
Spec. No. 3201
Offshore Design Section FUNCTIONAL Rev. No. 04 (a)
Engineering Services SPECIFICATION FOR Disciplin
Instrumentation
ISO – 9001:2008 FLOW TOTALIZER e
Page: 3 OF 4
4.1.1 The Flow totalizer shall have 2-line display. The top line shall display the instantaneous flow rate while the
second line shall display the totalized flow. LCD type display shall be provided in the Flow totalizer.
Display range for rate shall be 6 digit display or better and for cumulative flow (Total) shall be 8 –digit
display or better. Rate / total display decimal point shall be selectable.
4.1.2 The input power supply to the Flow totalizer shall be 24 V DC. The device shall have two analogue output
for alarms. It shall have capability of processing analogue mA & VDC signal as its input.
4.1.3 It shall have Keypad for process programming and calibration. All programming and total values are
stored in non-volatile memory and can be retrieved even if the power is removed from the unit. The
totalizer shall have provision to save accumulated total flow even if the power is lost.
4.1.4 When Flow totalizer and other devices are grouped and mounted on a gauge board or instrument stand it
should be in such a manner that removal of each instrument shall be possible without the need to
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
Spec. No. 3201
Offshore Design Section FUNCTIONAL Rev. No. 04 (a)
Engineering Services SPECIFICATION FOR Disciplin
Instrumentation
ISO – 9001:2008 FLOW TOTALIZER e
Page: 4 OF 4
disconnect, dismantle or remove any other instruments or tubing. Mountings accessories required for
Flow totalizer shall be 316SS or better.
4.3 Reading Scales: Units for Flow in totalizer shall be set in M3/HR for liquids and SM3 /HR for gases. In
addition, other selectable engineering units ( m3/sec, m3/day, etc) shall be available in the device.
4.4 Enclosure Class: Where specified for field mounting, the flow totalizer enclosure shall be Weather proof
to IP 65 and shall conform to Area Classification. In control room, it shall be housed n general purpose
enclosure to IP 42.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 2 OF 9
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 3 OF 9
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 4 OF 9
by reputed accredited testing labs) or with calibrators tested and traceable to the standard
labs for calibration.
4.1.10 ‘Universal Hand Held Configurator’ shall be supplied for transmitters’ calibration. The
number of calibrator shall be two per process platform & one per well platform.
4.1.11 All vent and drains of the transmitter/tubing/valve manifolds shall be routed to the Drain
Header. If the meter is on the sour service and harmful fluids like chemicals etc, then it will
be routed to close drain header.
4.1.12 Transmitters shall be immune to Radio frequency interference due to walkie-talkie, paging
system, communication system etc. All electronic modules shall be designed for short
circuit protection.
4.2 Sensor Type:
4.2.1 The pressure element in the measuring unit shall be Diaphragm / Delta cell Type.
4.2.2 For measurement at slurries, viscous & corrosive fluid Diaphragm Seals shall be used.
Wherever Diaphragm seals are required they shall be “Liquid Filled System” type with a
1½” Flanged process connection and flexible armor. The diaphragm seal shall also have a
flushing filling connection with plug.
4.2.3 The process connection of the transmitter shall be ½” NPTF.
4.3 Material:
4.3.1 The material requirements for Flow Transmitters shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria. Material Selection Chart provided in Annexure
– I of this document .and FS-2004A for Piping Design (2008) & Piping Material
Specification
4.3.2 The element material of the measuring unit shall be suitable for the process conditions.
The Wetted parts of the diaphragm seal shall be same as that of the element material. The
capillary material shall be SS 316 and the armour material shall be SS 304.
4.3.3 All wetted parts shall be suitable for intended process application.
4.4 Accuracy:
4.4.1 Flow Transmitters shall have an accuracy of ±0.1 % of span or better.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 5 OF 9
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 6 OF 9
ANNEXURE – I
Flow Transmitter
S. No. Piping Class Valve
Body Sensor
Manifold
HASTALLOY
5 A7 TITANIUM TITANIUM
C
HASTALLOY
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
C
[** All Process wetted parts shall be NACE MR-01-75 (Latest Edition ) as minimum ]
ANNEXURE – II
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 7 OF 9
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 8 OF 9
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3202
Offshore Design Section Rev. No. 5A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 FLOW TRANSMITTER
(ELECTRONIC) Page: 9 OF 9
ANNEXURE – III
Units : Flow →→Liquid-M /Hr, Gas → Kg/Hr, Steam → Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C, Level/ Length →→mm
3
S:
1. Over range protection shall be 130% of maximum static pressure.
2. Local digital Integral output meter shall be intrinsically safe and to be calibrated in engineering unit.
3. Environmental protection cover to be provided for each transmitter
4. For Extended Diaphragm seal with fill in liquid, data sheet shall be suitably filled up.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 1 OF 8
FUNCTIONAL SPECIFICATION
FOR
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 02 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 2 OF 8
CONTENTS
4.1 Application 3
4.2 General 3
4.3 Material 4
4.4 Range 4
4.5 Scales 4
4.6 Flanges 4
4.9 Miscellaneous 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 3 OF 8
4.1 Application:
4.1.1 Orifice Plates shall be used as the flow-measuring element wherever dictated by the process
requirements.
4.1.2 For a standard orifice meter, only one fixed Orifice Plate shall be designed for the rangeability of 3:1 or
less.
In case of flow rangeability higher than 3:1, senior orifice meter with two or more orifice plates shall be
required to cover the entire flow range and the each plate shall be sized for the range of 3:1 or less.
4.2 General:
4.2.1 Fabrication of the orifice plate shall be in accordance with AGA – Gas Measurement Committee, Report
No. 3, latest edition for gas measurement.
4.2.2 The Orifice meter shall in general comprise of a concentric square edged orifice plate designed for flange
tap except for particular process requirements. (Eccentric, segmental or quadrant edged orifices may be
used for special services such as slurry, wet gas or highly viscous service).
4.2.3 Where the orifice plate flow element is coupled with a force balanced or bellows type meter, the meter
shall be with a built-in adjustable dampening device.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 4 OF 8
4.2.4 The Orifice Plate Assembly shall be capable of withstanding differential pressure equal to full line
pressure without zero or calibration change.
4.2.5 Orifice plate beta ratio (orifice diameter/ inside pipe diameter) in general shall be between 0.2 and 0.75.
4.3 Material:
4.3.1 The material requirements for orifice plates shall in general be according to clause 3.6.4.5 of
Instrumentation Design Criteria and the material selection chart provided in Annexure I of this
specification.
4.4 Range:
4.4.1 Differential ranges for orifice flow meters shall not exceed 5000 mm (200 inches) of water. Typical meter
ranges for gas, steam, or vapor, streams shall be as follows:
4.5 Scales:
4.5.1 Scales for orifice metering system shall be 0 - 10 square root with multiplication factor to suit rate of flow
requirements for DP (Bellows ) type Pneumatic flow meter.
Orifice flow meter with totaliser (with or without pressure correction) shall be provided with a proper
multiplication factor in line with the flow calculation as per AGA-3 with AGA-8 (for gas). Linear scale of
DPT shall be combined with the Square root scale of Totaliser.
In case of orifice meter with MVT ( with integrated flow computer / separate Flow computer at site) and
FT with panel ( at CCR) mounted flow computer, the range of process parameters like Pressure,
Temperature, Diff. Pressure, Flow etc shall be as per the Basic Bid Work / approved P & IDs of the
respective projects.
4.6 Flanges:
4.6.1 Orifice flanges and fittings shall be installed according to AGA - Gas Measurement Committee Report No.
3.
4.6.2 Orifice flanges shall be in accordance with the standard ANSI B 16.36 with a minimum flange rating of
300# ANSI and a minimum of 1½-inch pipe size.
4.6.3 Two pairs of flange taps located diametrically opposite shall be provided. Location of taps & Tap sizes
shall be in accordance with the AGA-3 standard, latest edition. The spare tappings shall be plugged with
SS 316 as a minimum.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 5 OF 8
4.6.4 Unless otherwise specified, Orifice flange shall be RF, weld neck type for low pressure application (< 600
# rating). For high pressure application ( > or = ANSI # 600), flanges shall be of RTJ type. Based on
process requirement, final material and selection of flanges shall be in accordance with the standard
ANSI B-16.36 & AGA-3.
4.9 Miscellaneous:
4.9.1 Orifice meter design and installation shall be in accordance with the AGA - Gas Measurement Committee
Report No. 3. It is preferred that metering orifices be located in horizontal lines.
4.9.2 Orifice flanges or meter tubes shall be installed horizontally near the deck or platform for ease of
accessibility and safe changing of the orifice plate.
4.9.3 Orifice plates shall be installed after line flushing is completed, before hydro testing.
4.9.4 Prior to installing the orifice plate, it shall be checked against the Instrument Specification sheet and
inspected by the Company’s representative.
4.9.5 The static pressure element shall be connected to the upstream pressure tap on gas flow measurement.
4.9.6 Piping and equipment shall be arranged so that flashing does not occur at or upstream of orifice plates.
4.9.7 The piping layout shall always be arranged such that straightening vanes are not required and gas meter
runs are self-draining.
4.9.8 Upstream elbows in more than one plane shall be avoided to minimize vorticity.
4.9.9 Orifice plate shall be checked for correct alignment, and correct orientation with respect to the process
flow.
4.9.10 Orifice Plates shall be checked visually for nameplate data and for an upstream sharp edge. Bore shall
be callipered to check for compliance with specifications.
4.9.11 All socket-weldings shall be 100% Dye penetration / Magnetic particle tested. All other welding shall be
100% radio graphed.
4.9.12 The orifice plates shall be suitably marked with tag. Nos., bore size & direction of mounting.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 6 OF 8
ANNEXURE – I
Orifice Assembly
S.
Piping Class Flange /
No. Plate
Body
A1, B1, D1, E1, F1,
XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1,
A2, B2, D2, E2, XG1, CARBON
1 STEEL
SS 316
A1H, A3, B3, A8
(EXCEPT WAT. INJ.
SERVICE)
90-10 Cu
4 A5 Ni / MONEL
MONEL
5 A7 TITANIUM TITANIUM
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 7 OF 8
Slope : 1:12,
upwards
96
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 8 OF 8
NOTE:-
1. Orifice assembly must include supply of plates, flanges, stud, bolts, nuts, jack screw, gasket / plate, holder & plugs.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 1 of 5
FUNCTIONAL SPECIFICATION
FOR
RESTRICTION ORIFICE ASSEMBLY
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
VS SRS GRP 5 18.02.2008 3
ET RS GRP 7 28.03.2007 2
AK MC RK 7 22.07.2005 1
ET MC AC 7 13.05.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 2 of 5
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 3 of 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 4 of 5
4.2.2 The orifice plates shall be welded together to make ‘RO’ assembly. However, the last
plate shall not be welded and an arrangement shall be made to remove and replace the
last plate.
4.2.3 For the RO Assembly, certain overlaps shall be provided between successive plates.
4.2.4 The installation of Restriction Orifice Assembly shall in general be according to clause
3.6.4.6 of Instrumentation Design Criteria and as per clause 6.0 of FS 3203: Functional
Specification for Orifice Flow Meter.
4.2.5 Sizing calculations for restriction orifice assemblies shall be furnished along with the
purchase specification. These calculations shall include number of plates, bore diameter,
thickness of each plate, stress calculation, etc.
4.3 Material:
4.3.1 The material requirements for orifice plates to be used in the Restriction Orifice
Assembly shall in general be according to clause 4.3 of Document No. MR / OD / INST /
FS / 3203: Functional Specification for Orifice Flow Meter.
4.3.2 The material requirements for Restriction Orifice Assemblies shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria.
4.4 Range:
4.4.1 Range selection for Orifice Plates used in the Restriction Orifice Assembly shall in
general be according to clause 4.4 of Document No. MR / OD / INST / FS / 3203:
Functional Specification for Orifice Flow Meter.
4.5 Flanges:
4.5.1 Flange requirements for Orifice Plates used in the Restriction Orifice Assembly shall in
general be according to clause 4.6 of Document No. MR / OD / INST / FS / 3203:
Functional Specification for Orifice Flow Meter.
4.6 Meter Runs:
4.6.1 Meter runs required for Restriction Orifice Assembly shall in general be according to
clause 4.7 of Document No. MR / OD / INST / FS / 3203: Functional Specification for
Orifice Flow Meter.
4.7 Orifice Plate Sizing:
4.7.1 Sizing for Orifice plate to be used in the Restriction Orifice assembly shall be based on
and AGA Report No. 3. Orifice plate sizing calculations shall be submitted to Company
for review.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 5 of 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 1 OF 5
FUNCTIONAL SPECIFICATION
FOR
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 2 OF 5
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 3 OF 5
4.2 General:
4.2.1 Details of the Orifice Plates to be used in the Senior Orifice Assembly shall in
general be as per FS / 3203: Functional Specification for Orifice Plate Assembly.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 4 OF 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 5 OF 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 02.12.2008
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 1 of 6
FUNCTIONAL SPECIFICATION
FOR
ROTAMETERS
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 6 18.02.2008 3
ET RS GRP 9 28.03.2007 2
ET MC RK 9 23.06.2005 1
ET MC AC 9 10.03.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 2 of 6
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 3 of 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 4 of 6
4.3.1 The material requirements for Rotameter shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided
in Annexure I of this specification.
4.3.2 The Rotameter tube, float and end fittings shall in general be SS 316, unless
otherwise mentioned.
4.3.3 The Contractor shall ensure that all wetted parts are compatible with the process
conditions.
4.4 Range:
4.4.1 The range of the Rotameter shall be selected such that the normal flow rate is
between 50% and 100% of the instrument range.
4.5 Reading Scales:
4.5.1 Scales for Rotameters shall be direct reading, marked for 10-100% of flow.
4.5.2 The flow rate shall be indicated by the vertical position of the float or magnetically
coupled pointer.
4.6 Accuracy:
4.6.1 Rotameter shall have an accuracy of +/- 2% or better.
4.7 Transmitter:
4.7.1 Wherever transmitters are to be provided, they shall be 2-wire magnetic type. The
transmitter shall operate on 24 V DC and shall give an output of 4 – 20 mA. The
transmitter shall be intrinsically safe with the enclosure class for Rotameter being
Weather proof to IP 65 or better
4.8 Miscellaneous
4.8.1 Rotameters shall be installed vertically with the outlet connection at the top and the
inlet connection at the bottom.
4.8.2 Rotameters shall be installed as received. A level plumb shall be used to check for
proper installation.
4.8.3 The Rotameter location shall be free from vibration.
4.8.4 The Rotameter shall be located with sufficient clearance for maintenance purposes,
including float removal, without dismantling the meter body from the pipeline.
4.8.5 Elbows, valves & other fittings shall not be closer than 5 pipe diameters upstream.
4.8.6 The meters shall be provided with two full-bore isolating valves and by-pass valve
for maintenance.
4.8.7 A check valve shall be installed downstream, where backflow may be expected in
gas service, or where there is the possibility of liquid hammer.
4.8.8 Rotameters shall be checked and tested after installation both at yard and at
offshore site to confirm that shipping stops have been removed.
4.8.9 The transmitting mechanism of the Rotameters shall be checked by mechanically
raising and lowering the float and then checking the output.
4.8.10 Rotameter calibration curve shall also be furnished along with the purchase
specification.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 5 of 6
ANNEXURE – I
Rotameter
S. No. Piping Class
Body End Fitt. Float
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 SS 316 SS 316
(EXCEPT WAT. INJ. SERVICE)
4 A5 MONEL MONEL
5 A7 TITANIUM TITANIUM
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3206
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 6 of 6
NOTE:-
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 1 OF 6
FUNCTIONAL SPECIFICATION
FOR
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 2 OF 6
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 3 OF 6
Numbers Description
AGA Report - 7 Measurement of Natural Gas by Turbine Meters
API MPMS Chapter 4 Proving system
Chapter 5 Section 3
NACE MR-0175 Metals for Sulphide Stress Cracking and Stress corrosion
(Revision 2003 or later) Cracking Resistance in Sour Oilfield Environments
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 4 OF 6
4.2.2 The flow direction shall be clearly stamped or cast on the body.
4.2.3 Meter cable entry shall be ¾” NPTF.
4.2.4 The turbine meter shall have dual pick-ups with dual pre-amplifiers. Fidelity and Security of
Flow Measurement Pulsed-Data Transmission Systems shall be in accordance with API Manual
of Petroleum Measurement Standards, Chapter 5 Section 5. Any unused pick-up amplifier
combination shall be covered as per area classification requirement.
4.2.5 The Turbine Meter pick-up coil shall be hermetically sealed.
4.2.6 The enclosure for pre-amplifier /transmitter/ Totalizer shall be weather proof to minimum IP 65
and shall be certified for use in Class I, Division I, Group D, T3 hazardous area by a statutory
body.
4.3 Material:
4.3.1 The material requirements for Turbine Flow Meters shall in general be according to Cl. 3.6.4.5
of Instrumentation Design Criteria, FS- 2004A for Piping Design (2008) & Piping Material
Specification.
4.3.2 The Contractor shall ensure that all wetted parts are compatible with the process conditions.
Rotors shall be constructed from SS 316 as a minimum, unless otherwise mentioned.
4.3.3 All wetted parts of Turbine assemblies shall meet NACE MR-01-75 2003 or later for Sour
service.
4.3.4 Tube bundle material for flow conditioner if used shall be same as that of meter internals.
4.3.5 Bearing shall be of tungsten carbide and self lubricating type.
4.4 Over Speed Protection:
4.4.1 The turbine flow meter shall have an over-speed protection of 130% of maximum flow rate.
4.5 Rangeability
4.5.1 Rangeability shall be 10:1 for liquid service and better for Gas Service
4.6 Accuracy:
Turbine Flow Meter shall have accuracy of ±0.2% or better over the total flow range.
4.6.1 Linearity:
Turbine Flow Meters shall have a linearity of ±0.5% of rated flow range.
4.6.2 Repeatability:
Turbine Flow Meters shall have a repeatability of ±0.02% (Minimum Flow to Maximum Flow).
4.7 Totalizer:
4.7.1 The Totalizer shall have local indication for resettable totalized flow (batch), non resettable
cumulative flow and instantaneous flow rate indication.
4.7.2 The Totalizer will have in general, two displays of totalized flow on 6 digit (min) LCD backlit
screen. Resettable display will also toggle to display instantaneous flow rate. Totalizer shall
display flow rate, totalized flows in engineering units. It shall also have data logging facility for
minimum fifteen days
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 5 OF 6
4.7.3 Permanent batteries (Li-ion or equivalent) with life of minimum 3 years will be provided for
Totalizer .Battery change shall not cause any loss of data.
4.7.4 The Totalizer shall be capable of providing ‘low battery’ indication on the LCD screen.
4.7.5 Totalizer/ integral LCD meter provided with the Turbine flow meter shall be easily accessible
from grade level. Where this is not possible, Totalizer shall be remotely mounted for easy access
and mounting accessories for 2” stanchion shall be provided with the turbine flow meter.
4.8 Pre-Amplifier:
4.8.1 Pre-amplifier provided with the turbine flow meter shall be intrinsically safe, and shall be located
on the meter.
4.8.2 The pre-amplifier shall operate on 24 V DC signal.
4.8.3 The cable entry to the pre-amplifier shall be ¾” NPTF.
4.9 Transmitter:
4.9.1 The transmitter if provided with the turbine flow meter shall be SMART and intrinsically safe
and shall operate on 24 V DC power.
4.9.2 The cable entry to the transmitter shall be ¾” NPTF.
4.10 Flow conditioner:
4.10.1 Flow conditioner shall be used where adequate straight runs are not available. The flow
straighteners if used for Turbine Flow Meters may be of either tube type or vane type.
4.10.2 Construction of conditioning plates / straightener shall correspond in general to API MPMS
Chapter 5 Section 3.
4.10.3 Straightening vanes when used shall be of flange type.
4.11 Miscellaneous
4.11.1 Suitable strainers will be considered to provide adequate protection to the internals of the turbine
meter. Material of the constructions shall be minimum 316SS.
4.11.2 The Turbine Flow Meters shall be installed after hydro testing and line flushing.
4.11.3 Turbine Flow Meters shall be calibrated using mechanical displacement meter prover as per API
Manual of Petroleum Measurement Chapter 4.
4.11.4 All castings and welding (other than slip-on welds, which shall be Dye Penetration tested) shall
be 100% radio graphed.
4.11.5 For Custody transfer application, International Organization of Legal Metrology (OIML)
certification for Liquid Turbine Meter (Model Type) shall be submitted by vendor.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 6 OF 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
FUNCTIONAL Spec. No. FS 3208
Offshore Design Section
SPECIFICATION FOR Rev. No. 4a
Engineering Services
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 2 OF 6
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. FS 3208
Offshore Design Section
SPECIFICATION FOR Rev. No. 4a
Engineering Services
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 3 OF 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. FS 3208
Offshore Design Section
SPECIFICATION FOR Rev. No. 4a
Engineering Services
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 4 OF 6
- Necessary software (and hardware) as required in the control room for computation the
mass, volume flow rate shall be provided by the Vendor. Provision of manual input
/feed of density value shall be kept in the system so supplied.
- Water in oil calculations (Net oil Computations) shall be provided with all necessary
provision for manual entry of densities of oil and water. A separate meter for net oil
computation shall be provided by way of flow computer or Net oil computer, with
display of computed values.
- Necessary software for computation and / or provision to access the computed values
shall be provided, where computation and display in DCS is specified.
4.0 CORIOLIS TYPE MASS FLOW METER:
4.1 Application:
4.1.1 Coriolis type mass flow Meter shall be used as the flow-measuring element and / or
density-measuring element wherever dictated by the process requirements.
4.1.2 In general, Coriolis type mass flow Meters shall be used for direct measurement of
mass flow and / or density of liquids, and where very high turndown ratios are required.
Prototypes or meters with no proven track record in relevant oil and gas service shall
not be supplied.
(a) Typically, Coriolis type mass flow meters shall be used for measurement at the
downstream liquid outlet of conventional test separator for fairly accurate assessment of
the flow of liquid from individual wells
(b) Where precise / accurate measurement of oil flow in custody transfer application is
required Coriolis type mass flow meter may be used in typically low to medium flow
range condition, after which meter size may become a limitation on the availability of
space.
4.2 General:
4.2.1 The Coriolis type mass flow Meter shall be selected such that the nominal bore size of
the sensor is equal to or less than the line size.
4.2.2 The Coriolis type mass flow Meter shall have flanged end connections, with “rating”
and “type” suitable for the associated piping class.
4.2.3 Coriolis type mass flow meter(s) shall be preferably installed in horizontal
configuration (on horizontal piping) and avoid stresses on the piping on which it is
installed. 1” & 2” meters may be installed in flag configuration following the
manufacturer’s recommendations and with suitable supports, where the installation of
the meter on vertical piping becomes inevitable.
4.2.4 The Coriolis type mass flow Meter shall be provided with intrinsically safe local LCD
display (integral or separately mounted near the flow meter or as a part of the locally
mounted transmitter) irrespective of the requirement of display in control room or any
other remote display location mentioned in the basic bid work. In case the display is
not integral, all mounting accessories required for the display shall be provided by the
Contractor. The Contractor shall also provide interconnecting cable (between the
sensor and the local display unit) and the cable glands suitable for the enclosure type
provided. These interconnecting cables shall be kept as short as practicable.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. FS 3208
Offshore Design Section
SPECIFICATION FOR Rev. No. 4a
Engineering Services
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 5 OF 6
4.2.5 Any special cable and / or hardware which is proprietary but required to make the
system complete shall be supplied by the Contractor. (Rev 4a)
4.2.6 All the welding and castings (if any) shall be 100% radiographed.
4.2.7 All the electronics shall have enclosure suitable for Class I, Div I, Group C & D
Temperature Class T3 applications, and, shall be Weather proof to IP 65 or better.
(Where instruments cannot be provided with enclosures suitable and certified for Class
I, Div I Group C & D by the meter manufacturers, enclosure suitable and certified for
the area classified as Class I, Div II may be accepted in areas approved as “Class I Div
II Group C & D”). Local Indicator, Transmitter, Input / output to peripheral devices like
laptop computers & networks, etc., shall be intrinsically safe. Enclosure type shall be
certified by recognized bodies like IEC / FM / UL / BASEEFA / CENELEC / CSA /
DGMS / PTB / CMRI etc.
4.2.8 Where intrinsically safe electronics / instruments are provided, suitable barriers shall be
recommended along with the instruments / electronics for use in the instrument loop.
4.2.9 Coriolis type mass flow meter shall not be mounted on piping / pipelines subject to
frequent & high vibrations. Suitable precautions shall be taken for locating the meter on
piping down-stream of ‘vibrating’ equipments.
4.2.10 The Coriolis type mass flow Meter Transmitter shall be ‘SMART’ type with 24 V DC
power supply and 2 numbers of 4 – 20 mA output, serial output/s with a local indicator.
4.2.11 On high temperature applications, the transmitter shall be mounted separately from but
local to the sensor. Sensor cables shall be kept as short as practicable.
4.2.12 OIML Certification (Weights & Measures) shall be furnished where the meter is used
for liquid custody transfer applications.
4.3 Material:
4.3.1 The material requirements for body and wetted parts of the Coriolis type mass flow
Meter shall in general be according to clause 3.6.4.5 of Instrumentation Design Criteria.
4.3.2 The Contractor shall however ensure that the sensor and all other wetted parts are
compatible with the process fluid conditions. The metal tubing (sensor element) shall
be made of SS 316L as a minimum for NACE applications and SS 316 as a minimum
for non NACE applications, unless the process conditions dictate the use of ‘alternate
materials’ / ‘higher corrosion resistant’ materials.
4.4 Accuracy:
4.4.1 Coriolis type mass flow Meters shall have an accuracy of + 0.2% of flow rate or better,
with repeatability of + 0.1 % or better.
4.4.2 Accuracy for density measurement shall be + 0.001 g/cc or better. Where the meter is
used for custody transfer, the accuracies shall follow the requirements of MPMS
standards for density measurements and computations. (API MPMS 14.6).
4.4.3 Where a Coriolis type mass flow meter is installed in a bypass line for ‘density
measurement’, the design shall ensure that the flow rate through the meter provides the
desired accuracy in measurements.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. FS 3208
Offshore Design Section
SPECIFICATION FOR Rev. No. 4a
Engineering Services
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 6 OF 6
ANNEXURE – I - Typical Data Sheet For Coriolis type mass flow Meter
CORIOLIS TYPE MASS FLOW METER
UNITS: Flow [ Liquid – (KG or M )/HR :: Gas – NM3/HR].:: Pressure – Kg/cm2 ::Temperature – oC::Level – Mtrs
3
1 Tag Number
2 Line Number
3 Service
GENERAL 4 Function
5 Area Classification
6 Enclosure Class
7 Sensor Material
8 End Connection & Face Finish
9 End Connection Flange Material
10 Sensor Spool Piece Material
11 Other Wetted Parts Material
12 Enclosure Material
13 Measuring Range
METER 14 Adjustable Range
15 Accuracy
16 Sensitivity
17 Repeatability
18 Effect of Temperature
19 Minimum Detection Limit
20 Cable Entry Connection
21 Local Display
22 Power Supply
23 Output
TRANSMITTER 24 Electrical Area Class
25 Enclosure
26 Cable Entry
27 Fluid State
28 Flow Min. Maximum
29 Flow Normal
30 Inlet Pressure Operating Maximum
31 Temperature Operating Maximum
32 Sp. Gr. At Oper. Temp. Mol. Wt.
SERVICE 33 System Pressure Drop
CONDITIONS 34 Operating Viscosity (Cp)
Max. Allowable pressure drop across
35
meter
36 Density
Maximum
37 Water Content Normal
Minimum
38 Manufacturer
ITEM DETAILS 39 Model No.
40 Remarks
NOTE:-
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Design Division Spec # 3210
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 1 of 6
FUNCTIONAL SPECIFICATION
FOR
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 6 18.02.2008 3
AK BK GRP 9 28.03.2007 2
AK BK GRP 9 31.09.2006 1
ET MC AC 9 13.05.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3210
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 2 of 6
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3210
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 3 of 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3210
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 4 of 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3210
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 6 of 6
UNITS: Flow Liquid – M3/HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Display Capability:
a) Instantaneous Flow Data Yes / No
b) Compensated Flow Data Yes / No
GENERAL
c) Cumulative Flow Data Yes / No
d) Compensation Parameters Yes / No
e) Others (Specify)
3 Wall Mounted Yes / No
4 Field Mounted Yes / No
TYPE OF GAS FLOW
a) With Integral Solar Cell Array Yes / No
COMPUTER b) Without Integral Solar Cell Array Yes / No
c) With Integral Multi Variable Sensor Yes / No
5 Display:
a) No. of lines of display
GAS FLOW
b) No. of characters per line
COMPUTER
c) Alphanumeric display Yes / No
CHARACTERISTICS
6 Programmable Keypad Yes / No
7 Self Diagnostics Yes / No
8 Power Supply
Rechargeable /
9 Battery Back-Up Type
POWER SUPPLY & Permanent
BATTERY BACK-UP 10 If Permanent Battery, life of battery
11 One set of spare battery provided Yes / No
12 If Rechargeable Battery, Battery Charger provided Yes / No
13 4 – 20 mA signal (mention quantity of such i/ps)
14 Pulse inputs (mention no. of such i/ps)
INPUT TO GAS 15 Digital inputs (mention no. of such i/ps)
FLOW COMPUTER 16 RTD inputs (mention no. of such i/ps)
17 0 – 5 V signal (mention no. of such i/ps)
18 Others, if any, with no. of such i/ps
19 4 – 20 mA signal (mention no. of such o/ps)
OUTPUT FROM GAS 20 Digital inputs (mention no. of such o/ps)
FLOW COMPUTER 21 RS-232 port
22 Others, if any, with no. of such o/ps
23 No. of days for which data can be stored
DATA ARCHIVING
24 Frequency of data logging permissible
25 Enclosure
MATERIAL
26 Multi Variable Sensor, if provided
ENCLOSURE 27 Rating
ACCURACY 28 Gas Flow Computer Accuracy
29 Fluid State
30 Flow Min. Maximum
31 Flow Normal
32 Inlet Pressure Operating Maximum
SERVICE 33 Temperature Operating Maximum
CONDITIONS 34 Sp. Gr. At Oper. Temp.
35 Molecular Weight
36 Operating Viscosity (Cp)
37 Allowable pressure drop
38 Corrosive Content
39 IS Certification
40 Manufacturer
ITEM DETAILS
41 Model Number
42 Remarks
NOTE:-
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Spec. No. 3211
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 1 OF 7
FUNCTIONAL SPECIFICATION
FOR
FLOW COMPUTER
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Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 2 OF 7
CONTENTS
3 Scope Of Supply 4
4 Flow Computer 4
4.1 Purpose 4
4.3 Diagnostics 6
4.4 Accuracy 6
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Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 3 OF 7
1.1 This functional specification describes the essential design considerations for the selection of
Flow Computer for the intended purpose.
2.1 The following codes and standards (latest edition) are referenced to and make a part of this
specification.
Numbers Description
AGA -3 Orifice Metering Of Natural Gas And Other Related Hydrocarbon
Fluids
AGA-Report 7 Report No. 7, Measurement of Gas by Turbine Meters,
AGA-8 Compressibility factor of Natural Gas and other related Hydrocarbon
Gases
AGA- Report 9 Measurement of Natural Gas by Ultrasonic Meter
AGA- Report 10 Speed of Sound in Natural Gas & other related Hydrocarbon Gas,
May2003
AGA-Report 11 Measurement of Natural Gas by Coriolis Meter
API MPMS 11.1 Physical Properties Data Section 1—Temperature and Pressure Volume
Correction Factors for Generalized Crude Oils, Refined Products, and
Lubricating Oils
API MPMS Manual of Petroleum Measurement Standards Chapter 12—Calculation
Chapter 12 of Petroleum Quantities
API MPMS 21.1 Flow measurement using electronic metering system section-1
Electronic gas measurement
API MPMS 21.2 Flow measurement using electronic metering system section-2 - Inferred
mass.
ASTM D 1250 Standard Guide for Use of the Petroleum Measurement Tables
ISO 5167 Measurement of fluid flow by means of pressure differential devices
ISO 5168: 1998 Measurement of fluid flow – Evaluation of Uncertainties.
ISO 6976 Natural gas - Calculation of calorific values, density, relative density
and Wobbe index from composition
ISO 10723 Natural Gas-Performance Evaluation for On-line Analytical Systems
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Spec. No. 3211
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Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 4 OF 7
3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic
Bid Work and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Flow Computer suitable for its
intended application, its procurement, tagging, packing, testing & calibration, preparation for
shipment, along with accessories, spares, and assistance where required for its installation &
commissioning at site. This FS shall be read in conjunction with the Instrument Design
Criteria.
4.1 PURPOSE:
4.1.1 The purpose of Flow Computer is to perform flow calculations, data archival, data retrieval and
data transmission to the required destination.
4.1.2 For Gases, Flow Computer shall be used obtaining compensated flow, instantaneous flow,
cumulative flow and compensation parameters (Pressure and Temperature), Molecular
weight , & Totalized flow ( Mass / Volume ).
4.1.3 For Liquids , Flow Computer shall be used for obtaining uncompensated flow , Compensated
flow , Instantaneous Flow , Compensation Parameters (Temperature, Viscosity) , Density ,
Totalized flow ( Mass / Volume ) and Net Oil and water cut, wherever applicable.
4.2.1 Flow Computer shall be wall mounted or field mounted in case of Unmanned Platforms and
for Process Platform flow computer shall be Panel mounted in Central Control Room.
4.2.2 Wall Mounted Flow Computer shall be mounted in the TIC room on unmanned platforms. It
shall have an enclosure suitable for use in safe area with rating of IP 54.
4.2.3 Field Mounted Flow Computer shall be provided with an enclosure with NEMA 4 X or
equivalent rating and shall be certified for use in hazardous area by a statutory body as
defined in Clause 3.6.4.4.5 of Instrumentation Design criteria. Necessary certifications shall
be attached with Purchase Specification.
4.2.4 Field Mounted Flow Computer can be of the following types:
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ISO – 9001:2000 FLOW COMPUTER
Page: 5 OF 7
• With integral solar cells: This type of Field Mounted Flow Computer shall be provided
where power availability is a constraint.
• Without integral solar cells: This type of Field Mounted Flow Computer shall be
provided where power is available from the existing / new power supply system.
4.2.5 In case the Field Mounted Flow Computer (for Gas application) has to cater to only one set
of flow parameters (i.e. 1 Differential Pressure value, 1 Upstream Pressure Value and 1
Temperature value for compensation), then MVT with flow computation capability can be
used. Separate RTD shall be provided for process temperature compensation.
4.2.6 Wherever Flow Computer with integral multi-variable sensors is used, material of sensors
shall be compatible with the process fluid and shall be SS 316 minimum. Wherever the
process demands NACE compliance, the same shall be provided.
4.2.7 For field mounting, mounting accessories required for Flow Computer shall be 316SS or
better. All Instrument supports for installation shall be galvanized.
4.2.8 Flow Computer shall be capable of archiving data for a minimum of 15 (fifteen) days for a
minimum of 10 (Ten) parameters.
4.2.9 The time interval of data capturing / frequency of data logging shall be user-programmable
with standard 1 hour, 10 minutes and 1 minute intervals.
4.2.10 Flow Computer shall be capable of providing data of trends displays over user selectable
time base.
4.2.11 Flow Computer shall have facility for changing the range selection, multiplication factor.
4.2.12 Necessary software shall be provided with the flow computer as per application.
4.2.14.1 The Flow Computer shall be capable of accepting the following inputs:
• 4 – 20 mA signals ( HART)
• Pulse inputs
• Digital inputs
• RTD inputs
• 0 – 5 V signals
• Serial input (RS 232, RS 485, and Modbus) for gas molecular weight / liquid density
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Functional Specifications Rev. No. 4
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Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 6 OF 7
Specific inputs that are to be connected to Flow Computer shall be as per P & IDs and
process requirement.
The specific outputs that are required from Flow Computer shall be as per P & IDs and
process requirements.
4.2.16.1 Flow Computer shall have in general two displays with LCD backlit screens, one resettable
for indicating instantaneous flow, compensated flow and compensation parameters
(minimum 6 digit) and other non resettable ( min 8 digits).
4.2.16.2 Flow computer shall have facility to configure engineering units required for display as per
requirement. Flow Computer unit shall have a user-friendly keypad for selection of
functions and displays. Calling up a function or a display shall not require more than 3 key
presses. The keypad shall suitable for performing simple programming / customization of
Flow Computer software. It shall be possible to configure certain keys on keypad for
launching quick functions.
4.3 DIAGNOSTICS:
4.3.1 Flow Computer shall be capable of performing self-diagnostics of electronics and software.
It shall also provide relevant error display.
4.3.2 ‘Low battery’ indication shall be generated on LCD screen.
4.4 ACCURACY:
4.4.1 The accuracy of the Flow Computer shall be ± 0.025% or better.
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Spec. No. 3211
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 7 OF 7
FLOW COMPUTER
UNITS: Flow Liquid – M3/HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Display Capability:
a) Instantaneous Flow Data Yes / No
b) Compensated Flow Data Yes / No
GENERAL
c) Cumulative Flow Data Yes / No
d) Compensation Parameters Yes / No
e) Others (Specify)
3 Control Panel Mounted Yes / No
Wall Mounted
TYPE OF FLOW 4 Field Mounted Yes / No
a) With Integral Solar Cell Array Yes / No
COMPUTER b) Without Integral Solar Cell Array Yes / No
c) With Integral Multi Variable Sensor Yes / No
5 Display:
a) No. of lines of display
FLOW COMPUTER b) No. of characters per line
CHARACTERISTICS c) Alphanumeric display Yes / No
6 Programmable Keypad Yes / No
7 Diagnostics Yes / No
8 Power Supply
9 Battery Back-Up Type
POWER SUPPLY &
10 If Permanent Battery, life of battery
BATTERY BACK-UP
11
12
13 4 – 20 mA signal (mention quantity of such I/O)
14 Pulse inputs (mention no. of such I/O)
INPUT TO FLOW 15 Digital inputs (mention no. of such I/O)
COMPUTER 16 RTD inputs (mention no. of such I/O)
17 0 – 5 V signal (mention no. of such I/O)
18 Serial inputs/Others, if any, with comm., protocol
19 4 – 20 mA signal (mention no. of such I/O)
OUTPUT FROM FLOW 20 Digital outputs (mention no. of such I/O)
COMPUTER 21 Communication Port (i.e. RS-232, etc.)with protocol
22 Others, if any, with no. of such I/O
23 No. of days for which data can be stored
DATA ARCHIVING
24 Frequency of data logging permissible
25 Enclosure
MATERIAL
26 Multi Variable Sensor, if provided
ENCLOSURE 27 Rating
ACCURACY 28 Flow Computer Accuracy
29 Fluid State
30 Flow Min. Maximum
31 Flow Normal
32 Inlet Pressure Operating Maximum
33 Temperature Operating Maximum
SERVICE CONDITIONS
34 Sp. Gr. at Oper. Temp.
35 Molecular Weight
36 Operating Viscosity (CP)
37 Allowable pressure drop
38 Corrosive Content
39 IS Certification
40 Manufacturer
ITEM DETAILS
41 Model Number
42 Remarks
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Offshore Design Section Spec No. 3212
Functional Specifications
Engineering Services Rev. No. 01(a)
ISO 9001: 2008 ULTRASONIC FLOW Discipline Instrumentation
METER Page 2 of 11
CONTENTS
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Number Description
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ISO 9001: 2008 ULTRASONIC FLOW Discipline Instrumentation
METER Page 4 of 11
3.1 The quantity to be supplied and installed shall be as per the requirements indicated
in the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Multipath Ultrasonic Flow
meter suitable for in line Gas /Liquid Measurement for the intended application,
its procurement, tagging, packing, testing & calibration, preparation for shipment,
along with accessories, spares, and assistance where required for its installation &
commissioning at site.
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ISO 9001: 2008 ULTRASONIC FLOW Discipline Instrumentation
METER Page 5 of 11
4.2.1 The Ultrasonic meter shall be based on multipath technology using non reflective
type technology. The sizing shall be done for the given process conditions as per
AGA-9 (latest edition)/ API Ch 5.8 and full sizing calculations for the same
shall be submitted.
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METER Page 6 of 11
Sizing shall be done including the minimum inlet operating pressure and gas
composition and other process conditions. Meter shall be inherently bidirectional,
however where application requires bidirectional meters, the downstream run shall
be identical to upstream run as per applicable standards. For custody transfer
application the meter shall be minimum ‘four path’.
4.2.2 It shall be possible to replace or relocate transducers in-situ under the line operating
conditions without a significant change in meter performance. After an exchange of
transducers and a possible change of the associated software constants, the resulting
shift in the meter's performance should not be more than the allowable repeatability
of the meter as per relevant standards.
4.2.3 For multi path meters, loss of one path (1 pair of transducers) shall generate an alarm
, but continue to operate , it should not result in shift of accuracy. During the
working of the meter with loss of one path or due to any component change the
overall accuracy shall be maintained within accuracies specified in the AGA-9.
Vendor to provide documentary evidence from certifying agency to substantiate the
same.
4.2.4 The vendor shall comprehensively advise the impact of transducer failure on the
performance & accuracy of the USM with documentation.
4.2.5 Electronics (signal processing unit etc.), computer programs (i.e. firmware, software,
diagnostic features etc.) shall be designed and tested as per relevant codes and
standards. Documentary proof for the same shall be submitted to the company for
review.
4.2.6 The Installation requirements and piping configuration shall be selected to meet the
performance requirements as mentioned in the AGA-9 and in this specification.
Algorithm used in their electronic for computation of average velocity and flow
profile/ wall roughness correction etc. for achieving the specified accuracy,
including the Ultrasonic Flow meter sizing velocity calculation shall be submitted to
company for review and approval.
4.2.7 The data sheets for the associated instrumentation used shall be submitted to the
company for review.
4.2.8 Ultrasonic flow meter and accessories operation shall be protected from
electromagnetic exposure / interference. The electromagnetic compatibility shall be
as per IEC-801.
4.2.9 Ultrasonic flow meter spool inside diameter to meet the specified I.D. and internal
surface roughness shall be as per relevant codes and standards.
4.2.10 External body shall be blast cleaned to near white metal as per international
standard and primed with inorganic zinc premier (two coats each of 40 micron
minimum dry film thickness) and the final coat epoxy paint of 40 micron dry film
thickness.
4.2.11 The transducer/ probes shall be of robust construction for uninterrupted long life
and accurate performance. The transducer / probe shall be hermetically sealed type,
electroplated with suitable material so as to perform under dirty gas condition also.
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ISO 9001: 2008 ULTRASONIC FLOW Discipline Instrumentation
METER Page 8 of 11
stability of measurement accuracy, duly taking into consideration that the pipe wall roughness
is expected to change over the period.
4.4 OUTPUT / INPUTS
4.4.1 The meter shall have at least one serial data interface (RS-232 / RS-485).
4.4.2 Standard Frequency output(s) representing flow rate at line conditions. (Frequency output
shall be electrically out of phase by 90 deg for pulse integrity check).
4.4.3 The meter shall have Analog (4-20mA, DC) output for flow rate at line conditions.
4.4.4 Flow should be scalable up to 120% of the meter’s maximum flow rate , a programmable
low cut off function shall be provided that sets the flow rate output to zero when the
indicated flow rate is below a minimum value ( not applicable to serial data output). Two
separate flow rate outputs and a bidirectional state output or serial data values should be
provided for bi-directional applications to facilitate the separate accumulation of volumes
by the associated flow computer , and provide bi directional state output signal.
4.4.5 All the outputs shall be isolated from the ground and have necessary voltage protection to
meet electronics design testing requirements as per relevant codes and standards.
4.6.3 The ultrasonic meter must be flow calibrated in general as per the AGA 9. The flow
calibration shall be performed at the following test flow rates as a minimum : at Qmin ,
0.10 Qmax , 0.25 Qmax, 0.50 Qmax, 0.75 Qmax and at Qmax.
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METER Page 9 of 11
A detailed report of the flow calibration test shall be submitted to the Company for
review.
4.6.4 The algorithms and data used for computation of average velocity and flow profile /
wall roughness correction etc. for achieving the specified accuracy shall be submitted to
the company.
4.7 DIAGNOSTICS
4.7.1 The Ultrasonic flow meter shall provide the following diagnostic requirements as a
minimum via RS-232 / RS-485 serial data interface from the meter to the Operator
Console / Flow Computer / Station Computer / etc., as specified in the Basic Bid Work :
• Average axial velocity through the meter.
