GENERAL SPECIFICATION FOR FIELD INSTRUMENTATIONS

AND PLANT INSTRUMENT PANEL

PT. PLN (PERSERO)

PEMBANGKITAN SUMBAGSEL

PROYEK PLTMG SEI GELAM

104.717 MW JAMBI

CONTRACT NO. : 055.PJ/610/GM-KITSBS/2012

001/KONTRAK/PLTMGJAMBI/PP-IFE/2012

PLN’s DOC. NO. : -

PURPOSE :

FOR APPROVAL

1 Issued For Construction 30/04/12 KDR NS/MH HYT/AI

0 Issued for Approval 29/03/12 KDR NS/MH HYT / AI

Rev. Description Date Prepared Checked Approved

CONTRACTOR:
Doc. No.:

SG-E-00-J0-GS-102

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REVISION HISTORICAL SHEET

Rev No Date Description

0 29/03/12 Issued for Approval

1 30/04/12 Issued for Construction

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TABLE OF CONTENT

SECTION PAGE

1. GENERAL.............................................................................................................. 4
2. REFERENCE DOCUMENT.................................................................................... 4
3. CODE & STANDARD............................................................................................. 4
4. FIELD INSTRUMENT…………………………………………………………………..…5
4.1 LIMIT SWITCH………………………………………………………………………..5
4.2 TRANSMITTER……………………………………………………………………….5
4.3 TEMPERATURE MEASUREMENT………………………………………………...6
4.4 PRESSURE MEASUREMENT………………………………………………………6
4.5 FLOW MEASUREMENT……………………………………………………………..6
4.6 LEVEL MEASUREMENT…………………………………………………………….8
4.7 SPECIAL MEASUREMENT EQUIPMENT…………………………………….......8
4.8 PANEL MOUNTED INSTRUMENT…………………………………………………9
4.9 CONTROL VALVE……………………………………………………………………10
5. PLANT INSTRUMENT PANEL…………………………………………………………..11
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1. GENERAL
This specification, together with paragraph and documents noted herein, defines the minimum
requirements parameter for Design of Instrumentations and plant instrument panel, which shall
be supplied for the PT PERUSAHAAN LISTRIK NEGARA (PLN), “Proyek PLTMG SEI GELAM
“located at Jambi -South Sumatera, Indonesia.

2. REFERENCE DOCUMENTS
The following documents shall be referred as part of this specification
 RKS (Rencana Kerja dan Syarat-Syarat Pekerjaan) Section 2.7 I&C Instrumentation
& Control Works

3. CODES AND STANDARD

The current versions complete with the latest amendment, of codes, standards shall from part of
this specifications.

 ISA S5.1 Instrumentation Symbols and Identification.

 ISA S5.2 Binary Logic Diagrams for Process Operations
 ISA S5.3 Graphic Symbols for Distributed Control/Shared Display
Instrumentation, Logic and Computer System
 ISA S5.4 Instrument Loop Diagrams
 ISA S5.5 Graphic Symbols for Process Displays.
 ISA S18.1 Annuciator Sequence and Specifications
 ISA S20 Specification Forms for Process Measurement and Control
Instruments, Primary Elements and Control Valves.
 ISA RP60.8 Electrical Guide for Control Centers
 ISA RP60.9 Piping Guide for Control Centers
 ISA S75.01 Flow Equations for Sizing Control Valves
 ISA S75.11 Inherent Flow Characteristic and Rangeability Control Valves
 API Spec6D Specification for Pipeline Valves (Steel Gate, Plug, Ball, and Check
Valves)
 API RP500C Classification of Areas for Electrical Installation at Petroleum and Gas
Pipeline Transportation Facilities
 API RP520 Sizing, Selecting, and Installing Pressure Relief Devices
 API RP521 Guide for Pressure-Relieving and Depressuring Systems
 API Std526 Flange Steel Safety Relief Valves
 API Std527 Commercial Seat Tightness of Safety Relief Valves with Metal-to-
Metal Seats
 API RP540 Electrical Installation in Petroleum Processing Plants
 API RP550 Manual on Installation of Refinery Instruments and Control Systems
 API Std598 Valve Inspections and Test
 API Std2000 Venting Atmosperic and Low-Pressure Storage Tanks (Non-
refrigerated and Refrigerated)
 API 2530 Orifice Metering of Natural Gas (AGA report#3)
 ISO 5167 Measurement of Fluid Flow by Means of Orifice Plates, Nozzles and
Venturi Tubes Inserted in Circular Cross-section
 ANSI B16.37 Hydrostatic Testing of Control Valves
 ANSI MC96.1 Temperature Measurements Thermocouples
 ANSI/FCI 70-2 Quality Control Standards for Control Valve Seat Leakage
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 ASTM American Society for Testing and Materials

