26_ASGP LTEM in MR 2212 0 _Instrumentation Requirements for CPU

LARSEN & TOUBRO LIMITED E&C DIVISION

INSTRUMENTATION REQUIREMENT FOR

CPU PACKAGE

DOCUMENT NO:- ASGP-LTEM-IN-MR-2212

PROJECT : AMMONIA SYNGAS GENERATION PLANT

REVISION : 0

CUSTOMER : GNFC, BHARUCH PAGE : 2 OF 8

MASTER INDEX

SL. NO. DESCRIPTION PROJECT/DCI

DOCUMENT NO.

REVISION

PAG

ES

ENC

LOSE

D

Sheet Date No

TITLE INSTRUMENTATION REQUIREMENT FOR CPU PACKAGE

ASGP-LTEM-IN-MR-2212

1 2 3 4

CONTENTS

1.0 SCOPE 8

2.0 APPROVED MAKES

3.0 APPLICABLE CODES & STANDARDS

4.0 TECHNICAL SPECIFICATIONS

5.0 CONFLICTS

6.0 INSPECTION & TESTING

7.0 SPARES

8.0 COMPLIANCE

9.0 TRACK RECORD

10.0 VENDOR DOCUMENTATION

11.0 ATTACHMENTS REFERENCE DOCUMENT NO.

11.1 ATTACHMENT-1.0 PROJECT SPECIFIC REQUIREMENT

4

11.2 ATTACHMENT-2.0 PURCHASER’S SPECIFICATION

43

11.3 ATTACHMENT-3.0 DATASHEET

1

11.4 ATTACHMENT-4.0 DESIGN/ENGINEERING DRAWINGS/GUIDELINES

1

11.5 ATTACHMENT-5.0 APPROVED MAKES

3

11.6 ATTACHMENT-6.0 INSPECTION & TEST PLAN

L&T/GNFC/IP/002, L&T/GNFC/IPMI/004, GNFC-IITP-203, 204, 206-209, 210, 211, 215, 218-227, 230, 232-235, 236, 239-248

63

11.7 ATTACHMENT-7.0 SPARES LIST

5

11.8 ATTACHMENT-8.0 COMPLIANCE FORMS

4

11.9 ATTACHMENT-9.0 PAST TRACK RECORD

2

11.11 ATTACHMENT-10.0

VENDOR DOCUMENTS REQUIREMENT

3

NOTES: Prepared, Reviewed and Approved Sign on the ‘REQUISITION’ coversheet is valid for the subsidiary

documents/attachments. Attachments which are not ticked in the check box are not applicable for the ‘REQUISITION’.



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1.0 SCOPE This document together with its ‘Attachments’ outline the procurement requirement of instrumentation to be supplied with Condensate Polishing Unit package .The Scope of Supplies and Services for the Condensate Polishing Unit are as follows.

1.1 Scope of Supply

Sr.No. Description Quantity Scope Split Remarks Purchaser Vendor 1.0 Items : 1.1 Package Control System

comprising : Package Monitoring, Control, Shutdown and Operational requirement

--- √ To be implemented in Purchaser’s DCS/ESD system.

1.2 Special Instrument System(s) comprising : PH & Conductivity Analyser & Other analyser(s) if applicable

1 lot √

1.3 Field Instrument (s) Temperature Instruments Pressure Instruments Flow Instruments Level Instruments Switches (if can not be

avoided) Control & Shutdown

Valves Actuators Positioners Safety Relief Valves Solenoid Valves Others

1 lot (As required)

√ √ √ √ √ √ √ √ √ √ √

1.4 Bulk Items Field Signal Junction box

and Cable glands and plugs

Signal Cables and trays up to field JB

Cables and trays from field JB to control room

Special / proprietary cable Power distribution JB

(PDB) and cable glands &

1 lot (As required)

√

√ √ √ √ √



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plugs Power cables and trays

from PDB to Instruments / consumers

Hookup material for instruments and valves, Canopies, Mounting hardware

Instrument air manifold, tubing and fittings for Instrument air distribution.

Any tools & tackles required

√ √ √ √

2.0 Spares : 2.1 Commissioning Spares 1 lot Vendor to

recommend and Supply

2.2 2-years Maintenance Spares 1 lot List to be furnished by Vendor ; Not to be supplied

2.3 Mandatory Spares 1 lot Vendor to supply as per philosophy/ list attached

1.2 Scope of Services (√) Design/Engineering (√) Installation at site (√) Manufacturing & Assembling (√) Supervision for installation (√) Inspection and tests at shop (√) Supervision for commissioning (√) Painting and packing (√) Documentation (√) Transportation (√) Training to Client’s personnel

1.3 Battery Limit /Exclusions Utilities (Power/Water/Air) Terminal Point: By Purchaser, at one point of the vendor battery limit. Vendor to consider the necessary hardware for further distribution of utilities.

Instrumentation Terminal Point: Vendor to supply all the instruments under the Battery Limits. For the interconnected piping between Purchaser and vendor the following instrumentation shall be considered by Vendor:

Wherever, Piping is Designed and supplied by Vendor – Instrumentation also by Vendor

Wherever, Piping is Designed and supplied by Purchaser : Instrumentation by Purchaser

Wherever, Piping is Designed by Vendor but supplied by Purchaser - Instrumentation by Vendor

Scope of Supplies & Services: As specified under 1.1 & 1.2

HAZOP : Any augmentation of the instruments during HAZOP study shall be borne by the Vendor



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Exclusions: Installation at site, Supervision & Field Equipment Interfacing

2.0 APPROVED MAKES

While proprietary components of the vendor/ vendor’s manufacturer would be acceptable, it is expected that all other bought out item/components shall be sourced by the vendor from reputed sub vendors.

Vendor shall strictly source items / components as per approved sub-suppliers list furnished under Attachement-5.0 - ‘APPROVED MAKES’

3.0 CODES AND STANDARDS

The material / item to be procured shall in general confirm to latest revision of IS/IEC/other international standards applicable for the country of origin of the equipment.

Design, material of construction, manufacturing, examination, testing, inspection & documentation shall confirm to the applicable codes & standards as listed in the relevant section(s) of the ‘Technical Specification’ attached to this ‘REQUISITION’.

Where neither code nor standard is specified in the Data sheet & /or Project specifications & reference documents, vendor shall propose applicable codes & /or standards on which vendor’s design & manufacturing is based, for review & approval by Purchaser.

4.0 TECHNICAL SPECIFICATION

This section of the document covers the Technical/ Engineering specification of the instrumentation required for CPU package unit. The technical specification in general spans over the following ‘Attachments’.

Attachment Description Sub Contents

Attachment-1.0 Project Specific Requirement

Site Condition, Add-on Codes & Standards, Specific Requirements, Project Specific Certification, Special Clauses (if applicable)

Attachment-2.0 Owner’s/Purchaser’s Standard Specification

Standard Codes, Standard Technical requirements, Nameplate & Painting, Standard Inspection & Testing, Packing & Despatch

Attachment-3.0 Owner’s/Purchaser’s Datasheet

Datasheets/Datasheet format

Attachment-4.0 Design/Engineering Data Engineering data /drawings, related to Design, Sizing, Interfacing & Layout (if applicable)



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5.0 CONFLICTS

The ‘REQUISITION’ and its Attachments shall be referred in the following order of precedence. • This document • Project Specific Requirement • Project Specific Design/Engineering Data • Owner’s/Purchaser’s Datasheet • Owner’s/Purchaser’s Standard Specification • Applicable Codes & Standards Should there be any conflict among the stated documents, Bidder shall notify the purchaser and obtain written clarification about the conflicts in question. With regard to the resolution of the same Purchaser’s decision shall be adhered. The requirement of any statutory bodies, such as Factory Inspector, Other certifying authorities shall govern where the specifications are more stringent than the specified ones. If however, there is no conflict/contradiction among the related specifications and documents, then mutually exclusive requirement spelt out in the attached documents shall be adhered.

6.0 INSPECTION & TESTING All instrumentation items shall undergo factory Inspection and Testing by purchaser’s authorised representatives, PMC, Owner / PMC, unless specified otherwise. Inspection and Tests for the add on instrumentation for CPU package unit shall be carried out as per standard Inspection and Test procedures mentioned under Owner’s/Purchaser’s Standard Technical Specification (Attachment 2.0). Besides, if applicable, to assure that the chemical composition of metallic alloy material and weld is consistent with the base material specification, the items shall undergo Positive Material Identification (PMI) testing using a ‘Alloy Analyzer’. The Indicative Inspection & Test Plan (IITP) and the Positive Material Identification (PMI) specifications are covered under the purview of Inspection related attachment- Attachment- 6.0 ( If applicable ).



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7.0 SPARES

7.1 Commissioning Spares Vendor to recommend list of commissioning spares as required. The commissioning spares shall form an integral part of the scope of supply. Vendor shall be responsible for the quantification of the commissioning spares for the smooth start up of the plant/package system.

7.2 Mandatory Spares Mandatory spares shall form an integral part of the scope of supply . Vendor shall supply Mandatory Spares as per Attachment-7.0/ Form B.

7.3 2 year’s Maintenance Spares Vendor shall furnish list of spares for 2 years trouble free operation. 2 Years’ Maintenance Spares need not be supplied by the vendor unless specifically asked. 2-years maintenance spares shall be 10% of each type of the item, subject to a minimum of 1 no. In case, 2 year’s Maintenance Spares are not specified, vendor to furnish a list for the same for the subsequent approval of the purchaser/owner. Exhibits / Forms for specific type of Spares to be filled in/to be adhered by the Vendor are: Commissioning Spares : Form A Mandatory Spares : Form B 2 years Spares : Form C

The above forms are attached under ‘SPARES’ related attachment- Attachment-7.0.