• Gas / Liquid velocity for each acoustic path
• Corrected and uncorrected volumetric flow rate
• Speed of sound along each acoustic path
• Average speed of sound
• Velocity sampling intervals
• Average time intervals
• % of accepted pulses for each acoustic path
• Status and measurement quality indicators
• Alarm failure indictors & other Diagnostic data
4.8 MISCELLANEOUS
4.8.1 The vendor shall specify the flow rate limits for qmin, qt, and qmax, for the selected
USM size and type, as detailed in relevant codes and standard.
4.8.2 As a minimum, flow conditioners shall be 316 stainless steel of between-flanges.
These shall comply with the requirements as per relevant codes and standard.
4.8.3 Where flow conditioners are recommended, care must be taken to select flow
conditioners that do not generate acoustic noise with harmonic frequencies that
may interfere with the USM performance.
4.8.4 Cast body of the ultrasonic meter shall be preferred compared to the welded body
for better immunity from vibration, reduced corrosion and better internal surface
of the meter, as well as negligible impact due to pressure and temperature.
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METER Page 10 of 11
4.8.5 All the meters shall be tested based on testing requirements mentioned in the
AGA-9 / relevant codes and standards. The certificates including the detailed test
report shall be submitted for company’s review along with purchase
specification.
4.8.6 In addition to the requirements mentioned in the instrument design criteria
3.6.6.1, the multipath ultrasonic flow meter shall have all the information tagged
as per AGA-9 on a Stainless steel tag plate.
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METER Page 11 of 11
UNITS: Flow→ Liquid M3/Hr Gas→ M3/Hr Steam → Kg/Hr Pressure → Kg/Cm2 G Temp→ 0C Level / Length→ mm
1. Qty
2. Service
3. Manufacturer
4. PI & D No.
Service Conditions
1. Fluid
2. State
3. Minimum gas velocity
4. Flow Min/nom/max m3/h
5. Pressure (Min/ Nor/ Max) Bar
6. Temperature C Nor/ Des
7. Design Pressure Barg
8. SG or Density (Typical)
9. Area Electrical Classification
10. Line Size
Flow Meter/ Transducer
1. Tag No./Model No.
2. Type
3. Size & End Connection/Rating
4. Wetted Parts
5. Mounting
6. Pressure Drop @ Max Flow
7. Face to Face Dimension
8. Transducer Material
9. Transducer construction
10. Electrical protection
11. Pressure Tapping
12. Testing
Flow Transmitter
1. Tag No./Model No.
2. Type
3. Input Power
4. Calibration Range
5. Output Signal (Note 1)
6. Gross Volume Flow Accuracy (Note 2 & 3)
7. Input signal
8. Housing ( Enclosure class)
9. Direct connectivity with on-line Gas Chromatograph
10. Manual entry of gas composition
11. AGA- 8 Calculations
12. Serial Communication port
13. Communication Protocol
Accessories
1. Flow conditioner
2. Pressure transmitter
3. Temperature Probe/ transmitter
4. Flow computer
5. Third party certification
6. Flow Calibration
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Design Division Spec # 3213
Functional Specifications
Engineering Services Rev # 1
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 1 of 6
FUNCTIONAL SPECIFICATION
FOR
ELECTRO-MAGNETICFLOW METER
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Functional Specifications
Engineering Services Rev # 1
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 2 of 6
CONTENTS
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Design Division Spec # 3213
Functional Specifications
Engineering Services Rev # 1
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ISO 9001: 2000 FLOW METER Page # 3 of 6
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Functional Specifications
Engineering Services Rev # 1
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 4 of 6
4.2.6 The Electro-Magnetic Meter’s field coils shall be hermetically sealed. Coil
insulation shall be class F suitable for high temperature. Suitable grounding type
system and material shall be selected for the metering element.
4.2.7 Field coils may operate on the alternating supply voltage. Replaceable electrodes /
Frequency excitation methods are also acceptable where the magnetic flow meter
is operated on AC / DC voltages. Vendor shall indicate the power supply
requirements and furnish the power consumption for the meter (sensor, transmitter,
display, etc.) along with the sizing calculations for the selected meter. Standard
Signal types and communication protocols shall be offered. Appropriate EMI / RFI
protection for the meter shall be considered.
4.2.8 Meter shall not necessarily be of the line size indicated in the P&ID, but shall be
sized for range of flow regime and the conductivity /velocity requirement desired
for the meter. However, the meter shall be ‘Full bore’ meter with respect to its
meter run. Straight run requirement shall be sized as per the manufacturer’s
recommendations. Meeting the flow profile requirement for the meter by providing
necessary straighteners / flow conditioners etc., shall be vendor’s responsibility.
4.2.9 Magnetic Flow Meter shall be Microprocessor based system, in explosion proof
housing. Meter shall have a non-volatile memory for data access and data transfer
to remote controllers / indicators / DCS. There shall be no data loss upon the loss
of the power supply to the meter.
4.2.10 Where the process fluid may result in coating of the electrodes, suitable measures /
special installation requirements to minimize such coating shall be a part of the
design consideration in selection of meters. Monitoring of such adhesions
[Electrode scaling/ Electrode corrosion], Electrode leakage, Liner deformation, gas
bubbles and solid identification, shall be a part of the meter diagnostics. Meter
shall also have diagnostics features such as incorrect installation and partial filled
meter . Electrodes shall be replaceable type.
4.2.11 Where the fluid is having low conductivity / contain solids in the streams (like
slurries containing magnetic particles), vendor shall offer system with suitable
circuitry for compensating the signal changes so induced by the permeable solids.
4.2.12 The ‘minimum’ fluid conductivity shall be specified for which the meter
performance is within specified values.
4.2.13 The configuration capabilities of the meter shall be for LCD display of indication
of actual flow rate, forward, reverse, sum total flow indications, conductivity,
temperature, status indications. The same shall be available as user selectable
parameter on the LCD display of the meter.
4.2.14 The ‘local’ 2 line, 6 ½ (min.) digit alphanumeric backlit LCD display shall be
provided ‘integral’ with the meter / transmitter and shall be easily visible from
grade.
4.2.15 Software security shall be provided in the meter. Upscale / downscale alarms &
Engineering units shall be user selectable. Programming for range , alarms, display
settings shall be possible through front face of the meter and without opening the
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Design Division Spec # 3213
Functional Specifications
Engineering Services Rev # 1
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 5 of 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3213
Functional Specifications
Engineering Services Rev # 1
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 6 of 6
ENT
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 1 of 8
FUNCTIONAL SPECIFICATION
FOR
TEMPERATURE GAUGE
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 4
AK BK GRP 9 28.03.2007 3
AK BK GRP 9 31.09.06 2
AK MC RK 9 31.09.06 1
ET MC AC 9 25.08.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 2 of 8
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 3 of 8
4.2.2 Case material for all temperature gauges shall be SS 316. Capillary and Armour
shall be of stainless steel.
4.2.3 The Window material shall be Shatter proof glass.
4.3 Range:
The range shall be selected such that the normal operating temperature shall fall in
the middle third of the span.
4.4 Accuracy:
The accuracy shall be ±1% of the span.
4.5 Reading Scales:
Indicating scales and recorder charts shall read out in degrees Celsius.
4.6 THERMOCOUPLE & THERMOWELL:
4.6.1 Thermowell shall be installed for all temperature-sensing elements installed on
process lines or vessels.
4.6.2 The thermowell shall be suitable for the process media, generally 316 SS, or other
material as required by the project piping specification. The thermowell shall be
machined from drilled bar stock with minimum wall thickness of 4.8mm, and 6mm
bore. Bore shall be concentric with the outside diameter to within 10% of wall
thickness. The thermowell shall be provided with hexagonal head.
4.6.3 (The thermowell material requirement for various piping classes shall be as per
Annexure – I of this specification)
4.6.4 Thermowell flanges shall be of stainless steel and shall be rated one piping class
higher than the pipe to which it is connected.
4.6.5 Thermometer well shall have ½” NPT female thread for element and 1½” flanged
for vessel or piping connection.
4.6.6 Thermowells to be used as test wells shall be provided with a stainless steel
screwed plug and chain.
4.6.7 Wells for insulated vessels and lines shall have extension necks.
4.6.8 The Thermowell tip shall be at centerline of pipe but immersion length shall not
exceed 400 mm for higher size pipes.
4.6.9 Thermowell shall be designed to withstand vibration stresses caused by stream
velocity. Wake frequency at maximum flow velocity shall be less than 80% of the
natural frequency of the Thermowell. The Contractor shall provide calculations to
ASME performance Test Code 19.3, Part 3: Instruments and Apparatus
temperature Measurement.
4.6.10 A thermometer well shall be installed adjacent to all flow recorder, temperature
recorder and controller measuring elements.
4.6.11 Thermowell welding shall be full penetration type with ‘U’ length as follows:
4” to 6” lines - 280 mm
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 5 of 8
Above 6” - 320 mm
Vessels - 400 mm
4.6.12 The typical thermowell installation shall be as per Annexure – II of this
specification.
4.7 EQUIPMENT PROTECTION:
In addition to clause no. 3.6.4.4 of Instrumentation Design Criteria Gauge
following protection requirements shall in general be as per.
4.7.1 Temperature Gauges: 130% of range shall be provided as Over-range protection
for the temperature gauge. The temperature gauge shall be weather proof to NEMA
4X / IP 66
4.7.2 Thermowells: Thermowells shall be designed to withstand vibration stresses
caused by stream velocity. Wake frequency at maximum flow velocity shall be less
than 80% of the natural frequency of the Thermowell. Temperature elements
having extended lengths shall be handled with care and suitably protected to
prevent damage.
4.8 Miscellaneous:
Thermowells shall not be installed in elbows. Lagging extensions shall be
provided on insulated piping and insulated vessels. Thermowells shall be oriented
so that gauge dials are clearly visible and readable from the deck or the appropriate
access platform. Where a thermowell location causes poor access or visibility, the
Contractor shall provide a remote-mounted capillary-gauge, located in an
accessible and readily visible location.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 6 of 8
ANNEXURE – I
Thermowell
S. No. Piping Class
Thermowell Flange
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1,
PE1, PXF1, PF1, A2, B2, D2, E2, XG1, A1H, A3,
1 B3, A8 SS 316 CARBON STEEL
(EXCEPT WAT. INJ. SERVICE)
4 A5 MONEL MONEL
5 A7 TITANIUM TITANIUM
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 7 of 8
ANNEXURE – II
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3300
Functional Specifications
Engineering Services Rev # 4
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 8 of 8
TEMPERATURE GUAGES
Units : Flow →Liquid-M3/Hr, Gas → Kg/Hr, Steam → Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C, Level/ Length →mm
1 Type :- Bimetal : Filled : Other : FILLED SYSTEM
6 Case Material :- Cast Aluminium : Other : 16 Bulb Union 1/2" NPT(M) : Other :
Threaded To :
7 Window Material :- Glass : Acrylic : Other : 17 Extension Type :- Rigid : Bendable: Angle :
8 Conn. Location :- Back : Bottom : 18 Bulb Dia :- Mfr. Std. : To suit well : Other :
Back Adjustable : All Angles Adjustable : 19 Capillary Material :
BIMETAL THERMOWELL
12 Stem : 21 Material : Other :
Type : Adj. Union : Threaded : 22 Construction : Driller bar Built up :
Stock
Material : Other :
Other : 23 Process Connection : 11/2" 1" NPT(M) :
flanged :
13 Stem Dia :- Mfr. Std. : Other :
Other : 24 Gauge Connection 1/2" NPT(F) Other :
To suit well : :
25 Thermowell As Per Drawing. :
26 Options : (a) SS tag plate
(b) Make / Model No. :
Tag Temp Deg C Range Well Dim Mm Flange Service Options
No. Deg C
Nor Max U T Material Rating,
face/fin.
NOTES :
1. Immersion lengths of thermo wells on vessels to be confirmed by respective vessel vendors.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 1 of 8
FUNCTIONAL SPECIFICATION
FOR
TEMPERATURE SWITCHES
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 2
ET RS GRP 10 28.03.2007 1
AK MC AC 10 13.05.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 2 of 8
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 3 of 8
4.1.2.8 There shall be minimum bounce during making and breaking of switch contacts
and switch mechanism shall be designed to minimize the vibration.
4.1.2.9 The switch element shall be selected in such a way that it can withstand an over-
range pressure of 1.5 times maximum range without loss of calibration.
4.1.2.10 Temperature switches shall be heavy duty, with user adjustable set point.
Adjustments shall be tamper-proof.
4.1.2.11 The thermo well shall be designed to withstand vibration stresses caused by
stream velocity. Wake frequency at maximum flow velocity shall be less than
80% of the natural frequency of the thermo well.
4.1.2.12 Vendor shall ensure that set point falls between 35% and 70% of adjustable
range of the selected model in general.
4.1.2.13 Thermowells shall not be installed in elbows. All Temperature instrument shall
be mounted as close as possible to sensing point. Mountings accessories required
for Temperature Instrument shall be 316SS or better. When switches and other
devices are grouped and mounted on a instrument stand it should be in such a
manner that removal of each instrument shall be possible without the need to
disconnect, dismantle or remove any other instruments or tubing.
4.1.2.14 Temperature switch shall have tamper-proof set point adjustment. Electrical
Temperature switches shall be calibrated for there set points.
4.1.2.15 All switches shall be Ex d.
4.2 Material:
4.2.1 The material requirements for Temperature switch shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and the material selection chart
provided in Annexure II of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.3 Accuracy: The maximum error shall not exceed 1% of the span. Repeatability
shall be ±1%.
4.4 Reading Scales: Units for Temperature switch shall be in deg C.
4.5 Enclosure Class: In addition to weatherproof, the switch enclosure shall be
explosion-proof to NEMA-7 and certified by third party Statuary bodies like
UL/FM/BASEEFA or equal for use in hazardous area (CL 1, DIV.1, and GR.D).
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 5 of 8
ANNEXURE – I
4 A5 MONEL MONEL
5 A7 TITANUM TITANUM
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 6 of 8
ANNEXURE – II
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 7 of 8
ANNEXURE – II CONT..
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3301
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 SWITCHES Page # 8 of 8
TEMPERATURE SWITCH
UNITS: - Flow Liquid – M3/HR Gas – NM3/HR Steam – Kg/hr Pressure – kg/cm2 Temperature – deg C Level/length -mm
1 Type MEASURING UNIT
2 Well 25 SAMA Class
3 Case material 25.1 Compensation
4 Mounting 26 Bulb Type
5 Enclosure 26.1 Bulb Material
Enclosure Class 26.2 Bulb Union Thread
6 Elec. Area Class 26.3 Bulb Extension Type
7 Intrinsically Safe 26.4 Bulb Dia
9 27 Capillary Materials
Power Supply for switch 28 Armour flexible
29 Armour Material
10 Accuracy 30 Capillary Length
31 Over Range protection
11 Repeatability THERMOWELL
SWITCH 32 Material
13 Electric contact 33 Construction
14 Qty. 34 Process Connection
15 FORM 35 Gauge Connection
16 TYPE 36 Thermo well as per
attached Drawing
17 Contact Rating OPTIONS
18 Load Type a) All mounting
accessories need to be
supplied.
19 Cable Entry b) Integral output meter
20 No. of Entries 37 Make
21 Set point Adj
22 Differential
TAG RANGE SET TEMPERAT WELL FLANGE SERVICE OPTIONS
No. POINT DIM.mm
NOR. MAX. U T MATERIAL #, FACE,
FINISH
NOTE:-
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 10 OF 10
(ELECTRONIC)
ANNEXURE – IV
TEMPERATURE TRANSMITTERS
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Steam – Kg/hr Pressure – kg/cm2 Temperature – deg C Level/length -mm
1 Function MEASURING UNIT
2 Type 15 SAMA Class
3 Case 15.1 Compensation
4 Mounting 16 Bulb Type
5 Enclosure 16.1 Bulb Material
Enclosure Class 16.2 Bulb Union Thread
6 Elec. Area Class 16.3 Bulb Extension Type
7 Intrinsically Safe 16.4 Bulb Dia
8 Power Supply 17 Capillary Materials
9 Power Supply for 18 Armour flexible
Transmitter
10 Cable Entry 19 Armour Material
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 2 OF 10
(ELECTRONIC)
CONTENTS
4.1 General 3
4.3 Accuracy 5
4.4 Repeatability 5
4.6 Material 5
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 3 OF 10
(ELECTRONIC)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 4 OF 10
(ELECTRONIC)
4.1.9 Thermocouples shall only be used above 350 centigrade, or when it can show that the
mechanical construction of an item does not permit the fitting of an RTD.
4.1.10 Surface metal temperatures shall be measured by thermocouples secured to the surface.
4.1.11 Thermocouples shall normally be the mineral-insulated metal- sheathed type, isolated from
earth. Characteristic of mV versus temperature shall conform to BS-4937.
4.1.12 Thermocouples shall be Type K (Chromel-Alumel) for the temperature range –20 degree
centigrade to 1000 degree centigrade. For temperature above 1000 degree centigrade, Type
R (Platinum/13 % Rhodium-Platinum) shall be used.
4.1.13 Transmitters shall be “SMART” type and use HART protocol for communication.
4.1.14 Transmitters shall be immune to Radio frequency interference due to walkie-talkie, paging
system, communication system etc. All electronic modules shall be designed for short
circuit protection.
4.1.15 Span shall be continuously adjustable over the transmitter range.
4.1.16 The TT shall be provided with ½”NPT (F) cable entries.
4.1.17 The change in out put due to change in ambient temperature should be very minimum.
4.1.18 The range shall be selected so that the normal operating temperature shall fall in the middle
third of the span.
4.1.19 Contractor shall submit wake frequency calculation as per PTC 19.3 for review. In case the
wake frequency exceeds 80% of natural frequency the recommended changes in length and
wall thickness of well, as per PTC 19.3 shall be submitted for approval.
4.1.20 TT shall have adjustable zero and span. Setting adjustment shall have locking
arrangement.
4.1.21 Over range protection shall be 130% of range.
4.1.22 All Transmitter instrument shall be mounted as close as possible to sensing point.
Mountings accessories required for Temperature Instrument shall be 316SS or better.
4.1.23 All the Temperature Transmitter shall be intrinsically safe and certified by statutory body
like UL/FM/BASEEFA/CMRI/DGMS or equivalent. The certificate for the same shall be
provided with the Purchase Specification.
4.1.24 TT Housing shall be Dual Compartment Type.
4.1.25 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed.
4.2 THERMOWELL:
4.2.1 Thermowell shall be installed for all temperature-sensing elements installed on process
lines or vessels.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 5 OF 10
(ELECTRONIC)
4.2.2 The thermowell shall be suitable for the process media, generally 316 SS, or other material
as required by the project piping specification. The thermowell shall be machined from
drilled bar stock with minimum wall thickness of 4.8mm, and 6mm bore. Bore shall be
concentric with the outside diameter to within 10% of wall thickness. The thermowell shall
be provided with hexagonal head.
4.2.3 (The thermowell material requirement for various piping classes shall be as per Annexure –
I of this specification)
4.2.4 Thermowell flanges shall be of stainless steel and shall be rated one piping class higher
than the pipe to which it is connected.
4.2.5 Thermometer well shall have ½” NPT female thread for element and 1½” flanged for
vessel or piping connection.
4.2.6 Thermowells to be used as test wells shall be provided with a stainless steel screwed plug
and chain.
4.2.7 Wells for insulated vessels and lines shall have extension necks.
4.2.8 The Thermowell tip shall be at centerline of pipe but immersion length shall not exceed
400 mm for higher size pipes.
4.2.9 Thermowell shall be designed to withstand vibration stresses caused by stream velocity.
Wake frequency at maximum flow velocity shall be less than 80% of the natural frequency
of the Thermowell. The Contractor shall provide calculations to ASME performance Test
Code 19.3, Part 3: Instruments and Apparatus temperature Measurement.
4.2.10 Thermowell welding shall be full penetration type with ‘U’ length as follows:
4” to 6” lines - 280 mm
Above 6” - 320 mm
Vessels - 400 mm
4.2.11 The typical thermowell installation shall be as per Annexure – II & III of this specification.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 6 OF 10
(ELECTRONIC)
4.6.2 Transmitter body studs shall be high tensile stainless steel, or other corrosion-resistant
material for higher stress levels.
4.6.3 In general MOC for TW shall be as per Annexure I. T/W, rating class shall be one
class higher than Piping Class.
4.6.4 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 7 OF 10
(ELECTRONIC)
ANNEXURE – I
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1, PE1,
1 PXF1, PF1, A2, B2, D2, E2, XG1, A1H, A3, B3, A8 SS316 CS
(EXCEPT WAT. INJ. SERVICE)
4 A5 MONEL MONEL
5 A7 TITANUM TITANUM
[** All wetted parts of Thermowell shall conform to NACE MR-01-75 (Latest edition).]
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 8 OF 10
(ELECTRONIC)
ANNEXURE – II
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3302
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 9 OF 10
(ELECTRONIC)
Annexure-III
Temperature Transmitter W/Thermo well
VERTICAL MOUNTING
HORIZONTAL MOUNTING
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FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 2 OF 7
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 3 OF 7
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 4 OF 7
4.1.6 Gauges that are 150 mm (6”) or larger diameter shall have micrometer pointers
for external or internal zero adjustment. Gauge pointers shall be adjustable
without removal from shaft.
4.1.7 Differential Pressure gauge measuring element shall generally be Bellows /
Diaphragm type. Diaphragm seals shall be used for measurement of slurries,
viscous and chemicals (effluent/ injection services etc.). Diaphragm seals with
capillary shall in general be 1 ½” flanged.
4.1.8 Additionally, where damping is required for gauges, differential pressure gauge
shall be liquid filled or any other proven (with PTR) advanced damping
technology can be used (without liquid filled damping) to arrest the process
fluctuations and vibrations due to installation. Glycerin / Silicone oil shall
generally be used for liquid filling. Liquid filled gauges (considering both
process and ambient temperature limits) shall have a small vapor space for
thermal expansion of liquid fill.
4.1.9 Differential Pressure gauge enclosure shall be weather proof to NEMA 4 / IP 65
or better. Over range protection of 130 % of maximum static pressure shall be
provided without affecting its calibration / accuracy.
4.1.10 Gauges located on lines subjected to pulsating pressures (such as all pumps,
compressors discharge service etc.) shall be provided with Snubber type pulsation
dampeners.
4.1.11 Gauge savers shall be provided wherever specified to prevent the gauge when
maximum working pressure exceeds 130% of maximum static pressure. Gauges
in vacuum service shall have over range protection to full vacuum. A visible Stop
Pin shall be used to restrict the upper limit of the pointer travel.
4.1.12 DPG shall be installed in such way that length of impulse lines is kept minimum.
4.1.13 Gauges shall be capable of passing Vibration Test , Fatigue Test , Endurance
cycle Test etc. as specified in International Standards (EN -837 etc.) .
4.2 Material:
4.2.1 Process connections and ‘Material of construction’ of all wetted parts shall be
compatible with the process fluid however it shall be SS 316 minimum . For Sour
service applications, MOC shall be compliant to NACE MR-01 75 requirements .
For raw seawater service, all wetted parts shall be of Monel material.
4.2.2 Material for Pointer shall be SS 316 or Aluminium.
4.2.3 Material for movement shall be SS 316 however for liquid filled gauges SS 304
can be acceptable.
4.2.4 Valve Manifold shall be SS 316 as minimum and compliant to NACE MR-01 75
wherever required. Superior material can be accepted.
4.2.5 Case material for all Differential Pressure gauges shall be SS 316 with a screwed
bezel / bayonet bezel retaining ring and weatherproof design.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 5 OF 7
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 6 OF 7
ANNEXURE – I
(Hook Up Drawing)
BILL OF MATERIAL
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL Spec. No. 3400
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 7 OF 7
ANNEXURE – II
NOTE:-
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 2 OF 7
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 3 OF 7
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 4 OF 7
4.1.7 Gauges that are 6” (150 mm) or larger diameter shall have micrometer pointers
for external or internal zero adjustment .Gauge pointers shall be adjustable
without removal from shaft.
4.1.8 Pressure gauge measuring element shall generally be Bourdon / Bellows /
Diaphragm type. Diaphragm seals shall be used for measurement of slurries,
viscous and chemicals (effluent/ injection services etc.). Diaphragm seals with
capillary shall in general be 1 ½” flanged. For corrosive fluids, in lieu of
diaphragm seal , measuring element of suitable material can be considered for
such services .
4.1.9 Additionally, where damping is required for gauges, pressure gauge shall be
liquid filled or any other proven (with PTR) advanced damping technology can be
used (without liquid filled damping) to arrest the process fluctuations and
vibrations due to installation. Glycerin / Silicone oil shall generally be used for
liquid filling. Liquid filled gauges (considering both process and ambient
temperature limits) shall have a small vapor space for thermal expansion of liquid
fill.
4.1.10 Pressure gauge enclosure shall be weather proof to NEMA 4 / IP 65 or better.
Pressure gauge shall be capable of withstanding 130% of maximum range without
affecting its calibration / accuracy.
4.1.11 Gauges located on lines subjected to pulsating pressures (such as all pumps,
compressors discharge service etc.) shall be provided with Snubber type pulsation
dampeners.
4.1.12 Gauge savers shall be provided wherever specified to prevent the gauge when
maximum working pressure exceeds 130% of range. Gauges in vacuum service
shall have over range protection to full vacuum. A visible Stop Pin shall be used
to restrict the upper limit of the pointer travel.
4.1.13 Gauges shall be capable of passing Vibration Test , Fatigue Test , Endurance
cycle Test etc. as specified in International Standards (EN -837 etc.) .
4.2 Material:
4.2.1 Material requirements for pressure gauges shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria.
4.2.2 Process connections and ‘Material of construction’ of all wetted parts shall be
compatible with the process fluid however it shall be SS 316 minimum . For Sour
gas applications , MOC shall be compliant to NACE MR-01 75 requirements.
However for raw seawater service, material for all wetted parts shall be Monel.
4.2.3 Material for Pointer shall be SS 316 or Aluminium. Movement material for liquid
filled gauges can be SS 316 or SS 304. For gauges with other proven technology
(without liquid filled damping) , movement material shall be SS 316.
4.2.4 Case material for all pressure gauges shall be SS 316 with a screwed bezel /
bayonet bezel retaining ring and weatherproof design.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 5 OF 7
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 6 OF 7
ANNEXURE – I
(Hook Up Drawing)
Note : For Sour Gas service drain valve shall be ball valve and drain connection shall be
connected to closed drain .
BILL OF MATERIAL
5 1 CAP ½” NPTF
TUBINGS ½” NPTM
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Offshore Design Section FUNCTIONAL
Rev. No. 5b
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 7 OF 7
ANNEXURE – II
TYPICAL DATA SHEET – PRESSRUE GAUGE
PRESSURE GAUGES
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C Level/length -M
1 Type 15 Diaphragm Seal (wherever required)
2 Mounting a) Type
3 Dial Size/Colour b) Wetted Parts
4 Case Material c) Other Material
5 Bezel Ring d) Process Connection
6. Window Material e) Facing & Finish
7 Enclosure Class f) Capillary Material
8 Pressure Element g) Armour type
9 Element Material h) Armour Material
10 Socket Material i) Capillary Length
11 Accuracy j) Flushing Filling
Conn.
12 Zero Adjustment 16 Over range protection
13 Connection & Location 17 Blow out protection
14 Movement 18 Options
a) Snubber
b) Siphon
c) Gauge saver
d) Liquid filled casing
e) Vacuum protection
f) Space ring
g) Solid front
NOTE:-
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Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 1 of 8
FUNCTIONAL SPECIFICATION
FOR
PRESSURE SWITCH
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 2
AK SRS AC 9 28.03.2007 1
AK MC AC 9 25.08.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 2 of 8
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 3 of 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 4 of 8
4.1.2.8 The pressure-sensing element shall be designed to meet a service life of one
million switching cycles.
4.1.2.9 Vendor shall ensure that set point falls between 35% and 70% of adjustable
range of the selected model in general.
4.1.2.10 Pressure switch shall have tamper-proof set point adjustment.
4.1.2.11 All pressure instrument shall be mounted as close as possible to sensing point.
4.1.2.12 Mountings accessories required for Pressure Instrument shall be 316SS or better.
When switches and other devices are grouped and mounted on a instrument stand
it should be in such a manner that removal of each instrument shall be possible
without the need to disconnect, dismantle or remove any other instruments or
tubing.
4.1.2.13 All the switches shall be Ex d .
4.2 Material:
4.2.1 The material requirements for Pressure switch shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and the material selection chart
provided in Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.3 Accuracy:
The maximum error shall not exceed 1% of the span. Repeatability shall be ±1%.
4.4 Reading Scales: Units for pressure switch shall be in kg/cm2.
4.5 Enclosure Class:
In addition to weatherproof, the switch enclosure shall be explosion-proof to
NEMA-7 and certified by third party agencies like UL/FM/BASEEFA or equal for
use in hazardous area (CL 1,DIV.1, GR.D).
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DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 5 of 8
ANNEXURE – I
4 A5 MONEL
5 A7
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Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 6 of 8
ANNEXURE – II
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 7 of 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3402
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 8 of 8
UNITS: - Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C
Level/length -M
1 Type Pneumatic MEASURING UNIT
2 Function Indicate Pressure 26
Service
3 Mounting 27
Element Type
4 Case, Window 28
Element Material
5 Electrical Area Class - 29
Socket Material
6 Enclosure Class 30
Body Material
7 Intrinsically Safe 31
Connection location
8 Air Supply 32
DIAPHRAGM SEAL (Wherever
Required)
9 Power Supply Type
10 Cable entry Wetted Parts
11 Accuracy Other Material
12 Repeatability Process Connection
SWITCH Facing & Finish
13 Electric Capillary Material
14 Quantity Armour Material
15 Form Capillary Length
16 Type Flushing Filling conne.
17 Rating MISCELLANIOUS
18 Load Type 33 Over range protection
19 Cable Entry 34 Blow out protection -
20 No. Of Entries 35 Options
21 Pneumatic A Mounting accessories
22 Type B Air filter regulator with Gauge
C Intrinsically safe weather proof out put
meter
D Pressure gauges for supply, input and
output
E Snubber
F Gauge saver
G Air filter regulator
23 Signal H Vaccum protection
24 Set point adjustment 36 Pneumatic Connect.
25 Differential Load driving capability
TAG RANGE SET SET PRESSURE TEMP. FLUID SERVI OPTI
CE
No. POINT POINT OVER MAX OPER MAX ONS
1 2
NOTE:-
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
FUNCTIONAL Spec. No. 3403
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 PRESSURE TRANSMITTER
(ELECTRONIC) Page: 2 OF 6
CONTENTS
4.1 General 3
4.2 Material 4
4.3 Accuracy 4
4.5 Repeatability 4
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FUNCTIONAL Spec. No. 3403
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 PRESSURE TRANSMITTER
(ELECTRONIC) Page: 3 OF 6
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3403
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 PRESSURE TRANSMITTER
(ELECTRONIC) Page: 4 OF 6
4.1.10 The Pressure transmitter shall be intrinsically safe and certified by statutory body like
UL/FM/BASEEFA/CMRI/DGMS or equivalent.
4.1.11 ‘Universal Hand Held Configurator’ shall be supplied for transmitters’ calibration. The
number of calibrator shall be two per process platform & one per well platform.
4.1.12 All vent and drains of the transmitter/tubing/valve manifolds shall be routed to drain header .
If the meter is on sour service and harmful fluids like chemical etc. then it will be routed to
close drain header.
4.2 Material:
4.2.1 The material requirements for PT shall in general be according to clause 3.6.4.5 of
Instrumentation Design Criteria, FS-2004A for Piping Design (2008) & Piping Material
Specification.
4.2.2 All wetted parts shall be suitable for intended process application.
4.2.3 Transmitter body studs shall be high tensile stainless steel, or other corrosion-resistant
material for higher stress levels.
4.2.4 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed.
4.3 Accuracy:
±0.1% of FSD or better.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3403
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 PRESSURE TRANSMITTER
(ELECTRONIC) Page: 5 OF 6
ANNEXURE – I
(Hook Up Drawing)
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3403
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 PRESSURE TRANSMITTER
(ELECTRONIC) Page: 6 OF 6
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C Level/length -M
1 Type
DIAPHRAGM SEAL (Wherever Required)
2 Function 21 Type
3 Mounting 22 Wetted Parts
4 Case & Material 23 Other Material
5 Electrical Area Class 24 Process Connection
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
FUNCTIONAL Spec. No. 3404
Offshore Design Section Rev. No. 0
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“CURRENT TO PNEUMATIC
CONVERTER” Page: 2 OF 5
CONTENTS
2.1 3
Scope of Supply
3.0 General 3
4.0 P to I converter 3
4.1 Converter Type 3
4.2 Material 3
4.3 Accuracy 3
4.4 Reading scales 3
4.5 Enclosure class 3
4.6 Hazardous area certifications 3
Annexure I Data Sheet Format 4
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FUNCTIONAL Spec. No. 3404
Offshore Design Section Rev. No. 0
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“CURRENT TO PNEUMATIC
CONVERTER” Page: 3 OF 5
3.1.1.3 The change in out put due to 10 degree Celsius change in ambient temperature
(Max-400C, Min-160C) should be very minimum.
3.1.1.4 I/P shall have externally adjustable zero and span.
3.2 Material:
3.2.1 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
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FUNCTIONAL Spec. No. 3404
Offshore Design Section Rev. No. 0
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“CURRENT TO PNEUMATIC
CONVERTER” Page: 4 OF 5
3.2.2 Housing material -Die-cast low copper aluminum alloy body and cover, with
an epoxy powder finish.
3.2.3 Mounting accessories: shall be SS316.
3.3 Accuracy: better than ± 0.5% of span.
3.4 Reading Scales: Units for I/P converter shall be in PSI.
3.5 Enclosure Class: The I/P converter shall be weatherproof to NEMA-4X (IP-
65) and shall be intrinsically safe.
3.6 Hazardous area certifications: By third party agencies like
IEC/UL/ATEX/CMRE/FM/BASEEFA/CENELEC/CSA/PTB for use in
hazardous area (Class 1, Division.1, Groups C and D, T3).
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3404
Offshore Design Section Rev. No. 0
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“CURRENT TO PNEUMATIC
CONVERTER” Page: 5 OF 5
1 Type 10 Accuracy
2 Mounting 11 Actuation
7 Pneumatic connection
8 Area Classification
9 Conduit Connection
Electrical
Pneumatic
NOTE :-
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SPEC. No. 3500
Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 2 of 35
CONTENTS
Clause
ITEM Page No.
No.
- Title page 1
- Index of contents 2
1.0 Scope of This Document 3
2.0 Reference Documents and Specifications 3
3.0 Scope of Supply 4
4.0 Fire & Gas Detection System 4
4.1 General 4
4.2 System Requirements 6
4.2.1 Detectors and Field Devices 6
4.2.1.1 General 6
4.2.1.2 Gas Detectors 7
4.2.1.3 Fire Detectors 12
4.2.1.4 Manual Alarm Stations 15
4.2.1.5 Other Associated Field Devices 15
4.2.2 Control Devices 17
4.2.2.1 General 17
4.2.2.2 Fire & Gas detection system panel 17
4.3 Functional Requirements 25
4.3.1 Control Philosophy 25
4.4 Spares Philosophy 29
4.5 Material 29
5.0 Equipment Protection 29
6.0 Installation Requirement 30
7.0 Testing and Inspection 30
8.0 Quality Assurance 32
9.0 Documentation 33
10.0 Tagging & Nameplates 34
11.0 Review & Approval 35
12.0 Vendor Pre-Qualification Requirements 35
13.0 Preparation for Shipment 35
14.0 Receipt & Storage 35
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SPEC. No. 3500
Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 3 of 35
1.1 This specification defines the minimum requirements for the design,
engineering, fabrication, inspection-testing, supply, installation and
commissioning of Fire & Gas Detection System for use on offshore platform.
1.2 This specification describes Fire & Gas Detection System with field detectors
and the functionality of the system as a whole. It does not cover the detailed
specifications of:
1.3 Any deviations from the requirements of this specification shall be stated in
‘Deviation List’ in contractor’s proposal. Unless specific deviations are stated,
it shall be understood that the Fire & Gas Detection system is in accordance
with the specification.
1.4 Contractor’s proposal shall also include revision status sheets, which shall
show revision status of each page of the proposal / purchase specification for
every submission.
1.5 Any ambiguity in this specification and the reference specifications pertaining
to the requirements of Fire & Gas Detection System shall be referred to the
company for clarification prior to finalization of Purchase Specification.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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SPEC. No. 3500
Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 4 of 35
3.1 The Fire and Gas Detection System shall include the following equipment:
a) Field Detectors including thermal, smoke, point and open path type
Hydrocarbon gas detectors, Hydrogen gas detectors, toxic gas (H2S)
detectors, Triple IR (outdoor and GG-PT Enclosure) and UV/IR (indoor)
flame detectors, Fire loop system with Fusible plugs, ESD & FSD pull
stations (valves), manual alarm stations, flashing and audible alarm
beacons etc.
b) Accessories including mounting units, etc to make the system
operationally and functionally complete.
c) Interfaces to the field as well as Control Room for Alarm & initiation of
Fire Suppression actuating devices including Fire Water Pump control
panel, opening of Blow down valve for reducing hydro-carbon
inventory, deluge valves and for release of DCP/Clean Agent & other
Fire extinguishing agent.
d) Interfaces to other systems of the platform including DCS, ESD system,
Package equipment (such as Gas Turbines, Process gas compressors)
fire & gas detection system, Paging system, emergency generator,
pneumatic panel.
e) Fire and Gas Matrix panel, Critical alarms annunciation.
f) Other items including portable purge calibrators, calibration cylinders,
commissioning spares, special tools & tackles.
4.1 GENERAL
4.1.1 The Fire & Gas Detection system is required to address the risk associated
with imminent or established fire and combustible/ toxic gas release.
4.1.3 Unless otherwise specified all contacts shall be volt free contacts which shall
be 2 X SPDT or DPDT type, rated 24 VDC – 2 amps.
4.1.4 The Fire & Gas Detection system scheme shall be one out of the following
two schemes (refer ‘Basic Bid Work’ for type of scheme to be followed for
the project)-
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Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 5 of 35
4.1.5 Scheme - A : Fire & Gas Detection system for Well-Head Platform shall
constitute the following :
a) Field detectors including point and open-path type hydrocarbon gas
detectors, Hydrogen gas detectors, H2S gas detectors, Smoke detectors,
Triple IR Flame detectors, Thermal detectors, Pneumatic Fire loops with
Fusible plugs, FSD & ESD pull stations (valves), Flashing & Audible
Alarm Beacons and Clean Agent System for Fire Suppression.
b) Each loop shall generate at least two independently adjustable volt free
contact outputs.
c) Accessories including mounting units, etc to make the system
operationally and functionally complete.
d) Detectors controller / monitor card mounting unit with relays logics or
F&G PLC (SIL 3) (as per basic bid work) which shall be installed in
SAFE area.
e) Interface to the Electrical Rooms actuating devices as well as field
including ESD/FSD, deluge valve actuation logic, Clean Agent system,
Fire Water Pump etc.
f) Interfaces to other systems of the platform including pneumatic
shutdown Panel / PLC based SDP/ General Purpose Standalone PLC,
RTU etc..
g) Other items including portable purge calibrators, calibration cylinders,
commissioning spares, special tools & tackles.
4.1.6 Scheme – B : Fire & Gas Detection system for Process Platform shall
constitute the following :
a) Field devices including thermal, smoke, point and open-path type
Hydrocarbon gas detectors, Hydrogen gas detectors, toxic gas (H2S)
detectors, Triple-IR (outdoor & GG-PT enclosure) and UV/IR (indoor)
flame detectors, Pneumatic Fire loops with Fusible plugs, FSD & ESD
pull stations (valves), manual alarm stations, flashing and audible alarm
beacons for actuation of Fire suppression system.
b) Accessories including mounting units, etc to make the system
operationally and functionally complete.
c) Interfaces to the field as well as Control Room actuating devices
including actuation of Clean Agent system, deluge valves & FWP
Control Panels, pneumatic solenoid & pilot valves, extinguishant
release, Blow-down valve open etc.
d) Interfaces to other systems of the platform including DCS, ESD system,
RTU, Package equipment (such as Gas Turbines, Process gas
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 6 of 35
4.2.1.1.3 Detector Location: The Contractor shall specify each type of detector and
their locations and mountings, to ensure the earliest response to imminent or
established fire or hydrocarbon release or toxic (H2S) gas release and
accumulation, with consideration to the following as a minimum:
a) Requirements of referenced standards, particularly API RP 14C, 14G,
ISA 12, ISA 92, NFPA 72 and SGDA (Smoke and Gas Dispersion
Analysis).
b) Equipment layouts: Placement of detectors shall not interfere with
process equipment maintenance.
c) Ease of Maintenance: The fire and gas detectors shall be installed in a
location accessible for calibration and maintenance, preferably from
deck or fixed platform, but not in frequently used access ways.
d) Certain areas shall be avoided, such as sample stations where spurious
alarms would negate the effectiveness of the detection system.
e) All the detectors shall be addressable type (in addition to having the
conventional outputs) for the Process platform.
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Design Division FUNCTIONAL 4
Rev. No.
Engineering Services SPECIFICATION FOR
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 8 of 35
flexible conduit.
f) Combustible and toxic gas sensors shall be located in accordance with
the protection area limitations of the detector manufacturer.
g) Sensors shall be typically located approximately 1 m from the expected
emission point, and preferably in the direction of ignition sources and /
or populated areas.
h) Special consideration shall be given to the properties of the process gas
(refer Process Design Criteria for properties of process fluids),
specifically its vapour density and predominant component. For lighter-
than-air gases, the detectors shall be placed above the release point. For
heavier-than-air gases, the detectors shall be placed 300-450 mm above
the floor.
i) Detector locations shall take into account the possible flow pattern of the
leaking gas or vapour and ventilation system airflow.
j) The number of detectors shall be based on the number of potential
release sources.
k) Perimeter detection of releases shall be considered in areas containing
large amounts of light hydrocarbons (e.g. process areas or pressure
storage areas) to alert operations to initiate a manual response or to
actuate an automatic response (e.g. unit shutdown or firewater spray
system). These detectors shall be installed along a unit boundary
adjacent to an ignition source.
l) Indoor or partially enclosed installations that may require gas detection
(such as turbine enclosures, compressor stations, etc.) shall be protected
with open path or point detection system.
m) Where buildings are equipped with HVAC, pressurizing or a ventilation
system, a combustible-gas and / or toxic-gas detector shall be located in
the inlet to the system and also in air locks.
n) In high-temperature enclosures, such as enclosures for gas turbines, a
remote sampling head shall be used, with a standard detector located
outside the enclosure and the gas sample aspirated to the detector head.
o) Detectors shall be provided to detect presence of gas into engine air
intakes, and presence of gas in enclosure exhaust vents.
p) Sampling in indoor locations shall be accomplished by diffusion and
convection air currents.
q) No pump or other means of forced air movement shall be required for
normal application.
4.2.1.2.2.2 The detecting unit included in the sensor head shall provide adequate
sensitivity and stability, under all conditions, with ±5% accuracy (For Range
of 100 LEL).
4.2.1.2.2.3 The fixed HC gas detectors shall be powered from 24 V DC supply, with a 4-
20 mA signal loop to cover the calibrated range. Detector faults shall be
signaled by 4 mA signal.
Note: In Scheme-A, detector shall provide 2 nos. of volt free contact outputs
for Non-PLC Panel. These 2 nos. of contact outputs shall be independently
adjustable over entire range of gas detection.
4.2.1.2.2.4 Junction Boxes: Explosion proof junction boxes shall be provided with the
detectors for cable termination.
4.2.1.2.2.5 Detector system shall initiate responses at two different concentrations: for
warning alarms and for initiation of executive action. Typical values of these
set-points are:
• 20% and 60% LEL for general process areas
• 15% and 40% LEL for HVAC air intakes
• 5% and 10% LEL for turbine engine air intakes
4.2.1.2.2.6 The alarm condition shall not be resettable until the specific detector reading
has dropped below the warning alarm level as applicable (Manual-resettable
type).
4.2.1.2.2.7 Operator response shall be required to clear the audible and visual alarms.
4.2.1.2.2.10 Open Path HC Detectors: Open Path IR detectors shall be located where the
beam will provide a clear view over process equipment. The detectors shall
be selected for the correct path length with a separate transmitter and receiver.
The installation of transmitter and receiver shall be as per International Codes
and Standards. Combined transmitter and receiver with mirrors shall not be
used. Units shall not be affected by direct sunlight, fog or mist.