 NEC National Electrical Code
 NEMA National Electrical Manufactures Association
 IEC International Electrotechnical Commision
 IEEE The Institute of Electrical and Electronics Engineer
 NFPA National Fire Protection Association

4. FIELD INSTRUMENTATIONS
The plant instrumentation shall be able to operate under all operating condition such as on
plant startup, normal operation, plant shutdown, transient and abnormal condition.
Instrumentation and related devices shall meet with the requirement of the IEC standard, ISA
standard, NEMA/ANSI standard, NFPA standard and other reputable standards.

4.1 Limit Switch

 The limit switches shall be of snap acting, single-pole, double-throw type
(SPDT),able to switch 15 ampere continuous at 250 V ac or more and 0.5 ampere
continuous at 125 V dc or more.
 Limit switch operating mechanism shall have sufficiently long stroke to permit
positive operating of the contacts. Limit switch for motorized valves shall be
equipped with two torque switches.
 Limit switches shall be mounted in readily accessible locations, with suitable
clearances to permit easy service and maintenance. The materials of the limit
switches shall be corrosion resistant to gas and chemicals present in the plant
environment.

4.2 Transmitters
 As a general rule, only 2-wire transmitters shall be used. The measured process
values shall be converted into the standard signal 4 - 20 mA.
 The transmitter shall be able to support future advancements in instrumentation
capabilities.
 The transmitters shall be fitted with a digital integral indicator and shall be provided
with terminal strip with screw terminals for ring tug connections to which all outgoing
and test connection are made.
 All transmitters shall be supported in a vibration free manner independently of the
plant connections and shall be mounted in the correct attitude. No stress shall be
imposed through the connections between plant and the transmitter.
 Transmitter outputs (except for resistance temperature detectors and
thermocouples) shall be d.c. current with a.c. ripple and noise reduced to 0.25% of
the maximum signal or less (including effects of linearity, hysteresis and
repeatability). Output circuits shall be completely isolated from ground (except for
grounded thermocouples) and from the ac power circuit. The signal and power wires
of the four-wire transmitter shall be fully segregated.
 Flow, pressure, differential pressure and level transmitters shall be of the intelligent
(smart) type and shall be with HART protocol, and shall be furnished with all
required flow elements, instrument valves, blow down valves, manifold piping,
condensate reservoirs, nipples, welding adaptors and other necessary pertinent.
 Transmitters shall provide test jack terminals output signal of 4 - 20 mA dc with
superimposed digital, serial, two way communications with the hand held type smart
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communicator based on HART/BRAIN protocol. This communication signal shall

never interrupt and affect the process signals and control systems at any time.
 All process analog signal transmitters shall be grouped in the local instrument panel
distributed throughout the plant according to the location of the measuring points in
the process. Only qualified mounting hardware shall be used.The Bidder shall
publish performance specification of the transmitter with capabilities of withstanding
1.5 times of the design operating maximum pressure and temperature.