8.0 VENDOR COMPLIANCE

The scope of Supply and Services shall be in compliance with the requirement stated in the ‘REQUISITION’. No deviation / alternative to this requisition shall be permitted except for those deviations / alternative offered with the Vendor’s quotation and consented in writing by the Purchaser.

8.1 Deviation List

If vendor intends any deviation or proposes alternative as vendor recommendation , then vendor shall submit a detailed comparison between project requirement and vendor recommendations. The deviation in this case shall first be entered in the ‘Vendor Offered’ column wherever relevant, and then shall be tabulated in attached Form-D, Deviation List format.

8.2 Compliance Statement

Vendor shall also fill in an overall ‘Compliance Statement’ (Form-E).



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8.3 Comment Resolution Sheet

The Deviations/ Compliance of the vendor, as tabulated under Form-D/ Form-E, and the comments made by Owner shall be resolved by Purchaser/Vendor. The comment resolution generally is an activity in PR (Purchase Requisition) stage. The comments shall be resolved as tabulated under ‘Comment Resolution Sheet’ (Form-F)

Forms D, E &F are attached under ‘COMPLIANCE ’ related attachment –Attachment-8.0.

9.0 TRACK RECORD

Vendor shall offer subject item which are brand new of make with state of art technology and have Proven Track Record (PTR) with at least 2 years of satisfactory operation at minimum 2 installations in Hydrocarbon industry. No prototype shall be offered by Vendor for Purchaser’s/ Owner’s consideration.

Vendor shall fill in the PTR form (Form-G)/or submit Vendor’s standard PTR. An exhibit of PTR is attached under ‘PTR’ related attachment – Attachement-9.0.

10.0 VENDOR DOCUMENTATION

VENDOR shall submit the following documents along with quotation: (√) Datasheet- complete with manufacturer data (√) Deviation List (√) Compliance Sheet (√) General Arrangement Drawing (√) Catalogue (√) Past Track Records All documents, drawings, manuals, reports and written & oral instructions shall be in English language. MKS system units shall be preferred.

In post-order stage, vendor shall submit documents as per Attachment –10, ‘VENDOR DOCUMENT REQUIREMENT’

11.0 ATTACHMENTS

Attachments listed out in ‘Master Index’ shall form part of this requisition.

The text of the ‘REQUISITION’ document gives an overview/ a structure for the requisition requirement of the material. The detailed requirements are covered under Standard Attachments 1.0-10.0 . Based on the requirement; all the attachments may or may not be attached with the Material Requisition (‘REQUISITION’). However, if an Attachment is dropped the same shall be reflected in the ‘Master Index’ of the ‘REQUISITION’.

LARSEN & TOUBRO LIMITED E&C DIVISION INSTRUMENTATION

REQUIREMENT FOR CPU PACKAGE

DOCUMENT NO:- ASGP-LTEM-IN-MR-2212 Attachment_1.0


REVISION : 0

CUSTOMER : GNFC, BHARUCH PAGE : 1 OF 4 PROJECT SPECIFIC REQUIREMENT

TABLE OF CONTENTS

SECTION PAGE

1.0 PURPOSE 2

2.0 SITE CONDITION 2

3.0 ADD-ON CODES & STANDARDS 2

4.0 SPECIFIC REQUIREMENT 3

5.0 CERTIFICATION 3





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1.0 PURPOSE

The Project Specific Requirement is earmarked as Attachement_1.0 to the ‘REQUISITION’. The purpose of this attachment is to notify the vendor about the requirement which are not met (or not having clarified) by Purchaser’s Specification.

2.0 SITE CONDITION

1.0 PLANT SITE GNFC, Bharuch, Gujarat, India

2.0 SITE CONDITION

2.1 Climatic Condition

2.1.1 Altitude of plant site 19.5 M over sea level Barometric Pressure (m bar)

(Maximum/ Minimum/ Average) 1012 /995 / 1006 m bar

2.1.3 Design Ambient temperature for outdoor equipment (Min/Maximum)

5 / 50 deg C.

2.1.4 Humidity / Air moisture Maximum/Lowest/Average

80% for design

2.1.5 Rainfall Maximum/ Annual Average (mm)

65 mm/hr (Max) ; Annual average 1000 mm

2.2 Area Classification

2.2.1 Hazardous Area Classification (Gas) Zone 1, IIC, T6 (Incase instruments with temperature classification T6 are not available T5 may be accepted

2.2.2 Hazardous Area Classification (Dust) Not Applicable

2.3 Seismic Zone As per IS-1893-1984 and Roorkee Earth Quake School report for Bharuch

3.0 ADD-ON CODES & STANDARDS

Add-on Codes & Standards refers to the additional codes with respect to the Standard Codes referred under Purchaser’s Specification. However, if conflict arises in terms of adherence to the applicable codes, the most stringent conditions shall apply.

The codes under Purchaser’s specification are quite exhaustive. Add-on codes are therefore, not applicable.

Sr. No.

Add-on Codes & Standards

Description

1.0

2.0

1.0

2.0





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4.0 SPECIFIC REQUIREMENT

4.1 Specific Technical Requirement

These are add-on technical requirements with respect to Purchaser’s standard Specification. The basis for this technical add-on is the scattered information across ITB/Contract, as also the technical clarifications obtained during pre-order stage.

Not applicable

4.2 Measurement Units

Unless otherwise, specified, the following unit shall be used for complete project, including package unit instrumentation, wherever the units are not specified, these will be based the internationally accepted SI units.

Mass Flow = kg/h

Volumetric Flow = m³/h

Steam Flow = kg/h or T/h

Gas/Vapor Flow = Nm3/h

Level Absolute = Absolute Meter or mm

Level Relative = 0-100% in Direct range

Pressure Gauge = Kg/cm2 -g

Pressure Absolute = Kg/cm2 -a

Temperature = °C

Analysis = % or PPM

Viscosity = cP

Conductivity = μ s/cm

Density = Kg/m³

Velocity = m/s

5.0 CERTIFICATION

Vendor shall in general submit the following test certificates from statutory authority so as to establish the integrity of the subject item with regard to the installation in and around the plant site, for purchaser's review:

( √ ) Certificate from Statutory authority e.g.CCOE/DGFASLI for flame proof and weather proof enclosure as applicable, for all instruments installed in hazardous area.

(√ ) All intrinsically safe instruments shall be certified for the use in the specified hazardous area classification by any recognized authority like C’REQUISITION’S/CENELEC/PTB/BASEFFA etc.





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(√ ) Certificates as applicable for the material NDT reports like radiography/ X-ray / die-

penetration/ MP, special testing reports like IGC testing etc. (√) Material certificates according to EN 10204 (2.2 or 3.1.B) are required for pressure retaining

parts for on-line instruments (√) IBR Certifications (III-C), w.r.to Hydrotesting and (or) Pneumatic testing shall be provided by

Vendor in the appropriate format duly signed by IBR authority or their authorized agency Standard Specification

(√) NACE ‘REQUISITION’0175 (National Association of Corrossion Engineers) certification for the

pressure gauge and the diaphragm seal confirming the usage of Sulfide Stress Cracking-resistant Metallic Materials for Oil field Equipment

Though the subject item / instrument/ instrument system of the CPU Package shall be accepted on the basis of the satisfactory result of the testing at the shop and the certification provided by the vendor, it shall not absolve the vendor from liability regarding the proper functioning of the instrument/instrument system when installed around the plant equipment/process, for supervision and (or) control.


INSTRUMENTATION REQUIREMENT FOR CPU

PACKAGE

DOCUMENT NO:- ASGP-LTEM-IN-MR-2212 Attachment_2.0-1


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CUSTOMER : GNFC, BHARUCH PAGE : 1 OF 49 PURCHASER’S SPECIFICATION

TABLE OF CONTENTS

SECTION PAGE

1.0 PURPOSE 2

2.0 CODES & STANDARDS 2

3.0 TECHNICAL REQUIREMENTS 5

4.0 NAMEPLATE & PAINTING 42

5.0 TESTS & INSPECTION 43

6.0 PACKING & DESPATCH 43





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1.0 PURPOSE This Specification and the Datasheets in combination describes the minimum requirement related to the Design & Engineering, Manufacturing, Inspection & Testing, Certification, Packing & Despatch etc. for the instrumentation of the Condensate Polishing Unit Package.

2.0 APPLICABLE STANDARDS

The various applicable Codes and Standards are as mentioned below. The instrument /component specification shall conform to current versions of applicable Codes & Standards. However, if conflict arises in terms of adherence to the applicable codes, the most stringent conditions shall apply. In all such cases, before taking any decision, VENDOR shall get formal approval of data/specification sheets from Purchaser (L&T) / OWNER (GNFC).

The following standards shall be followed as a minimum during basic and detail engineering of plant by vendors.

Sr. No. Codes & Standards

Description

1 ASME B1.20.1 Pipe Threads, General Purpose (inch)

2 ASME B46.1 Surface Texture (Surface Roughness, Waviness and Lay)

3 API RP 551 Process Measurement Instrumentation.

4 API RP 550 Manual on Installation of Refinery Instruments and Control Systems - Part I - Process Control and Instrumentation.

5 BS 3643 ISO Metric Screw Threads: Part 1: Principles and Basic Data. Part 2: Specification for Selected Limits of size.

6 CE “Conformite Europeenne”

Harmonized Codes directed by the European Community.

7 DIN ISO 228 Pt. 1 Pipe Threads where Pressure-tight Joints are not made on the Threads. Pt. 1: Designation, Dimensions and Tolerances

8 DIN V19250 Measurement and Control Fundamental Safety Aspects for Measuring and Control Protective Equipment.

9

EN Standards (CENELEC)

Electrical Apparatus for Explosive Gas Atmospheres.

10 EN 10204 Inspection Documents for the Delivery of Metallic Products

11 IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres

12 IEC 60364 Electrical Installation of Buildings

13 IEC 60529 Degrees of Protection Provided by Enclosures (IP Code).

14 IEC 60654 Operating Conditions for Industrial Process Measurement and Control Equipment.

15 IEC 60757 Code for Designation of Colors.





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16 IEC 60902 Industrial Process Measurement and Control Terms and Definitions.