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4.2.1.2.3.3 The portable HC gas detector shall have an integral audio-visual alarm and
shall be factory calibrated for 20% and 60% LEL HC. Alarm shall be
adjustable over the entire detection range of gas detectors.
4.2.1.2.3.4 The portable HC detectors shall be standard size battery (AA/R6 or C/R14 or
D/R20) operated. The batteries shall not be rechargeable type.
4.2.1.2.3.6 The portable HC detectors shall also include accessories such as carrying
case, aspirator, calibration adaptor, etc.
4.2.1.2.3.7 The portable HC detector shall be suitable for Class I, Div I, Group B, C, D,
T3 hazardous area.
4.2.1.2.4.2 The fixed H2S gas detectors shall be powered from 24 V DC supply, with a 4-
20 mA signal loop to cover the calibrated range. Detector faults shall be
signaled by 4 mA signal.
Note: In Scheme-A, detector shall provide 2 nos. of volt free contact outputs
for Non-PLC Panel. These 2 nos. of contact outputs shall be independently
adjustable to over entire range of H2S gas detection.
4.2.1.2.4.3 The H2S detectors shall be capable of detecting 0 – 50 ppm of H2S and shall
have an accuracy of ±3 ppm.
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4.2.1.2.4.4 The fixed H2S detectors shall initiate responses at two different
concentrations: for warning alarms and for initiation of executive action.
4.2.1.2.4.5 Nominal system alarm settings shall be 10 ppm for “Alert” Level and 20 ppm
for “Danger” Level.
4.2.1.2.4.6 The alarm condition shall not be resettable until the specific detector reading
has dropped below the warning alarm level as applicable (Manual-resettable
type).
4.2.1.2.4.7 Two H2S detectors shall be installed at each ventilation air intake of control
rooms and normally manned buildings. For Living Quarters H2S detectors
shall have 0 to 10 ppm range with accuracy ±2 ppm. Nominal system alarm
settings shall be 3 ppm for “Alert” Level and 5 ppm for “Danger” Level.
4.2.1.2.4.8 Local display on the sensors and visual alarm indication shall be there.
4.2.1.2.5.1 The number of Portable H2S Gas Detectors required per platform shall be as
per the Basic Bid Work.
4.2.1.2.5.2 The portable H2S detectors shall be capable of detecting 0 – 20ppm of H2S
and shall have an accuracy of ±3 ppm.
4.2.1.2.5.3 The portable H2S gas detector shall have an integral audio-visual alarm for
activation upon detection of 5 ppm and 10 ppm of H2S.
4.2.1.2.5.4 The portable HC detectors shall be standard size battery (AA/R6 or C/R14 or
D/R20) operated. The batteries shall not be rechargeable type.
4.2.1.2.5.5 The portable H2S gas detector shall be capable of generating a “Battery Low”
Alarm.
4.2.1.2.5.6 The portable H2S gas detectors shall also include accessories such as carrying
case, aspirator, calibration adaptor, etc.
4.2.1.2.5.7 The portable H2S detector shall be suitable for Class I, Div I, Group B, C, D,
T3 hazardous area.
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4.2.1.2.6.1 Fixed catalytic H2 Detectors shall be provided in the battery room and process
areas, which may see release of H2 gas. Minimum of two H2 detectors shall
be provided in an area.
4.2.1.2.6.2 The fixed H2 gas detectors shall be powered from 24 V DC supply, with a 4-
20 mA signal loop to cover the calibrated range. Detector faults shall be
signaled by 4 mA signal.
Typical set-points values for warning alarms and for initiation of executive
action are 20% and 60% LEL respectively.
4.2.1.2.6.3 The H2 detectors shall be capable of detecting 0 – 100% LEL of H2 and shall
have an accuracy of ±5% over the entire detection range.
4.2.1.2.6.4 The catalytic H2 detectors shall not be located in oxygen enriched or depleted
atmospheres.
4.2.1.3.1 General
4.2.1.3.1.1 The fire detection system shall comprise a variety of fire detection devices
and sensors, including:
• Optical Flame Detectors
• Smoke Detectors
• Thermal Detectors
• Fusible Plug Loops
• Manual Alarm Stations
4.2.1.3.2.1 Optical flame detectors shall be the Triple-IR type and shall make use of such
sensor, filters, and / or design to reject phenomena such as electric arcs,
heaters, artificial light sources, lightning and shall be completely “solar
blind”.
4.2.1.3.2.2 The detectors shall be able to detect all types of flaming fires.
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4.2.1.3.2.3 Detectors shall be powered from 24 V DC, with a 4-20 mA signal loop to
cover the calibrated range. Detector faults shall be signaled by a 4 mA signal.
Sufficient margin shall be allowed between fault, normal and alarm levels to
minimize spurious alarms.
4.2.1.3.2.4 Optical flame detectors shall have automatic, self-diagnostic circuitry that
continuously monitors the optical surfaces, sensor sensitivity and electronic
circuitry, and shall give fault status. Any detector malfunction shall be
alarmed on the Fire and Gas detection system panel and DCS.
4.2.1.3.3.1 Smoke detectors shall be installed indoors in all rooms, including space above
false ceiling and below false flooring.
4.2.1.3.3.2 The smoke detectors shall incorporate an integral LED indicator for
confirmation that the unit is active.
4.2.1.3.3.3 Detectors those are not visible, such as above false ceiling or under false
flooring, shall be provided with remote LED’s located in the room being
monitored.
4.2.1.3.3.4 Two independent smoke detector loops in cross – zone concept shall be
installed in each area where executive action is required on detection of
smoke.
4.2.1.3.3.5 Photoelectric type smoke detectors shall be used to provide early response to
smoldering or flaming fires in their incipient stages. A detector base shall be
provided for connecting the individual detectors to the Fire and Gas (F&G)
control system.
4.2.1.3.3.6 Smoke detectors shall remain in alarm state until reset by the fire and gas
control system.
4.2.1.3.4.2 Rate of rise thermal detectors shall be used where an early warning of
smoldering fires is required, such as storerooms and equipment rooms where
air flow or high humidity may inhibit the response of smoke detectors.
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4.2.1.3.4.3 Fixed temperature or rate compensated type heat detectors shall be used
within areas unsuitable for smoke detection where a rapidly achieved high
temperature can be expected, such as machinery rooms or equipment
enclosures. These shall be set at approximately 12oC above maximum
ambient temperature within the area.
4.2.1.3.4.4 Thermal detectors shall remain in alarm state until reset by the fire and gas
control system.
4.2.1.3.4.5 All visible detectors shall incorporate an LED indicator as an integral part of
the detector head or its mounting base. Concealed thermal detectors shall be
provided with an LED “repeater” that is located in a visible location.
Normally, unmanned equipment rooms or offices shall have indicators in the
corridor. The detector circuitry shall cause the LED to remain illuminated
while the detector is the alarm condition.
4.2.1.3.5 Fusible Plug Loops, FSD (Fire Shutdown) valves & ESD (Emergency
Shutdown) valves.
4.2.1.3.5.1 Pneumatic Fire loop having Fusible plug shall be provided to initiate alarm in
F&G System and initiate opening of deluge valve and FSD system. The Fire
loop shall be laid out and segregated according to the fire zones.
4.2.1.3.5.2 Fusible plugs shall be selected to melt at 85oC. Each area covered shall have
independent loop.
4.2.1.3.5.3 Pneumatic Fire loops having fusible plug shall also be provided with
manually operated FSD valves installed at strategic locations all over the
platform as per API-RP-14C. FSD valves shall be RED in color. PSL shall be
provided to pick up the signal from each loop and communicate to F&G PLC
for further necessary action as per Cause and Effect diagram.
4.2.1.3.5.4 Each Fire loops having fusible plug and FSD valve loops shall be originated
from a field mounted Pneumatic Master Shutdown panel / Pneumatic
Charging Panel. Functional specifications of pneumatic panel are addressed in
Spec. no.- MR / OD / INST / FS / 3501.
4.2.1.3.5.5 Fusible plug / FSD valve loops shall be divided into independent group for
each deck corresponding to each fire water deluge networks. These sub-
groups of Fusible plug loops shall be provided with independent loop
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charging facility.
4.2.1.3.5.6 Manually operated ESD valves shall be provided on the pneumatic loop
generated from Pneumatic Shutdown Panel (Refer Spec. no.- MR / OD /
INST / FS / 3501). ESD valves shall be installed at strategic locations all over
the platform adjacent to each FSD valves. ESD valves shall be BLACK in
color.
4.2.1.4.2 Manual alarm stations for Fire alarm shall be located throughout all areas of
the platform, especially at exits and in the main equipment rooms. These
stations shall be located at easily accessible, well lighted, conspicuous areas
and located no more than 30 meters apart.
4.2.1.4.3 Manual alarm stations for Platform Abandonment shall be located in Control
Room and adjacent to each survival craft (exit Point).
4.2.1.4.4 All manual alarm stations shall require a double action to activate the alarm.
They shall be the break-glass, pushbutton type.
4.2.1.4.5 Each unit shall be surface mounted at a height of 1.4 meters and shall be
provided with a striker connected to the station by a chain.
4.2.1.4.6 Each unit shall be wired to the F&G control system in the Control Room.
4.2.1.4.7 The manual alarm stations- Fire alarm shall be red in colour & manual alarm
stations- Platform abandonment shall be black in colour.
4.2.1.5.1.1 The Flashing alarm beacons shall be direct ignition, Xenon type. Flashing
alarm beacons shall be powered from 24 V DC, supply.
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4.2.1.5.1.2 The Flashing alarm beacons shall have flashing speed of 60 flashes per
minute.
4.2.1.5.2.1.2 Field sounder shall be provided for audible alarm for confirmed HC-H2 / H2S
gas release.
4.2.1.5.2.1.3 Field sounder shall be located near personnel rest room on Main deck of the
platform.
4.2.1.5.2.1.4 Power Isolation switch for the Field Sounder & Flashing Alarm Beacons and
Remote Alarm Acknowledgement facility shall be provided to save Power.
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4.2.1.5.3.2 Methane, Hydrogen and Hydrogen Sulphide Calibration gas shall be supplied.
Sufficient quantity of calibration gas shall be supplied to enable complete
calibration, testing, inspection of all sensing heads during commissioning and
successive two time’s complete calibration during post-commissioning
period.
4.2.1.5.4 Extinguishant
4.2.1.5.4.1 Areas protected by extinguishant shall have warning lights and alarms, both
on the inside and outside of the enclosure that will be activated prior to and
during the release of extinguishant.
4.2.1.5.4.2 Two lights shall be provided apart from a blue flashing strobe. One of the
lights shall be used to indicate “Extinguishant release imminent” and the other
to indicate “Do Not Enter – Extinguishant Released”.
4.2.1.5.4.3 The release of the extinguishant shall be indicated on the F&G panel and the
DCS.
4.2.1.5.4.4 A manual release station and a lockable inhibit valve shall be provided at the
entrance to the protected area.
4.2.2.1 GENERAL
4.2.2.1.1 The F&G Control components shall be located in safe area on the platform.
4.2.2.2.1 The Fire & Gas detection system panel for Scheme - A shall constitute the
following:
a) Controller / Monitor Cards, Control & other auxiliary components like
logic relays, auxiliary relays, power distribution for detectors-flashing
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alarm beacons-sounders, etc. or F&G SIL 3 PLC (as per Basic Bid
Work) shall be installed in the SAFE area and housed in Electrical /
RTU/Telemetry Interface Cabinet (TIC) Room. [PLC shall be provided
as per Functional Specification No. MR / OD / INST / FS / C101.]
b) For confirmed HC, H2 & H2S gas release separate SPDT volt free
contacts shall be provided for RTU connection.
c) Fire & Gas system panel shall be interfaced with Pneumatic Shutdown
panel to confirm to SAFE chart requirements.
d) Hooter shall be provided for alarms only.
e) The front panel mounted Gas/Fire detection controllers/monitors shall
be installed in mating cases or mounting bins recommended and
supplied by the manufacturer for panel mounting. All wiring to these
controllers shall be terminated on terminal blocks and/or multipin
connectors provided as an integral part of the case. Routing calibration
adjustments shall be accessible from the front of the panel without
having to remove any wiring or causing loss of the instrument function.
In addition total removal of the instrument and replacement with a spare
shall be possible from the front of the panel.
f) The modules shall be plug-in type permitting the removal of the
modules without disturbing the system wiring. Each module shall have
a maximum of 4 channels (one detector per channel) per modules.
Gas/Fire circuit shall be so designed that any channel can be put out of
service for repair, without affecting the other.
of detection) SPDT relays for each alarm level for the purpose of
alarming & logic solving.
4.2.2.2.2 The Fire & Gas detection system panel for Scheme- B shall constitute the
following:
a) Fire & Gas detection system panel for Scheme- B shall be SIL-3 PLC-
based providing independent automatic control. PLC shall be provided
as per Functional Specification No. MR / OD / INST / FS / C101.
b) Fire & Gas detection system panel shall be interfaced with the following
systems of the platform and confirm to Safety requirements:
- ESD system.
- Pneumatic Shutdown Panel / Charging Panel
- Central Control Panels for package items (such as Gas Turbines,
Process gas compressors, etc)
- Paging system for alarm tones
- Flashing Beacons & Sounders
- Extinguishant systems
- HVAC System
- Deluge panel
- Diesel and electric fire water pumps
- DCS for graphic displays
c) Besides PLC related cabinets other main components of Fire & Gas
Detection system panel shall be:
(i) Critical Annunciator Panel.
(ii) Matrix panel.
(iii) Common Facilities.
e) Matrix Panel: Matrix panel shall provide graphic status of Fire & Gas
Detection system & Fire suppression system area-wise for the entire
platform.
(i) Area-wise status indication shall include the following as minimum:
- Low HC
- High HC
- Low H2S
- High H2S
- Low H2
- High H2
- Flame
- Heat
- Smoke
- Manual Alarm Call point- Fire Alarm.
- Manual Alarm Call point- Platform abandonment.
- Fusible Plug
- Extinguishant- Inhibited.
- Extinguishant- Auto.
- Extinguishant- Manual.
- Extinguishant- Initiated.
- Extinguishant- Released.
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4.2.2.2.3 The Fire & Gas detection system panel shall be freestanding, self-supporting
cubicle type, fully enclosed construction made of CRCA sheet. The contractor
shall be responsible for matching this panel with the other panels of Control
room.
4.2.2.2.4 Plates shall be cut on Squaring shear to ensure tight flush joints when bolted
together. All sharp edges and corners shall be smoothened off to protect
personnel. The final assembly shall be free of buckles, warps, dents or blemishes.
Steel strips stock shall be edge welded to the back of the panel from face above
and below the cut-outs as required to ensure a rigid, self supporting structure. In
order to reduce the loading on the panel face, channel or equivalent support shall
be run horizontally beneath the module cases/shelves to provide rear support.
The finished panel frame work shall be of sufficient strength to allow
transportation and lifting by a crane, with all instrumentation installed without
causing buckling or deflection. Each panel section shall have four (4) removable
lifting lugs at the top of facilitate handling.
4.2.2.2.5 Hinges shall be full-length type. Doorframes shall be formed in the enclosure to
ensure that the doors fit tightly all around. Doors latches shall be the flush-
mounted, 3-point type with recessed chrome-plated handles. An installed
clearance will be maintained inside the panels to allow for door opening and
access the equipment. Doors shall open outwards of the panel.
4.2.2.2.6 The enclosure and its internal equipment arrangement shall be designed to
provide adequate cooling of panel hardware by natural convection alone. Louvers
shall be provided on the top of enclosures for air circulation purposes along with
exhaust fans, as required.
4.2.2.2.7 All sheet and structural steel shall be vapour degreased after shearing, cutting and
forming and prior to welding. Welded construction shall be used throughout,
except where specifically noted otherwise. All welds shall be continuous on the
pieces being joined. Skip welding is not acceptable.
4.2.2.2.8 Proper precautions shall be taken to prevent material wreckage during the
welding process. All welded surfaces shall be thoroughly brushed chipped and
ground to provide a clean, smooth surface.
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4.2.2.2.9 The entire steel structure is to be sand blasted, phosphatized and painted with two
coats of sealing primer on surfaces. The final finish shall be a minimum of three
coats of non-glossy Admiralty Grey epoxy paint on exterior surface and pale
cream on interior surface. The fabricator shall supply separately one (1)
Kilogram of paint for touch up.
4.2.2.2.10 Panel cutout sizes, instrument supports and stabilizers and panel reinforcements
shall be strictly in accordance with the instrument manufacturer's
recommendations. Cutouts shall not be made with flame production devices.
4.2.2.2.11 Sufficient access shall be provided for all instruments via cable duct/trays to
allow checking and/or changes to the wiring to the instrument case.
4.2.2.2.12 Auxiliary Equipment: All rear of panel equipment (terminal blocks, auxiliary
relays, solid state logic cards, etc.) shall be physically located off the exterior
walls of the panel by means of suitable mounting brackets/plates welded to the
wall prior to finishing and painting. Drilling and tapping the outside walls of the
enclosure for mounting internal equipment is prohibited. The auxiliary
equipment shall be located and arranged for easy access, for calibration and
maintenance. It shall not be necessary to remove any item in order to gain access
to check or remove any other item. All cable runs shall be grouped, routed and
secured to provide a neat appearance and prevent interference with the operation
and maintenance of auxiliary equipment. Auxiliary relays, if used shall be of the
plug-in enclosed type.
4.2.2.2.13 Electrical Construction: The installed electrical equipment component parts and
associated wiring in the panel shall be in accordance with the practices outlined in
NEC, latest edition, for non-hazardous area. The panel itself shall meet the
requirement for NEMA-1 (General purpose in door) electrical enclosure.
4.2.2.2.14 Cables from field shall enter through bottom of the panel through multi-cable
transits.
4.2.2.2.15 Cable glands are to be provided in panel to clamp the incoming/outgoing cables.
Glands shall be of Double Compression type and nickel-plated brass. Gland
plates shall be provided to facilitate cable gland installation.
4.2.2.2.16 The 24V DC main power supply feeder to the box shall be protected by a suitably
sized circuit breaker with manual trip lever. The breaker shall be housed in a
suitable surface mounted enclosure. All components shall be suitable for 24V DC
± 10%. Power distribution to controllers and associated group of auxiliary relays
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circuits shall be via fused terminals with a blown fuse indicator, and input/output
fuse status alarm.
4.2.2.2.17 Panel Ground and signal ground shall be separate. Signal ground shall be
provided for circuit grounds of Electronic instruments, Detector Circuit shields,
Drain wire of cable shields, I.S. Barrier earth etc. For this purpose an insulated
ground bus bar 25 mm wide x 6 mm thick of copper material shall be provided
which shall run along the entire panel length. Ground wiring shall be directly
connected to the ground bus bar by means of suitable wire lugs. Intermediate
terminals are not allowed. This ground bus bar shall be provided with grounding
terminals at both ends. Terminals shall be compression type suitable for AWG
No. 4 copper ground cable. The same shall be provided on each panel structure
for panel grounding.
4.2.2.2.18 The panel shall be designed such that field wiring from remote sensing head for
Fire & Gas may be terminated directly on the associated detection controller input
terminals, rather than interposing field wiring terminal blocks. All gas and fire
detection circuits shall be grounded as per recommendations of the manufacturer
and good engineering practices. All the detector circuit shields shall be grounded
at the same point as the signal circuit.
4.2.2.2.20 Suitably sized Terminals shall be provided for terminating main power supply
cable. The size shall be decided by the Contractor.
connection.
4.3.1.1 General
4.3.1.1.1 The Contractor shall produce a set of Cause and Effect diagrams during the
design stage reflecting the proposed location / action for review by the Company.
Cause and Effect diagram diagrams shall be as per API RP 14C requirements
together with the requirements of this specification.
4.3.1.1.2 All shutdown interlock and alarm circuits shall be designed to operate in a fail-
safe mode.
4.3.1.1.3 Fire & Gas logics shall be designed to de-energize to actuate gas / fire shutdown
interlock.
4.3.1.1.4 Alarms-
a) In addition to signaling on the F&G matrix and alarm annunciator, fire and
gas detection shall result in separate and distinct audible and visual alarms at
Control room / equipment enclosure room / field area. (Scheme- B)
b) Visual alarms shall be colour coded to the company’s requirements to
distinguish between fire, combustible gas release, and toxic gas. (All
Schemes).
c) For gas detection, distinct visual and audible alarms in the Control room shall
be provided for the two levels of detection. (Scheme- B)
d) Silencing of audible alarms shall not deactivate visual alarms until detection
falls below the alarm level.
e) Fire & Gas Detection system shall be suitably interfaced with platform DCS.
DCS shall have an over view graphic for each F&G zone. The graphic shall
display individual detector analogue value, alarm and fault status, and deluge
valve and extinguishant release status. A separate graphic will display the fire
water pumps run and fault status and fire water pressure. (Scheme- B)
4.3.1.1.5 Detector Voting: Confirmed fire or gas-release shall be indicated by the
following:
(i) 2ooN flame detector (N ≥ 2)
(ii) 1ooN thermal detector (N ≥ 2)
(iii) 2ooN gas detector 60% LEL (N ≥ 2)
(iv) 2ooN smoke detector in Cross Zone (N ≥ 2)
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ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 26 of 35
‘N’ denotes the quantity of detectors required for covering an area as per the
requirements of this specification in general and clauses 4.2.1.1.3, 4.2.1.2 and
4.2.1.3 of this specification in particular. Each area, viz., each process component
area, each equipment area, each building module area, shall be covered
individually.
4.3.1.1.6 Distinct platform audio-alarm shall be provided for confirmed HC-H2 gas release,
confirmed H2S gas release, confirmed fire through paging system. Dry volt Free
Contacts shall be provided for the input signals.
4.3.1.1.8 All remote gas/fire alarm outputs shall be provided through paging system.
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DETECTION SYSTEM. Page 27 of 35
4.3.1.2.1 The control actions to be initiated upon fire and / or gas detection on
wellhead- platform are as follows:
Location Fire Or Gas Detection Action
(See Below)
Process area Confirmed Fire (Fusible plugs) 1&4
Process area Confirmed Gas release 2&3
(HC or H2S detector)
Battery room Confirmed Gas release 2
(H2 detector)
RTU/Sw.Gr./VFD Room Confirmed Fire (Smoke, 1&4
Thermal etc.)
Transformer Area Confirmed Fire (Thermal, 1&4
Triple- IR etc.)
1. Alarm- Field Sounder.
2. Alarm- Flashing & Field Sounder
3. Initiate ESD.
4. Initiate FSD, open deluge.
Note: FSD (Fire Shut down) shall close all Shutdown valves including
SSSV and open deluge valves & activate fire water network.
ESD (Emergency Shut down) shall close all Shutdown valves.
1. Alarm on DCS, Annuciators and Paging system, Indication on Fire & Gas
matrix.
2. Shutdown Power to Living Quarters, trip ventilation system and automatic
actuation of Fire Water spray system / Extinguishant system.
3. Shutdown Power to the concern area, trip ventilation system.
4. Initiate ESD and trip unit.
5. Initiate FSD and open deluge valve of the detected zone/area
6. Initiate FSD, trip unit, release extinguishant instantly.
7. Initiate FSD, Trip unit in ventilation mode, trip ventilation system, release
extinguishant instantly (GG-PT Enclosure) / open deluge valve
(Compressor area).
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8. Initiate ESD, Trip unit in ventilation mode and trip ventilation system.
9. Trip unit and ventilation system and release extinguishant instantly.
10. Initiate FSD, trip unit and release extinguishant after some time delay.
11. Shutdown Power to the concern area release extinguishant after some time
delay.
Note: i) FSD (Fire Shut Down) shall close all Shut Down Valves, shall
open blow down valves, shall start firewater pumps and open
deluge valves / Release extinguishant.
ii) ESD (Emergency Shut Down) shall close all Shut Down valves,
trip the main generator set and start the emergency generator.
4.4.2 For installation, testing, commissioning of Fire & Gas detection system
vendor shall recommend and provide all the necessary spares. These spares
shall be properly & separately packaged with clear marking- ‘Commissioning
Spares’.
4.4.3 Vendor shall include along with the proposal a separate priced list of
recommended spare parts for one year normal operation and maintenance.
This list should take into account related factors of ‘Fire & Gas detection
system’ reliability, effect of downtime upon normal operation & safety and
availability of servicing facilities.
4.5 Material
4.5.1.2 The Fire & Gas detectors shall have SS 316 sensor body housing material.
4.5.1.3 Enclosure for sensor electronics shall be copper-free marine grade Aluminum
suitable for offshore marine environment.
5. EQUIPMENT PROTECTION
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5.1 The protection requirements for the components of the Fire and Gas Detection
System shall in general be as per clause no. 3.6.4.4 of Instrumentation Design
Criteria.
5.2 The fixed gas detectors shall be provided with manufacturer-approved rain
hoods. Shop fabricated rain hoods shall not be used.
6.1 The installation requirements for the components of the Fire and Gas
Detection System shall in general be according to clause 3.6.4.6 of
Instrumentation Design Criteria.
6.2 All detectors shall be installed such that they are easily accessible from a
walkway or access platform for calibration and maintenance. Where this is
not possible, test tube connections for detector calibration shall be provided.
6.3 All field equipment shall be readily accessible without the need to move other
items or equipment, except ceiling and floor tiles in the case of concealed
detectors.
6.4 All components of the fire & gas detection system panel, which require
regular maintenance and / or monitoring, shall be easily accessible to the
operations and maintenance personnel with minimum wiring removal and no
special tools.
7.1 Inspection category of Fire & Gas detection system is B. Equipment / items
shall be inspected by company representative only at final stages as per
project finalized documents viz. Purchase specification (s), applicable project
documents, vendor documents at vendor’s works, in addition to stage
inspection by contractor and / or third party inspection agency.
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7.3 Prior to shipment from vendor’s works vendor shall carry out 100 percent
testing of hardware and software of Fire & Gas detection system in the
presence of company representative / Third Party Inspection Agency-
representative .
7.4 After finalisation of testing procedures Vendor / Contractor shall notify to the
company one month before the scheduled date of testing of Fire & Gas
detection system.
7.6 The minimum requirements for testing of Fire & Gas detection system shall
be:
a) Visual, dimensional, workmanship checks.
b) Internal inspection reports verification.
c) Test certificates, Material test certificates, Statutory certificates
verification.
d) Verification of components of Fire & Gas detection system (type, size,
configuration, ratings, etc).
e) Wiring check- visual check (type, size, segregation ferruling, etc),
continuity test, and insulation test.
f) Functional check: Gas detectors- Each detector shall be subjected to
calibration check. Inject test gas and check analogue readout and alarms
as per this spec requirement. Test filters shall be used wherever required.
g) Functional check: Heat detectors- Each detector shall be subjected to
calibration check.
h) Functional check: Flame detectors- Each detector shall be subjected to
testing and shall be powered for a minimum of 2 hrs before testing.
i) Functional check: Smoke detectors- Apply manufacturer approved test
fluid to each detector for testing.
j) Other field devices including Flashing beacons, sounder, etc shall be
tested for their functions.
k) Test all shutdowns in accordance with the ‘Cause and Effects diagrams’.
l) For ‘Loop testing / acceptance’ testing, ‘Panel’ inspection / testing, etc
refer to ‘Design Criteria- Instrumentation’.
m) Fire & Gas detection system shall be subjected to elaborate ‘Factory
Acceptance Test’ (FAT) at vendor’s works. After successful installation
system shall under-go ‘Site Acceptance Test’. For ‘Scheme- III’ vendor
/ contractor shall also refer to Spec. no. MR / OD / INST / FS / C101,
‘Functional Specifications for PLC’.
n) The Vendor shall demonstrate the design life and overall system
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a) All fixed gas sensors shall be capable of direct calibration at the sensor
head from deck level or from a fixed platform, without the need to open
the detector enclosure.
a) Kits for testing and calibrating the fire detectors shall be provided.
b) All fire sensors shall be capable of direct calibration at the sensor head
by one person from deck level or from a fixed platform.
8.2 The vendor, and his sub-vendor, shall operate a quality system satisfying the
applicable provisions of ISO 9000 (series). A detailed quality plan shall be
provided with the bid.
8.3 The company reserves the right to carry out quality and technical review at
both vendor’s and sub-vendor’s works.
9.0 DOCUMENTATION
9.2 Specifically for Fire & Gas Detection system following minimum documents
shall be submitted:
Type of
S.N. Document Name
Document
Following documents shall be generated by the contractor and shall be included in
main DCI of the project. These documents shall be provided to the vendor to aid
design & engineering of Fire & Gas detection system.
1 F & G detectors, other field devices layouts. FR
2 Cause & Effect diagrams. FR
3 System I / O listing / point configuration database FI
Information for displaying all displays and reports FI
4
(For Scheme- III only)
5 F & G Cable schedule FI
6 Control room layout- F&G system details FR
Following documents shall be generated by the vendor. Before submitting the
documents for review / information to the company contractor shall verify &
confirm the documents in respect of approved PS requirements.
7 Package Schedule FI
8 Document index & schedule FI
9 System configuration drawings FR
10 Logic print-outs / diagrams FR
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Notes:
FR For ONGC Review
FI For ONGC Information
9.3 For other PLC related documents refer to Spec .no. MR / OD / INST / FS /
C101
9.4 Purchase specification shall cover all the details as indicated in ‘Design
Criteria- Instrumentation’. Beside these details indicative formats of the
documents 6, 7, 9, & 18 (typical only for each type of detector, field devices,
etc.) shall also be incorporated in the proposal / purchase specification.
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10.2 For the purpose of tagging field devices including detectors, manual alarm
stations, flashing beacons, sounders, etc following philosophy shall be used:
13.1 The components of the Fire and Gas Detection System shall be prepared for
shipment in accordance to clause 3.6.6.5 of Instrumentation Design Criteria.
14.1 Receipt and storage of the components of the Fire and Gas Detection System
shall be in accordance to clause 3.6.6.6 of Instrumentation Design Criteria.
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SHUTDOWN PANEL
CONTENTS
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SPECIFICATION Rev. No : 4
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SHUTDOWN PANEL
1.1 This specification describes the essential considerations in the selection, design,
procurement, engineering, installation, calibration, testing and commissioning of Shut
Down Panel (SDP).
1.2 The Contractor shall be responsible for the design, engineering, procurement, packing,
calibration, testing at yard and offshore, shipment to yard and offshore site, installation
and commissioning at site of the Shut Down Panel (SDP).
1.3 The Contractor shall be responsible for the technical integrity of the Shut Down Panel
offered, including design, materials, manufacture, assembly, testing, performance and
specified engineering services. All activities shall be in accordance with the scope of
supply, functional specification, data sheets and interface information supplied by the
Company.
3.1 The scope of work shall include a Shut Down Panel (SDP) complete with SSV control
(pneumatic / hydraulic), SSSV control (hydraulic), ESD functions, FSD functions, Well
start-up system, Tele-metering functions and other components and / or functionality as
described in this document and in the scope of work. The number of Well Control
Modules required in the SDP, the type of SSV system i.e., pneumatic or hydraulic, etc
shall be as indicated in the Scope of Work.
3.2 The scope of supply shall also include commissioning spares and Mandatory Spares as a
part of the equipment as suggested by the Manufacturer & list of one years’ operational
spares along with other type of spares as indicated in clause 3.6.4.8 of Instrumentation
Design Criteria.
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SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
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SHUTDOWN PANEL
4.1.1 The purpose of the Shut Down Panel on offshore platforms is to control all safety
shutdown functions of the platform, and thereby ensure safety of personnel and
equipment.
4.2 General:
4.2.1 The Shut Down Panel shall perform platform safety functions such as shut-in of Surface
Safety Valve (SSV), shut-in of Sub-Surface Safety Valve (SSSV), Emergency Shut
Down (ESD) functions, Fire Shut Down (FSD) functions, well start-up functions, etc. as
described in the following document and in the basic bid work.
4.2.2 The SSV, ESD, FSD and well start-up systems shall in general be pneumatic and the
SSSV system shall in general be hydraulic. The functional requirements and system
requirements of these sub-systems shall be as given below in clause 4.3 and 4.4
respectively.
4.2.3.1 Pneumatic supply to the panel shall in general be as per clause 3.6.4.2.1 of
Instrumentation Design Criteria.
4.3.1 The Shut Down Panel shall initiate shut-in of all Surface Safety Valves (SSV) under any
of the following conditions:
a) When any one of the points shown in the platform SAFE Chart / P&ID for SSV
shut-in receives an abnormal signal i.e. loss of holding signal.
b) When the associated wellhead pressure gives an abnormal signal i.e. loss of
holding signal.
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c) When the Common manual reset / shut-in button provided on the panel for each
SSV is activated.
The SSV control system shall be either pneumatic or hydraulic as indicated in the Scope
of Work. The control system required for performing this function shall be as per clause
4.4.1 of this document.
4.3.2 The Shut Down Panel shall initiate shut-in of all Sub-Surface Safety Valves (SSSV)
under the following conditions:
a) After respective Surface Safety Valves have shut-in and / or when any one of the
points shown in the SAFE table / P&ID for SSSV shut-in receives an abnormal
signal. A timing circuit shall be utilized to provide a time delay of 3 minutes
(which is adjustable) between SSV shut-in and SSSV shut-in. The time circuit
shall be of pneumatic type only.
b) When the Common manual reset / shut-in button provided on the panel for each
SSSV is activated.
The control system required for performing this function shall be as per clause 4.4.2 of
this document.
4.3.3 The Shut Down Panel shall initiate platform ESD and / or FSD as per the platform SAFE
charts. The system requirements for performing ESD and FSD functions shall be as per
clause 4.4.3 of this document.
4.3.4 The Shut Down Panel shall use the following control signals for the different shut down
circuits:
4.3.5 The Shut Down Panel shall be capable of telemetry and tele control of all parameters
shown in the platform SAFE Charts and P & IDs. The shutdown system shall be capable
of operation even when the telemetry system is not installed or communication failure
takes place. The system requirements for achieving this function shall be as per clause
4.4.4 of this document.
4.3.6 The SDP shall be capable of initiating remote opening of individual SSVs. Remote
opening of individual surface safety valves (SSV) shall be achieved only after initial
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start-up and commissioning and shall be effective only when all the conditions specified
in the platform Safe Table /P&ID are in healthy state. The opening of surface safety
valves (SSV) and any other valve through Telecontrol shall be accompanied by
automatic starting of an audible alarm with different tone. This audible alarm shall sound
for maximum time of three (3) minutes unless reset earlier. Visual indication for the
same shall be provided at the panel front on well control modules.
4.3.7 The SDP shall have a Well Start-up system for manual opening of individual wells since
pneumatic supply is generally not available on the platforms for initial start-up of the
wells. These operations shall be accomplished by operating hydraulic pumps manually.
4.3.8 The logics in the SDP shall take care that after tripping, the system is not be brought
back to normal, unless, “RESET” is actuated and tripping conditions have come back to
normal.
4.3.9 In case of shutdown, the air supply to the hydraulic pumps shall be cut off until
shutdown signal is normalized and the ESD is reset manually. Vendor shall ensure the
same in the logic.
4.3.10 It is the responsibility of vendor to design the logic in such a way that after tripping any
shutdown valve, the valve shall not open automatically until the signal causing the trip is
normalized and the operator opens the valve using manual reset of that particular valve.
4.4.1.1 The control signal for Surface Safety Valve (SSV) control system shall be as per clause
4.3.4 above and the supply for the SSV control system shall be either pneumatic or
hydraulic as per clause no. 4.2.3 or 4.2.4 above respectively.
4.4.1.2 Each SSV circuit shall have a permit circuit connected to its associated SSSV circuit, to
prevent the SSV opening before the SSSV as well as to shut the SSV, if the hydraulic
pressure to the SSSV is interrupted or decreased. This circuit shall consist of a high-
pressure hydraulic pilot, timing system and 3-way valve. This pilot shall be set at
approximately 200 kg/cm2g.
4.4.1.3 The bulkhead fittings to the individual SSV shall be suitable for 3/8” O.D. 6000#
tubings.
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4.4.2.1 The control signal for Sub-Surface Safety Valve (SSSV) control system shall be as per
clause 4.3.4 above and the hydraulic supply for the SSSV control system shall be as per
clause no. 4.2.4 above.
4.4.2.2 The SSSV control system shall comprise of SSSV equalize system and SSSV primary
system.
4.4.2.3.1 The purpose of this system is to apply initial pressure to the SSSV, to enable the
difference in pressure between primary system and start-up system to equalize, without
applying unnecessary shock to the SSSV. A manual 3-way selector valve shall be
provided on the panel front to select primary / start up header.
4.4.2.3.2 The bulkhead fittings to the individual SSSV shall be suitable for 3/8" O.D. 316 SS
tubing and their rating shall be 6000#.
4.4.2.4.1 The SSSV primary loop shall be connected to SSSV start-up loop. The SSSV primary
loop shall not have entry to the SSSV till the SSSV equalize pressure is obtained. This
shall be automatically achieved by use of hydraulic pilot.
4.4.2.4.2 The SSSV's shall be provided with redundant return line connected to redundant return
header. This header shall be provided with relief valve and pilot valve. The pilot valve
shall operate from SSSV shutdown system with suitable adjustable time delay.
4.4.2.5 Hydraulic System for SSSV ( and for SSV system wherever applicable):
4.4.2.5.1 The hydraulic system shall consist of pumps, reservoir, accumulators, headers and other
accessories as required. The relief valve shall be provided in the system based on design
pressure given elsewhere. The reservoir and accumulator sizing is to be carried out by
the Vendor and all calculations are to be submitted to company for approval. Pump
exhaust shall be vented outside the panel through flame arresters in case instrument gas
is used.
4.4.2.5.2 The accumulator header shall be 1" XXX SS 316 with 6000# SS 316 fittings. The
hydraulic tubing shall be 316 SS 3/8" OD with 0.049" wall thickness.
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4.4.2.5.3 Pneumatic ( electrical type where PLC based SDP is asked in the scope of work)
pressure pilot shall sense low hydraulic pressure in the system and it shall cause
shutdown in the same way as defined for PSL on instrument air/gas header.
4.4.2.5.4 Hydraulics supply to header shall be through line size dual filters with necessary
isolation and differential pressure indication. Hydraulic fluid shall meet its functional
requirement in high pressure application as described in the scope of work.
4.4.2.5.5 All hydraulic pumps shall be gas/air driven as well as hand operated. Each pump
discharge shall be provided with relief valve and external check valves. Each pump-
suction shall have suction strainer and differential pressure gauges across it. The pump
for start up header shall have panel front mounted filter regulator.
4.4.2.5.6 Wherever regulators are used to derive a particular pressure level the same shall be
achieved using dual redundant isolation valves, regulators and relief valves.
4.4.2.5.7 The accumulators shall be provided to take care of leakage in the system and shall be
capable of one operation of all valves of one dual completion well in case of failure of
hydraulic pumps.
4.4.2.5.8 The accumulators shall be provided with isolation and drain valves.
4.4.2.5.9 Each pump exhaust shall be tube connected to the panel exterior with suitable exhaust
header.
4.4.2.6 Reservoir System for SSSV ( and for SSV system wherever applicable):
4.4.2.6.1 The reservoir shall have an oil volume of 75 litres minimum Vendor to check and
provide correct volume as required considering future requirements and adequate air
gap. The reservoir system components shall be in SS 316 material.
4.4.2.6.2 A relief tube, properly sized shall be placed between the hydraulic drain header and the
reservoir.
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vi) The common drain header shall be 3/4" Sch. 40 316 SS pipe.
vii) The reservoir system shall include pneumatic gas / air driven pumps with a
hand pump to keep the hydraulic system pressurized for opening SSVs /
SSSVs.
viii) Low level switch (potential free contacts)
4.4.3.1 The ESD and FSD Systems shall be pneumatic in general. The control signal for these
systems shall be as per clause no. 4.3.4 above.
4.4.3.2 The SDP shall accommodate the charging and detection system for ESD on the platform.
One manually actuated ESD valve shall be mounted on the panel to perform ESD
functions. Panel shall have provision for quick charging facility of ESD loop.
4.4.3.3 The SDP shall accommodate the charging and detection system for FSD and Fusible
Plug Loop on the platform. One manually actuated FSD valve shall be mounted on the
panel to perform FSD and Fusible Plug Loop functions. Panel shall have provision for
quick charging facility of FSD and Fusible Plug loop.
4.4.4.1 Explosion-proof cum weatherproof pressure switches shall be provided in the panel for
telemetry of the required parameters.
4.4.4.2 Explosion-proof cum weatherproof solenoid valves shall be provided in the panel for
tele control of the required parameters. These solenoid valves shall be pulse operated,
magnetically latched type and shall not draw continuous power in both the open and
closed states.
4.4.4.3 RTU bypass valves shall be provided at the back of the panel with wire seal to prevent
inadvertent operation.
4.4.5.1.1 The Shut Down Panel shall be Removable Modular type, Skid-mounted and Free
standing. The Panel shall be of Welded construction.
4.4.5.1.2 The Panel front shall be smooth and flat. Stiffeners shall be provided wherever required
to prevent buckling due to weight while operating the switches.
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4.4.5.1.3 To ensure rain tightness, cracks around bolts, lifting eyes, panel-mounted instruments
etc. shall be sealed with suitable media.
4.4.5.1.4 The bulkhead fittings and electric conduit connections shall be located on the Left/ Right
side of the panel.
4.4.5.1.5 The panel shall have lifting eyes to facilitate handling during transportation and
installation.
4.4.5.1.6 All internal braces and supports shall be fabricated from stainless steel.
4.4.5.1.7 The panel shall be of welded construction all around and all buff welds are to be ground
smooth. Filter welds require no grinding provided they are neat in appearance.
4.4.5.1.8 The double door type panel shall have swing out rear doors hinged with a continuous
stainless steel hinge fully gasketted and held closed with a heavy T bar latch. The panel
door shall also have lock and key arrangement. The Back-side Door shall be opened
fully without any hindrance and latching mechanism to held the door open position for
O&M purposes.
4.4.5.1.9 The panel shall be self-standing with channel frame at the base to support all the heavy
items such as pumps, accumulator reservoir. A drip pan with ¾” drain valve shall be
provided covering entire base of panel.
4.4.5.1.10 The components mounted on the panel shall be easily accessible for routine maintenance
with minimum tubing removal. All panel front components required for operation and
operator's observations shall be mounted at 600 to 1800 mm elevation from grade.
4.4.5.1.11 Engraved name plates shall be fixed by SS 316 screws at appropriate positions.
4.4.5.1.12 Arc suppression diodes shall be provided across solenoid valve terminals.
4.4.5.1.13 Cable entry size for solenoid valves provided for gas detection system shall be 3/4"
NPT (F).
4.4.5.1.14 Separate junction boxes shall be provided outside on the panel for telemetry and
telecontrol parameters. Multicore cable entries to each junction box shall be 1 ½” NPT
(F) minimum. Junction Box to be located outside /inside(preferably) on the Shut Down
Panel.
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 11 of 17
SHUTDOWN PANEL
4.4.5.1.16 The tubing shall be SS 316, seamless & fully annealed. Double ferrule 316SS tube-
fittings with ASTM-F-1387 compliance of reputable make from ONGC approved
vendor list shall be used and shall be as per FS-3507 (FS for Instrumentation Bulk
Material).
Fittings/ tubing / Instrument valves and accessories shall meet all the functional
requirements of FS-3507.
4.4.5.1.17 External connection for SSSV, SSV, ESD Loop and FSD Loop shall be suitable
for 3/8” OD 316 SS tubing and for other shall be suitable for 1/4" OD 316 SS tubing.
4.4.5.1.18 All components and logic devices inside the panel shall be made of SS 316. Block and
bleed logics / relays shall be used.
4.4.5.1.19 The panel shall provide the following, in case of abnormal process conditions:
a) Visual indication
b) Audible alarm (the alarm shall sound for a maximum of 3 minutes, unless
reset earlier)
4.4.5.1.20 The pneumatic supply header shall be 3/4" SS 316 pipe. A 1/2" drain valve shall be
provided at the end of supply header opposite to the supply connections. The pneumatic
supply to the panel shall be through dual filter regulators with isolation valves, pressure
gauges, shuttle valve and relief valve.
4.4.5.1.21 Low instrument air/gas supply pressure in the panel shall be sensed by pneumatic
pressure pilot (set @ 5 kg/cm2g) and it shall cause shutdown in same way as defined for
PSL on Instrument air/gas header.
4.4.5.1.22 The panel shall provide a manual by pass for individual relays except ESD, FSD, low
hydraulic pressure, and low pneumatic pressure in panel, 60% LEL in gas detection
system and 50-ppm H2S signal in case of platform handling Sour Well Fluid. These
manual bypass valves shall be provided at panel back with wire seal.