4.3 Temperature Measurements

 The RTDs shall be industrial heavy-duty and shall be contained in an electrical
insulating material and a sheath or sleeve of stainless steel. They shall be so
mounted that they can withstand the greatest shocks and vibration that can be
imposed upon them in high-pressure pipes as well as in circulating water pipes
without deterioration. It shall comply with IEC-751 class B, DIN 43760 and BS1904
Grade II.
 The calibration shall be traceable to the International Temperature Scale as defined
by the platinum resistance thermometer at the United States National Bureau of
Standards. The ice point of this temperature sensor shall not change more than 0.1
Ohm after being in service for one year at maximum operating temperature.
 Thermocouples specified as “Calibrated Thermocouples” shall have a minimum
three point calibration, guaranteed to an accuracy within ±0.2% of full range and
shall be furnished with individual certified calibration. It shall comply with ANSI
MC96.1 and ASTM E-230-87

4.4 Pressure Measurements

 Pressure and differential pressure sensing elements shall be non hysteresis type,
unless otherwise specified on the instrument data sheet. Different pressure
transmitters shall have bodies, typically consisting of sensor module, isolating
diaphragms, process flanges and adapters (pressure containing parts), unless
otherwise specified on the instrument data sheets. It shall be fitted with digital
indicator.
 Pressure and Differential Pressure Transmitter shall be completed with manual zero
and span adjustment and also shall be supplied fully assembled with manifold.
 Pressure, including absolute pressure, transmitters shall be designed for an over
range pressure greater than 100 psig or 150% of the maximum sensor range
without affecting the calibrating of the instrument. All pressure measurements on
water service over 65 oC shall be completed with siphons. Pulsating dampers shall
be furnished.
 The accuracy of pressure and differential pressure transmitter is 0.075 % of span
and scanning speed 45 msec.

4.5 Flow Measurements

 The differential pressure method to measure the flow of liquid and gases is
preferable. The sensing element shall be of venture nozzle, or orifice with stainless
steel material. The instrument shall be installed with the necessary accessories.
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 Complete design data, calculations and instrument data sheets shall be provided
with each flow element. Design calculation will be subject to be reviewed and
approval by Owner.
 Coriolis type flow meter shall be used under the following conditions:
a. They shall be used where a higher degree of accuracy and reliability in liquid
flow integration is required than that which can be obtained by orifice.
b. Water meters and gas flow meter are acceptable if they can be economically
justified after comparison with other method.
c. For flow metering of oil, coriolis meters or area meters shall be used.
 Orifice plates shall be concentric square edged type. Machining shall be buffed
mirror finish, sharp 90° corner at inlet face with outlet beveling to 45°. Orifice plates
shall be provided with integral handle with orifice data stamped on both sides. Lifting
holes and jacking screws shall also be provided.
 Venture tubes and flow nozzles shall be provided in cases where low loss is
required. These equipments shall be also designed in accordance with relevant
standard. Variable area flow meter (if required) shall be only used for local flow
indication.
 Electro-magnetic flow meter (if required) shall be provided with pulsed DC excitation.
The flow meter shall be preferably SMART type and shall be provided with hand
held communicator for calibration. SMART transmitters shall be provided with all
digital, serial, two ways communication. Accuracy (including combined effects of
linearity, hysteresis and repeatability) shall be ± 0.5% of calibrated span or better.
 Vortex Flowmeter (if required) shall be provided with temperature compensation with
output 4-20 mA, accuracy for liquid application is 0.65% of rate, accuracy for gas
application is 1.35% of rate.
 Coriolis flowmeter shall preferably be u-tube type with accuracy + 0.1% of rate and
repeatability + 0.05% of rate with local flow integrating indicator shall be provide.
Output 4-20 mA of flowrate and pulse signal for totalizer shall be provided.
 Turbine flow meters (if required) shall be provided with temperature and pressure
compensator, and signal converters. Outputs shall be 4 - 20 mA DC isolated.
Accuracy (including combined effects of linearity, hysteresis and repeatability) shall
be ± 0.5 % of calibrated span or better.
 Positive displacement meter shall preferably be oval gear type or spiral rotor type
with accuracy (including combined effects of linearity, hysteresis and repeatability)
of ±0.2% of calibrated span or better and local flow integrating indicator shall be
provided. Output 4-20 mA DC signal of flow rate and pulse signals for totalizer shall
be provided.
 Ultrasonic flow meter shall be provided (if required) with accuracy (including
combined effects of linearity, hysteresis and repeatability) of ±1.0% of calibrated
span or better with temperature and pressure compensator. Output 4-20 mA DC
signal of flow rate shall be provided.
 The Bidder shall furnish the flow elements with certification reports and in
accordance with the requirements of ASME G00079 “Fluid meters, their Theory &
Application”
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4.6 Level Measurement