17 IEC 61000 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment.

18 IEC 61508 Functional safety of electrical / electronic / programmable electronic safety related systems.

19 NACE MR0175(95) Standard Material Requirements - Sulfide Stress Cracking-resistant Metallic Materials for Oil field Equipment

20 IBR form IIIC Indian Boiler Regulations

21 CCOE Chief Controller of Explosions, India for intrinsic safe and Explosion proof apparatus.

22 97/23/EC Pressure Equipment Directive

23 DIN 16128 Nominal Ranges, Scale Spacing and Scale Numbering of Accuracy Classes 1.0, 1.6, 2.5 and 4.0 Pressure Gauges.

24 ISO 5167 Measurement of Fluid Flow by Means of Pressure Differential Devices.

25 ANSI/ASME PTC 19.3

Power Test Code. Thermowell strength Calculations

26 DIN 43729 Electrical Temperature Sensors; Connection Heads for Thermocouple Thermometers and Resistance Thermometers

27 IEC 60584 Thermocouples - Part 2: Tolerances. Thermocouples - Part 3: Extension and Compensating Cables Tolerances and Identification System.

28 IEC 60751 Industrial Platinum Resistance Thermometer Sensors

29 DIN 19234 (NAMUR)

Electrical Distance Sensors; DC Interface for Distance Sensor and Signal Converter.

30 EN 60947 Electrical Distance Sensors; DC Interface for Distance Sensor/converters

31 ANSI/FCI-70.2 Control Valve Seat Leakage

32 ANSI/ISA 75.01 Flow Equations for Sizing Control Valves.

33 API 607 Fire Test for Soft-seated Quarter-turn Valves.

34 API RP 520 Sizing, Selection and Installation of Pressure Relieving Devices in Refineries: Part 1: Sizing and Selection Part 2: Installation

35 EC 60534 Industrial Process Control Valves: Part 1: Control Valve Terminology and General Considerations. Part 2: Flow Capacity: Section 1: Sizing Equations for Incompressible Fluid Flow under Installed Conditions. Part 2: Flow Capacity: Section 2: Sizing Equations for





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Compressible Fluid Flow under Installed Conditions. Part 8: Noise Considerations: Section 1: Laboratory Measurement of Noise Generated by Aerodynamic Flow through Control Valves.

36 API 670 Vibration, axial position and bearing temperature monitoring systems.

37 IEC 60085 Thermal Evaluation and Classification of Electrical Insulation

38 IEC 60227 Polyvinyl chloride insulated cables of rated voltages up to and including 450/750V

39 IEC 60228 Conductors of insulated cables

40 IEC 60331 Test for electric cables under fire conditions. (Fire resistant)

41 IEC 60391 Marking of Insulated Conductors

42 IEC 60332 Test for electric cables under fire conditions. (Flame retardant)

43 ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings

44 IEC 60423 Conduits for Electrical Purposes: Outside Diameters of Conduits for Electrical Installations and Threads for Conduits and Fittings.





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3.0 TECHNICAL REQUIRMENTS

THE PACKAGE: Packages are divided into three types, from Instrumentation perspective. Process Unit Package ( Process Plant sub-sections or Utilities which are supplied as

package units) System Unit Package ( Packages which are supplied as skids or otherwise, inclusive of

large Rotary/ Static Equipment and the supporting auxiliary systems ) Equipment Unit Package ( Stand alone Rotary/ Static Equipment)

Condensate Polishing Unit is a Process Unit Package. CPU is designed for treating the process condensate, turbine condensate, and continuous boiler blow down and intermittent boiler blow down. Each condensate streams are passed through individual heat exchanger to bring down the temperature of the feed to ambient temperature. The cooled feed from the heat exchanger are mixed in the mixing tank. From the mixing tank the feed is pumped to the polishing unit where in the same is filtered through Activated Carbon Filter and Mixed Bed for further storage in the DM water storage Tank. The effluent from the polishing unit, and activated carbon filter is sent to effluent pit. The effluent is not self neutralizing. Excess acid and alkali is added for neutralization of the same. The following are the major equipment/ facilities of the CPU Unit: CPU Feed Pumps Anthracite Filter Activated carbon filter Mixed Bed Exchanger Mixed Bed blower MB Regeneration pump Acid unloading pump Acid Bulk Storage Tank Acid Measuring Tank Ejector for Acid Alkali Unloading Pump Alkali Bulk Storage Tank Alkali Measuring Tank Ejector for Alkali Effluent Pit DM water storage tank Effluent transfer pumps

The above list of equipments/ facilities are only indicative. The same shall be Vendor specific based on proprietary design considerations. The instrumentation required for the above CPU package are categorised under following major heads.

Package Control System(s) Special Instrument Systems





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Field Instruments Bulk Erection Items Others

3.1 PACKAGE CONTROL SYSTEM(S)

Based on the requirement, package unit’s control and shutdown (Control/Monitoring and Interlocking/Logics) requirement can be implemented in any one or more of the following: Plant DCS/ESD System Dedicated PLC based Controller Dedicated Microprocessor based Controller Relay based panel Control & Shutdown of the equipment of the package System in Plant DCS/ESD system

and proprietary controls related to the performance and safety of the package in a Dedicated PLC/Microprocessor based Controller

For CPU, package equipment’(s) the Control & Shutdown schemes are to be implemented in Plant DCS/ESD system. Vendor to note the following requirement , in general, for the integration of the Package Unit, its Local Control Panel, Instruments /Instrument systems etc. with the DCS/ESD system.

Local Control Panel

• Local Control Panels (LCP) are normally not to be used for package unit Control and shutdown schemes. However, if LCP is used at all for a machine/package unit the same shall be used only for Local Push Buttons and a few clustered LED type Lamps for start/stop and health/running status indications of machine/peripherals and their initial start up procedure only

• The field mounted Local Panel shall be weather proof to IP55 as a minimum. If panel is installed in hazardous location, all push buttons/clustered LED type lamps etc. and all other sundry hardware installed inside the local panel shall be certified for Flameproof to Ex-d IIC/T6 as per CENELEC/ATEX, if not interfaced with intrinsically safe circuits/barriers from control room/cabinet room. Purged panels are not acceptable. The panel make shall be RITTAL only and colour shed shall be RAL7032.

• A common field alarm hooter at each package unit / local control panel shall be generated from central control room DCS to alert the machine trip condition. Complete control should be possible from central DCS for the subject package. Also emergency shutdown of this entire machine/package unit shall be governed by central ESD only.

Field Signals

• To the extent possible, direct interconnection from field instrument to DCS/ESD system shall not be employed. All the signals to the DCS/ESD system Marshalling rack shall be routed through multi pair cables via field mounted junction boxes only.

• Analog Signals with standard 4 – 20 mA DC signals (24 V DC, two-wire system) shall be applied as measuring inputs and controller outputs. Where 2 wire system is not suitable, 4 wire transmitter with isolated 4-20 mA DC output signal and 110 V AC UPS supply shall be used. Proximiter signals shall 2 wire NAMUR sensors as per EN 60947 (NAMUR). Digital signals may be applied either as potential-free inputs.





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• The standard signals for transmitting measuring and control shall be a current of 4 to 20 mA. DC, superimposed with digital communication protocol (HART) with local LCD type display. All interlock/logic shall also be realized from 4-20 ma analog input transmitters in the ESD. No field switches shall be used for interlock purpose, except NAMUR type proximity sensors for on-off valve positions switches.

• Foundation Field Bus/ PROFIBUS or any other cluster/Multiplexer type I/O philosophy shall not be allowed

• Process field switches like level switch; pressure switch, temperature switch etc shall not be used. In place of field switch, transmitters shall be used to provide analog signal

• Field instruments shall be intrinsically safe as per IEC6079-11, certified for EEx-i(a), suitable for Zone 0, IIC / T6, irrespective of plant's hazardous area classification.

• All field instruments shall be weatherproof to IP 67.Min.

• UPS power supply (110 V AC, 50 Hz) for whole instrumentation system shall be equipped with half an hour battery back-up source as a minimum, for safe shutdown of plant, in case of total power failure.

The above specification of the instrument/instrument systems are from the perspective of integration of the subject package with DCS/ESD systems. However Instrument specifications will be provided in detail under the heading of Field Instruments.

3.2 SPECIAL INSTRUMENT SYSTEMS

Special Instrument e.g Analyser Systems, Chromatograph, Temperature, Flame detection and standalone Vibration monitoring systems are generally considered under the purview of Special Instrument Systems. For CO2 dryer package the following special instruments shall be considered.

3.2.1 Analyzers

3.2.1.1 General

• In general analyzer and sampling systems shall be designed and constructed in accordance with API-MPMS (Relevant portions). Analyzers shall be suitable for outdoor installation and the specified environment. Vendor shall not offer any prototype instruments in his bid. All instruments offered should 'have been proven in refinery or petrochemical plants before bidding.

• No single analyzer (detection system) shall be used for measurement of more than one component . Process Stream sampling shall be continuous. As a minimum, all analyzers shall provide one isolated 4-20ma signal along with 2 potential free contacts to the control system. In addition to the above, IR analyzers shall be provided with 2 wire RS485 serial link with MODBUS protocol for communication with central DCS.

• Specific Analyser Guidelines: Type of analyzer selected shall based on process data. All field transmitters including Gas and Liquid Analyzers shall be Microprocessor based and SMART with HART protocol, 24 V DC, loop powered and intrinsically safe to EEx-i(a) and Wp to IP67, irrespective of plant’s hazardous area classification. Wherever two wire 24 VDC, loop powered versions are not available, these shall be powered with 110 V AC UPS @50Hz and the enclosure shall be Flameproof to Ex-d IIC/T6 and WP to IP67, irrespective of plant’s hazardous area classification.