4.4.5.1.23 Manual override facility (for start up alone) shall be provided, for all trip conditions,
except, ESD, FSD, 60% LEL gas, and 50-ppm H2S detection (in case of platform
handling sour well fluid). This shall release as soon as the trip condition returns to
normal.
4.4.5.1.24 All incoming and outgoing signals shall be as per approved P&IDs & SAFE Chart, and
other sections of this Bid document. The Vendor shall check and provide all logic and
all other components as required.
4.4.5.1.25 All Remote operated solenoid valves except remote ESD XSV shall be provided with
Block and By-pass Valves.
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 12 of 17
SHUTDOWN PANEL
4.4.5.1.26 Manual shut-in / Reset valve shall be provided for each SSV, SSSV, XSDV and any
other output for shutdown purpose.
4.4.5.1.28 Local closing facility for Main line XSDV shall be provided.
4.4.5.1.29 Panel front mounted liquid filled pressure gauges shall be provided, for pneumatic
supply pressure, hydraulic supply pressure, each input signal pressure and each output
signal pressure. All pressure gauges are to be provided with isolation valves.
4.4.5.1.30 Laminated photocopy of the Logic diagram shall be pasted on the inside of the SDP
door.
4.4.5.1.31 The indicative dimensions of the Shut Down Panel shall be as follows: (contractor shall
submit panel internal layout for approvals)
Width: As per no. of modules as described in scope of work.
Height: 2000 mm
Depth: 1200 mm
Door Width: 600 mm (max.)
4.4.5.2.1 All electrical components in the shut down panel shall be housed in an explosion proof
junction box outside / inside (preferably) on the panel.
4.4.5.2.2 The junction box shall house all electrical components that are a part of the shut down
panel. This junction box shall be constructed as per FS-3507 and shall be explosion
proof to NEMA 7.
4.4.5.3.1 The number of Well Control Modules (WCM) required shall be as per the Basic Bid
Work.
4.4.5.3.2 Each well control module shall have following facilities as a minimum:
• Manual shut in/Reset for each SSV
• Manual shut in/Reset for each SSSV
• Control Supply Pressure Gauge for each SSSV
• Control Supply Pressure Gauge for each SSV
• Remote opening / closing of each SSV
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 13 of 17
SHUTDOWN PANEL
• Three-minute time delay for SSSV shut in, in case of simultaneous shut
in of SSV and respective SSSV.
• Start up and primary manifold
• All incoming lines to module shall be provided with isolation / check
valves before entry to module to facilitate removal for maintenance
purpose.
• Lift Gas and / or Water Injection control logic as per requirement
4.4.5.3.3 In-built Gas Lift Logics shall be incorporated in all well control modules, including all
spare well control modules irrespective of type of well.
4.4.5.3.4 At least one spare well control module shall be provided if not indicated in the basic bid
work.
4.4.5.4 Indicating System:
4.4.5.4.1 The Shut Down Panel shall provide first-out visual indication and audible alarm in case
of any abnormal process condition.
4.4.5.4.2 Pneumatic horn shall be provided for audible horn. The horn shall be mounted at the top
of the panel. The horn shall sound for a maximum time of three (3) minutes unless reset
earlier.
4.4.5.5.1 The Contractor shall provide all panel mounted instruments and accessories required for
future facilities. The Contractor shall also carry out necessary hook-up inside the panel,
related to spare module.
4.4.5.5.2 The Contractor shall also provide all other materials / equipment (e.g. Interconnecting
cables, junction boxes, cable glands, etc.) required to make the Shut Down Panel
complete and functional.
4.4.5.5.3 Inside the Shut Down panel, lay out of the instruments and accessories shall be in a
manner that all the items and terminals and fittings shall be directly accessible for
maintenance.
4.4.6.1 PLC based shutdown panel if specified in the scope of work, PLC unit shall be
provided as per FS-C101 and the unit shall be placed in safe location. Pneumatic
shutdown panel unit shall be located in the field and to be integrated with PLC with
suitable interfaces.
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 14 of 17
SHUTDOWN PANEL
4.4.6.2 All the field instruments ( PSHL, PT, DPT, TT, FT, etc ) shall be electronic type as per
P&IDs and scope of work. Signals from PSHLs shall be directly hooked up with PLC.
All the functional Logics shall be executed in PLC only . However, the related output
signal ( pneumatic/ hydraulic) to field instruments shall be processed in Pneumatic
shutdown panel unit at site.
4.5 Material:
4.5.1 The material requirements for Shut Down Panel shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria.
4.5.2 The material of construction of the various components of the Shut Down Panel shall be
as follows:
Item Material
Skid : Carbon Steel
Panel : 4.0 mm thick SS 316 ( with compatible
panel door)
Components inside the panel : SS 316 (shall meet the requirement of
NACE MR-01-75).
Junction Box : As per FS-3507.
5.1 Shut Down Panel protection requirements shall be as per clause no. 3.6.4.4 of
Instrumentation Design Criteria.
5.2 Panel shall be weather proof to NEMA 4X.
5.3 Electronic / electrical components like solenoid valves, electric pressure switches,
junction boxes etc., mounted on the panel shall be weatherproof and explosion proof as
per cl 3.6.4.4 of Instrumentation Design Criteria.
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 15 of 17
SHUTDOWN PANEL
6.1 The installation of Shut Down Panel shall in general be according to clause 3.6.4.6 of
Instrumentation Design Criteria.
6.2 All components, which require regular maintenance and / or monitoring, shall be easily
accessible by operations & maintenance personnel, with minimum wiring removal.
6.3 Maintenance space requirement shall be kept to a minimum.
7.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria. In addition, the following shall also be taken care of:
7.2 Panel shall be completely finished, piped and tested by the Vendor before submitting for
inspection. The panel testing prior to inspection shall be as follows:
• All pneumatic lines and hydraulic lines shall be tested, for leaks by applying 1.5
times the maximum working pressures.
• Wiring Checks (Loop Checks), Continuity Checks
• Utility Consumption
• Internal resistance check and insulation checks for electrical circuits
• Insulation test shall be done for wiring inside the panel.
• Simulation and full functional test (Panels shall be tested by simulating actual
operating conditions.)
• Any additional tests as laid down by the Company
7.3 The Vendor shall perform all other test as required, to place the panel in operating
condition.
7.4 In addition to the tests listed above any other test(s) required for approval shall be
performed to the satisfaction of Purchaser or his representative before shipment.
7.5 Sufficient time, ample space and necessary assistance shall be provided by the Vendor to
assure inspection and testing to the satisfaction of the Purchaser or his Representative.
8.0 DOCUMENTATION:
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 16 of 17
SHUTDOWN PANEL
8.2 The Contractor shall obtain Company’s approval for overall architecture diagram for all
well fluid data monitoring & controls as per scope of work, panel logic diagrams, sizing
calculations for reservoir and accumulator, before proceeding with the panel fabrication.
8.3 The Contractor shall submit complete QA / QC plans for the proposed Shut down panel
for Company’s review / approval.
8.4 The Supplier, and his sub-supplier, shall operate a quality system satisfying the
applicable provisions of BS5750/ISO 9000 (series). A detailed quality plan shall be
provided with the bid.
8.5 The purchaser reserves the right to carry out quality and technical review at both
supplier’s and sub-supplier’s works.
Receipt and storage of the Shut Down Panel shall be in accordance to clause 3.6.6.6 of
Instrumentation Design Criteria
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FUNCTIONAL Spec No : 3501
Offshore Design Section
SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
FOR
ISO – 9001:2008 Page : 17 of 17
SHUTDOWN PANEL
ANNEXURE – I
TYPICAL WELL CONTROL MODULE (WCM) LAYOUT
M 13 M7 M1 M3
M6 M8 M2 M4
M 11 M9 M 12 M 10
M5
M 14
SIZE
ITEM DESCRIPTION QUANTITY (INDICATI COLOUR
VE)
M1 PSHL-XXX Flow line Pressure Gauge 1 (Per Module) 70 x 20 White
M2 PSHL-XXX Flow line Status 1 (Per Module) 70 x 20 White
M3 PSHL-XXX L/G Injection Pressure Gauge 1 (Per Module) 70 x 20 White
M4 PSHL-XXX L/G Status 1 (Per Module) 70 x 20 White
M5 XSDV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M6 SSSV-XXX Output Status 1 (Per Module) 70 x 20 White
M7 SSV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M8 SSV-XXX Output Status 1 (Per Module) 70 x 20 White
M9 Push to Shut In / Pull to reset SSV/XSDV-XXX 1 (Per Module) 70 x 20 White
M10 SSV-XXX Remote S/D Status 1 (Per Module) 70 x 20 White
M11 Push to Shut In / Pull to reset SSSV/SSV-XXX 1 (Per Module) 70 x 20 White
M12 Start-up Primary Selector 1 (Per Module) 70 x 20 White
M13 SSSV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M14 Well-XXX 1 (Per Module) 70 x 20 White
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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FUNCTIONAL Spec. No. 3502
Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 10 OF 10
ANNEXURE - I
Status
Sr. Signal
Tag No. Service Range Units Remarks
No. Shut Type
Alarm
Down
Note:
The parameters that are to be Tele-metered shall be as per approved P&IDs based on
engineering documents.
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FUNCTIONAL Spec. No. 3502
Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 2 OF 10
CONTENTS
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FUNCTIONAL Spec. No. 3502
Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 3 OF 10
1.1 This specification describes the essential considerations in the design, fabrication,
installation, testing and commissioning of the Telemetry Interface Cabinet (TIC).
1.2 The Contractor shall be responsible for the design, procurement, fabrication, packing,
testing at yard and offshore, shipment to yard and offshore site, installation and
commissioning at site of the Telemetry Interface Cabinet. The Contractor shall be
responsible for hook-up of relevant field signals to the TIC and making necessary
provisions in the TIC for hook-up of the required signals to the Remote Telemetry
Unit (RTU). The hook-up of the parameters from the TIC to the RTU is, however, not
in the scope of the Contractor
1.3 The Contractor shall be responsible for internal wiring up to the terminal Blocks/strip
for all future facilities as well. For all facilities shown as future facilities, the
Contractor shall supply and lay electrical cables from the TIC to the junction boxes to
be located near these future facilities.
1.4 The Contractor shall ensure sufficient design flexibility at the time of detail
engineering to accommodate Company’s operational requirements including ease of
maintenance.
3.2 The Telemetry Interface Cabinet shall include Zener Barrier, Signal Isolator, door
switch-actuated fluorescent lamps for illumination, terminal blocks, Din rails power
distribution box, toggle switches, fuses etc. and all other accessories necessary to
make the system complete.
3.3 The scope of supply shall also include commissioning spares and one years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer.
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FUNCTIONAL Spec. No. 3502
Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 4 OF 10
4.1 Purpose:
4.1.1 The purpose of the Telemetry Interface Cabinet is to accommodate cable terminations
(input and output) for electrical and electronic instruments required for the purpose of
telemetry, tele-control and remote data gathering applications and providing
conditioned rated power supply for these instruments.
4.2 General:
4.2.1 The location for housing the Telemetry Interface Cabinet shall be as per Basic Bid
Work. In general, the TIC shall be located in the telemetry room/SAFE Area on the
platform, which may not be air-conditioned.
The environmental parameter for equipment installed in non air-conditioned
atmosphere shall be:
The temp range - 10 to 60o C
Relative Humidity – RH up to 95 % non-condensing.
4.3.1 The Telemetry Interface Cabinet shall be free-standing type mounted on a Pedestal of
appropriate height or wall mounted type.
4.3.2 The cabinet shall have lifting eyes to facilitate handling during transportation and
installation.
4.3.3 The cabinet shall be of welded construction. All butt welds shall be ground smooth.
Fillet welds may not require grinding, provided they are neat in appearance.
4.3.4 The cabinet shall have a swing out front door hinged with a continuous stainless steel
hinge, fully gasketed and held closed with heavy T-bar latches.
4.3.5 The top and bottom of the cabinet shall be provided with removable gland plates
suitable for direct screwing in of double compression type cable glands.
4.3.6 The cabinet shall be sand blasted, phosphatised and painted with two coats of sealing
primer and a surface coat. The cabinet finish shall be of high quality, semi glossy
melamine resin painting in a colour consistent with other panels on the platform. The
painting procedure shall be as per specifications for Protective Coating (Spec 2005
with Addendum).
4.3.7 A laminated photocopy of the wiring diagram shall be pasted inside the panel door.
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Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 5 OF 10
4.4.1 The power distribution box provided inside the cabinet shall consist of circuit
breaker, toggle switch with fuse for individual instruments / circuit / loop, etc.
4.4.2 All switches, circuit breakers, etc. shall be of double pole type.
4.4.3 The power distribution box shall be provided with the components required to cater to
all future facilities as well.
4.5.1 All wiring to/from the field (other than that of intrinsically safe loops) shall be
terminated at a terminal strip. The wires of intrinsically safe loops shall be directly
terminated on the safety barrier terminals. The type of barriers to be used (i.e., active
or passive) shall be as per the Basic Bid Work.
4.5.2 The terminal blocks shall be flame retardant type. The size of TB shall be not less
than 4 mm. The minimum elevation for the terminals shall be 300 mm from the panel
bottom.
4.5.3 The terminal blocks shall be clip on type having inbuilt fuse with LED indication for
loop status.
4.5.4 Terminal strips shall be spaced at least 125 mm centre-to-centre and 125 mm cabinet
edge-to-centre of terminal strip. Din Rail and terminal strip spacing shall be such that
maintenance shall be easy. The terminal strips shall be 600 V channel mount type.
4.5.5 The terminals shall be of Elmex type made of high-grade melamine suitable for 4.0
mm2 stranded copper conductors. The terminals blocks shall be non-hygroscopic,
vibration proof, stack-on type and shall use captive screws for terminals.
4.5.6 Atleast 20% spare terminals and 20% spare safety barriers shall be provided inside
the cabinet for hook-up of future facilities.
4.5.7 Intrinsic safety barriers shall be arranged in close groups and shall be located as close
to the field wiring entry point as possible.
4.5.8 The barriers shall be electrically insulated from the cabinet frame. The barrier field
terminals shall be covered by an insulator to protect the field wiring from coming in
contact with high-energy source.
4.5.9 The terminal strips and safety barriers shall be mounted in a vertical plane and
elevated to allow for ease of hook-up.
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Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 6 OF 10
4.7 Wiring:
4.7.1 All wiring shall be in accordance with the latest edition of the National Electric Code
and as per clause 3.6.4.7.7 of Instrumentation Design Criteria.
4.7.2 Electronic instrument signal wiring shall be 1.5 mm2-stranded copper. Power wiring
for instruments shall be 1.5 mm2 stranded copper. Other power wiring and earth
wiring shall not be less than 2.5 mm2 stranded copper. All wiring shall be 600 V
grade polyvinyl chloride insulated type.
4.7.3 All wiring shall be adequately supported and protected and shall be accessible from
the TIC front. Power circuits, instrument signal circuits (intrinsically safe) and alarm
circuits shall be segregated in separate wireways.
4.7.4 PVC wire way shall be used to support the wiring inside the cabinet. Wireways shall
be sized to provide at least 20% additional space for future wiring. The PVC
wireways shall be flame retardant type.
4.7.5 All wiring shall be marked with slip-on/sleeves type wire markers at each end.
4.7.6 A minimum 1” x 1.4” copper ground bus bar insulated from the cabinet structure
shall run the entire length of cabinet near the floor level. Compression type terminals
suitable for 4.0 AWG copper ground cable shall be provided at each end of the bar for
connection to platform ground.
4.7.7 All analog circuits shall be grounded at one point only, normally at 24 V DC loop
power supply common along with the analog signal shields and safety barriers.
4.7.8 Ground wiring shall be directly connected to ground bus bar by means of suitable
wire lugs. There shall be no intermediate terminals.
4.8 Cabling:
4.8.1 The cabling requirements shall in general be as per below:
4.8.2 Multi-core and single core armoured cables shall be used to transmit signals from the
field instruments to the TIC.
4.8.3 The cables from the field instruments shall enter the TIC from the bottom of the
cabinet.
4.8.4 The cables to the Remote Telemetry Unit (RTU) shall leave the TIC from the top of
the cabinet.
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Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 7 OF 10
4.9 Material:
4.9.1 The material requirements for Telemetry Interface Cabinet shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria.
4.9.2 The cabinet shall be constructed of 3.5 mm ± 10% thick cold rolled steel plates.
4.9.3 All internal braces and supports shall be fabricated of corrosion resistant material
such as galvanized steel.
4.10.1 The power supply for field transmitters shall be 24 V DC + 5 % Negative earthed.
4.11.2 Incoming signals from the RTU shall be potential free contacts enabling power
supply circuit to field transmitters, solenoid valves and flow totalizers.
5.1 Telemetry Interface Cabinet protection requirements shall in general be as per clause
no. 3.6.4.4 of Instrumentation Design Criteria.
6.1 The installation of Telemetry Interface Cabinet shall in general be according to clause
3.6.4.6 of Instrumentation Design Criteria.
6.2 The Telemetry Interface Cabinet shall be as complete as possible at the Vendor’s
facilities and no further work other than electrical termination shall be required at
platform during erection.
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Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 8 OF 10
6.3 The components mounted in the cabinet shall be easily removable for routine
maintenance with minimum wiring removal.
6.4 All components, which require regular maintenance and / or monitoring, shall be
easily accessible by operations & maintenance personnel, with minimum wiring
removal.
6.5 The package shall be designed such that all maintenance shall be carried out with the
minimum of special facilities.
7.1 Inspection and testing requirements shall in general be as per clause 3.6.4.7 of
Instrumentation Design Criteria.
7.2 The cabinet shall be completely finished, wired and tested by the Vendor before it is
submitted for inspection.
7.4 Full details of the operating design life of all major components that will be subjected
to planned maintenance / replacement during the life of the package, shall be
provided by the Contractor.
8.0 DOCUMENTATION:
8.2 The RTU parameters that are telemetered shall be listed in the format shown in
Annexure – I of this document.
8.3 The following detailed drawings shall be furnished for the Company’s review:
a) Vendor’s shop fabrication and construction drawings
b) Vendor’s wiring diagrams with identifying bill of material
c) Vendor’s proposed design layout for the cabinet
d) Vendor’s nameplate details and lettering
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Offshore Design Section Rev. No. 2A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 9 OF 10
8.4 The Contractor shall submit complete QA / QC plans for the proposed Telemetry
Interface Cabinet for Company’s review / approval.
8.5 The Supplier, and his sub-supplier, shall operate a quality system satisfying the
applicable provisions of BS5750/ISO 9000 (series). A detailed quality plan shall be
provided with the bid.
8.6 The purchaser reserves the right to carry out quality and technical review at both
supplier’s and sub-supplier’s works.
9.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1 of
Instrumentation Design Criteria.
10.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
12.1 The Telemetry Interface Cabinet shall be prepared for shipment in accordance to
clause 3.6.6.5 of Instrumentation Design Criteria.
12.2 Instrumentation and other equipment, which might be damaged in shipment, shall be
removed and packed separately. The vendor shall ensure that minimum amount of
dismantling is required for shipment.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 1 of 22
FUNCTIONAL SPECIFICATION
FOR
INSTRUMENTATION FOR
EQUIPMENT PACKAGE
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
ET RS GRP 22 28.03.2007 1
MC MC AC 22 13.05.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 2 of 22
CONTENTS
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 3 of 22
1.1 This specification describes the essential considerations in the selection, design,
procurement, testing, installation, calibration and commissioning requirements for
instrumentation forming part of equipment packages.
1.2 The Contractor shall be responsible for the selection of various type of instruments for
equipment packager suitable for their intended application, their procurement, packing,
calibration, testing at yard and offshore, shipment to yard and at offshore site,
installation and commissioning at site.
NIL
3.1 The type of instruments to be used with the equipment package and their quantity shall
be as per the process requirements indicated in the Basic Bid Work, the P & IDs and the
functional specification of the respective equipment package.
3.2 The scope of supply shall also include commissioning spares and two years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 4 of 22
4.1.1 Instrumentation system for equipment package shall provide complete monitoring, local
and remote display, start-up, automatic control, interlock, alarm, normal shutdown and
emergency shutdown for the equipment package.
4.2 General:
4.2.1 The Instrumentation system for the equipment package shall include all items necessary
for the efficient, correct and safe operation of the complete equipment package.
4.2.2 Supply of all necessary items for the equipment package shall be regardless of whether
specifically referred to in the Company’s specifications or not, including the supply of
instrumentation required for control of the equipment installed in pipe work or other
equipment not in Contractors supply, unless specifically excluded in the particular
equipment specification.
4.2.3 The functional requirements of these instruments shall be as per the relevant functional
specification enclosed in the bid document. General requirements as covered in the
Instrumentation Design Criteria shall be applicable to all the instruments forming a part
of the equipment package.
4.2.4 The Contractor shall completely mount, pipe and cable all instrumentation items on the
packaged unit.
4.2.5 All wiring and tubing which requires interconnections with any other equipment
external to the package shall be terminated in appropriate junction boxes and bulkhead
plates, mounted adjacent to the package boundary be the Contractor. The locations and
details of all such junction boxes and plates shall be agreed by Company prior to
installation and clearly marked on the Contractor’s drawings.
4.2.6 Process fluids shall not be piped off the unit for measurement purposes. Measured
variables shall only be transmitted off the package by electronic signals.
4.2.7 Cable entries for outgoing cables shall be clearly marked on the layout drawings,
including the location, size and quantities, and shall be plugged until cable installation.
4.2.8 Equipment package, which requires pneumatic supply for instruments, shall incorporate
a 316SS Supply header of the proper size of the package. The on-package supply
piping shall terminate at the package boundary and the location and size of the supply
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.2.9 Control and shutdown functions shall be segregated by the provision of separate
dedicated instruments, process connections and logic solvers.
4.3.1 The electrical power supply for the instrumentation for equipment packages shall in
general be as per clause no. 3.6.4.2 of Instrumentation Design Criteria.
4.3.4 All terminations shall be made on screw clamp type terminals, correctly certified (Exe)
where necessary. No flying leads shall be used.
4.3.5 Each cable core shall be labeled with a full circular cable ferrule, ‘C’ type are not
acceptable.
4.4.1 Where complex equipment packages such as turbo-generators, compressors and gas
chromatographs are supplied with integrated Unit Control Panels (UCP) as a part of the
package such system shall comply with the project specifications.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
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INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.4.2 Larger UCPs will communicate with the DCS via redundant serial data communication
links and with the ESD and Fire and Gas systems via hardwired signals. Such UCPs
shall be provided with suitable redundant communications ports to allow transmission
of monitoring, control and alarm information via serial interface (RS 232 C, RS 422 or
RS 485 etc.).
4.4.3 This function shall enable the unit to be monitored and controlled from the Central
Control Room (CCR), in addition to the local control and indication.
4.4.4 The Contractor shall ensure robust and secure integration of UCP communications into
the DCS using only standard software modules.
4.4.5 Shutdown and Safety Instrumented Systems (SIS), which are part of UCPs, shall
comply with the integrity requirements arising from the project risk assessment and
PISHAZOP, and IEC –61508.
4.5.1.1 Local panels or field equipment will not normally be manned and therefore, automatic
control systems shall be provided to achieve optimum process operation under the
specified plant conditions. Local indication and manual controls shall be provided to
allow for local monitoring, control, start-up and shutdown of the equipment.
4.5.1.2 A local UCP shall be provided where the grouping of indicators, controls, alarms, etc. is
required for ease of operation or for safety reasons when carrying out manual start-up
and shut down procedures.
4.5.2.1 The Control systems shall be designed to automatically ensure a safe shutdown
condition in the event of any malfunction, or when commanded by the platform ESD
system.
4.5.2.2 All shutdown signals, to and from a package, shall be cabled to a dedicated junction box
at the package limit for interfacing with the Platform ESD system.
4.5.3.1 In general, the alarm signal outputs from equipment package shall be transmitted from
the equipment package through potential free contacts. For larger system, non-critical
alarms may be transmitted to the DCS by serial link.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.5.3.2 Where an alarm annunciator is supplied as a part of the equipment package, the
annunciator shall have a “first –out” feature to indicate which of a group of alarm points
operated first.
4.5.3.4 Every signal, which initiates a shutdown, shall also have a pre-alarm signal to warn of
an impending shutdown situation.
4.6.1 General:
4.6.1.1 Proven commercial high quality instrumentation shall be utilized with particular
attention to reliability and materials of construction.
4.6.1.2 Instrument parts shall be resistant to the corrosive properties of the process fluid to
which they are exposed and to the external environment.
4.6.1.3 Seals and purges shall be used as necessary, to ensure reliable instrument performance.
4.6.1.4 Housing and exposed parts of field –mounted instruments shall be resistant to the
corrosive environment.
4.6.1.5 All instruments of one type shall be procured from the sane manufacturer.
4.6.2.1 All enclosures shall be suitable for the environmental conditions specified in the data
sheet for the particular equipment package.
4.6.2.3 Panels for outdoor use shall be fabricated from 316SS, with minimum sheet thickness of
1.5 mm, Panels shall be suitably reinforced to prevent warping or buckling.
4.6.2.4 Free standing Panels of width 1500 mm shall have a 100 mm channel base. Folding
around door opening shall be provided to prevent dust or water lodged on top of the
door from entering the panel when the door is opened. Panels shall have sloped roofs
and guttering to direct water away from doors.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 8 of 22
4.6.2.5 All hinged parts or doors shall be earthed to a fixed part of the frame connected by a
braided strap or fine stranded flexible wire connection.
4.6.2.6 Devices in separate compartments shall be capable of being replaced without shutting
down units in adjacent compartments and without exposing maintenance personnel to
live equipment. Door openings shall be large enough to permit removal of equipment.
4.6.2.7 All control and indicating devices mounted on penetrations shall maintain the IP rating
of the panel.
4.6.2.8 A minimum of 15% of clear mounting space shall be provided for large panels, and
25% for small panels to permit adding future control devices and panel instrumentation.
4.6.3.1 General:
4.6.3.1.1 The Contractor shall select the flow meter best suited to the service whilst considering
maintenance periods and cost. The Company’s preference is to use vortex, Coriolis, or
magnetic flow meters over turbine and PD meters. Vortex meters may also be utilized,
provided they are not installed in areas where vibration will affect accuracy.
4.6.3.1.2 Meter transmitters shall be “Smart” with 24 V DC power supply and 4-20 mA output
and be equipped with a local LCD indicator.
4.6.3.2.1 Magnetic flow meters may be considered where the turn down ratio is less than 1:10
where velocities are <10 m/s and fluid conductivity is >5microsiemens/cm.
4.6.3.3.1 Coriolis meters may be considered where the turn down ratio is less than 1:30. These
may be used for the measurement of hydrocarbon liquid flow and / or density with
process pressure < 40 Kg. /Cm2. Maximum line size shall be DN 80. Consideration
shall be given to the meter pressure drop.
4.6.3.3.2 Where the meter is installed in a bypass line for density measurement, the contractor’s
design shall ensure that the flow rate through the meter provides the accuracy and
response times required by the process.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.6.3.4.1 Multi path ultrasonic flow meters may be used for measurement of gases and liquids in
accordance with AGA 9. The piping design shall ensure that the meter measures a full
pipe. The Contractor shall ensure that all wetted parts are compatible with the process
conditions. Sensors shall be constructed from 316SS as a minimum.
4.6.3.5.1 Flow measurement to AGA 3 and AGA 8 shall generally be carried out by different
pressure measurement across square edge orifice plates with flange tap orifice flanges
or special fittings. Orifice plates shall be concentric for gas flow and eccentric bore for
multiphase flow.
4.6.3.5.2 Other types of orifice plates and methods may be considered for approval where
necessary to satisfy special applications.
4.6.3.5.3 Meter Rangeability shall not exceed 3 to 1, and the design flow shall preferably be
within 0.65 to 0.80 of full range.
4.6.3.6.1 These shall be considered where minimum head loss, and / or high capacity is required
and for use in non-homogeneous fluid with a low percentage of solids and shall be in
accordance with AGA3.
4.6.3.7.1 Transmitters shall be fitted with 5 way isolation and equalizing manifolds (AISI 316
minimum grade). Mercury type elements shall not be used.
4.6.3.8.1 Variable area flow meters shall be used only for local indication of non-hazardous
fluids. Glass tube meters shall not be used.
4.6.3.8.2 Meters shall be mounted in a vibration free location with pipe work anchored to prevent
stressing of the meter body. The meter shall be suitably protected against mechanical
damage.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 10 of 22
4.6.3.9.1 Turbine meters shall be installed directly in the lines with minimum straight run
distances calculated according to API – 2534. Appendix C, but not less than 20 pipe
diameters upstream and 5 pipe diameters downstream. A strainer shall be installed
upstream of each turbine meter.
4.6.4.1 General:
4.6.4.1.1 All components associated with level measurement shall conform to the vessel design
pressure and temperature, and the project specifications for piping design, materials and
fabrication.
4.6.4.1.2 Level transmitters and float switches shall generally be mounted in external chambers
piped to the vessel. To facilitate maintenance testing and calibration, drain points with
piped drain valves shall be provided. Chambers shall be provided with vent and drain
points.
4.6.4.2.1 Gauge glasses shall be either steel armoured transparent or reflex type. They shall be
provided with isolating valves, plugged drains and vent valves of size DN 15 minimum
except in certain specified applications.
4.6.4.2.2 Gauge glasses shall be selected on a basis of total visible length giving equal visible
coverage above and below the maximum and minimum anticipated operating levels.
4.6.4.2.3 The level gauge shall not exceed 1100 mm visible length.
4.6.4.2.4 Ranges in excess of 1100 mm visible length shall be covered by multiple gauge
assemblies. Visible length of multiple gauges shall overlap by a minimum of 50 mm.
4.6.4.3.1 The primary type of level instrument for remote transmission shall be the displacer type.
Other types of instrument may be proposed for the Company’s consideration where
displacers are not suitable.
4.6.4.3.2 Differential pressure transmitters are only to be employed when specific gravity
changes are considered to be negligible.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.6.4.3.3 Meter transmitters shall generally be “SMART” with 24 V DC power supply and 4-20
mA output, and be equipped with a local indicator.
4.6.4.4.1 Level switches shall generally be avoided, however where they are required, fixed
displacement or float type switches mounted in an external chamber shall be used.
4.6.4.4.2 Variable displacement type switches mounted in an external chamber shall be employed
where process requirements or operating conditions prevent the use of float type
switches.
4.6.4.4.3 Float switches shall generally have single pole double throw contacts, with contact
rating of 5A, 240 volt. Ac. The position of the float shall determine the set point. The
switch shall have a fixed differential.
4.6.5.1 General:
4.6.5.1.1 All pressure instruments shall be specified with a range approximately twice the
operating pressure except where process conditions dictate otherwise. They shall be
capable of withstanding an over pressure of 25% above the relevant relief valve setting
without permanent set or loss of calibration.
4.6.5.1.2 All pressure instruments shall be provided with individual block and bleed valves as
well as the primary process isolation valve.
4.6.5.1.3 All instrument used for handling viscous or corrosive materials shall be sealed. Seals
may be the chemical type of suitable material and a silicone oil fill between the
diaphragm and the pressure element of the instrument. Capillary tubing shall be 316SS
3 mm OD with 316SS spiral wound armour. Diaphragm seals shall be flush out type.
4.6.5.1.4 Pressure transmitters shall be ‘SMART’ with 24 VDC power supply and 4-20 mA
output, and be equipped with a local indicator.
4.6.5.1.5 Pneumatic transmitters shall have an accuracy of better than 1% of span and wherever
applicable shall be of the indication type. Process connections shall be ½” NPT.
Transmitter output tubing shall be provided with a plugged tee for installation of a
calibrated pressure gauge.
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Functional Specifications Spec No : 3503
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ISO – 9001:2000
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4.6.5.1.6 Pressure switches shall have single pole double throw contacts, with gold contacts rated
for low energy use 1A at 28 VDC. These switches shall have adjustable differential as
required.
4.6.5.2.2 Standard ranges shall be used wherever possible. Gauges shall have an accuracy of ±1.0
% FSD and have 25% over range protection.
4.6.6.1 General:
4.6.6.1.1 RTD transducer type Electronic transmitters shall be used for measurement less than
350oC.
4.6.6.1.2 The use of temperature switches shall be generally avoided. Where they must be used
they shall be single pole double throw contacts, rated for 1A at 28VDC.
4.6.6.1.3 Liquid or gas filled thermal systems are not preferred. However, if supplied they shall
be complete with stainless steel bulb, armoured capillary thermowell and union
connection. Alternatively the switch may be of bi-metallic type.
4.6.6.2 Thermowells:
4.6.6.2.1 Thermowells shall be a minimum of 316 SS, shall be flanged and be DN 40 for piping,
DN 50 for vessels. Screwed wells are not acceptable.
4.6.6.2.2 Thermowell extension shall be of sufficient length to ensure sensor head is clear of any
pipe or vessel insulation.
4.6.6.2.3 Sufficient clearance shall be provided to ensure the element can be withdrawn from the
sensor head without removal of any fittings, etc.
4.6.6.2.4 Test wells shall be equipped with a SS 316 plug. Plugs shall be attached to the well by
a SS 316 chain.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
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ISO – 9001:2000
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4.6.6.3.1 Dial thermometers shall be adjustable, every angle bi-metallic type. Construction shall
be of SS 316 with external adjustment and accuracy / better than 1% of full scale.
4.6.6.3.2 The range shall be selected so that the normal operating temperature lies at
approximately two-thirds full scale.
4.6.6.4.1 Electronic transmitters shall be used for all temperature measurements that are to be
displayed in the Control Room. Platinum RTDs shall be the preferred element. Other
sensor types may only be considered when it is demonstrated that an RTD is not
suitable. Transmitters shall generally be “Smart” with 24 V DC power supply and 4.20
mA output and LCD indicators.
4.6.7.1 General:
4.6.7.1.1 Control valves shall normally be located in horizontal lines and with the top work
mounted upright. Locations shall permit easy access for maintenance operations to the
valve body, actuator and any accessories.
4.6.7.1.2 Body and flange ratings shall be in accordance with the piping design and materials
specification. However, the minimum flange rating shall be ASME 300.
4.6.7.1.5 All components shall be designed so that they fail-safe, i.e. in all failures the valve shall
move to the safe position.
4.6.7.2.2 Alternative valves as allowed by the piping design and materials specification may be
used subject to Company approval.
4.6.7.2.3 Rotary globe valves (eccentric plug) with stellite facings with plug downstream may be
considered for flashing service.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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4.6.7.3.1 Minimum Control Valve body size shall be DN 25 when the control valve manifold
piping is DN25 or larger.
4.6.7.3.2 Valves in flashing service shall have a body size at least one size larger than that
necessary to contain the calculated trim size.
4.6.7.4.1 The packing material shall depend upon the service condition. The recommended
packing material is PTFE for services from –200 to 200 deg. C. Flexible graphite
packing with external lubricator and isolation valve shall be used for service
temperatures above 200 deg. C.
4.6.7.5.1 Valve flow coefficients shall be calculated for each operating condition in accordance
with the equations and methods in ISA 75.01.
4.6.7.5.2 Valve trim size for equal percentage characteristic valves shall normally be selected so
that:
Minimum flow valve travel is 20%.
Normal flow valve travel 60% to 80%.
Maximum flow valve travel 90%.
4.6.7.5.3 Valve trim size for linear characteristic valves shall normally be selected to be between
50 to 70% travel for normal flow. Maximum flow shall not exceed 90% of capacity.
4.6.7.5.4 Butterfly valves shall be sized so that the normal design flow rate does not exceed 60%
opening for throttling service.
4.6.7.5.5 In addition to the selection of valve and trim combination sized to suit the process
conditions, full consideration shall also be given to the inlet and outlet velocities and
possible occurrence of cavitation causing excessive noise, erosion and vibration. All
control valve sizing shall be verified by the valve vendor to ensure suitability to meet the
process requirements.
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ISO – 9001:2000
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4.6.7.6.2 A safety margin of 1.5 for regularly cycling valves shall be applied. For long standstill
service safety margin shall be a minimum of 2.
4.6.7.6.3 Each valve set shall be fitted with a 316 SS filter regulator air set combination.
4.6.7.7.2 Valve positioners shall be “smart type” with integral I/P, direct acting and have a spring
range for 4-20 mA signal.
4.6.7.7.3 Positioner by pass shall be fitted except where agreed with the Company.
4.6.8.1 General:
4.6.8.1.1 All shut down /sequence valves shall be of the ball valve type. They shall provide
bubble tight shut off (class VI) with the higher pressure from either direction.
4.6.8.1.2 All shut down valves shall be fail-safe and shall include a pressure accumulator where
necessary to achieve the required action or number of operations on loss of external
operating pressure.
4.6.8.1.3 All shut down valves shall be provided with a beacon type position indicator. Where
specified in the Datasheet, this shall house open and closed position proximity limit
switches. These shall be certified as Intrinsically Safe.
4.7.2 Materials used for parts of the assembly not specifically detailed by the Company shall
be selected by the Contractor on the following basis:
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ISO – 9001:2000
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5.1 The protection requirements for the equipment package instrumentation shall in general
be as per clause no. 3.6.4.4 of Instrumentation Design Criteria.
5.2 Control Room Environment: The control rooms shall be normally pressurized and air-
conditioned environments and shall provide an environment in accordance with ISA
S71.01 and ISA S 71.04. These areas shall be subject to the following condition:
Ambient Air Temperature: 21-24oC
Relative Humidity : 45% to 55%
The equipment in control rooms shall continue to operate properly under conditions of
air conditioning failure, when the ambient conditions may rise to 50 o C and 95% RH
for periods up to 8 hours.
5.3 The majority of the field mounted instrumentation will be mounted in a Division 2
hazardous area although some will be located in a Division 1 classified area and some
in a safe area.
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5.4 For reasons of standardization, all field mounted electrical equipment shall utilize the
following methods of protection :-
• All electrical instrumentation equipment except junction boxes and solenoid
valves shall be certified intrinsically Safe Ex “ia” for Class 1, Div. 1, Group D,
Temperature Class T5 minimum.
• Junction boxes to be certified ‘increased safety” Ex “e” for IS circuits and
explosion proof/Ex”d” for non-IS circuits for Class 1 Div.1 Group D
Temperature Class T5 minimum, hazardous area.
• If instrumentation cannot be provided with the above methods of protection,
then alternative methods suitable for the classified area and certified by an
acceptable Authority shall be proposed for the Company’s consideration.
5.5 All certificates and documentation required to satisfy the conditions of the certification
shall be provided (including IS system entity and cable parameter calculations) in the
Hazardous Area Dossier.
5.6 Equipment shall be designed so that, under normal operating conditions, it shall be
unaffected by radio transmissions. A 5 watt RMS hand –held transmitter in the 50-200
and 400 – 460 MHz bands, positioned with the mid points of its aerial no more than 300
mm from the electronic module shall not impair or degrade the performance of that
module.
5.7 All equipment including entries and blanking plugs shall be dust tight and water proof
to IP 65/NEMA 4X. Instruments not classified IP 65 to be subject to Company’s
approval.
5.8 Weather shields shall be installed over Ex ‘d’ junction boxes, and instruments that do
not meet this standard.
6.2 The principles and details of instrument mounting and location shall be selected so as to
have no adverse effect upon signal accuracy and repeatability. Any physical condition
such as mechanical stress, vibration, temperature etc. shall be limited to the maximum
figures specified by the instrument manufacturer by the use of appropriate mounting
methods.
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6.3 Special measures shall be taken to protect engine – mounted instrument from heat and
vibration, and ensure ready accessibility. Cable connecters for such items shall be
sufficiently robust to withstand the conditions and repeated disconnection/reconnection.
6.4 Instruments shall be positioned to provide sufficient space for ease of installation,
removal and maintenance.
6.5.2 Instruments shall be mounted on DN50 pipe stands (except pressure gauges, dial
thermometers and other instruments which are screwed directly on the line).
6.5.3 Local instruments shall be mounted so that the centerline of the instrument is
approximately 1400 mm above grade or walkway.
6.6.1 Individual instrument connections shall be provided on process piping and equipment.
Each process connection shall have an isolating valve.
6.6.2 Process piping up to and including the first block valve shall confirm to the vessel or
line classification.
6.7.1 The installation requirements for tubing and fitting shall in general be as per clause no.
3.6.5.3 of Instrumentation Design Criteria.
6.7.2 Instrument installation shall be in accordance with API RP 550, the instrument
manufacturer’s instructions and the following:
6.7.3 All Process Impulse Tubing and Fittings shall be rated to suit the design conditions but
the following shall be considered minimum requirements.
• ½” X 0.065” W/T Fully annealed AISI 316 seamless stainless steel tubing to
ASTM A269 or equivalent with hardness less than RB 80.
• Fittings to be AISI 316 stainless steel twin ferrule compression type.
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Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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6.7.4 All pneumatic tubing and fittings shall be in accordance with the following minimum
requirements.
• ¼” O.D. X 0.035” W/T.
• 3/8” O.D. X 0.035” WT.
• ½ “ O.D. X 0.035” W/T.
• Fully annealed AISI 316 Seamless Stainless Steel Tubing to ASTM A 269 or
equivalent. Hardness to be less than RB 80.
• Fittings to be Swagelok AISI 316 Stainless Steel Twin Ferrule Compression
type.
6.7.5 The tubing wall thickness of any larger size tubing shall be suitably rated to meet the
process design pressure to which it is subjected.
6.8.1 Electrical Installation requirements shall be in accordance with the relevant sections of
Electrical Design Criteria.
6.8.2.1 Intrinsically safe signal cables may be run on the same tray as the equivalent non LS
Signal cables but must be segregated by a metal barrier.
7.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria. In addition, the following shall also be taken care
of:
7.2 All equipment shall be comprehensively tested before delivery. The testing shall
demonstrate the full functionality of the equipment.
7.3 In addition to the inspection and testing specified in the accompanying equipment
specifications, the Contractor shall also comply with the following minimum
requirements.
7.4 The Contractor shall provide to the Company, not less than six weeks prior to the date
of commencement of the control and instrumentation system test, a detailed schedule of
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Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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the tests and sample rest record forms for approval. The tests shall not be undertaken
until the test schedule and test forms are approved by the Company.
7.5 The test procedures shall include but not be limited to the following:
• All wiring shall be tested for insulation and the test voltage shall be compatible
with the wiring being tested.(Equipment likely to be damaged shall be
disconnected for these tests).
• Full stimulated function tests of the complete system with all equipment in
position and connected to suitable temporary supplies. The Contractor shall
provide the test stimulator consisting of dummy loads with indication of the
status of every output. The test simulator shall only be connected to the field
connection terminals and the input/output interface shall be individually labeled
to facilitate testing. The Contractor shall obtain Company’s approval of supply
unit characteristics and simulated input/output interface.
• All equipment failure modes e.g. fail-safe, self-diagnostic, power supply dip,
etc. shall be checked.
• Calibration of all instrument items shall be witnessed to ensure the required
accuracy is achieved.
7.6 All tests and corrective work shall be recorded for the Company’s approval.
7.7 The Contractor shall ensure that all inspections and tests are completed satisfactorily.
The Company reserves the right to back-charge any additional inspection work if
Contractor’s preparations are found to be unsatisfactory by the Company.
7.8 Tests shall be witnessed and results recorded on test sheets, which shall include test
reports and be forwarded to the Company for approval and acceptance prior to
shipment.
8.0 DOCUMENTATION:
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Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 21 of 22
accordance with ISA S 5.1 Instrument tag No. on those drawings shall conform
to tag No.on P&ID drawings.
• A table of all instruments, including pressure gauges, relief valves, control
valves, thermometers, c. used throughout the package. This tabulation shall
show item number, model; number, manufacturer, service, size or range,
specification sheet No., set point and other data which would facilitate
identification and location of the instruments.
• Prices list of recommended commissioning spares.
• Prices list of spare parts for two years operation.
• Prices list of special tools.
• Itemized list of Contractor’s Deviations from Specification.
• Weights.
8.3.1 A manufacturing Record Book shall be compiled concurrently with fabrication such
that a full record of the fabrication, materials, inspection and testing is available.
8.3.2 All items in the manufacturing Record Book shall be numbered. Contents shall include,
but not be limited to the following:
• Front cover sheet detailing.
• Project Title.
• PO No.
9.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1 of
Instrumentation Design Criteria.
10.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
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Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
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12.1 Preparation for shipment shall in general be as per clause 3.6.6.5 of Instrumentation
Design Criteria.