 Temperature correction shall be provided whenever necessary (e.g. at lube oil tank,
etc.). Electrical circuitry shall have the same characteristics, as for pressure
measurements.
 Level transmitters analog output signal shall be directly proportional to the level of
the measured process medium unless otherwise specified. Level transmitter shall be
completed by level glass and mA current meter for calibration purpose.
 Level transmitter for vacuum service shall be of the displacement type and shall be
provided with 50 mm socket-welded connections.
 Local level indicators of tanks shall be of the magnetic type and shall be equipped
with a scale of sufficient length according to the tanks. For local measurement at
pressured vessels, the bi-color water indicator type shall be used. For clear
readability, electric illumination has to be installed.
 Indicators on tanks under vacuum shall have special sealing system. All indicators
shall be provided with fast closing valves and protective sleeves.
 Float and displacer external chambers to the vessel shall be provided and designed
for the pressure and temperature ratings of the vessel to which they are connected.
Connection shall be flanged, screwed, or socket welded as applicable.
 Float type or displacer type level transmitters also shall be provided. The accuracy
shall be within ± 1.5 % of full scale or better (including effects of linearity, hysteresis
and repeatability).
 Ultrasonic level transmitter shall be furnished with temperature compensation
equipment. The output signal of the ultrasonic level transmitter shall be 4 - 20 mA dc
and the accuracy within ±1.0 % of F.S. or better (including effects of linearity,
hysteresis and repeatability).

4.7 Special Measurement Equipment

 Vibration Measurement
a. The major pieces of rotating and reciprocating equipment shall be provided
with permanent vibration monitoring equipment and diagnostic electronics.
The vibration monitoring shall comply to the related API standard.
b. A microprocessor based monitoring unit shall permanently be connected to
the field sensors and signal conditioners. The monitoring unit shall be
mounted in a cabinet located in the Electronic Room.
c. The vibration monitors shall provide indication and control signals to facilitate
alarms and equipment shutdown as well as data for preventive maintenance
diagnostics and operating efficiency to the operator.
d. The monitoring unit shall trend information for preventive maintenance and
diagnostic programs. Adequate diagnostic capability shall be provided to
identify the types of problem and the location of the component within the
major mechanical piece of equipment.
e. The system shall provide sufficient sensors data to the Unit Control System
via a serial link for on-line operator information and equipment interlocks on
excess levels of vibration.
f. To ensure that the output of the proximity probes are representative of shaft
vibration, the shaft shall be free from surface irregularities and have a finish
which is concentric, homogeneous, demagnetized and have a run out of less
than 2 mm peak to peak. This shaft condition shall extend over a surface area
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that is equivalent to the full float of the machine and to a depth greater than
the magnetic field penetration. Shafts shall not be chrome plated.

 Flue Gas Oxygen Analyzers

a. The Flue Gas Oxygen analyzers shall be of the zirconium cell type capable of
operating directly in the flue gas stream with high sulphur condition and shall
not require any sampling equipment.
b. The flue gas analyzer shall be provided for combustion control. It shall provide
the 4 – 20 mA output signals with HART which shall be linear with percent
oxygen for used by combustion control system. Automatic calibration
equipment shall be included. The analyzer shall have diagnostic system for
calibration, sensor fault, heater fail and temperature sensor open. Test jacks
or terminals shall be provided.