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• Analyzers shall meet Zone 1 requirements unless the analyzer is located in a non-hazardous area and the composition or amount of the sample inside the analyzer is insufficient to produce an explosive or ignitable mixture in the event of component failure or leakage. Equipment associated with the analyzer operation, located within an analyzer room, shall meet at least Zone 2 requirements. All analyzers electronic enclosures shall be Flameproof to Ex-d IIC/T6 as per CENELEC / ATEX and Weatherproof to IP67 (Suitable for Zone-1 and Zone-2 environment). Approved analyzers and equipment which are required for hazardous areas shall be labeled, listed or certified by an internationally recognized testing organization such as Underwriters Laboratory (U.S.A.), BASEEFA (U.K.) OR P.T.B. (Germany). Where such equipment is not available, its design shall conform to standards of a nationally recognized testing organization. Purging of cabinets, analyzer systems etc shall be avoided as far as possible. Where there is no other option but purging to meet area classification, purging shall be carried out as per NFPA-496 " Purged Enclosures for Electrical equipment"

• Analyzers shall operate within specification at ±10% of the specified A.C power supply voltage and ± 2Hz of specified frequency. The analyzer power supply shall be provided from UPS via PDB located at central cabinet room. The power supply shall be 110 V AC @ 50Hz only.

• Unless otherwise specified material of all components wetted by sample shall be ANSI 316 SS materials of construction for all wetted part components shall be chosen to prevent reaction of materials with the sample, absorption of components from the sample and entrance of contaminants through osmosis or Diffusion.

• Repeatability shall be ± 1 % of span or better and Sensitivity shall be ± 0.5% of span.

• Analyzer enclosures and accessories shall be suitable for the specified electrical area classification. As a minimum, the electronic unit of all the analyzers shall be to the following standards :-

- Weather proof housing : IP65 as per IEC-529 / IS-2147

- Flame proof housing : Flameproof to Ex (d)-IIC/T6 as per IEC-79 / IS-2148 (Flameproof equipment shall also be made weatherproof) with isolated analog output circuit which shall be intrinsically safe to EEx-i(a).

• All interconnecting wiring shall be color coded / numbered and terminal blocks clearly identified.

• The design of analyzer system shall be in compliance with the electromagnetic compatibility requirements as per IEC-801.

3.2.1.2 General sampling system

• Separate sampling systems shall be provided for detection of each component unless stated otherwise. The sampling system shall be furnished with all the necessary equipment and accessories to condition and regulate the sample so as to supply the analyzer with a continuously representative and measurable sample.

• The sampling system shall be engineered, designed, fabricated and furnished completely assembled as an integral part of the analyzer or as a separate package. The sampling system shall be designed on the basis of the utilities available as indicated in the basis of design of this enquiry specification. The analyzer Vendor shall provide a completely fabricated sample conditioning system.

• Each sampling system component shall be capable of being removed without disassembling the entire system.





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• If a separate sampling system is furnished, it shall be designed for easy integration with the analyzer in the field.

• Sampling system design shall be such that the sample drawn for analysis is truly representative of the process stream. Extra care shall be exercised in the selection of the various components forming the sampling system. Minimum material of construction for the sample system components shall be SS 316.

• Sampling system shall be designed to move the sample from the process to the analyzer proper in the shortest possible time. Transportation time for the sample from the process tapping point up to the sampling system shall not exceed 30% of the cycle time specified for the analyzer. Sample tube material shall be selected based on process fluid requirements and tube size shall be recommended by vendor to suit process condition and avoid possible plugging. Any heat tracing requirement of sample tubing such as condensible process vapour shall be fulfilled using appropriate tracing with temperature control. No sample shall be vented to atmosphere unless specifically indicated otherwise. Sample disposal scheme shall be as per P&ID or agreed upon before implementation.

• Sampling system shall consist of one or more of the following components as required by the service conditions: filters (coarse and fine) pressure regulators, relief valves, flow indicators, flow controllers, temperature indicators, scrubbers, heaters, coolers, dryers, sample pumps, aspirators, flame arrestors, solenoid valves, etc. Any additional equipment required shall be included by Vendor. Vendor shall provide the facility of Auto calibration using solenoid valves unless stated otherwise.

• Filters shall be always dual and it shall be possible to remove and replace one of the filters without upsetting the operation of the analyzer. Pressure reduction where required, shall be provided with a safety valve downstream. Variable area flow meters shall be provided for Fast Loops.

• The sampling system, analyzer, etc. shall be supplied pre-mounted on a self-standing panel in general. The panel shall have holes to anchor it to the ground with anchor bolts. The panel shall be weatherproof to IP 55, as a minimum. All components in contact with the sample shall be stainless steel unless otherwise specified

• Process sample return point, if needed and utilities as required will be made available near the analyzer at pressure and temperature conditions specified in the data sheet for each analyzer as single point supply and return. In general, all the offered items are to comply with maximum pressure and temperature data specified. Multi-point distribution of utilities and process sample as needed, is to be arranged by vendor following good engineering practices.

• Consumables / accessories such as Calibration cylinders, Gas blending cylinders, Fuel gas cylinders, carrier gas cylinders etc. shall be supplied along with the analyzer system keeping in mind the requirement for Start-up, commissioning and 1 year's normal operation. Calibration gases shall be furnished with testing and validity certificates. Cylinders shall be stored external to the analyzer room with suitable mounting accessories for the same. Cylinders shall be supplied in 2 sets such that at any point of time, 1 set is in use and the other is in line for redundancy for carrier/fuel gases and for storage / refilling for calibration gases. Proper certificates w.r.t pressurized calibration cylinders shall be obtained from authorized bodies.

• The sampling system shall contain at least one wire mesh strainer of US standard sieve mesh size 100 or finer. Where data sheets indicate greater possibilities of plugging, Vendor shall provide more filters / separators as required. Where data sheets indicate possibilities of polymer formation of presence of excess polymers, vendor shall offer suitable design features to minimize plugging because of polymer residue.





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• Wherever the process stream pressure is low, vendor shall provide the sample pumps. vendor shall also indicate the utility requirements (e.g. Water or air) for such device. Sampling system shall include provision for connection of calibration standard.

• When fast loop is specified, vendor shall be provide flow meters for sample bypass flow. Sample return line to process shall be provided with isolation valves and check valves. In case of multi stream gas chromatographs, separate fast loop return lines shall be provided for each stream. Return pressure shall be higher than the pressure of the process destination point.

• Interconnecting wiring shall be color coded and numbered. All terminal blocks shall be dearly identified, and all individual terminals shall be clearly marked. All terminals used shall be WAGO make, screw less, side/side entry type, DIN rail mounted and as a min. suitable for 0.5 sq mm to 4.0 sqmm size cables. Bigger size and fused type WAGO terminals with the same specifications may be used based on the requirement. Vendor shall take care for separation or shielding of power and signal lines, or both.

• All electronic components/devices/instruments and related enclosures in SHS or part thereof shall be Flameproof to Ex-d IIC/T6 and WP to IP67.

3.2.1.3 pH & Conductivity analyzers

• The pH and conductivity type analyzers shall be with solid state sensors, 24 VDC, 2 wire, loop powered transmitters with SMART (HART) protocol and LCD. The electrode / sensor shall not have pre-amplifiers. The pre-amplifiers shall be part of transmitters. The ph and conductivity analyser shall be supplied with all accessories like flow chamber, sample handling system, etc. The mounting hardware shall be of S304 MOC. The cable between sensor and transmitter shall be min. 5 meter with SS armor. The mounting shall be 2” pipe mounting for transmitters. All type of pH and conductivity transmitters shall be intrinsically safe to EEx-i (a) and ATEX/CENELEC approved suitable for Zone-0, Gas Group-IIC/T6 area and Weather proof to IP67, irrespective of plant’s hazardous area classification.

3.2.1.4 Density / specific gravity analyzer

• The analyzer system shall consist of the following : 1. Sampling system 2. Detector, amplifier, transmitter electronics 3. Converter

However, vendor may offer direct probe type detector without a sampling system if the service conditions permit. In such a case, design shall ensure on-line removal of detector without any process upset and all system components shall be capable of withstanding max. design pressure/temperature of process fluid.

• The sensing portion shall not employ any mechanical moving parts.

• The measurement of density of liquids shall not be affected by variation in pressure, flow rate or viscosity of the process fluid. The density / specific gravity sensor shall have built in temperature compensation.

• The converter shall be a microprocessor based programmable unit and shall provide isolated analog current output as specified in the data sheet.

• The analyzer must offer +/-0.1% of span accuracy and +/-0.01% of span repeatability.

3.2.1.5 Moisture analyzer

• The analyzer system shall consist of the following :





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o Probe assembly or cell o Sampling system o Transmitter electronics o Analyzer control unit

• Probe Assembly o The probe when mounted inline shall not be damaged by severe shock and vibration

conditions. o Each probe shall be supplied as calibrated and shall be provided with its own calibration

curve.

• Analyzer control unit

• The control unit shall be solid state programmable type. The electronics shall be self calibrating.

The control unit shall provide the following: o Isolated analog current output signal o A built in dual high and low set point alarm with SPDT contacts rated 5 amp at 110V AC. o Direct read-out of ambient temperature in LCD o Automatic sequencer of sequential readings of same points in multi stream analysis.

• The following performance characteristics shall be met as a minimum.

Accuracy : ± 1% of full scale Repeatability : +/- 0.5% of full scale Sensitivity : 0.5 parts per million by volume

3.2.1.6 Analyzer system documentation

Copies of all instruction manuals and drawings shall be supplied for all the analyzer. These shall cover the following as a minimum

• Internal wiring diagrams,

• Interconnecting diagram showing all connections and shielding requirements.