13.1 Receipt and storage requirements shall in general be as per clause 3.6.6.6 of
Instrumentation Design Criteria.
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UNIT CUM CONTROL Page # 1 of 11
ISO 9001: 2000 PANEL
FUNCTIONAL SPECIFICATION
FOR
CONTROL PANEL
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
VS SSK GRP 11 16.06.08 1
AK MC RK 11 10.02.06 0
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ISO 9001: 2000 PANEL
CONTENTS
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ISO 9001: 2000 PANEL
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ISO 9001: 2000 PANEL
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ISO 9001: 2000 PANEL
3.1.1 The control system shall consist of the following major components in a single
skid mounted unit.
• Hydraulic power unit
• Control panel with all control and display instruments.
3.1.2 It shall be possible for the operator to actuate the subsea valves from the panel
(HPU) and to observe the status of the valves. Valve status shall be electrically or
electro-hydraulically transmitted by a separate pair of cable/umbilical chords.
3.1.3 The panel should have provision to accept and respond to ESD & FSD signal
commands from the existing platform ESD/FSD loop. An ESD /FSD signal from
the platform should cause a closure of the subsea shut down valve.
3.1.4 Vendor shall also supply the initial charge of hydraulic control fluid for the entire
system (up to the sub-sea valve) as well as nitrogen cylinders.
3.1.5 An integrated test of the HPU cum control panel, subsea shutdown valve and the
Umbilical shall be carried out by the contractor/vendors
3.1.6 The equipment shall be designed for outdoor location on an offshore platform with
site conditions as detailed in BID package.
3.1.7 The equipment shall be selected as per the area classification requirement.
3.1.8 Hydraulic Power Unit shall be designed for a complete life of 25 years minimum
of the platform as specified elsewhere in the BID. The Hydraulic Power Units shall
operate sub-surface intervention valves located at a distance from platform as per
the enclosed P&IDs and data sheet
3.1.9 The following shall be given due consideration in sizing, selection and design of
various components forming a part of the electric motor driven Hydraulic Power
Unit:-
• Working pressure requirement
• Pressure drops in umbilical
• Ease of operation and maintenance
• Overall compactness
• Reliability of Operation
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ISO 9001: 2000 PANEL
• Drain point
• Breather screen with desiccant type air filters cum particulate filters
• Level gauge
• Necessary pipe/tubing connections
Hydraulic accumulators shall be in stainless steel 316 constructions with
ASME code stamp and shall be provided with 100% standby capacity. The
Vendor in bid shall describe the make and design and operating conditions of
hydraulic accumulators along with typical drawing. The Vendor shall also
specify the make and material of accumulator bladder and other accessories
suitable for the service and application in bid and describe the operation of
accumulators
3.1.10.2 Pumps shall be driven by electric motor and the Vendor shall furnish full
details of pumps with bid for the technical evaluation.
3.1.10.3 Pump discharge pressure and flow rates shall be decided by the vendor based
on the design and operating conditions required for the operation of sub-sea
valves as per process design criteria and basic scope of work.
3.1.10.4 Hydraulic pipe work in the system shall be done with soft annealed seamless
SS 316 tubes and SS 316 fittings.
3.1.11 FILTERS
Filters at suction to pump shall be provided to provide 5 microns degree or
better of filtration for the safety of the pump. Filter housing shall be in
stainless steel construction with suitable vent and drain connections.
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ISO 9001: 2000 PANEL
3.1.13.1 Vendor shall furnish with the bid detailed P&ID, system description and bill of
material for the Hydraulic Power Unit.
3.1.13.2 HPU requirement shall be compatible with overall operation and control
philosophy of platform. However, following facilities shall be necessarily
included.
3.1.13.3 Reservoir capacity shall take into account the distances traversed by umbilical
and the type of actuator. Reservoir should have at least 30% reserve capacity
for leakages etc, capacity calculations shall be as per design criteria and
company approval shall be obtained.
3.1.13.4 Hydraulic system shall be capable of withstanding a proof test pressure that is
1.5 times the operating pressure.
3.1.13.5 Hydraulic reservoir shall be complete with breather valve, level gauge,
level switch, drain connection and access opening for inspection and cleaning
of reservoir..
3.1.13.6 The selection, fabrication and installation of piping work shall meet the
minimum requirements defined in the piping specification.
3.1.13.7 Electrical equipment and materials shall be in accordance with the attached
electrical functional specification and electrical design criteria.
3.1.13.8 All equipment selected for hazardous area shall be certified by BASEEFA, UL
or equivalent international testing, agency for the service and area in which it is
to be used
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ISO 9001: 2000 PANEL
3.1.13.9 The selection and installation of instrumentation works shall meet the
minimum requirements defined in the instrument design criteria and functional
specification. The material exposed to the sour service shall meet the NACE-
MR-01-75 standard (latest edition).
3.1.14 SKID
3.1.14.1 The skid shall be designed and built to ensure that all the equipment along with
accessories, panel and piping are mounted suitably for convenient operation.
3.1.14.2 A canopy shall be provided above the skid for protection against rain and direct
sun light.
3.1.14.3 The skid mounted unit will be equipped with lifts slots in the slid base. And the
upper from will be equipped with a lifting eye on each of the top four corners.
3.1.14.4 The lift points and skid structures will be designed to withstand four times the
unit’s static weight, in the event of snatch lifts. The skid structure shall be
sandblasted, primed and painted as per the bid requirements.
3.2.1 Vendor shall carryout various tests as per applicable Codes/Standards. Test
certificates shall be submitted for Company’s approval.
3.2.2 Company/its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacture. Company shall specify
hold points/witness points while approving purchase specification during project
execution. During inspection, material certificates, shop test data, certificates for
bought out components and other relevant information shall be furnished for
company’s perusal so as to ascertain that the specifications and quality are
complied with.
3.2.3 In case Vendor/their sub vendors of equipments/packages have in-house elaborate
Quality/Assurance Systems (operating in their shop) for Inspection & Testing of
equipments/packages shall obtain approval of their Quality Assurance System from
the Company prior to commencement of manufacturing activities.
Where such Quality Assurance System is not in operation with the
manufacturer/their sub-vendors, the Tests specified as “witnessed” in the
Specification shall be carried out in presence of the Company/as authorized
representative or certifying agency. The cost of preparation for shop testing of
equipments/packages including inspection fee etc. shall be borne by the
Contractor. Vendor/Contractor shall give minimum 15 days prior intimation to the
Company regarding testing schedules.
Company/its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacturer. During inspection,
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ISO 9001: 2000 PANEL
material certificates, shop test data, certificates for bought out components and
other relevant information shall be furnished for company’s perusal so as to
ascertain that the specifications and quality are complied with. Company shall
specify hold points/witness points while approving purchase specification during
project execution
3.3 WARRANTY
Vendor shall have final and total responsibility for the design and mechanical
performance of all equipment supplied under this specification. Vendor shall
warrant the equipment furnished by him and the performance of the said
equipment in accordance with this specification. Also refer to Warranty clause as
given in bidding documents (Volume I).
3.4 SPARES
3.4.1 Vendor shall recommend and provide list of spare parts needed for startup and
commissioning in purchase specification. In addition, vendor shall also furnish a
separate itemized priced list of recommended spares for one (1) year normal
operation and maintenance. Recommended spares should take into account related
factors of equipment reliability, effect of downtime upon production or safety, cost
of parts and availability of equipment service facilities.
3.4.2 All spare parts furnished by Vendor should be wrapped and packaged so that they
will be preserved in original as-new condition under the normal conditions of
storage to be anticipated in India and shall be properly tagged and codes so that
later identification as to intended equipment usage will be facilitated. They shall
be packaged separately clearly marked as “Spare Parts” and shipped at the same
time as the equipment. Packing lists shall be furnished so that the parts can be
handled without uncrating, if desired start-up spares shall be packed and identified
separately
3.5 TOOLS
Vendor shall provide two sets of special tools, if not stated elsewhere, for operation
and maintenance of the furnished equipment.
The offered equipment along with their accessories shall be shipped packed in
wooden crates. They shall be wrapped with polythene sheets, before being placed
in the crates to prevent damage to finish. Crates shall have skid bottom for
handling.
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3.7 DOCUMENTATION
Installation and commissioning procedures for HPU unit and control system. These
shall be submitted to the company for review at least 60 days before the start of
said activities. These shall include, but not necessarily be limited to the following.
• Procedure for installation and interconnection of surface elements of the
system.
• Final cleaning and flushing procedures for control system components.
• Pressure leak test procedures for the hydraulic circuit
• Final check out of the surface equipment prior to connection to the
umbilical.
• Check out of the subsea and surface electrical system
• Procedure for tie-up procedure of umbilical to surface equipments.
• Sequence and functional testing of entire subsea system
• Procedure for removal and reinstallation of subsea connection before and
after work over and wire line jobs, including safety procedures.
• Procedures should also include (where-ever applicable) The required test
sheets indicating clearly the activities /tests tube carried out and acceptance
criteria for each of the tests conducted during installation. Pre-commission
ing and commissioning.
3.8.1 The contractor shall prepare on operation and maintenance manual for all the
equipment (provided by contractor) and submit to company representative within
10 days subsequent to fabrication completion. This manual shall systematically
include all information on the system equipment. Its installation, operation and
maintenance. In particular, the following information shall be covered where- ever
applicable:
• Component / equipment system description should explain the design
criteria, functional description and mode of operation and start-up and
shut down procedures including logic flow charts
• Checks and test program and procedure for individual sub assembly
level tests and for final tests upon completion.
• Operating instructions during normal operations
• Operating instructions during failure conditions
• Description of monitoring control and safety system
• Fault finding procedures
• Procedure for periodic performance tests
• Maintenance and repair procedures
• Safety precautions and safe practices
• Drawings and equipment schedules
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3.8.2 The maintenance manual shall include the following attachment where
applicable:-
• Drawings showing supporting structure, pressure drawing(s) showing
piping system, value and instrumentation (P&IDs).
• Drawing showing individual component details. Drawing showing the
de tails of each subassembly and assembly.
• Drawing showing controls and safety systems.
• Flow diagrams and schematics.
• Equipment vendor data.
• Instrument list.
• Blank test sheets for all the tests.
• Drawings for electrical system.
• Drawings and description of test equipment and tools
• Recommended parameters for routine system monitoring
• Equipment and instruments parts list.
• List of tools and test equipments.
• As built drawings, inspection and test reports, operation manual and
other relevant documents shall be submitted to the company in hard
copies and as well as in CD ROM.
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FUNCTIONAL Spec. No. 3507
Offshore Design Section Rev. No. 02
SPECIFICATION FOR
Engineering Services Discipline Instrumentation
ISO – 9001:2008 INSTRUMENTATION BULK
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TABLE OF CONTENTS
Clause
ITEM Page No.
No.
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Offshore Design Section Rev. No. 02
SPECIFICATION FOR
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ISO – 9001:2008 INSTRUMENTATION BULK
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FUNCTIONAL Spec. No. 3507
Offshore Design Section Rev. No. 02
SPECIFICATION FOR
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ISO – 9001:2008 INSTRUMENTATION BULK
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iv) The branches to individual pneumatic instruments shall be as per the Hook-up drawing
provided in Annexure IV of Design Criteria.
v) Every pneumatic instrument requiring instrument air / instrument gas shall be provided
with appropriate volume 316 SS filter regulator fitted with integral relief valve and output
gauge to ensure that suitable quality and pressure of air is received by the instrument.
vi) Wherever the air / gas sub header ends in a distribution manifold, each manifold take-off
valve shall supply only one user and shall be labeled with the user’s tag number. At least
one spare outlets fitted with valves (full bore ball valves) shall be provided for every 20
meters of the distribution manifold, for future use. The total number of spares for future
shall be minimum 20% of the total number of Outlets.
vii) Manufacturer or fabricator supplying equipment or vessels mounted on skids, which
incorporate instrumentation requiring pneumatic supply, shall install a pneumatic supply
header, of proper size, on the skid with end connection at skid battery limit. All
pneumatic instruments mounted on skid shall be fed with pneumatic supply from this
header. The non-skid supply piping shall terminate at skid boundary and the location and
size of the supply connection shall be noted on vendor approval drawings.
viii) Where the process gas is used instead of instrument air, MOC selected shall be NACE
compliant SS316L for the service and composition of the gas, i.e., sour service, H2S,
CO2 etc.
4.2 INSTRUMENT AIR FITTINGS:
4.2.1 Material, Specifications & Sizes:
a) All fittings shall be imperial sizes, expressed in nominal outside diameter (OD) and all
threads shall be NPT. All threaded fittings shall have NPT threads as per ANSI B1.20.1
b) Fittings shall be of 316 SS material to ASTM A 276 or equivalent (i.e., BS 970-316-S31,
DIN4401 or ASME SA 479-316).
c) Stainless Steel Tube Fittings made from bar stock (straight configurations) should meet
ASTM A276/ ASME SA479 standards and those made from forgings (including elbows,
crosses and tees) should meet ASTM A182 / ASME SA182, BS 970-316-S31, DIN 4401
standards.
4.2.2 Fittings shall be ASTM F1387 MAF classification – IV , “Flare-less Mechanical collating grip
type” producing a firm grip on the tube without substantially reducing the tube wall thickness.
Fittings shall be capable of holding the maximum working pressure of the tubing without any
leak after only one and a quarter turn pull up of the nut.
4.2.3 Fittings shall have the body, front & back ferrules and nuts. All the components of tube fittings
shall be from of the same manufacturer.
4.2.4 Nuts for SS fittings shall have silver plated threads to act as a lubricating agent to avoid galling
and to reduce tightening torque.
4.2.5 All fittings shall have hardness not exceeding RB 90. All the fittings end connections shall be
compatible to tube of hardness in the range between RB 70 to 79 and hardness for fittings
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(ferrules) shall be such that, there is a minimum hardness difference of 5 to 10 between tube and
fittings for better sealing.
4.2.6 Bar stock shall be with carbon content <0.05% to provide increased resistance to corrosion.
4.2.7 Heat code traceability number shall be stamped or etched on both body and nut of fittings.
4.2.8 Threaded connections shall be NPT for all components and piping and tubing systems for
process and utilities connections. PTFE threads sealant shall be used on all threaded connections.
For high temperature application suitable sealant shall be selected.
4.2.9 Above API 10000 and above company’ approval shall be obtained for selection of Fittings.
4.2.10 Testing Requirements for tube fittings:
4.2.10.1 Type Testing Requirements:
a. The tests specified in the table below shall be carried out on the samples drawn and in the
sequence, as specified in ASTM F1387–99 (Re-approved 2005). The testing shall consist
of all the following tests as per ASTM F1387–99 (Re-approved 2005):
Mandatory Tests
1 Examination of specimen Annexure A2
2 Pneumatic Proof Test Annexure A3
3 Hydrostatic Proof Test Annexure A4
4 Impulse Test Annexure A5
5 Flexure Fatigue Test Annexure A6
6 Tensile Test Annexure A7
7 Hydrostatic Burst Test Annexure A8
8 Repeated Assembly Test Annexure A9
9 Rotary Flex Test Annexure A10
Supplementary Tests
1 Thermal Cycling Test Section S2
2 Stress Corrosion Test Section S4
3 Vibration Test Section S8
(MOC of Tubing used in
Sizes to be tested: ¼”, ½” 3/8”, 3/4” 1”
testing shall be SS316 as a minimum).
Valid Type Test Report from Accredited Lab/ National Test House for all the above tests
and sizes (as mentioned above in the table) carried out as per ASTM F-1387 (2005
Reapproved) shall be submitted along with the Purchase specification.
4.2.10.2 Following Tests shall be witnessed by TPIA for the lot of supply and report shall be
submitted, along with supply.
• Visual Inspection, Dimensional Check, Heat Code Traceability certificate Review,
Material Test Certificate Review & check for workmanship.
• Positive Material Identification
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• Reviews of certificate for Oxalic Etch Testing for inter granular corrosion resistance.
(ASTM A 262).
• Hydrostatic Pressure test
• Pneumatic Proof Test
4.3 INSTRUMENT AIR TUBING
4.3.1 Material, Specifications & Sizes:
• All tubing shall be imperial sizes, expressed in nominal outside diameter (OD) and all
threads shall be NPT ANSIB1.20.1.
• ‘Tubing’ shall be of TP 316 / 316L (dual certified) material to ASTM ‘A 269’ or
equivalent (i.e., BS 970-316-S31, DIN4401 or ASME SA 479-316), unless otherwise
specified. Molybdenum content shall be 2.5% minimum and carbon content of ≤
0.03%.The minimum size shall be ¼” OD.
• Manufacturing Process: Extrusion followed by cold Pilgering and / or cold drawing .
• Tolerance on OD : +/- 0.08 mm (As Per EN10305-1/DIN 2391)
• Tolerance on wall thickness : +/- 10% (As Per EN10305-1/DIN 2391)
• Pressure Rating: Shall be minimum 250 bar.
• Roughness value on OD: 1.2 Micron RA (max.)
• Concentricity : As per EN 10305(≤0.1)
• Tube Hardness : Up to 80 HRB As per NACE MR 0175 Certification
• Tubing Length : 4-6 meters
4.3.2 The manufacturer shall provide material compliance certificates confirming that the raw material
for fittings conform to ASME section – II.
4.3.3 Fully Bright Annealed Tubes: Tubes shall be annealed in a controlled reducing atmosphere to
ensure a clean oxide-free film on the free surface for reduced chances of corrosion.
4.3.4 Stainless steel tubing shall be soft annealed seamless TP 316 / 316L (dual certified) as per
ASTM A269. Sizes shall be as follows:
S. No. Application Size
¼”O.D. X 0.035” W.T.
1 High-pressure hydraulic lines
3/8” O.D. X 0.049” W.T.
2 ESD/FSD loop 3/8” O.D. X 0.035” W.T.
Pneumatic supply to shutdown valves 1/2” O.D X 0.065” W.T. 316 SS tube ,
3
, control valves 3/8” O.D. X 0.035” W.T. 316 SS tube
4 Process impulse lines 1/2” O.D X 0.065” W.T. 316 SS tube
4.3.5 Signal transmission shall be through ¼” O.D. X 0.035” W.T. tubing run singly or in bundles.
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4.3.6 Monel tubing shall be used on sea water and produced water service and shall be fully annealed
seamless as per ASTM B-165 with size ½” O.D. X 0.035” W.T.
4.3.7 Tubing shall be supported and protected by stainless steel angle / channel or ladder / tray along
the complete length of each run and shall be fastened with stainless steel saddles at a maximum
of 1 m intervals on straight runs.
4.3.8 Channel or tray support for tubing runs shall be sized for a minimum capacity of 30% greater
than that required.
4.3.9 All pneumatic exhaust ports and breathers shall be fitted with bug screens, installed facing
downwards.
4.3.10 Vendor to confirm that following tests shall be carried out by vendor and certificates for the
same shall be given along with supply. Test reports submitted by Vendor shall be reviewed by
TPIA at the time of Supply.
• Visual Inspection, Dimensional Check, Check for workmanship. Material Test Certificate
• Mechanical test : Tensile test (Yield strength, Tensile strength, % Elongation) , Impact
test
• Hardness test
• Chemical test (Product analysis)
• Microstructure examination : Ferrite content, Sigma phase
• IGC test (Austenitic): As per ASTM A 262 specification ,Practice E
• Corrosion test
• Eddy current test: 100% Eddy Current Test acc to ASTM 1016 A/ ASTM A450
• Burst Test: Tube shall be subjected to 'Tube Burst Test' to evaluate the grip of tube
fittings on tubing at the burst pressure of the tubing. LSTK contractor shall get this test
carried out at the manufacturer’s place and submit the test report along with Purchase
Specification.
• Flattening Test
• Heat Number Traceability certificate shall be ensured for above mentioned tests and shall
be reviewed by the TPIA.
4.3.11 Tubing Installation:
a) The primary instrument block valves for all instruments shall be as per piping
specifications. MOC of all the drain valves shall be 316 SS / MONEL as a minimum.
b) All impulse lines shall be run with a slope not less than 1 in 12 except where otherwise
specified. Direction of slope is to be downward from the process for liquid service and
upward from the process for gas service.
c) Tubing shall be joined by double compression fittings.
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d) Instrument lines shall be run in the vertical plane as far as possible and shall be run with
the minimum number of changes of directions consistent with good practice and neat
appearance. All pipe and tubing shall be run in horizontal and vertical planes only.
e) Tubing shall be bent with correct size tubing bender where required to avoid the use of
fittings. Tubing cutter shall always be used to cut tubing. The use of short lengths of
tubing in long runs shall be avoided, to avoid the use of fittings.
f) All tubing shall be run in such a manner as to give the maximum protection against
mechanical damage. Tubing runs shall be grouped together and clamped where possible.
Tubing shall be arranged so that couplings can be tightened without distorting lines.
Instrument tubing shall not run on trays intended for cables and shall not share the same
transit with cables.
g) Where tubing is run in permanent enclosures, the Contractor shall ensure that entry and
exit of such enclosures is clean and smooth.
h) Pipes or tubes installed but not connected, shall have the ends closed in approved fashion
to prevent the entry of foreign material by suitable caps or plugs.
i) All reasonable precautions shall be taken to prevent foreign material entering tubing /
pipelines before and during erection.
j) No pipe or tube shall be left with mechanical strain on it.
k) Where the length of transmission tubing exceeds 60 Mtrs. (200 Ft.) the Company should
be consulted as to the necessary of installing signal booster relays.
l) Where permanent enclosures are left with space for instrument tubing to be pulled in at
some future date, a galvanized pull wire of adequate size shall be left in the tray.
m) On tubing to pipe connections and in making of screwed pipe joints, Teflon tape shall be
applied to make thread in a manner to insure tape is not over the end of the male fittings.
4.4 Piping Supports:
a) Piping and tubing shall be adequately supported and fixed at distances not exceeding
those in the following table:
Single Tubing Max. Distance Between Supports
3
/8” O.D. and less Continuous
½” to ¾” Nom. Size 2 Mtrs. (6 ft.)
¾” to 1” Nom. Size 3 Mtrs. (9ft.)
Multi tube Bundles 3 Mtrs. (9ft.)
b) All field-mounted instrument air tubing shall be supported with galvanized steel angles or
channels of minimum 1/8” thickness fabricated to present a neat appearance.
c) All instrument tubing supports shall be galvanized prior to installation.
d) Mechanical ferrule seater shall be used on tubing for pressure 140 kg/cm2 (2000 psi) and
above.
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e) Pipe bushing shall not be used. Plugs shall be of bar-stock with hex heads.
f) If extended lengths of multiple tubing are to be run, multiple bundles and junction boxes
with weatherproof entries may be used to the best advantage.
g) Manufacturer or fabricator supplying skid mounted equipments or vessels with
instrumentation, which provides, or utilizes pneumatic, offside alarms, shutdowns, or
control functions shall tube signals to a central bulkhead, near skid boundary, available
for hook up by the Contractor for connection to offside equipment. Location of the
bulkhead shall be noted on vendor drawings.
h) Differential or static pressure sensing lines shall not exceed 6 Mtrs. (20 Feet) for direct
connected or locally mounted instruments.
4.5 JUNCTION BOXES:
a) Instrument junction boxes shall be certified for use in the hazardous area in which they
are installed. For intrinsically safe circuits, boxes certified Increased Safety Ex e shall be
used. For non-intrinsically safe circuits, boxes certified Explosion Proof / Flame proof
Ex d shall be used. Boxes (Ex e, Ex d) shall have minimum IP 66 ingress protection.
b) Separate junction boxes shall be used for intrinsically safe wiring. Junction boxes in any
cable path from field to control room shall be limited to one only unless otherwise
mentioned in Basic scope of work related to instrumentation. Instrument junction boxes
shall not be used for electrical power cables
c) For Ex d junction boxes cable entries shall have NPT threads; Where this is not possible a
certified 316 SS adaptor shall be fitted.
d) All Ex e and Ex d enclosures shall have all spare entries sealed with suitably certified 316
SS plugs.
e) Entries shall be suitably spaced to enable ease of installation of cable glands. Tapped
cable entries shall be of good quality, without stripped or damaged threads. The thread
shall be continuous and shall permit the cable gland to fit squarely against the gland plate
(or enclosure).
f) Where the gland plate is not thick enough for tapping, cable glands shall be fitted with
double locknuts.
g) The threads of all cable glands and adaptors shall be greased on assembly.
h) Cable glands fitted to all Ex e enclosures, and industrial enclosures, may have a nylon or
lead sealing washer between the Cable Gland and Gland Plate (or enclosure) to ensure IP
66 protection. Sealing washers shall not be fitted to glands entering Ex d enclosures.
i) All glands, adaptors, reducers and plugs for the Ex e as well as Ex d junction boxes shall
be certified for use in Class I .
j) All junction boxes shall be effectively sealed, once uncrated or fitted into position. All
lids shall be replaced during any break in work. Where this is impractical, e.g. large
multi-cable junction boxes, a heavy PVC sheet shall be used to cover the junction box to
exclude rain and dust.
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k) All terminals (including unused terminals) shall be tightened down. For communing of
terminals, feed through cross connection bar shall be used. Comb connectors shall not be
used.
The construction of junction boxes shall be as under:
a) Increased Safety
i. Junction box construction shall be 1.5 mm 316 SS. Boxes shall be bottom entry with a
removable 316 SS gland plate. The gland plate shall be drilled and tapped, 6 mm thick
for tapered threads and 3 mm thick for parallel threads. The plate shall be bolted to the
box with 316 SS bolts, sealed with a neoprene gasket and fitted with an 8 mm earthing
stud. All incoming cables shall enter from the sides of the junction box. Outgoing cable
shall be from the bottom of the junction box.
ii. Boxes shall have four external mounting lugs, two top and bottom, drilled with 10 mm
fixing holes. A full size removable stainless steel gear plate shall be fitted inside each
box. Terminals shall be Ex e rail-mounted tunnel-type made of melamine. Wiring ducts
shall be colored blue.
iii. Boxes shall have doors hinged minimum at two points with a neoprene seal fitted all
round. Hinges shall be the lift-off pintle type, constructed of stainless steel; piano hinges
are not acceptable. A restraining mechanism shall prevent opening more that 160o.
Screwdriver-operated door latches shall be fitted at the top and bottom.
iv. In addition to the manufacturer’s certification label, each junction box shall have
identification label attached to the box with 316 SS screws in a manner which will not
invalidate the hazardous area certification. The label shall be constructed of white-black-
white laminated plastic. The label shall include an engraved Tag No. An additional tag
stating “Intrinsically Safe Circuits” shall be installed. This shall be blue-white-blue
laminated plastic.
v. The contents of Ex e enclosure shall not be altered without the prior approval of the
company‘s electrical or instrumentation engineer .
vi. The damaged terminals shall be replaced with approved Ex e terminals
b) Explosion Proof
i. Explosion proof junction boxes shall be constructed from 316 SS / epoxy coated copper
free die-cast Aluminium. Boxes shall have at least four external mounting lugs, drilled
with 10 mm fixing holes, and an 8 mm external earth lug. A full size removable stainless
steel gear plate shall be fitted inside each box. Cables shall enter from the bottom, and
20% spare entries shall be provided. Cable entries shall be drilled and tapped to suit the
required glands, and fitted with certified 316 SS plugs. Junction box lids shall have cast
hinges integral to the box with stainless steel pins.
ii. Each junction box shall have an identification label, in addition the manufacturer’s
certification label, attached with 316 SS screws in a manner, which will not invalidate the
hazardous area certification. The label shall be constructed of white-black-white
laminated plastic. Terminals shall be rail-mounted tunnel-type, made of melamine.
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iii. Ex d enclosures shall not be drilled or machined under any circumstances after approval
from the company.
iv. Damaged enclosures shall be completely replaced. Flange surfaces shall be clean and
undamaged .All fixing bolts shall be present and tightened to the correct torque
v. All metal flanges and box lids shall be sealed after assembly with a grease-impregnated
cloth.
Note: Company approval shall be obtained for the use of Aluminium for any instrument
component. Aluminium may only be used if no other suitable material is available but
shall not be used for any component in contact with the process fluid. If Aluminium is
used for any housing or other component, it shall be suitably coated and certified as
copper free i.e. less than 0.4% copper by mass
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TABLE OF CONTENTS
Clause # DESCRIPTION Page No.
5.1 General 4
5.3 Conductor 7
7.0 CERTIFICATION 12
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3.2 Vendor shall submit detailed Specifications for Company’s approvals, with type of
Cables and Quantities mentioned therein.
4.0 GENERAL REQUIREMENTS:
4.1 Safety
a) Non-metallic materials, such as conductor insulations shall be non-hygroscopic,
flame retardant and / or fire resistance, self extinguishing and non toxic chaired.
b) Materials that are toxic to the environment or are a potential Carcinogen such as
asbestos, poly chlorinated bi-phenyls (PCBs), Mercury etc., shall not be used in the
making of the cables.
4.2 Materials, Workmanship and suitability:
a) All materials utilized in the construction of the cables shall be to the latest industrial
standard specifications, new and in current production. Should any material prove
unsatisfactory, it will be rejected not withstanding any previous satisfactory
examination or tests of similar material or of completed cables
b) Where required the Contractor shall provide cable sheath oil resistance performance
characteristics.
c) The use of polymeric materials as alternatives to elastomeric materials shall be
subject to acceptance by the company. The Contractor’s proposal for such
alternatives shall be supported by detailed certified evidence of continuous and
complete performance in offshore locations.
4.3 Design life:
Cables and cable accessory shall be suitable for operations without periodic maintenance
applied throughout the design life of the platform specified elsewhere in the bid package.
The overall availability and reliability of the cables and cable accessories shall be
demonstrated by the Contractor.
4.4 Units and information:
All quantities and dimensions shall be expressed in metric units. All information, manual,
certificates, data and inscriptions shall be in the English language.
5.0 TECHNICAL REQUIREMENTS
5.1 General
5.1.1 The cable shall be new and in good condition and shall be suitable for layering and
bunching in ladders, trays and ducts.
5.1.2 All signal, power and control cables on non critical loops shall be flame retardant, low
smoke type with sunlight and oil resistant outer sheets, ‘zero / low halogen’ suitable for
installation on offshore oil and gas processing platforms.
5.1.3 Cables on critical service for safety and emergency systems shall be fire resistant type in
addition to the specifications at 5.1.2 above.
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5.1.4 Conductors shall be stranded and Cables shall be flexible and suitable for easy
termination using standard crimps and terminals.
5.1.5 All instrument signal cables shall be continuously shielded with the shield grounded at
the same point / bus as the signal circuit, generally at the control instrument (panel) end.
5.1.6 Detailed specifications and testing requirements on “inner and outer conductor insulation
and sheathing” material for low halogen / fire resistant / Flame Retardant cables, refer FS
4011 (Electrical – Functional Specifications for Electrical Cables). Fire resistant
characteristics of the cables shall be as per IEC 60331 (750oC for three hours)
5.2 Cable Types:
5.2.1 The cables used shall in general be of the following types:
a) Fire Resistant Cables:
Cables of this type shall be used for all circuits / instrument loops that have a safety-
related function, or are required to remain operational under emergency conditions.
Specification shall be same as that of instrumentation cables as at 5.2.2 (b) below,
however with the Primary Insulation being “Fire Resistant” inclusive of the necessary
protective fire proofing insulations. In addition these shall be listed by UL/FM or equal in
fire service and shall comply with the requirements of IEC 60331 and IEC 60332-3
(Category A) or better. It shall have a fire resistant layer between tinned copper
conductor and extruded insulation of MICA glass tape material. This includes cables for
all parts of F & G Systems (analog / digital signals), ESD systems, PA Systems, warning
beacons and platform status lamps, fire control systems, and power supplies to those
systems.
b) Flame Retardant Cables:
Cables that are not Fire Resistant shall be Flame Retardant type and shall comply
with the requirements of IEC 60332-3 (Category – A). The flame retardant cables to
be used for different applications shall in general be as follows:
i) Signal Cables:
• Twisted Single Pair / Triad cables shall be 600 V rated and shall have 1.5 sq. mm.
PVC covered, 7 stranded Copper conductor, shield with aluminum backed by
Mylar tape with the metallic side down helically applied with either side 25%
overlap of 100% coverage. Minimum shield thickness shall be .05 mm for single
pair and 0.75 mm for triads and multi pair cables.
• 18 AWG, 7 stranded tinned copper drain wire shall be provided and shall be in
continuous contact with the aluminum side of the shield. The drain wire resistance
including the shield shall not exceed 30 Ohms / Km.
• Cables shall have PVC Inner & Outer jacket and galvanized steel armoring.
Jacket shall be light blue in color for intrinsic safe applications and Black for
others.
• Ripcord shall be provided for all cables.
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• All signal cables (Single or Multi-Pair), shall have individual and overall screen
for the conductor pairs / triads, when used for analog 4-20mA and low level
signals such as thermocouple signals, pulsed signals or similar signals. All other
instrumentation cables (alarm / digital / control) cables shall have overall
(collective) screen. For Cored cables there shall be no screen. Drain wire and the
cable conductor screens shall be grounded at one place i.e., at the panel end where
the electronics (signal circuit) in the panel is grounded.
• Pairs and triple (triad) type cables shall be uniformly twisted (at least 10 twists per
meter) to form pairs/triples and shall not be dissociated by normal handling.
Multi-pair / triple cables shall be laid to prevent cross-talk between pairs/triples.
• Instrument signal cable configurations shall in general be: 1 pair, 2 pair, 6 pair, 12
pair, 1 Triad, 6 Triad, 8 Triad etc.
• Multipair cables shall have following additional features:
o Individual Pair / Triad shall be twisted.
o Pair / Triad identification by color coding / numbering.
o Individual pair shielding apart from overall shielding.
o Single Pair Communication Cable, of 22 AWG 7 strand copper wire with
PVC insulation.
ii) Control / Alarm / Status Cables:
These shall be same as signal cables except there shall be no individual pair
shielding in case of multi-pair cables.
iii) Extension and Compensating Cables for Thermocouples:
The cables for thermocouple extension cables shall be of same material as that of
thermocouple, which shall be marked as X behind the identification letter for
thermocouple as per convention. Compensating cable material shall have same
thermo-electric properties as that of thermocouple material. These cables
generally shall be same as signal cables except conductor shall be solid 16 AWG
in single pair and solid 20 AWG in case of multipair cables. Colour coding,
thermoelectric characteristics and limits of errors shall be as per ANSI MC 96.1,
BS, EIN, DIN etc.
iv) Power Cables:
Power cables shall be 3-core, minimum 2.5 mm2 copper conductors, 600V 1.0
KV grade, with PVC insulation, galvanized steel armoring. Larger sizes shall be
used where required to keep cable voltage drop below 2% of the supply voltage.
c) Special Cables:
Cables for special instruments like analyzer, turbine meter, serial interface,
Magnetic flow meters, Ultra sonic flow meters, etc. shall be as per
manufacturer's recommendation.
d) Digital Communication Cables
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5.4.3 Properties of Conductor Sheath / Insulation shall meet the following requirements [refer:
FS 4011 (Electrical Discipline – Functional Specifications for Electrical Cables)].
a) Temperature Index: Min.250 oC as per ASTM. D 2863
b) Oxygen Index: Min.30 as per ASTM D 2863
c) Acid Gas Generation: As per IEC 60092-359
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d) Smoke Generation: Less than limit for types SW4 Compounds as per IEC
61034
e) Dielectric strength: Min.60% of original dielectric strength tested in
accordance with NEMA-WC-5 at 75°± 1°C.
f) Flammability: Flame retardant characteristics of electric cable as per
IEC- 60332 Part 3 Category –A
5.4.4 Cables nominated as Fire resistant shall comply with the following performance
characteristic in addition to the above requirements.
• Fire Performance: Fire resistant characteristic of electric cables as per IEC 60331
(750°C for 3 Hrs)
5.5 Bedding and Inner Sheath
5.5.1 The bedding shall be extruded, non-hygroscopic solid filler substantially filled to prevent
any ingress of water inside the cable. The material used for the bedding and fillers shall
be suitable for the operating temperature of the cable and compatible with the insulating
material. The inner sheath shall be effectively filled and shall comply with thickness
requirements as IEC 60502. Removal of inner sheath shall not cause adhesion or damage
to the conductor insulation. Taped inner sheath shall not be accepted.
5.6 Braiding/Armoring
5.6.1 Multicore cables shall be mechanically protected with hot dipped galvanized steel wire
braiding (GSWB) or galvanized steel wire armoring (GSWA) applied over the inner
sheath.
5.6.2 Single core low voltage and high voltage cables shall be mechanically protected with
tinned phosphor bronze wire braiding (PBWB) or hard drawn aluminum round wire
armoring which shall be applied over the inner sheath to confirm to the requirements of
international standards.
5.7 Outer Sheath
5.7.1 The outer sheath shall be heat and oil resistant, suitable for installation in an offshore oil
and gas processing platform, with uniform thickness and fit tightly over the braiding /
armour to ensure no undue residual strain is left in the material.
5.7.2 Outer sheath marking shall be such that details of size of cable (no of cores and conductor
cross section), type of insulation, manufacturers name and international standard
identification shall be embossed on the outer sheath at regular intervals at maximum of 1
metre.
5.8 Colour Coding
5.8.1 Cable outer sheaths shall be permanently colour coded such that colours do not
deteriorate with age or fade with exposure to direct sunlight. Cable shall be UV resistant
and coded as per the requirements of IEC 60502.
5.8.2 Cable Colour Coding
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1 Low Voltage Power and Control (Equal to or less than 1 KV) Black
2 Earth Green / Yellow
3 Instrument Intrinsically Safe (IS) Light Blue
4 Instrument (Non-IS) Black
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6.2 Inspection
6.2.1 The Contractor shall ensure all material employed shall be available prior to and after the
manufacture of cables, for inspection by the Company. The Contractor shall furnish all
necessary information concerning the supply to the Company’s inspector or
representative. The inspector shall have free access to the manufacturer’s works for the
purpose of inspecting the process of manufacture in all the stages and will have the
authority to reject any material which appears to be unsuitable or of unsatisfactory
quality.
6.2.2 In addition, the minimum inspection requirements, prior to shipment of cable shall be the
following:
a) Verify cable lengths
b) Verify sheath colour
c) Verify gland fit
d) Verify core configuration
e) Verify core colours
f) Check continuity of each core (and screen/drain wires where applicable) on each
drum (to match manufacturer’s data sheet for DC resistance)
g) Check insulation resistance between cores and armour, where applicable (test at
twice working voltage, not less than 10 M Ohm)
h) Verify drum markings
6.3 Factory Acceptance Testing
6.3.1 Electrical and instrument cables shall be tested in compliance with the standards to which
they are manufactured with all optional tests included.
6.3.2 Company shall be advised at least (4) weeks in advance of the scheduled date of each test
and again 20 days prior to the actual test.
6.3.3 Tests shall include but are not limited to the following:
a) Cables shall be tested in accordance with IEC 60092-359 tests to include electrical
resistance of conductors.
b) Verification of design limitations; cable for use in IS circuits shall have their
parameters measured to ensure that these comply with the relevant standards
namely L/R micro F / Km & mH /Km.
c) Instrument cables shall be tested to verify the following:
i. The maximum inductance to resistance ratio (L/R) between insulated conductors
of any one pair of screened cables shall not be greater than 26 micro-henries per
ohm.
ii. The mutual capacitance of screened cable at a frequency of 1 KHz shall not be
greater than 100 pF per meter.
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iii. The pair to pair capacitive unbalance values at a frequency of 1 KHz for
unscreened pairs shall not be greater than 250 pF per meter.
iv. Spark test: a spark test shall be carried out on all instrument cables. All cores shall
be tested at 6 KV rms.
v. Coaxial cables shall be tested for frequency response, attenuation and insertion
loss.
vi. Type tests shall be carried out in compliance with IEC 60331 and IEC 60332 (Part
3) when specified.
vii. Type test certificates may be acceptable, subject to acceptance by the company, in
lieu of the tests.
6.4 Sealing
6.4.1 Immediately after electrical tests, the ends of the cable shall be sealed with heat shrink
caps to prevent the ingress of moisture.
7.0 CERTIFICATION
7.1 All cables and cable accessories of similar design and construction features manufactured
by the same Vendor:
a) Shall have been type tested by an authority approved by the Company.
b) Shall have been in continuous satisfactory service in offshore for a minimum period
of two years.
c) Shall be having current certification/approval/listing by an agency approved by the
Company or UL or FM.
8.0 INSTALLATION REQUIREMENTS
8.1 Cable Runs and Segregations:
a) The Contractor shall ensure that there is no interference between cables having
different voltage or signal types. Instrument cables shall be segregated from antenna
cables and others carrying RF signals so as to avoid interference.
b) All instrumentation cables shall be supported / laid in trays. Power cables shall not
be run in trays carrying signal cables. The physical separation of power and signal
cables shall be as per API-550 Part –I SECTION VII. Cables in intrinsically safe
circuits shall preferably be not run in the tray for cables in non-intrinsically safe
circuits. If run in the same tray a metallic earthed separator shall be provided.
Conduits carrying intrinsically safe cables shall be painted with the blue color bands
at each end.
c) Where cables are run through conduit, the entry and exit shall be smooth and free
from burrs. The use of conduits shall be kept to a minimum, as far as possible.
d) Cables must be pulled into conduit in a way that ensures there is not damage to the
cable.
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Spec. No. 3508
Offshore Design Section FUNCTIONAL
Rev. No. 2
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 INSTRUMENTATION CABLES Page: 13 OF 14
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Spec. No. 3508
Offshore Design Section FUNCTIONAL
Rev. No. 2
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 INSTRUMENTATION CABLES Page: 14 OF 14
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Spec. No. 3510
Offshore Design Section FUNCTIONAL
Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 2 OF 12
CONTENTS
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Spec. No. 3510
Offshore Design Section FUNCTIONAL
Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 3 OF 12
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Offshore Design Section FUNCTIONAL
Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 4 OF 12
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Offshore Design Section FUNCTIONAL
Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 5 OF 12
Tube material shall be SS 316 L / Duplex / Super Duplex, suitable for the hydraulic
liquid, pressure and temperature conditions / ranges. Vendor shall take special care
in selection of the steel tube manufacturer and the steel tube shall be fully
prequalified by testing in accordance with requirements of ASTM A450 and the
associated components of ASTM A370, Ann A2.
i) Ambient effects: Cooling; Effects on pressure, Fluid expansion effects, Low
ambient temperature.
ii) Dynamic effects: Impact, Vibration, Discharge reactions, Long term effects on
elasticity
iii) Weight effects: Live loads, Dead loads.
iv) Thermal expansion/contraction effects: Thermal loads due to restraints, Loads
due to temperature gradients, Loads due to differences in expansion.
v) Effects of support and terminal head movements.
vi) Cyclic effects: Pressure, thermal and other cyclic loads.
vii) Galvanic reactions.
viii) All metal alloys used in the total umbilical system shall be corrosion resistant in
the specified temperature range, or equipped with a suitable corrosion protection
system. This shall also include the platform topside termination assemblies.
ix) The metal alloy tubes can be seamless or welded. The complete tube string shall
be hydrostatically tested to 1.5 x WP.
x) Repair welding of base material is not accepted. Repair of weld defects shall be
performed in accordance with an approved and qualified procedure.
A minimum of one spare tube shall be made available in the umbilical. (Supply
tube & return tube per actuator plus ‘one spare tube as a minimum’)
b) The design and construction considerations for the umbilical with thermoplastic
hoses shall include but not limited to the following: (Also Refer ISO Standards
527, 1402, 3949, 4406 for the Thermoplastic hoses selection and testing in
Umbilical)
i) The thermoplastic hoses shall be supplied by a prequalified supplier. The raw
material (pellets) shall be new unused material which is kept to a high level of
cleanliness.
ii) The extruded hose shall be compatible with the specified hydraulic, injection
and annulus fluids.
iii) The hose braiding material shall be made from a high strength fibre. The
braiding shall be applied in a way which minimizes the torsional forces
generated during the line pressurization and to minimizes volumetric expansion
and elongation.
iv) There shall be no jointing of the thermoplastic hoses, except when required for a
field joint or a complete umbilical factory joint.
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Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 7 OF 12
g) All metal alloy hydraulic tubes shall be numbered and be legibly marked with
manufacturer's name or brand, standard dimension, grade identification and
working pressure. The marking shall also indicate whether the tubing is seamless
or welded.
h) In the electrical cables, all conductors shall be identifiable with different coloured
insulation. The colouring shall be such as not to degrade the quality and
permeation characteristics of the insulation material.