 Emission Monitoring System

a. All equipment shall be designed to meet all applicable stack instrument
requirements of Environmental Protection Agency (EPA), and applicable
Indonesian Regulations.
b. The equipment shall be able to measure the concentration of Carbon
monoxide (CO), Sulphur Dioxide (SO2) and Nitrogen Oxide (NOx) mass
emission rates and opacity readings that exist at the chimney outlet to the
atmosphere.
c. The Emission Monitoring System shall use Direct Extractive system with
blowback feature for Sample probe. The analyzer will be installed inside
shelter which will be place outdoor area and has enclosure protection rating
NEMA 4X ; IP66.

Analyzers ranges for the gases monitored shall be as follows, unless otherwise
noted in the specification:
- Sulphur Dioxide (SO2): 1 - 1500 mg/Nm3
- Oxides of Nitrogen (NOX): 0 - 2000 mg/Nm3
- Carbon monoxide (CO): 0 - 500 mg/Nm3
- Oxygen (O2): 0 - 21% by volume
- Opacity/Dust: 0 - 500 mg/Nm3
The Bidder shall propose complete design stack gas monitoring system for reviewed
by owner.

4.8 Panel Mounted Instrument

 The panel-mounted instrument shall be installed in a vibration-free location
wherever possible. The housing shall be of sheet steel, gray colored (mounted at
the place of measurement) with hierarchy concepts.
 The panel mounted instrument shall be industrial standard together with accessories
but not limited such as indicators, recorders, alarm annunciators, push buttons,
control switches, totalizers, and indicating lamps.
 Panel Mounted terminal blocks shall be marked. A grounding terminal shall be
installed. All terminal connection shall have properly labeled and shall be completed
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with screwed cover caps providing a watertight enclosure. A chain shall be provided
to prevent loss of cap.
 All panel instruments, including back of the panel instruments shall be furnished and
ensure the panel design will accommodate any physical or orientation requirements
imposed by the instrument equipment to be mounted in/on the panel.

4.9 Control Valve

 General
a. Control valves shall be pneumatically operated receiving 0.2-1.0 kg/cm2 air
signal. The spring range other than 0.2-1.0 kg/cm2 may be used when
necessary to provide thrust for specific applications. Control valves shall be
sized by the lSA formula or manufacture’s standard.
b. Direction of Raw shall be cast or steel-stamped on the body.
c. Valve body color shall be silver.
 Size and Rating
a. All control valves shall have flanged connection except for large size butterfly
valves which are used for non-flammable services. The rating for valves shall
be in accordance with piping specification.
b. The following body size shall be used:
1, 1 ½”, 2, 3, 4, 6, 8, 10, 12 inch and larger.
c. The smallest body size to be used shall be 1” except for ¾” lines where ¾”
valves may be used. If a smaller port area is required, reduced trim shall be
used.
d. The minimum flange rating of control valve shall be class 300#, unless
otherwise specifically noted.
 Materials
a. Body material shall be carbon steel, unless process conditions require a more
suitable material.
b. Control valve trim material shall generally be of type 316 stainless steel,
unless another material is suitable for the particular process conditions.
 Construction of Valves
Valve bonnet and blind flange shall be of the same material as the body and of integral
of bolted type construction with fully retained gasket. Threaded bonnets are not
acceptable. Gaskets shall be corrugated 316 SS, unless otherwise specified. Stuffing
boxes shall be the bolted gland type. Valve stem shall be threaded and pinned to the
valve plug and its connection to the diaphragm stem shall be adjustable, with positive
locking of the adjustment.
 Valve Fail Position
The required fail position of a valve shall be determined by analysis of the process and
piping and instrument Diagrams.
 Determination of Valve Size
a. Control valve shall be sized from the latest data available from process flow
diagrams, hydraulic calculation sheet line designation tables and other
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sources. The sizing and selection of control valve shall be checked by the
manufacturer.
b. Valve Sizing
1) All control valve shall be sized using the formula of ISA or manufacturer’s
standard formula. All control valve shall be sized based on (1.65 time
normal flow) or (1.1 time maximum flow), which is greater.
2) All valves with linier flow characteristic shall be sized on the basis of
operating range between 50% to 80% of valve opening.
3) All valve with equal percentage flow characteristic shall be sized on the
basis of operating range between 60% to 90% of valve opening.
4) All butterfly valves for throtting service shall be sized so that design flow
rate does no require a valve disc opening greater than 60o, unless
technically accepted by purchaser. 90o opening is permissible for valves
in on-off service.
5) All valves shall be designed against for cavitations and flashing using the
method recommended by valve manufacturer to avoid damage of valves.
c. All valves shall be designed to meet a maximum predicted noise level of 85
dBA at 1 meter downstream of the valve and 1 meter from the pipe surface
under continuous operation, not start-up stage and emergency condition.
When the valve does not operate continuously, the noise limitations shall be
calculated. The calculation formula and reduction method shall be in
accordance with manufacturer’s recommendations.