• Markings for wire color coding or numbering, and for terminal identification, shall be identical to those actually in the analyzer

• Complete hook up diagram of all analyzer, a drawing of pipe connections for the analyzer and sample conditioning system.

• Detailed installation instructions,

• Calibration procedure

• Complete parts list

• Recommended spare parts for two years operation & commissioning

• Troubleshooting procedure

• Bill of materials for the sample conditioning system showing manufacturer's catalogue numbers for all major components,

• Copy of the factory inspection sheet and test/calibration reports

• Copy of the testing organizations certificates showing the analyzer's suitability for use in hazardous atmospheres.





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• System wiring diagram including analyzer / chromatograph, programme and communication interface etc.

• Wiring detail of communicator link and MODBUS protocol software details

• Circuit diagram of all electronic PWA.

• Cabling details including shielding / grounding requirements..

3.2.1.7 Analyzer testing and inspection

When the analyzer and associated sample conditioning equipment are completely assembled, they shall be subjected to inspection by GNFC. For a factory test as follows:

• Apart from visual inspection, test and Bill Of Material checking for complete system, the test shall be an operating test and it shall be the Vendor’s responsibility to provide all facilities to demonstrate the analyzer in accordance with the specifications.

• GNFC shall witness and approve all factory tests and reserves the right to approve the test procedure.

• Repeatability shall be demonstrated continuously for a period of eight hours minimum using a standard sample.

• For samples, which deteriorate over an eight-hour period, repeatability may be demonstrated by calibrating the analyzer before and after eight hours of operation and comparing results of calibration. Results should check within ±1%.

• Calibration shall be demonstrated with a test sample, giving approximately one half scales reading for the component of interest. The concentration of the component of interest for this test shall be at least 25% of span difference from the concentration of the same com-ponent in the standard sample used for the repeatability test.

• For infrared analyzers, the proportion of the components in the test sample shall be varied to demonstrate freedom of interference from components other than those of interest.

• A leakage test shall be conducted on the entire system. Maximum permissible leakage rates are as follows: -

- Gas systems, 5% change per hour of the specified design pressure - Liquid systems, no visible leakage.

3.3 FIELD INSTRUMENTS

3.3.1 General 3.3.1.1 Degree of Protection

• Systems enclosures shall have a degree of protection in accordance with IEC 60529, protection code IP 56 as a minimum. Preference to IP-65 due to heavy rains/storms. Cable glands to be IP-66 to avoid ingress of locally present electrical conductive dust.

• All field instruments shall be damp-proof and dust-proof, minimum protection class as per IEC 529 shall be as follows:

Electrical / Electronic instruments : IP 67





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Sensors; RTD, T/C, etc. : IP 65 Local Gauges; PG, etc. : IP 55 Pneumatic instruments : IP 54 Solenoid valves : IP 67 Local Panel / Skid Mounted Panels : IP 55

• All electronic instruments and junction boxes in the field shall be provided with individual FRP or aluminum fabricated canopies of minimum 2 mm thickness.

• Local panels at machine/package unit shall be used only for Local Push Buttons and a few clustered LED type Lamps for start/stop and health/running status indications of machine/peripherals and initial start up procedure only. The field mounted Local Panel shall be weather proof to IP55 as a minimum. If panel is installed in hazardous location, all push buttons/clustered LED type lamps etc. and all other sundry hardware installed inside the local panel shall be certified for Flameproof to Ex-d IIC/T6 as per CENELEC/ATEX, if not interfaced with intrinsically safe circuits/barriers from control room/cabinet room. Purged panels are not acceptable. The panel make shall be RITTAL only and color shade shall be RAL7032.

• All Emergency trip pushbuttons on Local panel shall be triplicated with 2oo3 philosophy with 3-switching elements in pushbuttons.

3.3.1.2 Measurement & Control

• Field transmitter shall of 2 wire, 24 V DC, SMART with HART protocol and with local LCD type display and shall be certified as Ex’ia', T6, IP65 as minimum.

• All Switch function shall be snap acting, Single-pole Double Throw (SPDT), hermetically sealed and potential-free gold plated contacts.

• Foundation Field Bus/ PROFIBUS or any other cluster/Multiplexer type I/O philosophy shall not be allowed.

• Minimum contact rating for disconnecting inductive loads shall be: - 1.0A for 24-48 V DC - 0.4A for 110-125 V DC - 5.0A for 60-260 V AC

• Ranges used for measurement and control instrumentation shall overlap alarm and trip settings by minimum 5% of the span.

• Mercury, Asbestos and asbestos compounds are not allowed.

• All field instruments, junction boxes, cabinets, panels etc. shall be provided screwed SS tag plate with tag no. engraved or embossed on it.

• All remote seal diaphragm type Pressure and Diff. pressure transmitters for pressure, diff. pressure, and flow and level application shall have 2” size Flange with diaphragm as process connection. The minimum pressure rating for this diaphragm flange shall be ANSI 300#.

• Instrument air headers, pipes and distributors shall be of SS304 and all tubing shall be of SS316, ½” or ¼” OD, seamless tubes, laid in perforated aluminum trays. All intermediate fittings shall be double compression, SS316 MOC, Swagelok double compression type only.

• Process field switches like level switch; pressure switch, temperature switch etc shall not be used. In place of field switch, transmitters shall be used to provide analog signal.





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3.3.1.3 Signal Types & Transmission

• In general the loop power will be supplied by the systems. - Analog Signals with standard 4 – 20 mA DC signals (24 V DC, two-wire system) shall

be applied as measuring inputs and controller outputs. - Where 2 wire system is not suitable, 4 wire transmitter with isolated 4-20 mA DC

output signal and 110 V AC UPS supply shall be used. - Proximity signals shall 2 wire NAMUR sensors as per EN 60947 (NAMUR). - Digital signals may be applied either as potential-free inputs.

• All the power/control and signal cables in a single or multi pair cables between field instruments to field junction boxes and between field junction boxes/local panels to the central cabinet room shall be thru’ overhead perforated cable trays / MS cable duct with min. 3 mm thickness on the pipe racks. No underground cabling for allowed.

• All the fiber optic cables / system cables, special cables shall be laid in GI conduit preferable in overhead trays/duct only. All type of single and multi pair power, control and signal cables in the field shall be with GI armored only for mechanical protection. All the cable exchange between the central cabinet room and field instrumentation shall be from any one side of the cabinet room through MCT blocks.

3.3.1.4 Accuracy and Repeatability

• Consideration shall be given to the relevant function of the instrument and/or system, its required accuracy and repeatability, the maximum obtainable industrial accuracy and its repeatability.

• Custody transfer instruments shall be submitted to a National Inspectorate of Weights and Measures for verification and certification (e.g. flow metering, tank gauging, weighing).

• The characteristics of sensing devices shall be specified to meet the following requirements:

• Measurement error (accuracy) percent value of span, unless stated otherwise, not worse than:

o ± 0.075 % for pressure transmitters. o ± 0.075 % for differential pressure transmitters and multi parameter transmitters. o ± 0.25% in case of special flow turn down requirements only. o ± 1.0% of calibrated range (acc.class 1) for pressure gauges. o ± 1.5% for (differential) pressure gauges. o ± 1% for ultrasonic flow measurement. o ± 0.5% for level and temperature transmitters. o For mass flow meters: a. ± 0.1% for liquid flow. b. ± 0.5% on gas flow. c. ± 0.1 kg/m³ on liquid density. d. ± 0.1 kg/m³ on gas density.

o Hysteresis shall be maximum 0.1% of the range. o All dp transmitters shall have minimum static pressure rating of 250 kg/cm². o Ambient temperature variation of 40 °C shall not change output signals by more than

1% of the range.

3.3.1.5 Electromagnetic Compatibility (EMC) The design of electronic instruments should be in compliance with the European Community (EC) harmonized codes and standards, which includes Radio Frequency Immunity (RFI) and EC 61000 electromagnetic Compatibility





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3.3.1.6 Instrument air supply

• Instrument air shall be used for the pneumatic operated actuators (e.g. control, on/off valves).

• Instrument air may be used for purging purposes, for pressurizing of instrument enclosures and breathing (safety) masks.

• All control valve actuators shall be sized at max. 4.0 kg/cm2g instrument air available at control valve.

• All the air to instrument control valves and individual consumer shall be routed thru’ 10 way instrument air manifolds from the field. Air manifold, instrument fittings, tubing and needle/ball valves shall be of SS304 MOC as a minimum. Instrument Air header MOC shall be CS up to individual air manifold. All air manifold shall be SS304 and further instrument air tubing shall also be SS316. The size shall be 1/4" OD up to 4" size valves. For valves with 6" and above size, the same shall be 1/2" OD SS tube.

3.3.1.7 Instrument Power Supply:

• The instrument power supply systems shall be used for instrumentation purposes only.

• Field instruments which are loop powered shall be used. Field instruments requiring a separate power supply shall be avoided. The loop powered transmitters shall be always 24 V DC, 2 wire, 4-20 mA DC signal type and HART with SMART protocol.

• Where two wire transmitters are not possible, 4 wire transmitters with 110 V AC supply shall be selected. The supply to these instruments shall be fed from central cabinet room located UPS PDB only.

3.3.1.8 Field Transmitters:

• All field transmitters shall be 2 wire type, 24 Volt DC, loop powered, SMART with HART protocol, and shall be equipped with Local LCD type digital indicator.

• The transmitters shall be suitable for 2” pipe mounting and shall be supplied with SS304 MOC mounting brackets, hardware, nut/bolts, etc.

• The basic accuracy of all transmitters shall be 0.075% of span or better with 1:30 rangeability to reduce the inventory. The accuracy shall remain constant throughout the above range. However the overall rangeability shall be 1:100.

• All transmitters shall be supplied with local digital display configured in engineering unit.

• All transmitters shall be supplied with ½” NPT (F) cable entry and either ½” NPT (F) process connection.