3.1.2 Design and manufacturing of hydraulic umbilical and its accessories shall meet the
functional requirements of minimum design life of 25 years for steel tube
umbilical, and 20 years for thermoplastic tube umbilical. The design offered by the
vendor shall be in the regular manufacturing range of the manufacturer and shall
have been (a) tested (b) in continuous and satisfactory service under similar
conditions for a minimum period of two years.
3.1.3 The ‘umbilical’ design shall meet the following installation requirements:
• It shall be installable using typical installation vessel and equipment such as
reels, baskets, carousels, turntables, tensioners, etc.
• It shall endure all installation loads, including load-out, handling on installation
vessel, lay tension, initiation, laying, abandonment, pull-in and connection,
trenching, rock-dumping, possible disconnection and recovery. It shall also
endure a backstroke, if required, during connection / disconnection.
• It shall be possible to repair the umbilical during installation. A sealing system
to preserve the umbilical shall be included for use in case of cutting and
abandonment during lay. There shall be a possibility for cutting the umbilical on
the seabed in case of failure. This aspect shall be reflected in the design with
regard to water ingress.
• The umbilical shall have sufficient specific gravity to lie stable on the seabed
and to enable installation in predefined route including laying curves. The
submerged specific weight shall also be sufficient to enable trenching.
• Umbilical termination units shall be capable to handle the extreme temperature /
pressure combinations, to which the umbilical is exposed to, and shall be
demonstrated before dispatch from factory. All electrical terminations shall have
2 independent barriers against water ingress, which shall be separately tested
during qualification and final product assembly.
3.2 MATERIAL AND CONSTRUCTION:
3.2.1 ARMORING
a. The Vendor / Contractor shall propose an armoring design, if relevant, with due
consideration to the mechanical properties of the components.
b. Number of layers of suitably sized hot dip galvanized steel wire, contra wound,
torque balanced, and armor shall be designed to suit the design criteria finalized by
the manufacturer. The wires shall confirm to the requirement of BS 1441 shall give
the umbilical elements mechanical protection. The design to be suitable to resist
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Rev. No. 01
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Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 8 OF 12
impact and abrasion, and shall be torque balanced over the range of loads (during
installation and operation).
c. The armor wires shall be of such a design and size as to carry all tensile loads,
protect the umbilical during all installation phases and shall provide adequate
corrosion resistance for duration of design life and as per environmental parameters
specified in the bid specification (Structural design criteria).
d. Outer covering ‘plastics’ shall be resistant to ultra violet light.
e. All the analysis for the umbilical shall be effectively performed, with its
components, as performed for the pipes / composite cables for subsea application.
(i.e., flexibility and fatigue analysis)
3.2.2 INNER JACKET
An inner jacket of polyethylene, minimum thickness of 4mm shall be extruded
over the bundle of components, i.e, hoses / stainless steel tube / electrical cable or a
combination of them as a ‘bundle’. The interstices shall be filled with suitable
material to ensure good jacket concentricity and uniform distribution of radial
compression from the armor layers under tension. The jacket material shall be
impermeable to water and shall be resistant to cold flow.
3.2.3 OUTER SHEATHING
A jacket of polyethylene or equivalent shall be extruded over the armor wires to
provide protection to armor wires against mechanical damage and to provide
additional corrosion protection. The thermoplastic material shall have a minimum
thickness of 5 mm and shall be resistant to sea water, degradation due to ultraviolet
exposure and pipe temperature of 50ocentigrade.
The outer sheath shall be yellow in color. a longitudinal black stripe, minimum
6mm wide shall be concurrently applied to the full length of umbilical as a means
of indicating twisting .
Length markings shall be applied every 10 meters for the first and last 250 meters.
Distance indication without numbers shall be applied every 100 meters for the
remaining length with length markings applied every 250 meters , marking shall be
clearly visible to divers and ROV’s.
3.2.4 JOINTING
The number of factory joints in each umbilical shall be kept to the absolute
minimum. The manufacturer shall submit full details factory joint including joining
method employed
3.2.5 ASSOCIATED UMBILICAL EQUIPMENTS
Each umbilical shall be supplied on a field deployment reel complete with the
following components:-
- J-Tube hang-off points
- Pull-in heads
- J-Tube seals
- TUTA (The Topside Umbilical Termination Assembly )
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Discipline Instrumentation
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Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 10 OF 12
The J-tube seal shall form a permanent seal between the inside and outside of the
steel J-tube just inside the bell mouth. The seal will permanently be in contact with
seawater at local seabed temperature. The seawater inside the J-tube will be
treated with a chemical corrosion inhibitor and / or oxygen scavenger. The J-tube
seal shall prevent the dilution of inhibited seawater inside the J-tube by seawater
from outside.
The unit shall seal against the J-tube by means of two or more sets of flexible
circular seals.
3.2.9 Subsea terminations
The umbilical manufacturer shall be closely involved with the chosen control
system manufacturer in the design of the subsea termination.
The umbilical manufacturer's scope of work in this area of interface include the
following:
• Tensile strength termination (Armour Anchorage Block)
• Termination bend restrictor and/or armour rods
• Fittings
• Electrical Penetrator.
There shall be penetrators including water blocking of each individual conductor
for fitting into the interface boundary, that is, the boundary of the electrical
connector subject to open face pressure.
The umbilical electrical termination at the subsea end shall be blocked by an
approved method to prevent water ingress in the cable or harness. A pressure
compensated oil filled inerface chamber shall be incorporated between the cable
water blocking/penetrator and the electrical connector/harness.
It shall be demonstrated that the termination system is capable to handle the
extreme temperature/pressure combinations, to which the umbilical is exposed to.
All electrical terminations shall have 2 independent barriers against water ingress,
which shall be separately tested during qualification and final product assembly.
The axial load requirements shall not allow structural damage to the termination or
template landing structure. Weak link(s) shall be used to prevent axial or tensile
damage to the termination and landing structure.
3.3 INSPECTION & TESTING
3.3.1 Vendor shall carryout various tests as per applicable Codes/Standards. Test
procedures and mutually acceptable tests for FAT shall be frozen at the time of
detailed engineering. Tests certificates shall be submitted for Company’s approval.
3.3.2 Manufacturer shall submit detailed test procedures for all applicable mandatory
tests required as per API Specification 17E as a minimum, for review and approval
by Company prior to commencement of any testing operations.
a. In addition, procedures for following test for the tubes in line with ASTM A 450,
shall be submitted. – ((Tensile test, Flattening test, Reverse flattening test (welded
tubes), Hardness test, Hydrostatic test, Radiographic testing of welds, Visual and
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Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 11 OF 12
dimensional checks & Corrosion tests)). The complete tube string shall be
hydrostatically tested to 1.5 x WP.
b. For the thermoplastics, the following tests shall be carried out on un-aged sample
hose lengths to the requirements of ISO 3949:
Change in length test, Burst test, Cold flexibility test, Oil resistance test, Impulse
test, Leakage test, volumetric expansion, Coupling retention & Compatibility test.
c. For Electrical Cables, Testing shall be as per NORSOK standards.
Following tests shall be carried out as a minimum:
- CR, IR and HV dc tests
- Attenuation
- Mutual Capacitance
- Signal Propagation Delay Time
- Crosstalk attenuation (signal/signal)
- TDR. (Time Domain Reflecto-metry)
FAT shall be carried out on all umbilical lengths complete with terminations at the
respective storage location. Test fluid shall be as specified in data sheet. Visual
test, Proof Pressure tests, Flushing and cleanliness verification tests, Flow rate test
shall be performed.
All lines shall be circulated with an acceptable hydraulic fluid at a Reynolds
number greater than 4000. If this is impossible to achieve, an alternative cleaning
method must be proposed. The cleaning process shall continue, minimum 3 total
volume change-outs, until three consecutive cleanliness readings indicate
cleanliness level equal to or better than ISO 4406 (for Hydraulic fluids
contamination levels by solid particles, SAE AS4059 Class B through F for
Hydraulic LP & HP tubes, & NAS 1638 class 8 for other umbilical tubes.
3.3.3 Company / its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacture. Company shall specify
hold points / witness points while approving purchase specification during project
execution. During inspection, material certificates, shop test data, certificates for
bought out components and other relevant information shall be furnished for
company’s perusal so as to ascertain that the specifications and quality are
complied with.
3.3.4 In case Manufacturer / their sub vendors of equipments / packages have in-house
elaborate Quality Assurance Systems (operating in their shop) for Inspection &
Testing of equipments / packages, the witnessing of inspection and testing by
Company is not necessary. However, witnessing of inspection and testing by Third
Party Inspector of Contractor is required as per approved Quality Assurance
System. Manufacturer / sub vendors of equipment / packages shall obtain approval
of their Quality Assurance System from the Company prior to commencement of
manufacturing activities.
Where such Quality Assurance System is not in operation with the manufacturer /
their sub-vendors, the Tests specified as “witnessed” in the Specification shall be
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Rev. No. 01
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SUBSEA UMBILICAL
Page: 12 OF 12
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division Spec # 3600
Engineering Services Functional Specifications Rev # 4
11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 1 of 7
FUNCTIONAL SPECIFICATION
FOR
HI – LO PILOT SWITCH
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
VS SRS GRP 7 18.02.2008 4
ET RS GRP 10 28.03.2007 3
ET MC RK 10 23.06.2005 2
ET MC RK 10 03.01.2005 1
AK MC AC 10 17.04.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3600
Engineering Services Functional Specifications Rev # 4
11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 2 of 7
CONTENTS
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Engineering Services Functional Specifications Rev # 4
11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 3 of 7
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Engineering Services Functional Specifications Rev # 4
11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 4 of 7
4.1.2.8 Dead band shall be less than the difference between the normal operating pressure
and set point. Dead- band shall be fixed type unless otherwise specified.
4.1.2.9 The high and low-pressure ports shall be clearly marked on the instrument.
4.1.2.10 The switching mechanism shall have long life and minimum wear and tear.
4.1.2.11 In general compressed instrument air/gas will be used, as pneumatic supply to
instruments and vendor shall indicate pneumatic supply pressure requirement.
4.1.2.12 Pressure switches shall be field adjustable. Adjustments shall be tamper proof.
4.1.2.13 Switch mounted in the field shall be Ex d.
4.2 MATERIAL:
4.2.1 The material requirements for Pressure switch shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and the material selection chart
provided in Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.3 ACCURACY:
4.3.1 The maximum error shall not exceed 1% of the span. Repeatability shall be ±1%
for fixed dead band.
4.4 READING SCALES:
4.4.1 Units for pressure switch shall be in kg/cm2.
4.5 MISCELLANEOUS REQUIREMENTS
4.5.1 Mountings accessories required for Pressure Instrument shall be 316SS or better.
4.5.2 Pneumatic Pressure switches shall be tested for set points. These switches shall be
calibrated using a hydraulic or dead weight tester or precision pneumatic calibrator
prior to installation. A precision output meter, gauge or manometer shall be used
to monitor the output. The manufacturer before shipment shall perform calibration
and alignment of all instruments
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11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 5 of 7
ANNEXURE – I
4 A5 MONEL
5 A7
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11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 6 of 7
ANNEXURE -II
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11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 7 of 7
NOTE ;-
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FUNCTIONAL Spec. No. 3601
Offshore Design Section Rev. No. 04A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 2 OF 7
CONTENTS
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FUNCTIONAL Spec. No. 3601
Offshore Design Section Rev. No. 04A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 3 OF 7
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Offshore Design Section Rev. No. 04A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 4 OF 7
6.1 Calibration, inspection and testing requirements shall in general be as per clause
3.6.4.7.8 of Instrumentation Design Criteria.
6.2 All the instruments shall be factory calibrated for the specified ranges.
7 TAGGING & NAMEPLATES:
7.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1
of Instrumentation Design Criteria.
7.2 The Pressure indicating controller shall be provided with SS name plate indicating
the following:
• Tag Number
• Manufacturer’s Name and Model Number.
• Element material
• Enclosure classification.
• Body material.
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Offshore Design Section Rev. No. 04A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 5 OF 7
ANNEXURE – I
(Hook Up Drawing)
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FUNCTIONAL Spec. No. 3601
Offshore Design Section Rev. No. 04A
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 6 OF 7
PIC (PNEUMATIC)
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C Level/length -M
1 Type
MEASURING UNIT
2 Function 19 Service
3 Mounting 20 Pressure Element
4 Case Material 21 Element Material
5 Enclosure Class 22 Socket Material
6 Supply Air Pressure 23 Body Material
7 Accuracy 24 Connection location
8 Repeatability 25 DIAPHRAGM SEAL (Wherever Required)
9 Air Consumption Type
10 Ambient temperature Wetted Parts
11 Relative Humidity Other Material
Process Connection
Capillary Material
Armour Material
Capillary Length
CONTROLLER
12 Output Flushing Filling
connection.
13 A/M Switch Position
MISCELLANIOUS
14 Set Point Adjustment 26 Over range protection
Setting range 0-100 %FS
15 Manual Regulator 27 Blow out protection -
16 Mode 28 Options
17 Chart a) Mounting
accessories
18 Moving Parts Material b) Air filter regulator
with
Gauge
29 Pneumatic Connect.
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SPECIFICATION FOR
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“PRESSURE INDICATING
CONTROLLER” Page: 7 OF 7
NOTE :-
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Design Division Spec # 3602
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai P to I CONVERTER Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FUNCTIONAL SPECIFICATION
FOR
P TO I CONVERTER
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 4 18.02.2008 2
AK RS GRP 6 23.03.2007 1
AK MC AC 6 03.03.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3602
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai P to I CONVERTER Discipline Instt.
ISO 9001: 2000 Page # 2 of 4
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3602
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai P to I CONVERTER Discipline Instt.
ISO 9001: 2000 Page # 3 of 4
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3602
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai P to I CONVERTER Discipline Instt.
ISO 9001: 2000 Page # 4 of 4
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Steam – Kg/hr Pressure – kg/cm2 Temperature – deg C Level/length -mm
1 Type 11 Conduit
Connection
2 Mounting Electrical
3 Ambient Temperature Pneumatic
4 Air Supply 12 Accuracy
5 Electric Supply 13 Actuation
6 Output 14 Housing Type
Input 15 Accessories
7 Pneumatic connection 16 Intrinsically safe
8 Measuring Circuit 17 Body material
9 Cold Junction 18 Internal material
Compensation
10 Burn-out Feature 19 Area
Classification
NOTE :-
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Design Division Spec # 3603
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai RECORDER Discipline Instt.
ISO 9001: 2000 (ELECTRONIC) Page # 1 of 3
FUNCTIONAL SPECIFICATION
FOR
RECORDER (ELECTRONIC)
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 3 18.02.2008 2
AK RS GRP 5 28.03.2003 1
AK MC AC 5 25.08.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3603
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai RECORDER Discipline Instt.
ISO 9001: 2000 (ELECTRONIC) Page # 2 of 3
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3603
Functional Specifications
Engineering Services Rev # 2
11 - High, Mumbai RECORDER Discipline Instt.
ISO 9001: 2000 (ELECTRONIC) Page # 3 of 3
FUNCTIONAL SPECIFICATION
FOR
PORTABLE CALIBRATOR
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 5 18.02.2008 3
ET BK GRP 6 28.03.2007 2
ET MC RK 6 03.01.2005 1
ET MC AC 6 25.08.2003 0
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Design Division Spec # 3605
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai PORTABLE Discipline Instt.
ISO 9001: 2000 CALIBRATOR Page # 2 of 5
CONTENTS
Page
Clause No. ITEM
No.
1.0 Scope of This Document 3
2.0 Codes and Standards 3
2.1 Reference specifications 3
3.0 Scope of Supply 3
4.0 Portable calibrator 3
Annexure I Data Sheet Format 5
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Design Division Spec # 3605
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai PORTABLE Discipline Instt.
ISO 9001: 2000 CALIBRATOR Page # 3 of 5
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Spec # 3605
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai PORTABLE Discipline Instt.
ISO 9001: 2000 CALIBRATOR Page # 4 of 5
actual inputs from the calibrator for checking the transmitter output / calibration.
It shall also have the facility to generate mV for checking the temperature loops.
4.9 Necessary connectors, length of cable / impulse tubes and all accessories shall be
provided.
4.10 The Portable Calibrators shall be weather proof to IP 53 minimum and shall be
intrinsically safe.
4.11 Intrinsic safety certificate for the Portable Calibrator shall be provided with the
Purchase specification.
4.12 It shall have data retention capability of at least 100 Tags with all calibration data
and time stamping.
4.13 It shall have facility of communication with the PC (EWS in Control room / PC /
Lap Top as the case may be) on serial bus RS-232 as a minimum. Necessary
software for downloading of all calibration data and creation of a data base on
the PC shall be supplied along with the calibrator.
4.14 The Contractor shall submit a reference list for Portable Calibrators, which are
operating in similar offshore platform with the purchase specification. This list
shall clearly indicate the name of the platform, name of client, application, model
number, quantity supplied and the month and year of commissioning of platform.
The Contractor shall also submit with the purchase specification, a list of makes
of Smart Transmitters with which the offered Portable Calibrator is compatible.
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Design Division Spec # 3605
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai PORTABLE Discipline Instt.
ISO 9001: 2000 CALIBRATOR Page # 5 of 5
Sl.
Details
No.
1. Quantity
2. Service
Simulation, Testing & Calibration of pressure / DP transmitters (Yes
3.
/ No)
Simulation, Testing & Calibration of temperature transmitters /
4.
Thermocouples (Yes/No)
5. Simulation, Testing & Calibration of P/I Converters (Yes / No)
6. Memory
7. Power Supply
8. Battery Back up provided (Yes / No)
9. Rechargeable Batteries (Yes / No)
10. User replaceable batteries (Yes / No)
11. No. of Batteries
12. Type of Battery
13. Battery Charger Included (Yes / No)
14. Cable with connectors (Yes / No)
15. Length of cable
16. Area classification
17. Intrinsically safe (Yes / No)
18. Ingress Protection
19. Manufacturer
20. Model No.
NOTE :-
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Design Division Spec # 3606
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai FILTER REGULATOR Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FUNCTIONAL SPECIFICATION
FOR
FILTER REGULATOR
CONTENTS
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Design Division Spec # 3606
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai FILTER REGULATOR Discipline Instt.
ISO 9001: 2000 Page # 3 of 4
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Design Division Spec # 3606
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai FILTER REGULATOR Discipline Instt.
ISO 9001: 2000 Page # 4 of 4
FILTER REGULATOR
UNITS: Flow Liquid – M3/HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1. Regulator type
2. Fluid
3. Inlet pressure
4. Outlet pressure
5. Range
6. Output gauge size
7. Regulator range adjustment mechanism
8. Drain cock
9. Connection size
10. Construction
Body
Bowl
Material
Filter
11.
Diaphragm
Internals
Spring
12. Mounting accessories
13. Manufacturer
14. Model
15. Notes
NIOTE :-
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 1 OF 13
FUNCTIONAL SPECIFICATION
FOR
CONTROL VALVE
MC MC AC 13 25.08.2003 0
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 2 OF 13
CONTENTS
Page
Clause No. ITEM
No.
1.0 Scope of This Document 3
2.0 Reference Documents and Specifications 3
3.0 Scope of Supply 3
4.0 Control Valve 3
4.1 Valve selection & construction 3
4.2 Control valve sizing 4
4.3 Actuator 4
4.4 Positioner 5
4.5 Material 5
4.6 Miscellaneous Requirements 6
Annexure I Material Selection Chart 8
Annexure II Hook-up drawing 9
Annexure III Data Sheet Format 13
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 3 OF 13
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 4 OF 13
4.1.9 Body rating, flange rating & facing and material of construction shall be in
accordance with PMS / FS 401 the piping class specification for the associated
piping.
4.1.10 Valve Packing boxes shall be flange bolted to the bonnet. Valve packing shall
be spring loaded and adjustable. Teflon V rings shall be used up to 2120C.
Above this temperature graphite shall be used with an external lubricator and
isolation valve.
4.1.11 Valve bonnets shall be flange bolted to the body. Screwed bonnets shall not be
provided. For operating temperature of 2000C or greater, a radiating finned
bonnet may be required. For temperature below 00C an extension bonnet is
required. If bellows seals are required they shall be constructed from 316SS.
4.1.12 Minimum body size shall be DN25.
4.1.13 Where a valve is for flare gas service, TSO valve with soft seats are required.
For high-pressure drop application in gas service, multiple orifice trim design
shall be used. Labyrinth design shall not be used.
4.1.14 Pneumatic connections shall be ¼” NPTF as minimum. Larger Port sizes shall
be used wherever required for larger sizes of actuators.
4.1.15 Flow direction shall be stamped or cast on the body of all valves.
4.1.16 The Contractor shall provide detailed pressure temperature envelope curves
for each combination of valve body, trim and elastomer material.
4.2 Control Valve Sizing:
4.2.1 The Control valve shall be selected to pass high extreme of flow at 80%
maximum opening of the valve travel and low extreme of flow at 20%
minimum opening of the valve travel. The control valve shall be sized for
required maximum diff. pressure and shut-off pressure. Butterfly valves shall
be sized to pass high extreme of flow at 60% maximum opening of the valve
travel.
4.2.2 The Contractor shall submit Control Valve sizing calculation performed in
accordance with ISA S 75.01 and based on approved Process data, Process
flow diagram and material balance.
4.3 Actuator:
4.3.1 Control valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal.
Piston type actuator shall be used where diaphragm actuator cannot be used
due to capacity limitation. Electric actuator shall be used wherever specified.
4.3.2 Actuators shall be sized for operation under maximum shutoff pressure drop
across the valve minimum instrument air pressure or voltage to the actuator as
specified in this specification.
4.3.3 Actuators shall be selected to achieve specified valve failure positions. All
accessories, including pilot valves, relays, volume bottles etc. for double
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 5 OF 13
acting actuator or air block relays for fail in position valves, shall be supplied
with the valve.
4.3.4 A valve stem position indicator shall be provided. All control valve scales
shall be calibrated from 0-100 % of valve travel. Smart positionar transmitters
shall be considered for valve status indications in Process control room.
4.3.5 Side mounted heavy-duty hand wheels shall be provided for control valves
wherever specified. Hand wheels material shall be corrosion resistant and with
C-allowances over and above the thickness required as per design
requirements. Hand wheels shall be normally in disengaged position and
locked during normal Platform operation. These are to be used only during
maintenance / manual operation.
4.3.6 Actuator action shall be designed and sized for Failure position indicated.
4.3.7 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon
reinforced Neoprene or Buna N Rubber Diaphragm and shall be corrosion
resistant / with sufficient corrosion allowances to last the life of the platform.
4.4 Positioner : (Unless otherwise specified it shall be SMART Positioner)
4.4.1 Control valve shall be supplied fitted with positioner for all services except
on/off control.
4.4.2 Wherever specified for non-smart positioner the control valve shall be
provided with integral positioner with intrinsically safe “smart” type integral
i/p converter, and shall be direct acting, with field reversible provision.
4.4.3 Gauges shall be fitted to indicate pressure of the pneumatic supply, signal and
output to the actuator.
4.5 Material:
4.5.1 The material requirements for Control Valves shall in general be according to
the Material Selection Chart provided in Annexure – I of Pressure Control
Valve.
4.5.2 Control valve bodies shall generally be cast or forged carbon steel to ASTM
A216 Gr WCB/WCC or A105 respectively with 316 SS trim as a minimum.
However, more demanding services may require other materials as specified
in the applicable valve specification/Material selection chart. Consideration
shall be given in selection of all other valve part materials for
erosion/corrosion due to process fluid and ambient conditions and valve trim/
plug shall be stellited.
4.5.3 For painting, in general, Manufacturer standard procedures shall be followed.
However, specification enclosed in the bid shall govern and shall form the
minimum requirements.
4.5.4 All mounting accessories such as mounting bolts shall be of SS 316.
4.5.5 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double
ferrule compression fittings.
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 6 OF 13
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 7 OF 13
4.6.7 Each Control valve shall have a 316 SS Name plate attached firmly to the
body furnishing the following information:
• Tag Number
• Body and Port size
• Stem Travel
• Action on air failure
• Spring Range
• Air supply Pressure
• Manufacturer Model Number for valve body, actuator and positioner.
• P.O. Number
• Serial Number
• Leakage Class
• Body rating and material grade
• Signal range
• Trim Characteristics
• Body Test Pressure
• Bench set Pressure
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 8 OF 13
ANNEXURE – I
Material Selection Chart for Control Valves
Control Valves
S. No. Piping Class
Body Trim
ALUMINIUM
4 A5 MONEL
BRONZE
5 A7 HASTALLOY C. HASTALLOY C.
SS 316 confirming
CS NACE
A1N, B1N, D1N, E1N, F1N, XF1N, PA1N, to NACE
6
PB1N, PD1N, PF1N, XG1N
PACKING - GRAPHOIL
SS 316 SS 316
7 A10, B10, D10, E10, F10
PACKING - GRAPHOIL
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Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 9 OF 13
ANNEXURE – II
(Hook Up Drawing)
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 10 OF 13
ANNEXURE II (Contd.)
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 11 OF 13
ANNEXURE II (Contd.)
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Offshore Design Section
Functional Specifications Rev. No. 4
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Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 12 OF 13
ANNEXURE II (Contd.)
SMART POSITIONER
SMART POSITIONER
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Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 13 OF 13
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Spec. No. 3701
Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 2 OF 8
CONTENTS
Page
Clause No. ITEM
No.
1.0 Scope of This Document 3
2.0 Reference Documents and specifications 3
3.0 Scope of Supply 3
4.0 Safety relief valve 3
4.1 Basis of selection 3
4.2 Sizing 4
4.3 Set pressure 4
4.4 Material 4
4.5 Valve springs 5
4.6 Miscellaneous requirements 5
Annexure I Material Selection Chart 7
Annexure II Data Sheet Format 8
1.1 This functional specification describes the essential design considerations for the selection of
Safety relief valve for the intended service.
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Spec. No. 3701
Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 3 OF 8
3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic
Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Safety relief valve suitable for its
intended application, its procurement, tagging, packing, testing & calibration, preparation for
shipment, along with accessories, spares, and assistance where required for its installation &
commissioning at site. This FS shall be read in conjunction with the Instrument Design
Criteria.
4.1.1 All relief valves of size 1" and above shall be full nozzle full lift type. Relief valves with size
less than 1" shall be base or modified nozzle type.
4.1.2 Flanged relief valves for process piping, excluding steam and air pressure piping, shall be
either the enclosed spring type or pilot-operated type.
4.1.3 Balanced relief valves shall be used if the variable backpressure is more than 10% of valve set
pressure or where the service is corrosive. Balanced relief valves suitable for variable
backpressure may also be used where appreciable savings in the discharge disposal system
piping can be affected by virtue of the increased allowable backpressure. Balanced bellow
materials shall be the same as the valve trim.
4.1.4 Rupture disc type pressure relief devices shall not be used as primary relief devices.
4.1.5 Relief valves 1" and larger shall be of the type having a nozzle bushing which extends through
and beyond the base of the inlet-bolting flange, and which forms the gasket-bearing surface for
the inlet flange.
4.1.6 ¾ " and 1" relief valves may have screwed ends. All process Relief valve 1” size and larger
shall have flanged inlet and outlet connections.
4.1.7 Thermal relief valves shall have a minimum orifice area of 38.7mm2.
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Spec. No. 3701
Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 4 OF 8
4.1.8 Venting and breathing equipment for low pressure above ground storage tanks shall be in
accordance with the API Std 2000 “Guide for Tank and venting atmospheric and low pressure
storage tanks”.
4.1.9 Lifting levers may be provided for periodic testing of the Safety Valve. Closed bonnet
construction shall be used.
4.2 Sizing:
4.2.1 The contractor shall size safety relief valve according to capacity, set point, reset differential
and the blow down requirements of the Process for the Project.
4.2.2 The selected orifice shall be the next standard orifice size available above the calculated area.
Valve capacity shall then be calculated based on the selected orifice code.
4.2.3 For two-phase liquid / vapour relief application, the total orifice area shall be the sum of the
orifice areas calculated individually for liquid and vapour at the actual conditions.
4.2.4 In Safety Relief valve sizing calculations, the fail open state of a control valve (if any) shall be
taken into consideration.
4.3.1 Set point of the Safety Relief valves shall not be higher than the design pressure of the system
being protected by the valve, except as permitted by the relevant ASME Codes & API 521/526.
4.4 Material:
4.4.1 The material requirements for safety relief valve shall in general be according to clause 3.6.4.5
of Instrumentation Design Criteria and the material selection chart provided in Annexure –1 of
this specification.
4.5.1 Relief valves for set pressures of 17.5 kg/cm2g (250 psig) or less shall have springs suitable for
a range of adjustment of plus or minus 10% of the set pressure.
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Spec. No. 3701
Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 5 OF 8
4.5.2 Relief valves set at pressures higher than 17.5 kg/cm2g (250 psig) shall have springs suitable
for a range of adjustment of plus or minus 5% of the set pressure. Range identification shall be
provided on the spring.
4.6.1 Relief valve shall have tamperproof sealing, by wiring of screw cap and body, and lead sealing.
4.6.2 The installation of Safety Relief Valve shall in general be according to clause 3.6.4.6 of
Instrumentation Design Criteria.
4.6.3 Where no possibility of hydrocarbon pollution (such as in water and air service), safety relief
valves may be vented to atmosphere, with due consideration of position and angle of venting.
4.6.4 Safety relief valve shall be installed after testing/setting for set pressure, blow down and seat
tightness.
4.6.5 Discharges from all safety valves shall be individually routed to a safe location, unless
specified otherwise.
4.6.6 All safety valves discharge lines shall join the relief header from top and shall be at an angle of
30 to 40 degrees with the axis of the header.
4.6.7 All safety valves discharge and equipment depressurizing lines shall be free draining to vent
header and shall have no pockets up to and including header.
4.6.8 Discharge piping shall be designed to avoid liquid collection, backpressure build up, and stress
on the valve body under all conditions. A low point discharge drain may only be fitted on relief
valves venting to atmosphere.
4.6.9 Inlet piping shall be arranged to ensure that pressure drop at full flow does not exceed 3% of
set pressure.
4.6.10 Isolation valves provided at up-steam of double PSVs should have both lockable open and
lockable closed provisions with mechanically interlocked arrangement so that both the valve
cannot be isolated simultaneously (one LO and other shall be LC).
4.6.11 Contractor shall provide all facilities free of cost to company engineer or their authorized
representative for inspection and witness to the following tests at vendor’s works:
4.6.12 Safety relief valves shall be tested for opening at specified set pressure and also for seat
tightness.
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Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 6 OF 8
4.6.13 Testing for seat tightness shall be in accordance with the latest edition of API Std. 527.soft
seating (coring) shall be provided wherever tight shutoff is called for.
4.6.14 Compressed air or nitrogen shall be used for testing safety-relief valves (gas service) and shall
be furnished by the CONTRACTOR prior to handover.
4.6.15 For liquid service safety valve, water may be used as testing medium.
ANNEXURE – I
Material Selection Chart for Safety relief valve
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Spec. No. 3701
Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 7 OF 8
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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Offshore Design Section FUNCTIONAL
Rev. No. 3
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 8 OF 8
3. Vessel Protected
4. Safety / Relief
5. Type
6. Full Nozzle, Full Lift / Modified Nozzle
7. Bonnet Type
8. Conventional/Bellows/
9. Inlet Connection : Size & Rating
10. Facing & Finish
Valve 11. Outlet Connection : Size & Rating
12. Facing & Finish
13. Cap over Adjustment Bolt
14. Screwed Bolted
15. Lifting Gear Type
16. Test Jig
17.
18. Body & Bonnet
19. Nozzle & Disc.
20. Spring
21. Bellows
Material
22. Resilient Seat Seal
23.
25.
26.
27. Code
Basis 28. Basis of Selection
29.
30. Fluid & State
31. Corrosive Constituents
32. Required Flow Capacity
33. Mol. Wt. / Sp. Gr. At Relieving Temp.
34. Operating Pressure
35. Operating Temp./Relieving Temp.
Service 36. Valve Discharges to : Flare/Vent/Close Drain
Conditions 37. Back Pressure : Constant / Variable
38. Set Pressure
39. Cold Bench Test Pressure
40. % Over Pressure / %Blow Down
41. P/Cv/Compressibility Factor
42. Viscosity At Relieving Temperature cP
43. Vessel Wall Temp. Surface Area M3
45. Calculated Area
46. Selected Area Orifice Designation
47. No. of valves required for capacity
Orifice
48. Total Area
49. Actual Flow Capacity
50.
51 Model Number
Model 52. ASME UV Stamp
53. IBR Certification
NOTE:-
VENDOR SEAL AND SIGNATURE
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ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 2 OF 7
CONTENTS
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ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 3 OF 7
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FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 4 OF 7
4.1.1.10 For 3″ and larger valve, lifting lugs or eyelets shall be provided to enable the valve to
be lifted and supported vertically during installation.
4.1.1.11 All castings and welding shall be 100% radio graphed.
4.2 Material:
4.2.1 The material requirements for Self actuated pressure control valve shall in general be
according to Annexure-1(Material selection chart).
4.2.2 The body castings shall be free from injurious blowholes, parasite, shrinkage faults,
cracks or other faults.
4.2.3 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed.
4.2.4 Orifice material shall be of Stainless Steel.
4.3 MISCELLANEOUS REQUIREMENTS:
4.3.1 Self-actuated pressure control valve shall be furnished with all necessary weather and
anti-corrosion protection / painting to prevent damage from saline and corrosive
process atmosphere.
4.3.2 All the instruments shall be factory calibrated for the specified ranges.
4.3.3 The Contractor shall submit SAPCV Sizing calculation performed in accordance with
ISA S 75.01 and based on process data, Approved Process flow diagram and material
balance.
4.3.4 The Self actuated pressure control valve shall be provided with SS name plate
indicating the following:
• Manufacturer’s Name and trade mark.
• Valve Model Number and Serial No.
• Tag number
• Valve catalogue number
• Valve size and body pressure rating.
• Trim material, size and characteristic.
• Output Set pressure range
• Input Pressure range
• Orifice designation
• Valve body, spring and nozzle material
• Valve inlet and outlet connection sizes and ratings
• Purchase order number
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FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 5 OF 7
• A metal tag shall be firmly fixed to the valve consisting Tag Number, valve
packing and type of lubricator (if used).
ANNEXURE-I
INJECTION WATER
2 SERVICE
CS MONEL SS316
ALLUMINIUM
4 A5
BRONZE
MONEL MONEL
HASTALLY-
5 A7 HASTALLY-C
C
HASTALLY-C
INCONEL
7 A10, B10, D10, E10, F10 SS316L
625
SS316L
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FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 6 OF 7
ANNEXURE-II
HOOK UP DRAWING
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FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 7 OF 7
ANNEXURE-III
1. Tag No.
2. Line No.
General 3. Line Size & Schedule
4. Service
5.
6. Type. Of Regulator :Std Pilot op
7. Size : Body Port
8. End Conn. : Size & Rating
9. Facing & Finish
10. Body Material
11. Trim Material
12. Set Point
13. Impulse Conn. : Int. Ext.
14. Conn. Size & Type if External
15. Material of Diaphragm
Valve
16. Bonnet Type
17. Cv : Min. Max.
18. Cv : Normal
19. Selected Valve Cv
20. Predicted Sound Level dBA
21. Inlet Velocity
22. Packing or Seals
23. Lubricator ISO Valve
24. Guiding No. of Ports
25.
26. Pressure Indicator
Access-aries 27. Relief Valve
28. Line Strainer
29. Fluid & State
30. Flow Min. Max
31. Flow Normal
32. Inlet Pr. Min. Max
33. Inlet Pr. Normal
34. Del. Pr. Max. Nor. Min.
Service 35. Del. Pr. Shut Off
Conditions 36. Temperature C. Oper. Min.
37. Oper. S.G. Mol. Wt.
38. Cp/Cv Compress. Factor
39. Flash % Oper. Visc. mPas(cP)
40. Deg. Of Superheat % Solids
41. Vapour Pr. Critical Pr.
42. Model No. valve Actuator
43. Max Sound Level dBA
44. IBR Certificate
45 Specification Remarks
NOTE :-
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Design Division Spec # 3703
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 1 of 7
FUNCTIONAL SPECIFICATION
FOR
DELUGE VALVE
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS SRS GRP 7 18.02.2008 3
ET RS GRP 7 28.03.2007 2
MC MC AC 11 13.05.2003 0
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Design Division Spec # 3703
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 2 of 7
CONTENTS
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Design Division Spec # 3703
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 3 of 7
4.1.11 Flow direction shall be stamped or cast on the body of all valves.
4.1.12 The offered make and model of the Deluge valve shall be certified / listed by
Underwriters Laboratory (UL) or BV or DNV for Fire Water Deluge service.
4.1.13 Valve shall be sized as per the requirements of the platform for fire fighting
4.2 Actuator:
4.2.1 Deluge valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal. Piston
type actuator shall be used where diaphragm actuator cannot be used due to
capacity limitation. Electric actuator shall be used wherever specified.
4.2.2 Actuators shall be sized for operation under maximum shutoff pressure drop
across the valve minimum instrument air pressure or voltage to the actuator as
specified in this specification.
4.2.3 Actuators shall be selected to achieve specified valve failure positions. All
accessories, including pilot valves, relays, volume bottles etc. for double acting
actuator or air block relays for fail in position valves, shall be supplied with the
valve.
4.2.4 Detachable side mounted heavy-duty hand wheels shall be provided for Deluge
valves wherever specified.
4.2.5 Actuator action shall be field reversible.
4.2.6 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon
reinforced Neoprene or Buna N Rubber Diaphragm.
4.3 Positioner: (if applicable)
4.3.1 Deluge valve shall be supplied fitted with positioner for all services except on/off
Deluge.
4.3.2 The Valve positioner shall be intrinsically safe “smart” type with integral I/P
converter and shall be direct acting, with field reversible action.
4.3.3 Gauges shall be fitted to indicate both input & output pressure.
4.4 Material:
4.4.1 The material requirements for Deluge Valves shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and according to the Material
Selection Chart provided in Annexure – I of this document.
4.4.2 Deluge valve bodies shall generally be Cast 5% Al Bronze to BS 1400.A.B.2C.,
however more demanding services may require other materials as specified in the
applicable piping specification/Material selection chart. Consideration shall be
given in selection of all other valve part materials for corrosion due to process fluid
and ambient conditions.
4.4.3 Accessories such as mounting bolts shall be of SS 316.
4.4.4 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double
ferrule compression fittings.
4.5 MISCELLANEOUS REQUIREMENTS:
4.5.1 Clearance shall be provided to allow in- line maintenance of valves. Adequate
clearance shall be provided above and below the valve and shall be installed on
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Design Division Spec # 3703
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 5 of 7
horizontal lines with actuator as per manufacturer’s installation standards, and shall
not impede access ways.
4.5.2 Deluge valve assembly shall be provided with double block, double bleed and
bypass piping and valves. The bypass valve shall be a globe valve no smaller than
one pipe size than the Deluge valve but with a CV no greater than that of the
Deluge valve.
4.5.3 Deluge valves shall be installed in the direction recommended by the manufacturer
and the valve shall not be subjected to stress due to pipeline movement or
misalignment.
4.5.4 All valves shall be tested in accordance with API 589, hydro-tested t ASME B
16.34 clause 7.1 and leak tested to ASME / FCI 70.2.
4.5.5 Contractor shall remove in line instruments and Deluge valve and provide
necessary spool pieces/ Flanges prior to flushing/hydro testing.
4.5.6 All diaphragm and piston operated Deluge valve shall be stroked pneumatically
using a pressure regulator and pressure gauge against spring range shown on name
plate Mechanical sealing and travel shall be checked against name plate. Check
shall be made in shop prior to installation.
4.5.7 All Deluge valves shall be checked carefully against nameplate data and
specifications.
4.5.8 Each Deluge valve shall have a 316 SS Name plate attached firmly to the body
furnishing the following information:
• Tag Number
• Body and Port size
• Stem Travel
• Action on air failure
• Spring Range
• Air supply Pressure
• Manufacturer Model Number for valve body, actuator and positioner.
• P.O. Number
• Serial Number
• Leakage Class
• Body rating and material grade
• Signal range
• Trim Characteristics
• Body Test Pressure
• Bench set pressure
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Design Division Spec # 3703
Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 6 of 7
ANNEXURE – I
COCK COCK
S. No. Piping Class CHAMBER
BODY TRIM
5 A7 Ti Ti Ti
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Engineering Services Functional Specifications Rev # 3
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 7 of 7
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FUNCTIONAL SPECIFICATION
DISTRIBUTED CONTROL
SYSTEM (DCS)
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TABLE OF CONTENTS
Clause No. ITEM Page No.
1.0 Scope Of This Document 3
2.0 Standards And Specifications 3
2.1 Reference Specifications 3
2.2 Other Specifications to be followed 3
3.0 Scope Of Supply 3
4.0 Distributed Control System 4
4.1 Definitions and Abbreviations 4
4.2 General 7
4.3 Electrical Requirements 10
4.4 System Requirements 13
5.0 Equipment Protection 63
6.0 Installation Requirement 64
7.0 Inspection And Testing 65
8.0 Documentation 76
9.0 Training 79
10.0 Tagging & Nameplates 80
11.0 Review And Approval 80
12.0 Vendor Pre-Qualification Requirements 80
13.0 Preparation For Shipment 80
14.0 Receipt And Storage 80
Annexure 1 Data Sheet – Proven Track Record 81
Annexure 2 Data Sheet – Responsibility Chart 82
Annexure 3 Typical format for certificate of logistic support 83
Annexure 4 Data Sheet – Distributed Control System 84
Annexure 5 Data Sheet – Communication Sub-System 85
Annexure 6 Data Sheet – Controller Sub-System 86
Annexure 7 Data Sheet – Data Acquisition Sub-System 87
Annexure 8 Data Sheet – Operator Interface Sub-System 88
Annexure 9 Data Sheet – Engineering Interface Sub-System 89
Annexure 10 Data Sheet – Printers 90
Annexure 11 Data Sheet – Hard Copy Unit 91
Annexure 12 Data Sheet – Hard wired Console 92
Annexure 13 Data Sheet – Foreign Device Interface 93
Annexure 14 Data Sheet – Hard wired Instruments 94
Annexure 15 Data Sheet – Intrinsic Safety Barriers 96
Annexure 16 Data Sheet – Console, Panels, Cabinet & Accessories 97
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4.1.4 Configurable:
A system feature that permits selection through entry of keyboard commands of
basic structure and characteristics of a device or system, such as control algorithm,
display format or I/O termination.
4.1.5 I/O:
I/O shall represent Input/Output with respect to process/operator.
4.1.6 System Size:
System size shall be defined as maximum number of process inputs or tags those
can be connected to the system and viewable from any one of the CRT / LCD TFT
MONITOR of an operating console in all hierarchical displays without changing
the configuration or without operator interaction considering.
a) All inputs as close loops
b) All inputs as open loops
4.1.7 Operator Console:
Operator console is the main operator's interface device via which operator can
view the plant and can give instructions to peripherals to execute commands, and
can configure and maintain the system to the extent it is permitted.
4.1.8 Engineering Console:
Engineering console shall be the engineer's main interface device via which
engineer can view the plant, give instructions to peripherals to execute commands,
and can configure and maintain the system.
4.1.9 Switch Over Time:
Time required for a back up instrument to come on-line automatically in case of
the failure of the main instrument.
4.1.10 Loop Integrity:
A system shall be said to have loop integrity if the failure of one component in the
system/sub-system does not affect more than one loop.
4.1.11 Interchangeability:
System/sub-systems shall be said to have full interchangeability if the functions
and information available on one system/sub-system shall also be available on the
other totality.
4.1.12 User’s Memory:
Free memory space available in addition to the memory required for system
configurations and other system related functions which a user can utilize to
execute his own programs for plant calculations, process optimization or MIS (line
free formatting of certain logs). The programs shall normally be written in high-
level language like FORTRAN, BASIC etc.
4.1.13 Redundancy:
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standard /special software package, if available with the package, shall be offered,
with a description of its capabilities.
4.2.8 Software Protection:
4.2.8.1 Software locking mechanisms that restrict users from copying (for backup
purposes) software source or compiled executable code from storage media shall
not be used. In addition, these mechanisms shall not be used to restrict users from
booting up. This means that no “key disks” or password protection shall be
required to use software that is supplied as part of the system.
4.2.9 Software Revision Levels:
4.2.9.1 Standard system operating software delivered to the installation site shall be the
most recent field proven revision available at the beginning of the pre-factory
acceptance test (pre-FAT) applicable to the system hardware. Unless otherwise
directed by the Company, standard system operating software provided at time of
placement of contract or purchase order shall be upgraded to pre-FAT revision
prior to the start of pre-FAT.
4.2.9.2 Third party software shall be the most recent field-proven revision available that is
applicable to system hardware at the time of the placement of contract or order.