5. PLANT INSTRUMENT PANEL

 The local instrument panels shall comply with IEC, ISA, NEMA, NFPA ANSI/ASME
standards. The local instrument panel shall be safety designed for operator and
equipments itself.
 All local instrument panels, cabinets and enclosures shall be furnished complete with
all devices, mounted, wired and piped in the factory before being shipped to the site.
Unless otherwise specified or agreed by the owner. Process fluids shall be excluded
from local instrument panels and confined to areas external to the panels. Only
pneumatic (Approval required) and electrical signal lines and air supply lines shall enter
the panels.
 These panels shall serve as the local control point for various plant processes and
pieces of equipment or electrical systems. Process or electrical local control panels
shall be free-standing, floor mounted, completely enclosed and dust-tight, with
instruments, relays, gauges, control switches, LCD monitor, etc. mounted on the front
or within.
 Each panel shall be fabricated of ASTM A366 sheet steel not less than 2.0 mm thick
shall not more than 2.5 mm thick. Each panel shall by enclosed rigid, free-standing
structure, suitably braced, stiffened and reinforced to withstand, without damage, all
stresses incidental to shipping, installation operation and maintenance.
 Nameplates shall be installed to designate the service of all switches, instruments,
meters, fuse blocks, relays, amplifiers, etc. both internally and externally located on the
panels. Standard nameplates included with instruments shall not be considered
adequate and separate nameplates bearing the service description, instrument number
and calibrated range shall be provided by the Bidder.
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 Devices shall be mounted with adequate spacing allowed for wiring and/or piping
connection so that instrument removal, replacement and servicing may be
accomplished without interruption of services to adjacent devices or without unduly
disturbing other wiring and/or piping connections.
 230 VAC fluorescent interior lighting with switches shall be furnished inside the panel. It
shall be connected via suitable fuses to a separate incoming 230 VAC power supply
from a lighting cabinet. The light fixtures shall have a degree of protection against
electrical shock of Class I or Class II according to IEC 60598-1. Class I fixtures shall be
grounded.
 All panels shall be equipped with anti-condensation heaters in accordance with ASME
and IEC standards. Local panels located in hazardous location shall be in accordance
with NFPA 70 Article 500 and IEC 6079.
 The equipment shall be tested in accordance with the requirement of ANSI C37.90.
The equipment shall not miss-operate during this test. Following this test the equipment
shall be given a calibration test to determine that it has not been damaged by the surge
withstand capability test.
 Bidder shall make tests on completely assembled system and shall provide Owner data
on the above tests. All tests and guarantees shall be made in accordance with
applicable IEC or ANSI standards.