• All transmitters shall be supplied with SS304 MOC, double compression cable glands, certified for weatherproof to IP67 with PVC hood.

• Wherever the above requirement of 2 wire, 24 V DC transmitters can not be fulfilled, the 4 wire transmitter (SMART with HART protocol) option shall be used such as RADAR type level transmitters, Magnetic Flow meters, Mass Flow meters, etc. All theses device shall be powered with 110 V AC UPS supply only. The power shall be fed from PDB located at central cabinet room.

• All the field transmitters/devices/instruments shall be Explosion proof to EEx-i (a), irrespective of plant hazardous area classification, to maintain interchangeability. Hence all field instruments shall be intrinsically safe as per IEC6079-11, certified for EEx – i(a),





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suitable for Zone-0, Gas Group IIC/T6, as per CENELEC/ATEX, irrespective of plant's hazardous area classifications. All field junction box shall be weatherproof to IP67 and all cable glands shall be of SS-304 MOC, double compression type, weatherproof to IP65 with PVC hood for field application. All instrument cables shall be IS type. All field junction box shall have min. 30% spares. All the field instruments shall be weatherproof to IP67.

• Through-out the complete project, only one philosophy of intrinsically safe field instrumentation shall be followed. Wherever intrinsically fail safe design is not available, only at those locations, only Flameproof to Ex-d IIC/T6 design shall be used with prior approval of GNFC.

• The wetted parts MOC of all transmitters/devices/instruments shall be suitable for process fluid, pressure and temperature. However min. SS316L is required.

• All DP transmitters used for flow/level and PDI measurement application shall be supplied with 3 way valve, SS316 MOC Manifold. All Pressure transmitters used for Pressure measurement application shall be supplied with 2 way valve manifold with SS316 MOC. The process connections shall be ½” NPT(F).

• All the transmitters’ housing MOC shall be die cast aluminum and it shall be supplied with EPOXY paint, suitable for protection against harsh environment. The lower housing MOC for various transmitters shall be SS316.

• While designing, a care shall be taken to choose transmitters ranges/ rangeability, etc. for various applications in such a way that there shall be min. type of diff. models of the same category of transmitters are to required to be maintained as spares.

• For all remote mount transmitters, the sensor and transmitter cable shall be with min. 15 meter in length and it shall be either armored or shall be laid in PVC protective conduit only.

• Head mounted Temperature transmitters are not acceptable. All temperature transmitters, wherever applicable shall be remote mount type only with dual compartment design.

• All remote seal diaphragm type PT/DPT transmitter size shall be 2” and irrespective of pressure rating, the minimum pressure rating for flange shall be ANSI 300#. However in case of measurement of vary low range pressure ( in the range of vacuum to 0.5 Kg/Cm2g)with remote seal diaphragm type , the diaphragm flange size shall be 3”

• All remote seal diaphragm type PT/DPT shall be supplied with min. 5 mtr. of capillary with SS armored in PVC sheath for protection on either sides(HP/LP).

• The following types of reports/certificates should at least be considered: o EC declaration of conformity; o Calibration report; o Functional test report; o Welding procedure/report; o NDE report; o Material certificates; o Electrical certificates; o IBR certificates for IBR service control valves, PSV, orifice assemblies, level gauges,

thermowells, annubars.

• The material components, which come into contact with the fluids to be measured, shall be resistant to corrosion caused by said fluids. It shall be compatible with the piping material when being clamped, welded or connected by other methods.

• All instruments and equipments shall be suitable for use in specified site climatic conditions and industrial environment in which corrosive gases and / or chemicals may be present. All





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external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere with epoxy painting / powder coating.

• The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirements as per IEC 801 'Electromagnetic Compatibility for Industrial Process Measurement and control Equipment.'

• All in-line instruments shall be with flanged connection. Sandwich type connections shall not be used. Pressure rating for all instrument items shall be ANSI 300 # minimum. For pipe classes with higher pressure rating the same shall be as per pipe class. For pressure class 600 # and above RTJ type connections shall be used. All thermowells with class 600# and above rating shall be welded only.

• Flange ratings for instruments may differ when instrument flanges and the mating flanges on piping / equipment are of different materials (e.g. SS-316 thermowell on CS pipes). VENDOR shall in such cases, ensure that the rating of flange is chosen for the instrument and the corresponding flange on piping / equipment.

• Material of process wetted parts shall be SS-316 minimum. Superior material shall be considered, if required, as per the process medium. This is a common requirement for all Instruments and hence applicable even if not explicitly specified against each type of instrument in the succeeding pages of this specification.

• Instruments like control valves, orifice flanges, level instruments, thermowells, etc. coming on pipes and vessels under Indian Boiler Regulation (IBR) shall be certified by IBR. (or IBR authorized representative if procured outside India).

• Piping/Instrument scope change for instrumentation shall always be after first isolation/drain valve for all types of instruments, including local Pressure gauges.

• Instrument air and impulse tube size shall be either ¼” or ½’ OD, SS MOC only

• All instruments for custody transfer shall have certification from weights & measures authorities.

• Transmitters shall be mounted on nearest platform / grade level keeping in view requirements of readability and accessibility.

• All instruments shall have an integrally mounted terminal box to terminate armored cables. Instruments with loose flying leads shall not be used.

• Canopy made of bolted Aluminum sheets shall be provided for all transmitters, electronic instruments and local panels housed in the open.

• All remote seal diaphragm type Flow, Pressure and Level transmitters shall be designed with 2” flange size. Also, irrespective of the pressure rating, the minimum pressure rating for all the flanged instruments shall be ANSI 300#.

• Irrespective of the pressure rating, the minimum pressure rating of all instruments nozzles, flange size shall be ANSI 300# ratings only. This includes control valves, orifice flange assembly, thermowell flanges, RADAR type level transmitters, Ultrasonic type level transmitters, Diaphragm type remote seal Pressure/Flow/Level transmitters, Magnetic and mass flow meters and any other flanged connection type instruments.

• For improving reliability and safety of operation and control, “2 Out Of 3” philosophy for Interlock shall be followed. The general guide line for selecting such loops may be a trip/interlock, which is causing complete plant shutdown, either directly or indirectly or causing production loss. This necessitates installing and connecting 3 transmitters for interlock purpose with PLC on the same parameter. If there is a closed loop control in DCS on the same parameter, there shall be fourth transmitter, dedicated for connecting with





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DCS. If at all installation of fourth transmitter is not possible (for ex. Level Tx on small vessel), a hardwired repeat output shall be taken from PLC to DCS for one / two transmitters for Control loop function.

• The local temperature gauges shall not be used in the whole project (including any of the package unit also). All temperature points shall be provided with either direct thermocouple (generally “K” type) or RTD (generally 3 wires, PT100) sensors with flanged thermowell assemblies, if meant for open loop indication. In all other cases, when a temperature measurements used in closed loops controls, trip interlocks / Logic or flow compensation, a field mounted, dual compartment design, 2 wire, 24 V DC, SMART transmitter shall be used, in addition to this.

• All thermocouple/RTD sensors shall be duplex type with Flanged thermowell along with nipple-union-nipple assly along with thermocouple head, certified to weatherproof to IP65 as a minimum. Thermowell shall be manufactured from drilled bar stock, tapered. The cable entry shall be ½” NPT(F) and complete assembly shall be provided with SS304 MOC, double compression cable glands certified for weatherproof to IP65 with PVC hood.

• Displacer type level transmitters and float type level switches with external / side mounted chambers shall have 2” flanged tapping size. Irrespective of pressure rating, the minimum flange rating shall be ANSI 300#.

• All instruments / devices shall be immune to interference due to normal walkie-talkies with output of 1W at UHF.

3.3.2 Temperature instruments 3.3.2.1 General

• All temperature measurement in the plant shall be carried out using only Thermocouple or RTD elements. No local temperature gauges shall be used throughout the project or any part thereof, including package unit instruments.

• All open loop temperature shall be carried with Thermocouple/RTD elements, which shall be directly connected with central DCS, without any temperature transmitters. These shall be connected to T/C and RTD type of input cards in DCS, respectively without any type of converters in-between.

• All closed loop temperature measurement, all temperature interlocks / logic related measurement, and all open loop temperature points, which are to used in Flow corrections or any other calculations, the measurement shall be carried with Thermocouple/RTD elements along with field mounted, Dual compartment design, 2 wire, 24 V DC, 4-20 ma, SMART temperature transmitters. No head mounted transmitters shall be used throughout the project or any part thereof, including package unit instruments.

• By default all temperature elements shall be duplex, unless otherwise specified. Irrespective of design pressure rating, the minimum pressure rating of Thermowell flange shall be ANSI 300#.

3.3.2.2 Thermowells

• All temperature elements shall be provided with thermowells, machined out of bar stock bar up to 600 mm length & of minimum 316 SS material for flange rating up to ANSI 600#. For thermowells above 600# rating, manufacturer may use their own design, which is proven and as per various recommended standards/practices. This could be welded with high pressure weldolet joints. The flange MOC shall be SS316 as a minimum. In case of corrosive and erosive services stellited thermowell shall be provided. The thermowell





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design shall ensure no air gap between the tip of the element and thermowell to minimize measurement lag. The internal diameter of thermowell shall be suitable for sensing element /bulk OD of mm or 8 mm.

• For very high-pressure applications (600# ratings and above), welded type thermowells must be used.

• The inside diameter of the finished thermowell shall be concentric with all other diameters with a tolerance of 0.2 mm.

• The thermowell shall be machined and rifle drilled to a smooth finish after welding and heat treatment. Surface finish of the stem shall be 10-15u inch (0.254-0.381 microns)

• All re-entrant angles shall be machined to a minimum radius of 3 mm.

• Built-up thermowells shall be used in low pressure and low velocity services like in fired heaters and also where thermowell immersion lengths greater than 600mm. (In all such cases, all welded joints shall undergo 100% radiography where radiography is not possible, dye penetration test may be carried out.