4.2.9.3 The system shall allow for upgrading of operating software on all redundant
modules of the system without shutting down the process, losing the operator
interface to the process or losing any basic control functions. If online control is
interrupted, control outputs shall be frozen for no longer than eight seconds.
Testing of this function shall be part of the acceptance testing.
4.2.9.4 There shall be a detailed, step-by-step procedure manual to accomplish all software
upgrades during and after procurement of the system.
4.2.9.5 The upgrade procedure shall allow different releases of software to coexist on
communications network and on different units of redundant modules during the
upgrade implementation. Otherwise the Contractor shall provide assistance to
ensure a safe and secure migration. The Contractor shall ensure compatibility with
all the Contractor’s existing software before the upgrade is performed.
4.2.9.6 The system shall have all necessary software to translate any system data to make
it compatible with the new software release.
4.2.9.7 Application code shall not require modifications to run under new releases of
standard software. If modifications are required, supporting documentation shall
be provided.
4.2.9.8 The system shall provide an indication of differences in system operating software
between redundant units.
4.2.9.9 The Contractor shall make no software revisions or upgrades after completion of
the FAT.
4.2.10 On-Line Card Changeover:
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4.2.10.1 All printed circuit boards shall be able to be removed or installed while the system
is operating without causing hardware damage or system errors
4.2.11 Third-Party Equipment:
4.2.11.1 All third party equipment provided as part of the system shall be currently
available for sale from the original supplier at time of placement of the contract or
order and shall be also available for next five years. All such equipment shall meet
the same standards applied to the original equipment and meet all applicable
project specifications and standards referenced in this specification.
4.2.12 ELECTRICAL REQUIREMENTS:
4.2.12 The electrical requirements for the DCS shall in general be as per clause no.
3.6.4.2.2 and 3.6.4.3 of Instrumentation Design Criteria. In addition to the
referenced clause, the following shall also be taken care of.
4.2.13 External Power Supply:
4.2.13.1 The DCS shall preferably use supplies from 24VDC battery systems, to reduce the
UPS requirements. AC voltage for illumination / lighting shall be 240 V, 50 Hz.
4.2.13.2 Power supply shall be made available at one point. Power supplies shall be
arranged so that a single power fault in any instrumentation branch of the system
shall not cause a trip of the entire system. Each consumer shall be provided with a
separate switch and fuse for isolation and protection of the system.
4.2.13.3 Each transmitter shall preferably be powered with individual power supply.
However when several transmitters are powered by a common DC source, each
power supply branch shall have a separate switch and fuse. The distribution
network shall be designed in such a way that overload in any branch shall not trip
the main power supply. Enough redundant power supplies/battery banks shall be
provided which shall take over automatically in case of main common power
source failure. Redundant floating power supply shall be provided for all sub-
systems, cabinet-wise.
4.2.13.4 The Contractor shall provide all necessary electrical equipment to condition and
distribute AC and DC power to the DCS including: AC UPS, DC batteries and
chargers, distribution switchboards, circuit breakers fuses, terminals and the like.
4.2.13.5 If power is sourced from the onsite generating plant, then the DCS equipment shall
be able to operate with power quality and fluctuations typical of such sources.
4.2.14 AC Power Conditioning and Distribution:
4.2.14.1 The Contractor shall provide a UPS system, where required, for each DCS
location, including UPS batteries and chargers that will support DCS operation
following loss of external main power to the system. Equipment shall be sized for
a nominal 2 hours, which will be confirmed by the Contractor following project
risk assessments and HAZOP. The Contractor shall provide detailed calculations
to support equipment sizing, including deratings for battery age and other effects.
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4.2.14.2 Each device with a direct AC power input shall be protected by a circuit breaker or
fuse.
4.2.14.3 The DCS power supply shall be 110 AC ± 10%, 50 Hz ± 3% or 60 Hz or 24VDC
with maximum static transfer time of 5 msec or better. In line AC transient
protectors shall be provided to protect all DCS power supplies.
4.2.14.4 DCS systems shall be grounded in accordance with the supplier’s
recommendations. Transient suppressors shall be grounded by the shortest
possible straight path to facility ground.
4.2.14.5 Circuit protection shall be properly sized and coordinated to protect equipment and
prevent shutdown of the whole DCS system by confining tripping to the affected
circuit.
4.2.14.6 DCS power supplies shall be designed to operate at less than 80 percent capacity.
4.2.15.7 Each power supply shall be connected to an independent circuit in the AC power
distribution panel.
4.2.16 Earthing:
4.2.16.1 Each panel cabinet, console and other equipment on control room shall be provided
with an earthing lug. All these lugs shall be properly secured to the AC mains
earthing bus.
4.2.16.2 All circuit grounds of electronic instruments, shields and drain wires of signal
cables shall be connected to instrument ground bus, which is electrically isolated
from the AC mains earthing bus. This bus shall be typically 25 mm wide and 6
mm thick of copper. The instrument ground bus is connected to independent
instrument system ground buses through insulated wires.
4.2.16.3 All Zener barriers, if used, shall be securely grounded. The Zener barrier ground
wire shall be capable of carrying a maximum fault level current of 0.5 ampere at
250V rms per barrier.
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The system configuration shall in general consist of the following major sub-
systems. The exact types of sub-systems for a particular facility shall be as per the
Basic Bid Work – Instrumentation.
4.3.2.1 Controller Sub System:
Controller sub-system shall interface with field instrumentation like transmitters
and final control elements to control process parameters like flow, temperature,
level etc. The sub-system shall include a comprehensive set of control algorithms
and auxiliaries to provide close loop control and data monitoring capability of the
system.
4.3.2.2 Data Acquisition Sub System:
Data acquisition sub-system shall interface with various types of open loop process
inputs, analog as well as discrete for process monitoring.
Note: The Controller and Data Acquisition Sub Systems may be combined or
may be offered separate.
4.3.2.3 Input / Output System for Data Acquisition and Controller Sub Systems:
The input / output system shall be capable of accepting analog and digital inputs
and generating analog and digital outputs. This system shall be similar for both the
Data Acquisition Sub System as well as the Controller Sub System.
4.3.2.4 Operator Interface Sub System:
Operator interface sub-system shall consist of one or more operator consoles for
monitoring and controlling process parameters and performing other process
related functions.
4.3.2.5 Engineer Interface Sub System:
Engineer interface sub-system shall consist of an engineering console primarily for
tuning, configuring and maintaining the system.
4.3.2.6 Communication Sub System:
Communication sub-system interconnects various sub-systems over which they
can communicate with each other to meet all functional requirements.
4.3.2.7 Supervisory Computer Sub System:
Supervisory computer, when specified, shall be employed for providing
supervisory level control, plant and unit optimization and other computer baed
plant management capabilities.
4.3.2.8 Foreign Device Interface:
Foreign Device like Gas Chromatographs, Analyzer systems, Gas turbine systems
etc. when specified shall communicate with other subsystems over the
communication sub system for plant monitoring and control using foreign device
interface.
4.3.2.9 Hardwired Instrumentation:
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4.3.3.9.1.6 Logical functions (and or, not, nor, exclusive or, exclusive nor)
4.3.3.9.1.7 Ramp generation, lead lag, dead time compensation, high/low select median select
time average, signal selector switch, limiter functions, auto ranging for dual
transmitter, override, etc.
4.3.3.9.1.8 Control algorithms shall include PID, PI, PD, P only, external feedback, PID based
on error, PID with anti-reset windup, auto/manual with bias control, ratio control,
integral only, PID with nonlinear gain and gap action
4.3.3.9.1.9 Output algorithms for providing linear inputs and linear outputs with clamping
(high and low restricted)
4.3.3.9.1.10 Output support for both positional and incremental control output modes.
4.3.3.9.2.1 Regulatory controllers shall scan inputs at a sufficient frequency to provide freshly
sampled data for each control loop execution cycle, as described below.
4.3.3.9.2.2 Control Loop Execution Cycle:
The system shall have automatic phase load leveling and warning messages for
pending CPU overloads.
4.3.3.9.2.3 Control Loop Scan Time:
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4.3.3.9.4.1 It shall be possible to configure any control loop for automatic bumpless and
automatic transfer between any control modes.
4.3.3.9.4.2 It shall be possible to put any individual control loop into manual mode. It shall
be possible for an operator to manipulate output of a control loop in manual mode.
4.3.3.9.4.3 An output signal from a field output module shall change within one second from
the last operator action commanding the change.
4.3.3.9.4.4 For cascade control, it shall be possible to configure remote set points from other
regulatory controllers or other DCS modules. All control blocks, which can accept
a setpoint, shall be capable of being switched between local set point (operator
entered) and remote set point.
4.3.3.9.4.5 In cascade loops, the primary controller shall be able to track the set point of the
secondary controller when the secondary controller is not operating in cascade
mode. For cascade loops with two loops in separate modules, signals to inner
controller shall be available within one second of the value calculated in the outer
controller. For cascade loops executed in the same module, this time shall be one
half second.
4.3.3.9.4.6 For cascade control loop, it shall be possible to configure the outer controller to
have its output clamped to the inner algorithm’s setpoint limits. The system shall
have interlocks to prevent a controller from being put into the cascade mode if
inner is in manual.
4.3.3.9.4.7 Control blocks shall be capable of performing automatic mode switching based
on external or internal logic inputs. Mode switching shall include:
• Auto/manual switching
• Local/remote setpoint switching (open/close cascade)
• Anti-reset windup capability shall be provided
• Status shall be propagated from secondary controllers to higher level
controllers.
• It shall prevent windup at the secondary controller.
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4.3.3.9.5.1 Variables that are being initialized (control block turned on, returning to normal
from invalid state) shall be subject to the following:
• The system shall suppress nuisance alarms created by first calculation of
the algorithm
• Calculations involving time based data, such as filters and rates of changes,
shall be reset
4.3.3.9.5.2 Control blocks shall offer the option of either initializing a setpoint to the input
value or maintaining last setpoint upon algorithm initialization. Configured
initialization shall occur when a block mode changed from manual to automatic or
from off to on.
4.3.3.9.6 Alarms:
4.3.3.9.6.1 Inputs shall be provided with high warning (HIGH) low warning (LOW), high
absolute (HIGH_HIGH) low absolute (LOW-LOW) rate of change, input-out-of-
range high/failure and input-out-of-range low/failure.
4.3.3.9.6.2 Control and computational points shall be provided with high/low deviation of
process variable from set point warning, high output and low output.
4.3.3.9.6.3 To minimize analogue input “chattering” (a point going in and out of an alarm
condition rapidly), there shall be configurable dead band parameters, on a per
alarm basis.
4.3.3.9.6.4 Contact input change of state shall provide an alarm condition.
4.3.3.9.7 Precision:
4.3.3.10.1.3 Sequential control and batch control shall conform to ISA S88.01
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4.3.6.4.6 The CRT / LCD TFT Monitor shall have touch screen facility if it is a standard
feature available in the manufacturer range of DCS. However start/stop from
‘touch screen’ shall be disabled under normal operator functions.
4.3.6.4.7 The display requirements of the operator console shall be as per clause no.
4.4.6.4.11 given below.
4.3.6.4.8 All the functions of CRT / LCD TFT Monitor and keyboards of an operator
console shall be fully interchangeable. Further any change made in the database of
one CRT / LCD TFT Monitor shall automatically update the database of other
CRT / LCD TFT Monitor of the same console.
4.3.6.4.9 The real time clock of each operator console shall be crystal controlled one, which
shall be independent of line frequency. All the real time clocks in the system be
synchronized shall with each other.
4.3.6.4.10 The operator console / workstation shall use 24 V DC power supplies.
4.3.6.4.11 Each CRT / LCD TFT Monitor shall have an industrial high-resolution, minimum
21" (Twenty One inch) color screen capable of displaying alphanumeric & graphic
displays. The displays shall provide as a minimum 256-colours, including black
and white. Distinct & Multiple colors shall be used to distinguish parameters such
as control, information, process and alarms etc.
4.3.6.4.12 Key board:
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d) Facility to enter any changed parameter like set point, manipulated variable,
digital commands and to cancel any wrong entry while making such change.
e) Facility for easy positioning of cursor for the selection of any parameter.
f) Selection of hardcopy printout, logging printout, alarm history printout and
assignable trend recorder points.
g) Auto / Manual / Cascade / Computer mode changeover of each controller
4.3.6.4.12.7 The keyboard shall be provided with function keys, each of which shall be
assigned to a plant area. Any alarm within that area shall cause an LED in the key
to flash. Pressing the key at any time shall immediately select the relevant graphic
display.
4.3.6.4.13 The operator console shall be capable of performing the following functions as a
minimum:
a) Indication of all analog and digital process variables of control loops, open
loops and all loop related parameters.
b) Manipulation of control loops including changing set point, mode, output,
configuration, tuning and computational constants.
c) Alarm displays and annunciation
d) Graphic displays and status indication
e) Logging, trending and archiving including historical trend recording.
f) Trend recording on assignable trend recorders.
g) Self-diagnostic screens.
h) Data storage and report generation software
i) Access to Emergency Shutdown (ESD) and Fire and Gas (F&G) system
j) Activation and alarming of start-up process bypasses in the ESD system
k) Access for maintenance, including provision for maintenance bypass and
corresponding “alert alarm” logging
l) Access for engineering, if the same workstation is used as both Operator as
well as Engineering Console: This shall be achieved via an appropriate level of
security access as stated in clause no. 4.4.7.2.
m) Simple data exchange with Microsoft applications including Excel and Access
n) Auto boot up by each operator station and auto boot up on power-up
4.3.6.5 Printers:
4.3.6.5.1 Two laser printers shall be provided with each of the Operator Console system –
one colour printer and one black-and-white printer.
4.3.6.5.2 Each operator and engineering console shall have access to all the printers for
printing of alarm logs, event logs, standard and special reports, screen dumps and
other information.
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4.3.6.5.3 The printer shall be capable of handling atleast 128 ASCII character types and
shall have a minimum printing speed of 300 lines / minute. The minimum number
of print columns shall be 132. The paper width shall be 381 mm and shall be
continuous fanfold type. The number of copies shall be three (3), inclusive of the
original. An acoustic cover shall be provided for each printer.
4.3.6.6 Displays:
4.3.6.6.1 The minimum number of display characters shall be 80 x 40 per line. The
minimum number of characters shall be 96 ASCII. The minimum number of
character construction shall be 5 x 7 dots and the construction pattern shall be 7 x 8
dots.
4.3.6.6.2 Each CRT / LCD TFT MONITOR screen shall be able to display the full
alphanumeric tag number of a process variable. A minimum of nine (9) digits shall
be required for the tag number and 15 digits for the process description as per
example given below:
Tag No. Description
12PIC 1401 12C201 PRESSURE
4.3.6.6.3 Display Refresh Times: Displays and graphics that show real-time data shall be
automatically updated when the display or graphic is on a screen. Updates shall
not require operator initiation. CRT / LCD TFT MONITOR data display update
rate shall not be more than two (2) seconds. During this period, changes in state of
discrete points shall be updated immediately they occur. This requirement applies
to both data displayed alphanumerically and symbolically (shape changes, colour
changes, etc.). Update frequency shall be configurable. For systems that update
data upon change of data, data shall be updated when the change exceeds a
configurable value between 0.1 and 0.2 percent of span. It shall be possible to set
the minimum change to zero. Call-up time for all types of displays shall not
exceed 1 second.
4.3.6.6.4 Display Response: Initial display response shall occur within one second of an
operator’s request. Display call-up shall require no more than two operator
keystrokes. All displays, including all updated fields, shall be completed, within
four seconds of an operator’s request. User interaction with the display shall be
possible within three seconds of request. If the update interval is configured at a
faster rate, interaction intervals shall match. Multipage displays shall respond to
page change requests with a fully operational new page within one second.
4.3.6.6.5 Operators shall be able to easily access specific displays and graphics by pressing
dedicated function keys, selecting from a list of displays in directories or menus or
by typing a display name.
4.3.6.6.6 It shall be possible to move between related displays and graphics of different
detail levels or of the same detail level with a maximum of two operator actions.
4.3.6.6.7 Multiple windowing of graphics shall be possible.
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It shall be possible to call up real time trend displays for any process point.
The trending facility shall not allow any display exception reporting i.e. all raw
data shall be displayed as it is collected or stored.
Trend displays shall be available as one trend on a full screen up to a minimum
of eight displays on a single screen. Each display shall handle a minimum of
eight pens.
It shall be possible to incorporate trends in graphic displays.
Consecutive trend data points shall be connected by straight lines.
In full screen format, resolution of the graph shall be equal to or better than 210
value points on the process value axis for at least 60 tag data points.
It shall be possible to trend at least three different analogue points
simultaneously on one trend display. It shall be possible to display the set
point, measured variable and output of any loop simultaneously.
If only one point is on the trend display, the vertical axis shall be used for
engineering units and engineering units for that point shall be shown. If
multiple points are on trend display, then the vertical axis shall be in percent of
engineering units for each point shall be listed in a table if they are not shown
on the vertical axis.
Time period of display and time interval of the trend shall be adjustable. As a
minimum, time period between 15 minutes and 31 days shall be available.
Real time trending shall have time intervals of 10 seconds and below.
Historical trends shall have time intervals of 1 minute, 10 minutes and 1 hour.
Auto scaling and time base changes of the trend shall be available to the
operator through a simple action (e.g. one or two key strokes).
Trend display shall be either single line or bar graph type and the parameter
table shall show the tag ID, minimum scale value, maximum scale value,
present value of the trended point, alarm status and engineering units for each
point, in the same colour as the tag graph. Zooming facility shall be provided
for this view.
f) Alarm Summary Display:
It shall be possible to provide separate alarm summary displays for each plant
section in the following format:
• Multi-page displays may be used for alarm summaries. It shall be possible
access these pages sequentially (forward or backward) by a single operator
action.
• The alarm summary display shall list alarms in tabular format in order of
occurrence with most recent alarm at the top. An option shall be available
to list alarms by priority with the highest priority alarms starting at the top
of the page.
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• Numeric data and other text shall be displayable in the minimum of two
different character sizes.
• It shall be possible to display numeric data in dynamic vertical and
horizontal bar graph formats. Height and width of each bar group shall be
configurable on an individual basis.
• Symbolic representation of data on graphics shall be performed by shape
changes, colour changes (foreground and background independently) and
flashing in any combination.
• It shall be possible to position any symbol anywhere on a graphic.
• Each graphic shall be capable of handling a minimum of any mix of 1000
calculated, analogue and discrete dynamic display elements including
graphical symbol representation of process status, for real time data
display.
• Within the console, it shall be possible to move displays from one screen to
any other using data entry devices. The operator shall have the ability to
manipulate operation of process directly from graphics using data entry
devices.
• Access to the faceplate for any analogue or digital controller by selecting
the associated graphic point.
• Pop-up facility for tag information.
4.3.6.7 ALARM MANAGEMENT:
4.3.6.7.1 The DCS shall have comprehensive alarm display and management facilities. The
alarms shall be configured so as to minimize unnecessary operator distractions,
utilizing intelligent alarm management including the following:
• Process and system alarms shall be annunciated audibly and displayed at
appropriate workstations. They shall be logged in alarm history files, and
printed on appropriate alarm printers if required.
• The operator console shall display alarms from the ESD and F&G systems
and from the other systems as required, communicated via the data
highway or other interfaces.
• An audible signal shall sound each time an alarm occurs. Audible sounds
shall have different configurable, priority tone levels such as increasing
tone pulse rate for higher priority alarms.
• A visual signal shall indicate at the operator workstation the plant section in
which the alarm has occurred, i.e., the relevant page shall be flashed and
the group number of the alarm input shall be displayed irrespective of the
type of display at the time of occurrence of alarm.
• It shall be possible to alarm any point in the system
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4.3.6.7.11 It shall be possible to disable audible alarm annunciation for a configurable period
of time.
4.3.6.7.12 The following types of process alarms shall be provided as a minimum:
• Process input high/low warning value
• Process input high/low absolute value
• Process input excessive rate of change
• Process input out of range high/low failure
• Process input set point deviation from control and computational point
high/low warning value
• Process input set point deviation from control and computational point
high/low absolute value
• Process input high/low dead band deviation
• Contact input change of state
4.3.6.7.13 Each process alarm shall be saved in an alarm history file and also, if so
configured, on black and white alarm printer.
4.3.6.7.14 The following information shall be logged in the alarm history file as a minimum:
• Alarm tag ID
• Alarm description
• Type of alarm
• Time of alarm, time acknowledged and time returned to no alarm expressed
in “hours:minutes:seconds” in a 24 hour format (day and month shall also
be logged)
• Process value at alarm
• Alarm priority
4.3.6.7.15 Log entries shall be generated for tags going into alarm state and for tags returning
to normal. Tags going into alarm shall be indicated by red colour or by some other
easily recognized characteristic. Tags returning to normal shall be indicated by
black colour or some other easily recognized characteristic.
4.3.6.7.16 It shall be possible to log up to 100 alarms per minute on each alarm logger. It
shall be possible to display and print out the alarm history of minimum 300 alarms
at a time.
4.3.6.7.17 It shall be possible to print alarm history on a shift basis.
4.3.6.7.18 It shall be possible to manually inhibit alarms on a point-by-point group or system-
wide basis. This capability shall be protected by system access control. These
actions shall be logged. A list of suppressed alarms shall be available at the
operator station.
4.3.6.7.19 An alarm output function shall be provided to automatically suppress alarms upon
occurrence of another alarm.
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4.3.6.7.20 A logic based alarm output function shall be provided to suppress selected
subsidiary alarms when a related higher priority alarm is raised.
4.3.6.7.21 A logic based alarm output function shall be provided to deactivate groups of
alarms for equipment that is out of service.
4.3.6.7.22 All devices connected to the communications network shall be monitored for
failure. An alarm indication shall be generated for each failure detected.
4.3.6.7.23 It shall be possible for system alarms to be logged on a printer separate from the
process alarm printer.
4.3.6.7.24 Alarm Summary Display requirements shall be as per clause no. 4.4.5.6.9.f of this
document.
4.3.6.8 HISTORICAL DATA LOGGING AND TRENDS:
4.3.6.8.1 The system shall have configurable real time and historical data collection package
to support trending.
4.3.6.8.2 It shall be possible:
• For operators to trend tags as needed
• To store the value of any analogue point or calculated value, operator
actions, alarms from operator consoles, etc. in history files
• To record the change of state of any discrete point in one of the event
histories
4.3.6.8.3 At last two DVD/CD read/write drives shall be provided in the Central Control
Room and one in each instrument equipment room.
4.3.6.8.4 It shall be possible to transfer data to removable media for historical data storage
and/or archiving. The historical device shall not support any type of data
compression algorithm that is not 100 percent recoverable. The system shall
provide historical storage for low, average and high data values as listed below and
shall be readily capable of further expansion:
• Eight hours of five second snapshots
• Ninety six hours of one minute snapshots
• Hourly averages for last 168 hours
• Eight hour averages for last 168 hours
• Daily averages for last 30 days
• Monthly averages for last 12 months
4.3.6.8.5 A configurable trend package shall be provided to fulfill the following real time
and historical trending requirements:
• It shall be possible to configure any analogue point for trending
• Historical data collection rates shall be configurable between five seconds
and one hour, inclusively
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• When an analogue point is not available (point off scale, out of range, etc.)
an unavailable code shall be entered in history.
• Standard reports shall be provided to print history values.
4.3.6.8.6 It shall be possible for the system to be configured to support online real time and
historical trends for at least the following data collection rates and retention times.
• One minute snapshot and/or average values for four days
• Five or six minute average values for a month.
4.3.6.8.7 A real-time trend feature shall be provided to make it possible for an operator to
initiate a real time trend for any analogue point.
4.3.6.8.8 The logging format shall be user definable. However, each event history file / log
file entry shall contain time and date of occurrence, tag ID, tag description and
value/state and type of event.
4.3.6.8.9 The following events as a minimum shall automatically be stored in history files
for later reporting and analysis:
Process Events
All discrete process events shall be stored in history files. These shall include:
• Inputs changing state
• All alarms occurring and returning to normal
• Equipment changing state (running/stopped, open/closed)
Operator Events
All operator actions that affect the process shall be stored in history files. This
shall include any operator command such as:
• Opening/closing isolation valves
• Starting/stopping of pumps and motors
• Changes to set points
• Changing control blocks between automatic and manual
If the system is provided with password or card key access for operators, these
events shall be printed with user’s identification.
Engineer Events
All engineer actions that change the control and monitoring of the process shall be
stored in history files:
• Placing stations and devices online and offline
• Changes to alarm set points
• Inhibiting/enabling alarms
• Changes to tag parameters
• Point placed on or off scan
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If the system is provided with password or card key access for engineers, these
events shall be printed with user identification.
System Events
The following system events shall be stored in history files:
• Failed process I/O modules
• Communication errors
• Program error messages
• Switchover between primary and backup
• Failed controller modules
• Other function module failures
4.3.6.8.10 Number of pages in each log report shall be sufficient to accommodate all the
parameters for logging.
4.3.6.8.11 Hourly report shall be printed only as and when initiated on demand by the
operator and shall not be printed automatically after the end of the hour. All other
reports shall be printed automatically at the end of the pre-defined time or when
required by the operator. The maximum storage time for log information shall be
15 minutes after the predefined print out time for a format.
4.3.6.8.12 Sequence of Events: Sequence of events (SOE) functions shall be integrated with
the system. Resolution of event detection shall be one millisecond or better. This
function may be accomplished by integration of third party equipment into the
system, provided function and indication of results is transparent to the operator.
• Reports shall be printed or displayed at the user’s option
• Report displays shall allow paging forward and backward through time
• Reports shall allow reporting of data by plant section, tag and time
• Events shall be time tagged and stored in history files
4.3.6.8.13 Event History Capacity: Historical files shall be capable of storing a minimum of
10,000 events.
4.3.6.8.14 It shall be possible to print logs on hourly, shift-wise (8-hours) and daily basis.
Provision shall also be made to print logs on weekly and / or monthly basis,
shutdown reports, initiator sequence, on-demand reports, trip initiator logs, etc.
4.3.6.8.15 Trend Display requirements shall be as per clause no. 4.4.5.6.9.g of this document.
4.3.6.9 ASSIGNABLE TREND RECORDERS:
4.3.6.9.1 The number of assignable trend recorders shall be as given in the Basic Bid Work
– Instrumentation.
4.3.6.9.2 It shall be possible to provide real time trend on the assignable recorders for any
process or calculated variable. The variable shall be assigned through the
keyboard of operator console on any point and any recorder connected to that
console.
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4.3.6.9.3 Assignable trend recorders shall be located on the hard-wired console of the
Distributed Control System. Each recorder shall have four pens. The recording
speed shall be 1” / hour in general.
4.3.6.10 HARD COPY UNIT:
4.3.6.10.1 Hard copy unit shall be used to make permanent copy of any CRT / LCD TFT
MONITOR page and when demanded through the operator console/Engineer
console.
4.3.6.10.2 CRT / LCD TFT MONITOR page shall not be locked for more than 5 seconds
while taking the video-copy.
4.3.6.10.3 Copies of display shall be in full colour.
4.3.7 ENGINEERING INTERFACE SUB SYSTEM:
4.3.7.1 Engineer interface sub-system shall be provided in the Central Control Room and
shall serve as an interface for the engineer to configure and tune loops, execute
system maintenance, display data, build reports, and, generate and edit database of
the Distributed Control System.
4.3.7.2 The Engineering interface sub-system shall consist of one Engineering console.
The Operator’s console may be used as engineering console, provided, adequate
access security by way of key-lock and password protection is given.
4.3.7.3 Each Engineering console shall consist of one colour CRT / LCD TFT MONITOR
and one engineering keyboard. The requirements of these shall be same as that of
the operator console. The engineering console shall also have one configuration
and maintenance (C&M) printer and a hard copy unit.
4.3.7.4 Engineering console shall have, as a minimum the same capability as operator
console. All the plant views as specified under operator console shall also be
available on Engineering console.
4.3.7.5 The Engineering console shall be capable of communicating with all other sub-
systems over the communication sub-system.
4.3.7.6 The engineering console be capable of executing the following functions as a
minimum, both online and offline:
a) All functions of the operator console
b) Data base configuration including overview, group, loop, multiloop and
multi variable configuration
c) Display, report building, database generation and editing
d) Generation and modification of user-defined displays
e) Generation and modification of control algorithm
f) Generation and modification of reports
g) Group or multi group alarm inhibit from the plant under maintenance.
h) Configuration or re-configuration of alarm settings, their values addition or
deletion of any control block or component in a loop.
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• The system shall support DECNET and TCP/IP standard link utilization.
4.3.9 SUPERVISORY COMPUTER SUB SYSTEM:
4.3.9.1 The necessity of a supervisory computer sub system shall be governed by the
requirements in the Basic Bid Work.
4.3.9.2 The supervisory computer shall be capable of the following functions as a
minimum:
a) Advanced Control
b) Unit and plant optimization
c) Management information service reports.
4.3.10 FOREIGN DEVICE INTERFACE:
4.3.10.1 Foreign device interface shall be capable to transfer data from all the foreign
devices like analyzer systems, gas chromatographs, gas turbine system, package
instruments etc. to other sub-systems connected to communication sub-system and
vice-versa wherever specified.
4.3.10.2 Each device interface shall be redundant.
4.3.10.3 Interface hardware and software shall be suitable to match the foreign device
communication requirements like hardware interface, communication protocols
etc.
4.3.10.4 While writing software or mapping the input/output in the interface device it must
be ensured that integrity of the data to be transferred like resolution, correctness
etc. shall be maintained.
4.3.10.5 Redundant interface switchover shall be designed based on the type of redundancy
available in the foreign devices.
4.3.10.6 The total responsibility of selection of hardware, writing of software, switchover of
redundant interface etc. shall be distributed control system Vendor only.
4.3.11 HARD WIRED INSTRUMENTATION:
4.3.11.1 Hardwired instruments shall be stand alone type and shall meet their functional
requirements fully without depending on DCS. The type of instruments required shall be
as per the Basic Bid Work – Instrumentation. Even power supply and input/output circuits
of hardwired instruments shall be totally independent of DCS system. 20% additional
spares shall be provided for each item on the hardwired console.
4.3.11.2 Hard wired instruments shall be microprocessor based. Each instrument shall have as a
minimum the necessary firmware to meet its functional and operational requirements.
4.3.11.3 Each device shall have its own analog to digital/digital to analog converter.
4.3.11.4 The display of each device shall preferably be paragraph type.
4.3.11.5 Controller shall be digital type capable on performing automatic control based on the set
points given locally or from a remote device like another controller or Distributed digital
Control System or Supervisory computer. The controller as an instrument shall also have
provision for manually controlling the process by means of a manual loader and cascade-
computer auto-manual transfer switch. The operation of the transfer switch shall be
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procedures-less and bumpless while changing mode from computer to cascade to manual
and from manual to auto to cascade to computer. During such a change the output shall
not change more than 1% of span. Controller shall have a facia giving continuous
indication of process variable, set value, controller output and controller mode. It shall be
possible to remove an instrument for maintenance without upsetting the process by use of
device like service station. Operation of the controller like set point change, manual
control, controller mode change shall be possible from the front of the controller.
Controller shall be flush panel mounting type on the panel/hard wired console.
Configuration and tuning of controller shall be possible through a portable and pluggable
configurator. The enclosure shall be general-purpose type. The Controller shall be
Intrinsically safe with external barriers. The Controller shall be capable of handling 4-20
mA signal and shall have self-diagnostic feature. The controller shall have local Bar graph
/ Digital display. The Controller shall have set point adjustment, manual loader and auto
tracking facilities. Other requirements shall be as per Controller & Data Acquisition
System specifications.
4.3.11.6 Recorder shall have independent circuit and pen drive assembly for each channel.
Recorder shall have capability of continuous line marking or digitized marking of input
value with high resolution. Recorder chart drives shall be of multi-speed type and shall be
operator selectable. Recorders shall be flush panel mounting type on the panel/hard wired
console.
4.3.11.7 Manual loader unit shall have continuous display of process variable and manual loader
output. It shall be possible to manually change the output to control valve. Manual
loaders shall be flush panel mounting type on the panel/hardwired console.
4.3.11.8 Temperature transducers and trip amplifiers shall accept inputs from standard industrial
thermocouples and resistance temperature detector. Linearisation of the thermocouples
and RTDs shall be done inside each instrument. Transducers and amplifiers shall be
suitable for rack mounting.
4.3.11.9 Alarm cards shall accept standard outputs and shall produce changeover contact output.
The alarm cards shall have SPDT contact. Each alarm card shall have one continuously
adjustable blind setting device. Alarm cards shall be suitable for rack mounting.
4.3.11.10 Hardwired pushbuttons with sealed contact housing shall be provided. These pushbuttons
shall have a silver alloy plated, make-before-break contact.
4.3.11.11 Trip amplifiers shall accept inputs from Grounded Thermocouples (types – T/E/K) & RTD
Pt 100. The maximum source resistance shall be 2000 ohms. Thermocouple burnout
protection shall be provided for both upscale as well as downscale readings. A field-
configurable, RTD open protection shall be provided. The contact type shall be SPDT
with a rating of 2 A @ 24 V DC. The trip amplifiers may be rack-mounted or surface-
mounted.
4.3.11.12 Signal isolators shall cater to 4-20 mA DC (2 wire) input signal and shall be capable of
generating an isolated 4-20 mA DC signal. Each signal isolator shall have two outputs.
The signal isolators may be rack-mounted or surface-mounted.
4.3.11.13 Alarm & Annunciator System
4.3.11.13.1 The alarm logics shall be plug-in modules. Where integral logic has been indicated, the
logic module shall be accessible from the front of the annunciator after opening the swing
door, the design of each module shall be such that by simply jumpering suitable point. It
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may be changed from normally open mode of operation to a normally closed mode of
operation and vice versa.
4.3.11.13.2 Lamps shall be replaceable from the front. The power consumption of each lamp shall
be approximately 10 watts.
4.3.11.13.3 The initiation of alarm condition in the annunciator shall take place approximately 330
milli second after the condition sensing contacts have assumed the off normal state. An
integral or separate alarm acknowledgement facility shall be provided.
4.3.11.13.4 Hooter, in general shall be solid-state type with audibility of the order of 100 db at a
distance of 3 meters. An interruption of power supply for a duration of 20 milli-seconds
or less shall not effect the functioning of the annunciator.
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4.3.13.11.1 Control panels, if required shall be non-graphic self supporting free standing
cubicle with back doors made up of sectional steel panels. Each section shall be
2100 mm high, 1200 mm wide and 1000 mm deep and shall be mounted on 100
mm high channel base. Care shall be taken to ensure that the face of the panel is
truly flat and smooth.
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4.3.13.11.2 Panels/hard wired console shall be fabricated preferably from 4 mm thick cold
rolled steel sheet. Angle iron frame shall use a minimum section of 50 x 50 x 4
mm angle.
4.3.13.11.3 Panel/hard wired console finish shall include sand blasting, grinding chemical
cleaning, surface finishing by suitable filler and two coats of high-grade lacquer
with wet sanding between coats. Two coats of paint in the panel color and final
coat shall be given after assembly at site for non-glossy high satin finish, colour of
the panels shall be as per job specifications.
4.3.13.11.4 Normal mounting heights on panel of instruments (centre lines of instruments to
floor) shall conform to the following, with minor adjustments depending upon
instruments selected.
• Miniature & sub-miniature Bottom Row 1100 mm
instruments
(3 rows) Middle Row 1350 mm
Top Row 1600 mm
• Annunciators 1950 mm
• Electrical Push Buttons 700 mm
4.3.13.11.5 Front of panel/console instrument nameplates shall be black laminated plastic
with white core. Nameplate shall be provided on the rear of the panel also for each
instrument.
4.3.14 REDUNDANCY:
4.3.14.1 Redundant Equipment:
4.3.14.2.1 The following requirements apply to those parts of a system identified in the
functional specification as redundant, except for historical data collection
hardware.
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• Failure of any one redundant part shall not interrupt other system
functions. A failure can be a hardware failure, software failure, power
supply failure or the loss of one AC feeder in a dual feeder system.
• Redundant equipment hardware and software shall be continuously
monitored for errors. Switchover to backup device shall occur
automatically upon failure of primary device. It shall be possible to
manually switchover (change from back up to active status) any redundant
module.
• Automatic switchovers shall not interrupt other system operations.
• Detection of failed equipment and automatic switchover to full operation
shall occur within the following times:
Maximum Allowable Fail over Time:
Function Seconds
Communication Device 3
Regulatory Control 3
Sequential Control 3
Supervisory Control 5
Input / Output Module 1
• Current operating parameters shall be continuously updated on backup
equipment so that only current process data is lost during switchover
• Switchback to repaired equipment shall be by manual command.
• Where multiple communications systems are used, failure on one system
shall not cause failure or adversely affect any other system. That is,
protection shall be provided to prevent failure of a device or a
communication system fro preventing communication to other devices or
other communication systems.
• It shall not be possible for an external or third party system connected
through a communications interface to interrupt operation of any device
within the system. There shall be security in these interfaces to limit
access of external systems.
• Redundant devices shall have two independent paths to the redundant data
communication system.
4.3.14.3 Monitoring of System Status:
4.3.14.3.1 All dual equipment and subsystems shall be continuously monitored for their
integrity. Automatic and manual switchovers shall be displayed, logged and
alarmed.
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4.3.14.3.2 The system shall continuously monitor and test all backup equipment to determine
whether backup equipment is capable of system control. If a failure is detected in
any backup equipment, the operator shall be notified and failure shall be logged.
4.3.15 SPARE REQUIREMENT:
4.3.15.1 Redundant capacity shall not be considered as spare capacity. The Distributed
Control System shall be delivered to the installation site with installed spare
capacities and future expansion capabilities as described in this specification.
4.3.15.2 Installed Spares:
4.3.15.2.1 Installed engineering spares of 20% shall be provided in each sub-system for each
type of module to enhance the system functional requirements including
programmable logic controller (if specified) and hardwired instrumentation.
4.3.15.2.2 Process I/O racks shall contain 20% installed spare I/O modules. Where
terminations are pre-wired to the process I/O, spares shall also be pre-wired to the
spare I/O.
4.3.15.3 Future Spare Capacity:
4.3.15.3.1 In addition to the installed spare capacity as given in clause 4.4.14.2 above, all
parts of the system shall have capability of further expansion by an additional 30%
to cater for future expansion. This shall include hardware, software, firmware and
communication.
4.3.15.3.2 The system shall have capability to extend its historical trending, logging and
user's memory by 30% to meet future expansion with/without adding additional
memory modules. Estimating tools to calculate the expected processing and
memory capacity usage shall be included with the system.
4.3.15.3.3 I/O racks of programmable logic controller shall have 20% usable spare space for
installing additional I/O cards of each type in future. However internal wiring for
the same shall be connected up to the I/O terminals.
4.3.15.3.4 Sufficient additional software capacity shall be available in the system to take care
of spares requirement as specified in this specification.
4.3.15.4 Processor, Memory and Communications Loading:
4.3.15.4.1 Contractors shall provide calculations demonstrating the design and future loading
of the processor, memory and communication systems to substantiate the following
requirements.
4.3.15.4.2 The expansions described above shall be possible without modifying or replacing
existing equipment communications cables or system operating software.
4.3.15.4.3 The installed communication system, including all the nodes required to interface
to the required systems shall have 25 percent node expansion capability for future
development, and still be capable of meeting the requirements of this specification.
4.3.15.4.4 System processing and memory capacity shall have 50 percent expansion
capability for future application programming and configuration including, but not
limited to:
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All fibre optic cable shall have 200 percent minimum spare fibres.
4.3.15.4.5
4.3.16 CONSUMABLES:
4.3.16.1 Any paper and ink required for printers, assignable recorders, video copier or any
other consumable item shall be supplied along with system required for minimum
of six months duration after system acceptance.
4.3.17 SPECIAL TOOLS:
4.3.17.1 Special tools if any shall be provided by the Contractor as a part of the system.
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5.5 The system as a whole shall be intrinsically safe based on entity concept. Intrinsic
safety shall be achieved via external Zener barriers. The selection of Zener barriers
shall be done based on the type of transmitter or I/P converter located in the field.
Any limitation or special requirements for cables to meet the intrinsic safety
requirement shall be brought out in the offer.
6.0 INSTALLATION REQUIREMENT:
6.1 Vendor shall offer the services of the installation team, which would install the
equipment in the control room, lay the interconnecting cabling inside the control
room, check out, test and commissioning the system.
6.2 All technical personnel assigned to the site by the Vendor shall be fully conversant
with the supplied system and software package, and shall have both hardware and
software capability to bring the system on line quickly and efficiently with a
minimum of interference with other concurrent construction and commissioning
activities.
6.3 Vendor's responsibility at site shall include all activities necessary to be performed
to complete the job as per material Requisition including:
a) Receipt of hardware/software and checking for completeness of supplies.
b) Installation of the system including free supply equipment and field cable
termination in the system.
c) Check out of the equipment installation.
d) Checking of interconnection, hardware & software configuration, overall
system functioning etc.
e) Loop checking.
f) Liaison with Vendor's home office.
g) Field tests
h) Commissioning and on-line debugging of the system.
i) Performance of final acceptance test.
6.4 The only exclusion from Vendor's responsibility shall include the following:
a) All civil works in the control room including false flooring, control room
lighting & air conditioning ducting.
b) Laying of Cables and identification of field cables
c) Field instrument installation and calibration.
7.0 INSPECTION AND TESTING:
7.1 General:
7.1.1 This Section defines the minimum requirements for inspection and testing of the
Distribute Control System, including all sub-systems, hardware and software.
7.1.2 On the basis of this specification, Vendor shall submit his own testing, installation,
commissioning and acceptance procedures for review and approval by the
Company.
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7.1.3 A complete plan for Factory and Site Acceptance Testing shall be submitted for
approval 8 weeks before the scheduled commencement of testing. This plan shall
be complete and in sufficient detail to indicate the exact nature and purpose of each
test, time required, type / definition of inputs expected results and step-by-step
procedure, and acceptance criteria. The plan shall include hardware and software
reliability testing requirements as well. For hardwares, the procedures shall include
purpose of test definition of input, procedure, results expected and acceptance
criteria. For software, it shall include details of the methods, list of tests, sequence
of execution, results expected and acceptance criteria.
7.1.4 The results of all tests including the Contractor’s internal tests, successful or not,
shall be available for inspection by the Company.
7.1.5 The Company / Company designated representative may choose to witness any or
all tests, including the Contractor’s own pre-acceptance tests. The Contractor shall
give at least two week’s prior notice of all testing.
7.1.6 Acceptance tests shall be conducted in thee stages:
• Pre-Factory Acceptance Test (PRE-FAT)
• Factory Acceptance Test (FAT) or staging test
• Site Acceptance Test (SAT)
7.2 PRE-FACTORY ACCEPTANCE TEST (PRE-FAT):
7.2.1 PRE-FAT for DCS shall be carried out by the vendor prior to FAT. All reports and
documentation on PRE-FAT shall be submitted to the Company 30 days in prior to
the commencement of FAT, for review by Company.
7.3 FACTORY ACCEPTANCE TEST (FAT):
7.3.1 The objectives of the FAT are to verify the DCS system (as configured for
delivery) meets or exceeds specified design and functional requirements. Tests
shall be conducted at the DCS staging site and shall be done according to Factory
Acceptance Test procedures for the project. These procedures shall include
hardware I/O simulation using the plant database, subsystem interface checkout
and performance checkout of any special gateways.
7.3.2 Before the system is delivered to the site, satisfactory performance of the entire
system shall be demonstrated. The system shall simulate the final onsite
configuration as closely as possible.
7.3.3 The Contractor shall have a technician and test equipment available full time
during testing.
7.3.4 The tests undertaken shall demonstrate each of the following responsibilities has
been fulfilled.
• The system has been tested as an integrated system
• The hardware and software responsibilities have been fulfilled
• All tests have been documented in a checklist fashion
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7.7.4 If a sub-system fails during the test and is not repaired and made successfully
operational within four hours of active repair time after the failure, the test shall be
suspended and restarted all over again only after the Vendor has replaced the
device into the acceptable operation.
7.8 FAT Procedures:
7.8.1 The inspection and factory acceptance shall be carried out in two phases i.e. Phase
I and Phase II. The minimum requirements for testing during these two phases are
as follows:
7.8.2 Phase –I:
7.8.2.1 Vendor shall perform tests at his works to ensure that all components function in
accordance with their respective specifications for each type of test. A test report
shall be submitted to the owner/consultant for review within two weeks of
completion of each type of test giving details. All sub-systems shall undergo a
minimum of 30 days burn-in period.