• All thermowells shall be assessed for resonance effects. Where Thermowells in lines subjected to high fluid velocities (exceeding 5 m/s for liquid and 20 m/s for vapors, gases), combined stress and frequency calculation shall be carried out by a proven method. In case the thermowell design fails vibration analysis , alternate design may be used by vendor. All design along with calculations shall be submitted for L&T's review.

• Immersion length U of the thermowell shall be as follows.

Line Size Immersion length

From 4' to 6" 280 mm

From 8" onwards 320 mm

Vessels / columns 400 mm

Immersion length is based on 200 mm length between flange face and inner wall of pipe. In special applications, where thermowell nozzle sizes are larger or where temperature is to be measured at any specific location, vendor shall decide the immersion length based on actual requirements.

• Any pipe line less than 4" nominal bore shall be blown to 4" size to installing the thermowells.

• All thermowell including and above 600# ratings shall be welded type.

• The preferred location for installation of thermowell shall be Elbows.

3.3.2.3 Temperature elements

• For all type of temperature measurement, either thermocouple or RTD elements shall be used depending on the requirements.

• All the temperature Elements shall be spring-loaded, duplex, mineral insulated and sheath MOC as SS316 as a minimum.

• Bulb OD of all the elements shall be 8 mm and the overall diameter of the sheathed element shall not deviate by more than 2%.

• RTD and Thermocouple metallic head assemblies shall be furnished with screwed in type heads / enclosure certified as Weatherproof to IP65 as a minimum; All head assembly shall have two ½” NPT(F) cable entry. All assemblies shall be supplied with either 1 no. or two nos. of double compression type SS304 MOC cable glands certified for weatherproof to





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IP65. Wherever second element is not in use, the spare cable entry shall be provided with ½” NPT SS304 plug.

• MOC for head assembly shall be die cast aluminum.

• The terminals shall be color coded as per element’s color code.

• Thermocouples shall comply with ANSI MC 96.1 and IEC 584, Eidtion-2, IS7358. They shall have wire size of 18 AWG for single and 20AWG for duplex elements.

• In general, the following guidelines shall be used for selecting thermocouple elements/wire size, as a minimum.

Type 8 AWG 14 AWG 18 AWG T >37’ C For all other E >871’ C >649’ C For all other K >1260’ C >1093’ C -do- S - - <1500’ C

• Thermocouples shall be compact Magnesium Oxide (MgO) filled and ungrounded, unless specified. Grounded junctions are to be used where fast response is required, if secondary system allows the use of grounded T/C elements. The insulation resistance shall be >100 Mega Ohm. The thermocouple wires shall be joined together by welding to form a hot junction. Bulb / Sheath diameter shall be 8 mm and the overall diameter of the sheathed element shall not deviate by more than 2%.

• The type of thermocouple shall be selected based on the following guidelines as minimum Copper-Constantan (ISA-Type-T) (-) 200 to 200°C Chromel-Constantan (ISA-Type-E) 200 to 600°C Iron-Constantan (ISA-Type-J) 0 to 600°C Chromel-Alumel (ISA-Type-K) 600 to 1200°C Platinum Rhodium-Platinum (ISA-Type-S or B) 600 to 1600°C

• The design of thermocouple assemblies shall be such that replacement of elements shall be possible on-line. It shall be equipped with SS304 MOC Nipple-Union-Nipple Joints. Assembly shall include nipple-union-nipple (1/2" NPT threaded) to allow approximately 150 mm between top of well and bottom of head, when made up.

• Thermocouple sheathing material shall be 316 stainless steel as a minimum and are constructed from a seamless tube with a wall thickness of at least 1 mm. Inconel 600 sheath shall be used for all application, where the temperature is above 600⁰C.

• RTD (Resistance Temperature Detector) shall be 3 wire type platinum elements with 100 ohms resistance at 0°C. RTD shall be calibrated as per IEC 751 / DIN 43760.

• RTD shall be used for a temperature range of -200 to 650°C. RTDs shall be three-wire.

• RTD shall generally be selected for applications requiring low temp with comparatively shorter temperature span requiring accuracies of better than +/-0.25%.

• All RTD elements shall be duplex by default. It shall be compact Magnesium Oxide (MgO) filled. The insulation resistance shall be >100 Mega Ohm.

• The design of RTD assemblies shall be such that replacement of elements shall be possible on-line. It shall be equipped with SS304 MOC Nipple-Union-Nipple Joints. Assembly shall include nipple-union-nipple (1/2" NPT threaded) to allow approximately 150 mm between top of well and bottom of head, when made up.





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• RTD bulb sheathing material shall be 316 stainless steel as a minimum and are constructed from a seamless tube with a wall thickness of at least 1 mm. Bulb/ Sheath diameter shall be 8 mm and the overall diameter of the sheathed element shall not deviate by more than 2%.

• The sheath MOC shall be selected based temperature and sulphur shall be selected based on temperature and sulphur content.

• Class 'A' / Class '1’ tolerance as per IEC 751 / 584-2 shall be specified for all RTD and thermocouple sensors in complete temperature measurements for all open/closed loops and interlocks/Logic.

3.3.2.4 Temperature Transmitters

• Head mounted temperature transmitters are not allowed at any location, throughout the project or part thereof. Field mounted transmitters shall be used for all temperature transmitters.

• Field mounted, Dual compartment design, temperature transmitters shall be specified for all closed loops in DCS, for all interlock inputs to ESD and all open loops in DCS, which are taking part in Flow correction or any other calculations. Remaining all other T/C & RTD for open loops, which are only for monitoring purpose shall be directly connected to DCS without temperature transmitters.

• All the Temperature transmitters shall be, 2 Wire, SMART type with HART protocol.

• Temperature transmitters shall be suitable for 2” pipe mounting and shall be supplied with all SS304 mounting brackets/nut/bolts, etc.

• All temperature transmitters shall be equipped with local, LCD type digital indication which shall be configurable in engineering unit.

• Temperature transmitters shall have a built-in linearising function.

• The minimum accuracy of all the temperature transmitters shall be 0.1% of FSD

• All transmitters shall be of universal input type, so that it can accept all type of Thermocouples or all type of RTD inputs with 2/3/4 wire options. This feature is a must to reduce inventory and have interchangeability of various transmitters.

• Burn out protection shall be provided with temperature transmitters. Upscale or downscale or holding last good value options shall be programmable in the transmitters.

• All the transmitters shall be provided with min. two cable entries with ½” NPT(F) size. One entry shall be used for sensor cable input and other shall be for 24 V DC/2 wire output cable.

• Irrespective of plants hazardous area classifications, all the temperature transmitters shall be intrinsically safe, i.e. Explosion proof to EEx-i(a) suitable for Zone-0, Gas group-IIC/T6 as per CENELEC/ATEX and weatherproof to IP67 as per IEC529.

• Transmitter housing MOC shall be die-cast aluminum with epoxy paint as a minimum.

• Each temperature transmitters shall be supplied with min. of two nos. of double compression type, SS304 MOC, cable glands with PVC hood. Cable glands shall be Weatherproof to IP65 as per IEC529.

3.3.3 Pressure Instruments





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3.3.3.1 Pressure Gauges & Differential Pressure indicators

• Gauges shall conform to the requirements of BS 1780 gauges of the elastic element type, unless-otherwise specified.

• All the Pressure gauges’ dial shall be white, non-glaring and non-rusting plastic with black figures. Dial size shall be 150 mm. Dial cover shall be of shatterproof glass. The dial face shall be marked with pressure element material. Pointers shall have micrometer adjustment. Pressure gauges shall have feature like screwed bezels, externally adjustable zero, over range protection and blowout disc.

• Pressure gauge sensing element shall be of SS 316 and movement of SS 304, as a minimum except where the process requires a special material. For general use gauges shall use a bourdon tube as measuring element. The movement shall be either rotary geared or cam and roller type. The movement mounting shall be integral with the bourdon tube socket.

• For low pressure and vacuum services pressure gauges with capsule sensing element to be used.

• The elastic element material, unless specified otherwise, shall be as follows: - For ranges 60 kg/cm2 g and less, AISI-316 seamless drawn stainless steel tube,

argon arc welded at AISI-316 forged or wrought stain less steel tube anchorage and tube end piece.

- For ranges above 60 kg/cm2 g, AISI-316 bored stainless steel otherwise as above.

• All pressure gauges and diff. pressure gauges Cases shall normally be of 304SS and weatherproof to IP-65 as per IEC-529 / IS-2147.

• Safety blow out discs shall be provided for all gauges and shall be located in the back or side of the case. For pressure gauges with maximum operating pressure below 60 Kg/cm2g, the minimum size of blow out disc shall be 1" and for maximum operating pressure of 60 Kg/Cm2 and above, pressure gauge shall be safety type with solid front where pointer and gauges are partitioned from the sensor by a solid disc of 316SS material.

• Pressure gauges shall have an accuracy of ± 1% of full scale as a minimum. Differential pressure gauges may have an accuracy of 2 % of full scale.

• Gauges shall be able to withstand, over-range pressure of 1.3 times the calibrated range for at least 30 minutes as standard without zero or calibration shift.

• Over-range protection such as gauge savers shall be provided where the process pressures may exceed 1.3 x full scale deflection. Gauge savers if provided shall be of non bleed type with internal pressure release/block.

• Ranges shall be so specified that the gauge normally operates in the middle third of the scale and shall conform to IS-3624 standard dials, wherever possible.

• Process connection shall normally be 1/2" NPT(M) bottom, except for diaphragm seal where 2” flanged connection shall be used in general. Irrespective of design pressure, the minimum pressure rating for the flange shall be ANSI 300#.

• Connection shall normally be 316SS unless otherwise the special material is required.

• Socket stem shall extend a minimum of 1 ¼” beyond gauge case and shall be provided with wrench flats.