7.8.2.2 The test log book shall contain the following information about the tests:
a) Date/Time
b) Assembly designation/loop tag number
c) Test input
d) Test results and sign off with personnel name
e) Action required (if deficiency is detected)
f) Action taken, date of completion and sign off
g) Special test methods (including special equipment requirement,
bypasses used etc.)
7.8.2.3 Test details:
The Vendor shall perform the following tests and report shall be forwarded to the
owner/consultant.
7.8.2.3.1 Quality Control Test:
a) Quality control tests shall be carried out to assure quality of all components and
modules in accordance with Vendor's quality control and assurance procedures.
Vendor shall for ward the details of these procedures for owner/consultant's
review.
b) The sampling procedures for all purchased components or components
manufactured by the Vendor, for quality assurance tests shall be in accordance
with relevant international standards.
c) All assemblies shall be aligned and adjusted and all test observations shall be
recorded as manufactures published set ups and testing methods.
7.8.2.3.2 System power-up test:
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Vendor as a minimum shall check the functions of all the systems hardware and
software including diagnostic software at sub-system level by simulating the
inputs.
7.8.3 Phase-II:
7.8.3.1 This test shall systematically, fully & functionally test all the hardware and
software in the presence of purchase representative. All the sub-systems shall be
inter connected to simulate, as close as possible, the total integrated system.
Vendor purchased item e.g. programmable logic controller etc. shall also be
connected in the system. Barrier cabinets shall be used as the connecting points for
test inputs and outputs.
7.8.3.2 The duration of the testing shall be mentioned by the Vendor with reasons. System
shall be shipped to site only after this testing and certified ready for shipment by
owner/consultant.
7.8.3.3 Data review:
a) Owner/consultant shall perform a comparison of all current data. Any revision
or changes required shall be informed to the Vendor.
b) The test report/log book forwarded by Vendor after Phase-I testing shall be
reviewed. Owner/consultant has right to witness any test performed in Phase I,
if found necessary.
7.8.3.4 Testing record:
a) During testing of Phase II, each test carried out shall be recorded. Any
deficiency or problem shall be clearly brought-out and shall be corrected.
b) Any change in the data or configuration etc. informed to the Vendor shall be
recorded and carried out by the Vendor.
7.8.3.5 Visual and mechanical testing Visual and mechanical testing shall be carried out in
principle to assure correct, proper, good and neat workmanship by the Vendor.
7.8.3.6 Functional testing shall include the simulation of each input and output to verify
proper system response for both analog and discrete signals.
7.8.3.7 Complete system configuration loading:
7.8.3.7.1 Demonstration of all controller functions from local as well as from central
level e.g. changing of tuning constants, loop tuning, checking of algorithm
functions changing algorithms, changing controller mode, changing controller
action etc.
7.8.3.7.2 Checking of scan time values for controllers and data acquisition sub-system.
7.8.3.7.3 Checking of loop configuration for correctness with respect to ranges, limits,
alarm points, engineering, units etc.
7.8.3.7.4 Checking of all types of CRT / LCD TFT MONITOR displays including
process and system displays on operator and Engineering and PLC console.
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7.8.3.8 The Vendor shall notify the owner/consultant at least three weeks prior to final
system testing. In the event that representatives arrive and the system is not ready
for testing, the Vendor will be liable for back charges for any extra time and
expenses incurred.
7.8.4 Loop Checking:
7.8.4.1 Loop check shall be carried out by the Vendor and checking the interconnection,
configuration and over all system functioning.
7.8.4.2 Calibration and installation of field instruments, installation of junction boxes,
interconnection between instruments and junction boxes, laying of single multi pair
cables upto control room, tagging all field cables, performing continuity/insulation
test of cable, core identification of field cables etc. shall not be in the Vendor
scope. The field Contractor shall carry out this work.
7.8.4.3 Vendor scope of work in loop checking shall include termination of field cables in
control room, checking of interconnection between instrument/equipment
ferruling, tagging of interconnecting cables in control room, ferruling of field
cables in control room and performing overall loop performance check.
7.8.4.4 Loop checking shall be carried out to check the functional performance of all
elements comprising the loop and thereby ensuring proper configuration,
functioning and interconnection.
7.8.4.5 Vendor shall co-ordinate with the field Contractor for smooth and proper loop
checking. Any discrepancy found during checking shall be brought to the notice of
Engineer-in-Charge. All loop checking shall be performed in his or his authorised
representative presence. All readings shall be recorded on a suitable format and
shall be submitted for approval.
7.8.4.6 All the components of the loop shall be checked for proper functioning. All field
instruments connected to control room shall be loop checking at 0%, 25%, 50%,
75% & 100% of FS (for both increasing and decreasing signals) and the mode of
generating signal from the field shall be as follows for different instruments types
Types of Instrument Mode of Signal Generation
a) Differential pressure/flow By applying impulse to the primary
instruments/DP type level by squeeze bulb or regulator at field
insts.
b) Pressure instruments By applying impulse to the
instrument using instrument air
regulator & standard gage or using
portable hydro pump and standard
gage.
c) External Displacer Gauge shall be filled type level
instrument with water for different
levels and specific gravity correction
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shall be applied.
d) Other type of tank level By lifting the float level instruments
instruments for 0%, 100% of range.
e) Temperature loops with Appropriate mV signals shall be fed
thermocouple from thermocouple head
f) Temperature loops with Appropriate resistance shall be fed
RTD from RTD head
g) Field switches for Abnormality shall be alarm and
shutdown simulated by
disconnecting and connecting the
wires at field instrument end
h) Owner supplied items As per Engineer-in-Charge's
Instructions
i) Special instruments & any As per Engineer-in-Charge's
other type of instruments Instructions
7.8.4.7 Receiver alarms cards shall be checked for different settings on both increasing
and decreasing signals. Shutdown schemes shall be checked for proper
functioning, configuration and actuation. Performance of individual loops may be
accepted for an overall accuracy of ± 1% unless otherwise specified. Where
deviation exists, re-calibration of instruments, based on the scope of work, shall be
carried out either by field Contractor or Vendor.
7.8.4.8 Signal from controllers/shutdown schemes control valves/shutdown valves shall be
checked at the respective valves. The stroke checking including checking of time
of operation of control valves/shutdown valves also forms a part of loop checking.
7.8.4.9 After loop checking is completed, Vendor shall connect back any terminals and
connections removed for loop checking.
7.8.5 Field Testing:
All the equipment shall be checked thoroughly after its receipt at site. The tests, as
a minimum, shall include:
a) Visual and mechanical testing.
b) Complete system configuration loading.
c) Demonstration of all system functions.
d) Checking of loop configuration.
e) Checking of all CRT / LCD TFT MONITOR displays.
f) Checking of correct functioning of all keyboards.
g) Demonstration of all system diagnostics.
h) Checking of correct change over of redundant devices.
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i) Checking of bus-degradation.
j) Checking of proper functioning of all printers and hard copy units, sample
printing of all types of log reports, shutdown reports and MIS reports.
k) Checking of all disc drives, historical trending points, alarm summary and
alarm history.
l) Complete checking of shutdown system
m) Complete checking of hard-wired instruments.
n) Demonstration of proper operation of system at specified power supply
specifications.
o) Loading of user's program and check out of results.
7.8.6 FINAL ACCEPTANCE TEST:
The owner will take over the system from the Vendor after the final acceptance
test, which is defined as successful uninterrupted operation of the integrated
system for three weeks for all units of the plant. Vendor's personnel shall be
present during the test any malfunctioning of the system components shall be
replace/repaired as required. Para 2.1.6 shall be applied for failure of components
& readjustments. Once the system failure is detected, the acceptance test shall start
all over again from the beginning. The warranty period commences from the day
owner takes over the system.
7.9 SITE ACCEPTANCE TEST:
7.9.1 The objective of the SAT is to verify the “as installed” DCS meets or exceeds
specified structural and functional requirements. The SAT shall be conducted in
two phases. The first phase shall consist of post installation inspection and
software module testing. The second phase shall be an abbreviated version of the
FAT. Tests shall verify that all equipment, interconnecting cables, external power
connections and grounding connections have been installed correctly. Data
communication cables installed by others shall be tested.
7.9.2 The SAT shall essentially be a repeat of the FAT with the following additions:
• The connecting wiring between distributed components shall be the actual field
installed wiring and cable
• The field inputs and shutdown devices shall be connected and exercised to
confirm the correct connection and compatibility of the field components
• The system will be interfaced with other systems (Package Contractor PLC’s
etc.)
• Electrical Installation Test as described below:
Electrical systems shall be tested for insulation resistance, correct
polarity and continuity. To prevent damage to electronic and extra-low-
voltage equipment all such equipment shall be disconnected at both
ends of the cable prior to the cable test and reconnected prior to the
functional test of the system
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Grounding shall be tested for faults, continuity and conformity with the
Contractor’s requirements
Terminations, glands, junction boxes and equipment enclosures shall be
inspected for correct application, installation assembly and closure.
Power supply tests over the required range
Series and common mode noise rejection on input signals to required
specifications
7.10 Shop Inspections:
7.10.1 The Company’s designated representative shall be entitled to inspect equipment,
materials and any part at the Contractor or any subsupplier’s premises during any
phase of manufacturing. Inspecting visits shall be coordinated through the
Contractor’s project manager. The Company shall have access to all quality
control and other records that document design, testing and integration of the
system. Photographs shall be permitted during system assembly to record progress
of manufacture with reasonable advance notice.
7.11 Quality Control Procedures:
7.11.1 The Contractor shall apply to the project a total quality assurance (QA) program
covering design conception, software implementation, assembly, testing and
delivery.
7.11.2 This QA program shall be based on ISO 9000 Standards such as ISO 9001 (1994),
ISO 9004-1 (1994) and ISO 9000-03 (1991) and shall have current third party
certification from a recognized body.
8.0 DOCUMENTATION:
8.1 General:
8.1.1 The documentation requirements shall in general be according to clause 3.6.6.2 of
Instrumentation Design Criteria.
8.1.2 Duly filled in data sheets shall be furnished along with the purchase specification.
Typical data sheets are provided as Annexure – 1 to 16 of this document.
8.1.3 Documentation shall include a functional design document that is developed in
conjunction with the Contractor. This document represents the agreed system
definition prior the beginning of fabrication. There shall also be a detailed design
document that provides details of the functional design and includes, but is not
limited to, the following:
• List of equipment and accessories on system drawings
• System overview drawings, cabinet and console layout and arrangement
drawings
• Module arrangement, insert drawings and internal arrangement drawings
for all system cabinets
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8.2.5 Documentation shall include updates for any and all system upgrades,
modifications, documentation errors or bugs discovered by the project. Contractor
or other users of the system projects. These updates shall extend through to
expiration of the warranty and any extended service or maintenance agreements
purchased.
8.3 Documentation for Contractor Services:
8.3.1 The Contractor shall provide a comprehensive suite of documentation for the DCS,
including standard documents, as well as a Functional Specification and other
documents, which are specific to the system described by this specification and its
references and attachments.
8.3.2 These documents shall include the requirements described below and shall be
submitted for review at the times specified in the requisition. The Contractor shall
also provide accurate “as-built” issues of all documents at the completion of
commissioning.
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8.3.3 All documentation for configuration, programming and other related project
engineering services shall be provided. As a minimum these shall include:
• System configuration diagrams and workstation assignments
• Source code for all application code written for this system
• Cross reference listings of tags, tag descriptors and addresses for all
elements of the system
• I/O assignment list
• Copies of graphics and printouts of reports and logs
• Documentation of completed FAT, SAT and SPT test results
8.3.4 All application software shall be well documented. Word processor files of all
application software documentation shall be provided on CD ROMs in addition to
printed descriptions.
8.3.5 Software coding and documentation shall be in English, including code syntax and
comments in the source code, and error messages.
8.3.6 The following shall be provided for all control strategies to supplement the
representations of applications on software listings, instrument loop diagrams and
P&ID’s:
• Functional diagrams
• Narrative descriptions of strategy and functionally and engineering
information including derivations of constants
• Implementation description for all elements, control processor blocks or
high level language programming elements
9.0 TRAINING:
9.1 Training System:
9.1.1 The Contractor’s scope shall include the provision of a training system, including
the following:
• One fully configured system processor and I/O cabinet
• Simulator to allow realistic simulation of actual operations
• A fully configured operator station, including data storage/archiving
facility.
• A second workstation providing access for system maintenance and
engineering
• A dual data highway network
9.1.2 The system shall be a stand-alone entire operating system, complete with all type
of I/O, processors and communications hardware and software used on the actual
system.
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9.1.3 The training system will be connected to an SIS training PLC of the same type
used for the ESD and F&G systems and will provide training access to that system.
10 TAGGING & NAMEPLATES:
10.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1
of Instrumentation Design Criteria.
11 REVIEW & APPROVAL:
11.1 Review and approval of purchase specifications and other related documents shall
in general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
12 VENDOR PRE-QUALIFICATION REQUIREMENTS:
12.1 The Vendor pre-qualification requirements shall in general be according to clause
3.6.6.4 of Instrumentation Design Criteria.
13 PREPARATION FOR SHIPMENT:
13.1 The DCS shall be prepared for shipment in accordance to clause 3.6.6.5 of
Instrumentation Design Criteria.
14 RECEIPT & STORAGE:
14.1 Receipt and storage of the DCS shall be in accordance to clause 3.6.6.6 of
Instrumentation Design Criteria.
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v) MIS reports
vi) User memory
vii) No. of digital I/Os for PLC
f) Scope of Vendor’s responsibility
i) Design & Supply
ii) System Engineering
iii) Installation
iv) Commissioning
v) Training
Salient features of the offered system over earlier
8.
systems, if any
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ANNEXURE 3
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1. Communication Topology
5. Type of communication
6. Type of protocol
7. Communication speed
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5. Memory size
6. Model number
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3. Printing speed
6. Paper feed
7. Mounting
8. Cord length
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3. Number of channels
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5. Type of interface
6. Type of redundancy
12. Time taken to transfer data from foreign device to operator console
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3. Power supply
4. Logic unit (integral / separate)
5. Display type
6. Window size
7. Hooter (External to DCS / Solid state)
8. Alarm acknowledgement (integral / separate)
C) Hardware Switches / Pushbuttons:
1. Make
2. Model Number
3. Contact type
4. Contact housing
5. Contact rating
D) Receiver Switches (Alarm Card):
1. Make
2. Model number
3. Type of input
4. Type of contact
5. Contact rating
6. Number of settings per module
7. Power supply
8. Mounting
E) Trip Amplifier:
1. Make
2. Model number
3. Type of input
4. Source resistance
5. Thermocouple burn out protection
6. RTD open protection
7. Type of contact
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2. Location
4. Power supply
6. Grounding
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d) Panel finish
13. Constructional Details:
a) Material of front plate
b) Material of top plates
c) Material of system cabinet front, sides & top
d) Material of door panel
e) Anchor bolt size
f) Frame angle size
g) Lifting eye bolt Yes / No
h) Card rack size
i) Card rack type
14. Wiring:
a) Size of power supply wiring used external to cabinet / panel
b) Type of insulation for power supply wiring used external to cabinet/panel
c) Size of signal wiring used inside cabinet / panel
d) Type of insulation for signal wiring used inside the cabinet / panel
e) Size of signal wiring external to cabinet / panel
f) Type of insulation for signal wiring external to the cabinet / panel
g) Terminal type
h) Terminal size for signal wiring
i) Terminal size for power distribution
j) Terminal block type
15. Power Distribution Box:
a) Location
b) Power supply isolation
c) Fuse type / rating
d) Switch type / rating
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 1 of 26
FUNCTIONAL SPECIFICATION
FOR
PROGRAMMABLE LOGIC
CONTROLLER
(PLC)
Rev-1: Revised for scan time of 250 mSec, LCD Monitor & DO Contact Ratings.
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
AK BK GRP 25 28.03.2007 1
MC MC AC 25 17.03.2003 0
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 2 of 26
CONTENTS
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 3 of 26
1.1 This specification describes the essential considerations in the selection, installation,
calibration, testing and commissioning of Programmable Logic Controllers (PLC). This
specification is applicable to PLC for package equipment, PLC for Safety Systems such
as ESD, FSD and F & G, and PLC for plant safety shutdown logics as a part of DCS.
1.2 The Contractor shall be responsible for the design, manufacture, configuration,
installation, testing, operational functionality, training, shipment to yard and offshore
site, installation and commissioning at site, documentation and support for the PLC.
3.1 The PLC System shall include all the sub-systems described in this specification,
Engineering software, two note book computers and all necessary interfaces for
maintenance modifications, monitoring, testing and troubleshooting.
3.2 The scope of supply shall also include commissioning spares and two years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer. The scope of supply shall also include spare parts for start-up and
commissioning, spare parts for two years’ operation, consumables for six (6) months
and all special tools as well as complete spare system for training.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.1 GENERAL:
4.1.1 Use Of Standard Products:
4.1.1.1 The PLC shall be chosen for simplicity, use of established proven components, use of
techniques that minimize the need for maintenance, ease of configuration and overall
integrity of design.
4.1.1.2 The system shall be microprocessor based and shall be composed of standard hardware
and system software, which can be configured to meet the stated requirements.
4.1.1.3 The standard operating system software shall not require modification to meet any of
the project requirements.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 5 of 26
4.2.1 The PLC shall be “Fault avoidant” and shall be based on high-reliability, high-
availability programmable electronic systems.
4.2.2 PLC envisaged for safety-related functions, such as ESD-FSD PLC and F&G PLC shall
be certified to TUV AK 6, and shall be suitable for use on systems requiring SIL 3
integrity in accordance with IEC-61508.
4.2.3 The overall system availability of the PLC shall be 99.99% or better. Single point
component failure shall not result in the loss of availability of entire PLC.
4.2.4.1 The I/O modules shall be mounted in the I/O racks located in the Control Room. The
maximum number of Input/Output per I/O module shall be limited as per the following
table.
Sr. No. Type of configuration No. of I/Os
4.2.4.2 Each I/O shall be galvanically isolated from external control circuit by suitable means.
The minimum isolation level between I/O and logic circuit shall be 1000 volts DC.
4.2.4.3 Each I/O shall be protected against the reversal of polarity of the power voltage to I/O.
4.2.4.4 Each I/O module shall have a LED per channel to indicate the status of each
Input/Output.
4.2.4.5 Each input shall be provided with filters to filter out any noise in the input line and
contact bouncing noise.
4.2.4.6 The PLC inputs shall be provided with only dry contacts (Potential free) unless
otherwise specified. All the inputs shall preferably be double ended i.e. two wires per
input and not with common return for all inputs.
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.4.7 The interrogation voltage to the input contacts shall be powered from separate power
supply / supplies and shall not be a part of PLC, unless otherwise specified. This power
supply shall be supplied at one point and shall be distributed by the Vendor.
4.2.4.8 In case of triple redundant system, if standard system architecture does not allow
triplicated signal conditioning circuits per I/O, dual redundant signal conditioning
circuits shall be provided per I/O.
4.2.4.9 Output contacts from the PLC shall be potential free dry contacts with contact rating as
per para 5.6.8.1.10. Wet contacts/powered contacts/TTL outputs etc. shall not be
acceptable. Vendor must provide arc suppression device for each output contact.
However, LSTK contractor shall, during design and detailed engineering stage
of the contract, propose the electrical scheme and the Voltage ratings for the
“Output Contact ratings” based on the electrical system / Switchgears selected,
and submit the same for Client’s approvals.
4.2.4.11 Each output shall be short circuit proof and protected by fuse. Visual indication of fuse
blown must be provided for each module.
4.2.4.12 The communication of I/O system with central processor shall be carried out redundant
with complete error checking.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.4.13 Wherever redundant communication bus and communication interface of I/O subsystem
with central processor are specified, Vendor must ensure that healthiness of each
redundant module is monitored.
4.2.4.14 It shall be possible to exchange I/O modules while the system is in operation:
a) Without influencing other logic function than the one's which are
covered by the I/O modules being exchanged for single I/O
configuration.
b) Without upsetting the process for dual I/O or dual PLC configuration.
4.2.5.1 The processor shall have capability to implement all the control functions required to
implement the logic scheme attached along with as logic/ladder diagram.
4.2.5.2 The size of the memory shall be sufficient for storage of the program instructions
required by the logic schemes and other functional requirements. Offer shall indicate
the amount of memory capacity occupied by the actual program and spare capacity
available for later program modifications or additions.
4.2.5.3 Memory shall be non-volatile. However in case volatile memory is provided, battery
back up shall be provided with a minimum of 3 months lifetime to keep the program
storage intact. A battery drain indication shall be provided at least one week before the
battery gets drained. A potential free contact shall be provided for hardwired
annunciation in the central control room.
4.2.5.4 Watchdog timer shall be a software device. Watchdog timer shall continuously monitor
the healthiness of processors. Any hardware or software problem in the processor
system, which shall include, CPU, memory, power supply, communication interface etc.
shall cause the watch dog timer to report processor failure.
4.2.5.5 Wherever dual redundant processor is specified, redundancy shall be provided in such a
way that in case of failure of the main processor, the standby shall take over
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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automatically. The changeover shall bump less and the system shall be fail proof,
unless any other requirement is specified in the job specifications. Redundancy shall be
provided for complete processor system including CPU, memory power supply and
communication sub system.
4.2.5.6 In case of triple redundant system all the three processor shall execute the same
instructions / programs and check their results and majority vote to correct any faulty
result. The faulty processor diagnostic shall be made available.
4.2.5.7 Failure of a single processor shall not affect the system. In case of failure of complete
processor system i.e. both processors in case of dual configuration and two or more in
case of triple redundant system outputs shall take fail-safe state automatically.
4.2.5.9 It shall be possible to generate the first out alarm contact by the PLC in case where a
group of parameters are likely to trip a system
4.2.6.1 The PLC Console shall be used for programming, program storing, fault diagnostics and
alarm monitoring. It shall also be possible to use this for plant operation, whenever
specified.
4.2.6.2 It shall consist of a single colour 19" size TFT LCD Monitor (also referred as Monitor)
screen unless otherwise specified and one programming keyboard and printer and
operating keyboard whenever specified.
4.2.6.3 PLC console when used for plant operation shall be supplied with dedicated operator
keyboard. Even when touch screen is specified, the console in addition must be
supplied with operator keyboard, which shall have the same capability as the touch
screen as a minimum.
4.2.6.4 The keyboard shall preferably be touch sensitive sealed type, easy to operate with each
key clearly identified. It shall be provided with a lock and key to prevent any un-
intentional program modifications.
4.2.6.5 All illegal entries shall be rejected by the terminal and shall be identified by warning
signal on Monitor.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.6.6 Manual forcing of any input or output contact connected to PLC shall be possible from
keyboard.
4.2.6.7 It shall be possible to modify, add or delete the application program on line without
affecting the outputs.
4.2.6.8 PLC Console Monitor shall display logic and/or ladder diagram indicating power flow
and shall show description and status of each contact. It shall also be possible to
display process alarms and diagnostic messages as and when they appear. Further it
shall also be able to display I/O map in a user-defined format.
4.2.6.9 Whenever PLC console is used for the operation of the plant, it shall be able to display
process dynamic graphics, overview and group display. It shall also be possible to
operate the plant i.e. start and stop of rotating machinery, opening and closing of valves
etc. from dynamic graphics and group displays. All such displays shall be user
configurable.
4.2.6.10 It shall be possible to print out the ladder/logic diagram on the dedicated PLC printer.
The Printer in addition shall also print out:
4.2.6.11 The PLC console shall be provided with self-diagnostics feature, which shall display
error messages and initiate an audible alarm if the fault is detected. A potential free
contact for diagnostic group alarm shall be provided which shall be connected to the
hardwired alarm and annunciator system.
4.2.6.12 In addition, a service unit or hand held programming unit for trouble shooting and
initial check-ups from local level shall be quoted separately.
4.2.6.13 The system shall be able to identify the failure at least upto the any module level
including I/O system and redundant processor through detailed TFT LCD Monitor
display and report print out.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.6.14 Isolation shall be provided between the programming panel and related subsystems if
there is any possibility of high voltage from MONITOR being transmitted to other
subsystems.
4.2.7.1 The PLC communication subsystem shall be a digital communication bus that provides
a high speed data transfer rapidly and reliably between the processor, I/O Sub-system,
PLC console and other devices connected in the PLC System. The PLC shall
communicate with the DCS via dual serial interfaces to the DCS dual redundant data
highway.
4.2.7.2 Safety-related shutdown signals to and from the PLC shall be via hard-wired I/O, not
via the data highway or other communications link.
4.2.7.3 Failure of equipment associated with communications shall not affect any aspect of the
PLC functionality.
b) For dual I/O configuration, each I/O sub set shall have separate
communication interface and bus for connecting to PLC processor.
c) For the triple redundant system, each processor shall have a separate set of
PLC communication subsystem.
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Design Division
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Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.7.6 The mechanism used by the system for error checks and control shall be transparent to
the application information/program. Error checking shall be done on all data transfers
by suitable codes.
a) Display of all input points under alarm/first out alarm connected to PLC or
generated by PLC on the main operator console.
c) To receive certain operating commands from the operator console for the
operation of certain output devices connected to PLC.
4.2.8.1 Redundant capacity shall not be considered spare capacity. The PLC shall be delivered
to the installation site with the following minimum spare capacity and expansion
capabilities:
• I/O Racks shall contain 20% installed spare I/O modules.
1) Module types shall be provided in the approximate ratio of non-spare
types and distributed throughout I/O racks.
2) Other system components to support installed spare I/O, such as I/O
power supply capacity, terminal blocks, I/O cables, I/O communications,
etc., shall be installed with capacity for all installed I/O plus an
additional 20% spare capacity.
3) If terminal blocks are pre-wired to the process I/O, then these shall also
be pre-wired to the spare I/O.
• I/O Racks shall have an additional 20% spare rack space without installed
modules.
• Processing modules shall be sized so that the average load uses no more than
60% of the processing capacity and memory. Historical storage shall have 75%
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Design Division
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Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.8.3 Paper and ink required for printers, copier or any other consumable item shall be
supplied with the system required for minimum of six (6) months durations.
4.2.8.4 Safety barriers shall be provided for intrinsically safe input/output circuits wherever
specified. In such cases, the system shall be designed intrinsically safe based on entity
concept. The barriers shall be certified by a statutory authority like BASEEFA,
CENELEC, FM, PTB, CMRI etc., for use in the area classification as specified
elsewhere in the job specifications. The proper selection of the safety barriers shall be
the Vendor's total responsibility.
4.2.9.1 The following shall apply when dealing with maintenance bypasses:
• Maintenance bypasses shall form part of the overall PLC design, to meet
maintenance and testing requirements. System design shall minimize the
requirement for bypasses, consistent with maintaining the required system
integrity.
• Under no circumstances shall manual emergency shutdown switches be
bypassed.
• Maintenance bypass switches shall be implemented by hard-wired manual
switches directly connected to the PLC as digital input signal, and bypass
functionality shall be carried out by the PLC’s application software.
• Maintenance bypass switches shall not operate multiple bypass functions.
• The system shall be configured so that only one maintenance bypass can be
activated at a time.
• Operation of any bypass switch shall be logged on the PLC and the DCS event
loggers and shall initiate a DCS alarm, a common alarm on the hard-wired
annunciator.
• Bypass switches shall not inhibit associated process alarms.
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Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.9.2 The following shall apply when dealing with start-up bypasses:
• System design shall minimize the need for start-up bypasses.
• Start-up bypasses shall be initiated from soft-switches of the DCS stations in the
Central Control Room.
• Start-up bypasses shall be automatically reset by a time-out or by the associated
process parameter reaching normal limits.
• Start-up bypass time-out values shall be minimized, and shall be evaluated
during risk evaluation and HAZOP. Adjustment of start-up time-outs shall not
be available to operators.
• Start-up bypasses shall be alarmed and displayed to the operator on the DCS.
• A hard-wired key switch shall be provided to prevent unauthorized operation of
the Start-up bypass system.
4.2.10.1 All PLC system cabinets shall be completely wired with all modules in place. Inside
cabinet wiring shall preferably be done using ribbon type pre-fabricated cables.
4.2.10.2 All the cabinets shall be free standing, enclosed type and shall be designed for bottom
entry of cables. Cabinet structure shall be sound and rigid and shall be provided with
removable lifting lugs to permit lifting of the cabinets.
4.2.10.3 Cabinets shall be fabricated from cold rolled steel sheets of minimum 2 mm thickness
suitably reinforced to prevent warping and buckling. Doors shall be fabricated from
cold rolled steel sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly
devoid of all sharp edges shall be grounded smooth after fabrication.
4.2.10.4 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filter and two coats of high grade lacquer with wet sanding between two
coats. Three coats of paint in the cabinet colour shall be given for non-glossy high satin
finish. Colour of the cabinets shall be as per job specification.
4.2.10.5 Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base), 1200
mm wide and 1000 mm deep, in general. Construction shall be modular preferably to
accommodate 19" standard electrical racks. All cabinets shall be of same height.
Maximum swing out for pivoted card racks, doors and drawers shall be limited to 600
mm. Dimensions given here are indicative/ tentative only, bidder shall take prior
approval from the company for the finalization of dimensions of cabinet at the time of
Detail Engg.
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Design Division
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Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.2.10.6 Cabinets shall be equipped with front and rear access doors,. Doors shall be equipped
with lockable handles and concealed hinges with pull pins for easy door removal.
4.2.10.7 In order to remove dissipated heat effectively from cabinets, yent louvres backed by
wire fly screen shall be provided in cabinet doors. Further, ventilation fans shall be
provided, if required.
4.2.10.8 Illumination shall be provided for all cabinets by incandescent lamps, which shall be
operated by door switch.
4.2.10.9 Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided for incoming and outgoing cables to prevent
excessive stress on the individual terminals. All metal parts of the cabinet shall be
electrically continuous and shall be provided with a common grounding lug.
4.2.10.10 Each I/O module shall be provided with separate terminals for individual inputs
and outputs. All inter cubicle and internal signal wiring shall be done using minimum 1
mm2 stranded copper conductor, and power wiring shall be done using minimum 1.5
mm2 stranded copper conductor. All terminals shall be suitable for minimum 2 mm2
cables.
4.3.1 The system software shall include all programs for the PLC and PLC console which are
required to perform all PLC functions including communication and self-diagnostics.
4.3.2 All operating and application software shall be the latest revision of all proprietary
software. The Contractor shall provide any new revisions of software during the
development of the project.
4.3.3 Logic program shall be recorded on the floppy disc or cassette tape, which shall be
delivered in duplicate together with the system.
4.3.4 The PLC programming language for implementation of logic operations shall be based
on the following representations:
a)) Logic diagrams - Binary logic symbols such as AND, OR, NOT Gates,
Timers and Flip Flops.
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Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.3.5 Details of the diagnostic package and its related equipment and software shall be
supplied by the Vendor with the offer. A list of additional diagnostic packages
available including their description and capabilities shall be provided as a separate
quote.
4.3.6 It shall be possible to print out the ladder/logic diagram on a dedicated printer. The
printer shall also print out all diagnostic reports. Vendor must supply the off line
software package to enable the owner to modify/add/delete any part of program and for
documentation.
4.3.7 Software for the generation of various displays including dynamic graphics, whenever
specified shall be provided.
4.3.8 The software for printing alarms, system as well as process and events on the PLC
printer must be provided. All alarms must be printed as and then they appear.
4.3.9 Software package for displaying I/O map showing status of inputs and corresponding
output as per logic shall be offered. The I/O map format shall be user definable.
4.3.10 System software for the report generation for reports like hourly, on demand, per shift,
daily and weekly report shall be provided in the user-defined format.
4.3.11 Software for printing system as well as process alarms and events shall be provided.
All alarms shall be printed as and when they appear.
4.3.12 All details and description shall be provided for the software package including the on-
line I/O testing software.
4.3.13 The system shall have an extensive set of self diagnostic routines which shall be able to
identify the system failure at least upto module level including redundant components
and power supplies through detailed MONITOR displays and report print out.
Diagnostic software shall have the capability to provide information about the failed
modules/system either in the form of a system configuration display or provide
information in the form of a statement.
4.3.14 Automatic self-testing and system diagnostics shall be incorporated in the PLC
configuration. At the local level, failure of a module in any subsystem shall be
identified by an individual LED. All testing and system diagnostics shall be a proven
integral part of the standard system and shall be completely transparent to the user when
the application is implemented. Self-diagnostic software shall have capability to detect
faults which make the system permanently close/open in the I/O modules or I/O signal
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Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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conditioning modules (in case of triple redundant system). This may be achieved by
automatically running the testing software at cyclic intervals. The automatic cyclic
testing feature shall also be provided for dual I/O configuration and dual I/O signal
conditioning for triple redundant system. The testing software cycle time may be field
adjust able by engineer. However, system performance shall not be degraded whenever
testing feature is specified.
4.3.15 System diagnostics shall identify all possible faults and provide a means to annunciate
diagnosed malfunctions. An alarm shall be initiated in the event of any malfunction or
authorized maintenance procedure, which as a minimum, shall consist of the following:
• Removal of, or any defect in, any logic unit, communication module or
processor
• Removal of, or any defect in, any input or output module, channel on a module
or I/O interface device.
• Power supply failure
4.3.16.2 As a minimum the following basic functions shall be verified by on-line testing:
• Individual check of the system’s ability to change the state of an input channel
• Individual check of the system’s ability to change the state of an output channel,
i.e., loop back testing feature
• Check of the logic-solving ability
• Standard PLC diagnostics (watchdog, etc.)
• Power-up initialization checks and checks for communication failures.
• Testing of field wiring and End-of-line devices (ELDs)
4.3.16.3 The frequency of the self-diagnostic tests shall be required to provide 99.99% system
availability.
4.3.17 In case of dual I/O or dual signal conditioning modules for triple redundant system,
whenever output module testing software detects any faulty channel, the power supply
to that particular module in that particular bank is removed automatically and further
testing on the corresponding module in the other mirror image bank is stopped.
However, the testing shall continue uninterruptedly in other output modules. Testing
software shall be capable of detecting faults in case of normally closed system as well
as in normally open system.
4.3.18 Feedback must be provided in case of triple redundant system from the output voter
system to detect any latest faults of the system in addition to other diagnostic software.
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Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.3.19 Diagnostic package and its related equipment and software shall be supplied. A list of
additional diagnostic packages available and the packages provided, including the
description and capabilities shall be provided with separate quote.
4.3.20.1 The protective system implemented by a PLC shall be adequately protected against
unauthorized access by key-lock or password or a combination of both.
4.3.21 Application Software:
4.3.21.1 The configuration language shall feature the choice of ladder, functional logic block,
sequential function chart or structured text programming, and shall comply with IEC-
61131.
4.3.21.2 Functional logic blocks shall be pre-defined as standard for the system. The Contractor
shall submit the proposed format to the Company for approval prior to implementation.
4.3.21.3 Logic blocks may be used when a function block is not available.
4.3.21.4 Combination logic implementation shall use functional logic diagrams or cause and
effect charts.
4.3.21.6 Whichever method is chosen, the representation shall be kept as simple as possible to
allow participation by non-control system specialists such as operations, loss prevention
and process engineers.
4.3.22 Consideration shall be given to using application development tools that allow the PLC
application software to be presented in one of the preferred methods to enable the
project to:
• Eliminate a large portion of work through the design phase
• Eliminate coding errors in not having to translate the application specification
from a functional logic diagram to ladder code
• Provide effective documentation.
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Design Division
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Discipline: Instrumentation
ISO – 9001:2000 Controller
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• A system configuration
• Logic or ladder diagrams
• A cross-referenced listing of tag numbers and program use locations
• The application software shall be structured and annotated to provide anyone
with a good understanding of the protection implemented.
4.3.25 All networks shall be fully annotated including logic description, alarm and trip set
points and point tag numbers. This shall appear on the maintenance / engineering PC
and hard copy printouts.
4.3.26 It shall be possible to download at least minor changes in software from the
programming terminal to the protective system while it is on-line without disturbing the
operation of the plant. Adequate testing procedure shall be available to verify the new
logic prior to activating it in the on-line program.
4.3.27 The Contractor shall provide a complete list of the limitations to on-line changes.
4.3.28 Software changes throughout all phases of the project shall be controlled in accordance
to IEC-61508.
4.3.29 Key lock and password protection shall be provided to prevent downloading of altered
software to the operating PLC, and unauthorized software code on the programming
terminal.
4.3.30 The application software shall not use more than 60% of the available system memory.
The central processing unit shall, under normal working conditions, be less than 50%
loaded. This loading shall be demonstrated during FAT. Worst-case conditions shall
also be simulated to determine if degradation of loading is within acceptable limits.
These include multiple alarms, automatic shutdowns and so forth.
4.3.31 Sequence of Events (SOE) handling shall be implemented so that time and date
stamping provides a correct sequence for troubleshooting. The PLC shall perform SOE
recording but the display shall be via the Engineering workstation. The DCS shall not
be used as SOE recorder. SOE resolution shall be 1 millisecond. The PLC shall be
provided with access to the local printer for printing SOE logged data, programme
listings, systems alarms and the like.
4.3.32.1 Normal access to the system for operations purposes shall be from the DCS
workstations.
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ISO – 9001:2000 Controller
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4.3.32.2 If engineering and maintenance functions cannot be accessed from the DCS
workstation, a separate engineering workstation computer shall be provided at each
PLC location.
4.3.32.3 The System shall allow application software to be developed and tested off-line on the
Engineering Workstation.
4.3.32.4 Failure of any component in the operator interface shall not cause a spurious shutdown,
nor shall the component failure go undetected.
4.4.1 The power supply configuration to the PLC shall be kept as simple as practical.
Complex external mechanical change over system using contactors shall not be used.
4.4.2 The PLC shall use supplies from 24VDC battery systems, to reduce the UPS
requirements. The 24 V DC battery power shall be provided with dual 50% battery
banks and dual chargers.
4.4.3 Operation of PLC shall be completely unaffected by a momentary loss of power of the
order of 20m sec.
4.4.4 The primary power source to the PLC shall be capable of supplying power for nominal
periods of not less than 2 hours for the ESD PLC and 24 hours for the F&G PLC.
These periods shall be confirmed by the Contractor following project risk assessments
and HAZOP.
4.4.5 The PLC and its sub-components shall be selected so that two supply sources can be
connected; the power supply paralleling shall be integral to the equipment design. This
eliminates the need for complicated paralleling schemes in the electrical supply
configuration and thus a common point of failure.
4.4.6 The primary power supply system for the PLC shall have at least one common alarm as
an input to the PLC or the facility DCS so that any fault on the power supply systems is
annunciated in a permanently manned location. The common alarm shall annunciate at
least loss of supply to the system, charging system fault and low battery voltage.
4.4.7 The primary power supply shall be sized to the requirement of the installed load with
approximately 50% excess capacity for the manufacturer’s design life of the batteries.
4.4.8 The electrical distribution to the PLC and its sub-components, including the distribution
network for interrogation voltage, shall be arranged so that there is no single point of
failure that will affect the availability of the system.
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Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.4.9 The PLC shall be suitable for correct operation in the event of the following supply
variations:
• Voltage depression to 80% of system voltage for up to 10 seconds during motor
starting
• System frequency tolerance of +/- 1% coincident with the AC voltage variation
4.4.10 Each I/O rack shall have a separate independent power supply system. Each power
supply shall be sized to take full load of the I/O rack/signal conditioning panel/rack and
shall be provided with dual redundant power supply. Suitable battery back up shall be
provided to protect volatile memory.
4.4.11 In general all output contacts and solenoids shall be powered with 110V + 10% dc /
24V ± 10% dc power supply. However, the actual interrogation voltages shall be as per
job specifications and logic diagrams.
4.4.12 Sequential starting of various load centers shall be provided whenever required.
4.4.13 Power distribution network shall use bus bars of adequate capacity with DPDT switches
and HRC (high rupture capacity) fuses in each branch network. Vendor may select
circuit breaker if short circuit characteristics do not match the HRC fuse.
4.4.15.1 Each cabinet, console and other equipment supplied, as a part of PLC system shall be
provided with an earthing lug. All these lugs shall be properly secured to the AC mains
earthing bus.
4.4.15.2 All circuit grounds, shields and drain wires of control cables shall be connected to the
system ground bus which shall be electrically isolated from AC mains earthing bus.
This bus shall be typically of 25 mm wide and 6 mm thick of copper.
4.4.15.3 All barriers, if used, shall be securely grounded. Safety barrier ground wire shall be
capable of carrying a maximum fault level current of 0.5 A at 250 r.m.s. per barrier.
4.5.1 The PLC used for safety-related / shutdown functions shall execute the following
distinct shutdown levels:
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.5.2
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
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4.5.2.1.2 Pre-shutdown alarms shall be generated and displayed by the plant DCS. Generally
these will be generated by the field devices connected to the DCS that monitor the same
process variable as the PLC shutdown initiation device.
4.5.2.1.3 Shutdown alarms displayed by the DCS shall be initiated by the same logic that
implements the shutdown. The DCS inputs shall provide an independent and positive
indication that a PLC has executed a shutdown.
4.5.2.1.4 Consideration shall be given to the technology of expert systems to enhance alarming.
Features shall include:
• Qualifying individual alarms by comparing against other input criteria
• Providing criteria for rate of change
• Predicting when a dangerous condition is about to occur and cutting back on
critical variables to bring the process or equipment into a safe operating region
4.5.2.2.2 Alarms from the F&G PLC shall be clearly segregated from those from the ESD PLC.
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 23 of 26
functionality, the test feature shall be directly built into the PLC, thus testing the entire
system.
5.0 EQUIPMENT PROTECTION:
5.1.1 The PLC shall in general be housed in pressurized, air-conditioned rooms, with
temperature and humidity maintained within the ranges 21-24 deg.C, and 45-55% RH.
The Contractor shall allow for air-conditioning failure, when the ambient conditions
could rise to 50 deg C and 95% RH for periods upto 8 hours.
5.1.2 The Contractor shall ensure that the PLC environment complies with ISA S71.01 and
ISA S71.04.
5.2.1 The system shall have a very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and Electro-
magnetic disturbances expected in a plant. The maximum acceptable noise level for the
PLC system in the Control Room shall be 55 db measured at a distance of 1 m lateral
from the source and 1.5m vertical from the floor with a sound level meter using the “A-
weighted” sound level scale.
5.3.1 The PLC will be located in non-hazardous area within pressurized rooms.
6.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria. In addition, the following shall also be taken care
of:
6.3 The tests undertaken shall demonstrate that each of the following responsibilities has
been fulfilled:
• The system is tested as an integrated system
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 24 of 26
6.5 The test procedures shall be developed by the Contractor as system engineering
proceeds and shall be published at least one month before commencement of the first
factory test.
6.6 Any component of hardware or software failed during a test shall be re-tested as
necessary to prove rectification has been completed satisfactorily.
6.7.1 Comprehensive hardware tests shall be completed by the Contractor prior to any
acceptance. Contractor shall carry out the following tests as part of their QA procedure
and sign off as part of the QA requirement:
• A heat soak test of 48-hour duration shall be carried out
• All modules will be tested individually after being installed in the purchased
system.
• The Contractor shall provide documented test programs that fully exercise all
functions in the purchased system.
• The Contractor’s quality control test records shall be made available for
examination.
6.8.1 Before the system is delivered to the site, satisfactory performance of the entire system
shall be demonstrated. The system shall simulate the final onsite configuration as
closely as possible.
6.8.2 Detailed test schedules, including at least the tests listed below, shall be submitted for
the Company’s approval one month before the testing. The Contractor shall have a
technician and test equipment available full time during testing. The tests shall be
conducted after the 48 hours heat soak test.
• Inspection of equipment
• Shock or vibration test (Contractor shall supply certification to demonstrate such
a test was passed for the generic system)
• Power supply variations
• Radio interference test
• Functional tests, including:
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 25 of 26
6.9.1 The SAT shall essentially be a repeat of the FAT with the following additions:
6.9.2 The connecting wiring between distributed components shall be the actual field-
installed wiring and cable.
6.9.3 The field inputs and shutdown devices shall be connected and exercised to confirm the
correct connection and compatibility of the field components.
6.9.5 A repeat of the FAT shall be required after field connections of the actual system
connections are made. Input output signal simulation shall be at the transmitter end to
enable the system to be tested end-to-end.
7.0 DOCUMENTATION:
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 26 of 26
8.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1 of
Instrumentation Design Criteria.
9.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
11.1 The PLC shall be prepared for shipment in accordance to clause 3.6.6.5 of
Instrumentation Design Criteria.
12.1 Receipt and storage of the PLC shall be in accordance to clause 3.6.6.6 of
Instrumentation Design Criteria.
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