• Diaphragm seals, filled type shall be furnished where plugging of the element may occur or where suitable material is not available in highly corrosive services. When chemical seals





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are required, they shall be provided with fabricated vent and drain arrangement. Diaphragm seal device shall be furnished completely assembled with the pressure gauge.

• Remote seal Diaphragm type pressure gauges with capillary shall be used wherever required for access and visibility. Use of Schaffer diaphragm type gauges will be avoided as far as possible.

• The diaphragm seal devices shall be stainless steel SS316. The flange MOC and Diaphragm rings and top housings shall be of SS304, unless a special material is required.

• Liquid filled gauge shall be used where extreme vibration of the gauge is expected. Glycerin or other suitable case filling liquid with non coloring property shall be used.

• An inert liquid shall fill the entire system between the diaphragm of the diaphragm seal device and the elastic element. Unless otherwise specified, filling liquid shall be suitable for an ambient temperature range of -18°C to 204°C.

• Oxygen service pressure/diff. pressure gauges shall be supplied with special inert fluids and shall be free from grease/oil. These shall be clearly marked with “For use in Oxygen services”.

• Receiver pressure gauges for local/ local panel or those of electro-pneumatic positioners’ input/output indication shall have 100 mm dial with stainless steel element and 1/4" NPTM back side connection.

• Pneumatic indicating receiver gauges shall conform to the applicable parts of this specification except as follows: - Elastic elements shall be SS designed for a 0.2 to 1 kg/cm2 g (3 to 15psig) pressure

range, but shall be able to withstand 1.4 kg/cm2 g (22 psig). - Dials shall be graduated for the range specified on the data sheet, with an additional

scale graduated 0.2 to 1 kg/cm2 g (3 to 15 psig) linear. - The dial range shall correspond to the 0.2 to 1 kg/cm2g (3 to 15 psig) element range

in the data sheet specified. (For example, when the range specified is 0-100, the "0" marking on the dial shall correspond to 0.2 kg/cm2 g (3 psig) and the "100" marking to 1 kq/cm2 g (15 psig).

• Over range protector and pulsation dampener, whenever used, shall be of SS 316 as a minimum. Pulsation dampener shall be used for all pulsating services. It shall be floating pin type, externally mounted and externally adjustable.

• Gauge savers shall be used in all pump service applications.

• All type of Gauges shall be supplied with engraved labels stating tag no.

• Design materials, connections and accessories not specified herein shall be in accordance with the Vendor's standards, suitable for the specified service conditions.

3.3.3.2 Pressure & Differential Pressure Transmitters

• All the field transmitters for flow, pressure, differential pressure and level applications shall be 2” pipe mounted, 2 wire, 24 V DC, 4-20 ma dc, SMART with HART protocol.

• Irrespective of plant’s hazardous area classifications, all these transmitters shall be intrinsically safe, i.e. Explosion proof to EEx-i(a) suitable for Zone-0, Gas Group IIC/T6 as per CENELEC/ATEX and weatherproof to IP67 as per IEC529.

• The min. loop load shall be 600 ohm for 4-20 ma output circuit of transmitters. Transmitters shall be able to work between 12 to 35 V DC with 600 ohm loop impedance.





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• Transmitter lower housing shall be of SS316 unless otherwise specified. The upper housing of transmitter shall be of die cast aluminum with Epoxy paint as a minimum.

• Pressure/ Differential Pressure Transmitter shall have electronic capacitance, silicon resonant wire, piezo crystal or any other type of proven sensor technology meeting all functional specifications. Inductive type measuring principle is not acceptable.

• Diaphragm, Element material for transmitter shall be SS316L as a minimum, and shall be able to withstand over pressure of at least 1.5 times the maximum working pressure. Other wetted part MOC shall be selected based on process requirement.

• All remote seal diaphragm type pressure/diff. pressure transmitters shall have 2” Flanged diaphragm as process connection. Irrespective of design pressure, the minimum pressure rating for the flange shall be 300#.

• The transmitter shall be so constructed that in case of a pressure sensing diaphragm /element failure, the process material will not enter the electronic portion of transmitter or wiring conduits

• Transmitters shall be provided with external zero adjustment and shall have integral vent/drain.

• All the transmitters shall be equipped with Local LCD type digital indicator capable of indicating engineering unit display.

• The transmitter shall be microprocessor based and it shall incorporate a non-volatile memory, which shall store complete configuration data of transmitter. All necessary signal conversions, including conversion to produce output with the required protocol shall be carried out in the transmitter electronics. The design of electronic parts shall be in compliance with the electromagnetic compatibility requirements as per IEC 801

• Transmitter shall also run complete diagnostic routine. In the event of detection of failure, the output shall be driven to predefined value, which could be either minimum (4 ma), maximum (20 ma) or last good value. This feature shall be programmable.

• Built in temperature sensors shall be provided to compensate for process temperature and ambient temperature variations.

• Transmitter rangeability shall be 100:1. The transmitter shall be able to assure an accuracy of +/- 0.1% of span for a rangeability of 1:30. The accuracy shall include the combined effect of linearity, hysteresis and repeatability. Effect of static pressure on the transmitter in either direction shall be negligible.

• Care shall be taken while selecting the transmitter models that there shall be minimum type of diff. models of the same category of transmitters to reduce spare/inventory.

• Transmitter shall be selected so as to have calibrated range within turndown ratio of 1:10. The normal pressure shall be read at no greater than 75 percent of the calibrated range for transmitter reading steady pressures. For fluctuating services the normal pressure shall be read at 60 percent of the range.

• In case of differential pressure transmitter with remote seals, adequate care shall be taken to consider head pressure effect of capillary fill fluid while selecting the transmitter.

• The response time of smart transmitters shall commensurate with process. It shall be equal or better than the half of the total scan time of any critical loops for process requirement like anti surge controllers. In any case, this shall not be less than 30 updates per second.

• HART protocol of latest version shall be used and shall be suitable for HART maintenance system with corner stone or AMS like software with the following features as minimum:





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- It shall allow multi masters (two for example, primary and secondary) for configuration, calibration, diagnosis and maintenance.

- The primary could be control system or host computer and the secondary could be the hand held communicator or a maintenance computer.

- It shall be capable of implementing universal commands. It must be possible to communicate all the commands of HART maintenance system to field transmitter and smart transmitters shall be selected accordingly.

• The explosion proof transmitters shall have their calibration adjustment from out side without any need to remove the cover of electronic enclosure.

• Retrofit type SMART transmitters are not acceptable. The model selected shall be the latest from the vendors product range and proven in the field for minimum of 1 year of operation.

• For hydrogen gas service transmitters, Hastelloy wetted parts shall not used to avoid damage due to hydrogen ion permeability. It shall be SS316L only. In general for whole plant, Hastelloy diaphragm MOC is banned to prevent accidental interchangeability with other transmitters. By default, wetted part/diaphragm MOC shall be S316L only, unless otherwise specified.

• Process connection for standard pressure & differential pressure transmitter shall be ½” NPT(F) and 2 " flanged for diaphragm seal type. The flange rating shall be minimum 300# for Diaphragm seal element.

• Diaphragm seal element with capillary shall be used for congealing, corrosive and highly viscous services at high operating temperatures. Filled fluid shall be capable of withstanding the process temperature/pressure/fluid.

• Capillary shall be SS armored with PVC cover and 5 meter in length. Its ID shall be selected to have minimum lag.

• For all the diaphragm type pressure and diff. pressure transmitters, a Flushing rings with MOC suitable to process conditions, shall be provided with screwed vent & drain connections duly plugged.

• All transmitters shall be provided with integral two valve / three valve / five valve manifold as per the specific requirements.

• Design materials, connections and accessories not specified herein shall be in accordance with the vendor's standards, suitable for the specified service conditions.

3.3.4 Level Instruments 3.3.4.1 Level Gauge

• The Level gauge shall provide visible coverage of complete level transmitter / controller range and the alarm/ trip level switches. In the case of diff. pressure level transmitters where large spans are involved, a gauge located at the top, centre and bottom of the installation with overlap in visible area shall be acceptable.

• All gauges glasses shall be steel armored reflex or transparent type with body & cover material of forged carbon steel as a minimum and shall have mechanical & thermal shock resistant type toughened borosilicate glass with suitable gaskets. Bolting shall be of SAE 4140 steel.

• Transparent type of gauges shall be provided with internal illuminators operating at 240 V 50 Hz supply and suitable for electrical area class specified. Illuminator shall be of the





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plastic solid wedge type designed to give an even diffusion of light over the entire length of the gauge glass. All gauge glasses must have a rating equal to or more than the vessel design pressure and temperature and shall be provided with suitable metal guard.

• Reflex type shall be used for clean and colorless liquids like water and hydrocarbon service, except liquids interlace level.

• For low temperature, low boiling point services, large chamber type will be used. Transparent type will be used for light fluids, acids, caustic, dirty or viscous liquids, coloured liquids and liquids interface level. Transparent type with Mica or Kel-F shields shall be used for treated water, boiler and condensate services and for corrosive liquids which will attack glass. Tubular gauge glasses shall, in general, not be used. They may be used for non-hazardous services at ambient temperature and low .pressures.

• All gauges shall have top and bottom chamber connections, unless otherwise specified. Vent and Drain valves shall be fitted, as applicable. Vent and drain valve shall be provided with nipple and end caps. Drain and vent shall be of welded construction. Level gauges with side-side connections shall be avoided. Each gauge shall be provided with ball check valves & pipe union.

• Large chamber gauges with frost shields shall be provided for cold services, below 0’C. Frost shield shall be transparent plastic type covering full width of vision slot and suitably sealed to the glass.

Depth of Block Design Temperature 38 mm above-19 °C 75 mm -20°C to -49°C 150 mm -50°C to -99°C 200 mm below-100°C Heating jacket shall be provided for viscous liquids.

• The minimum readable liquid level from bottom tangent line for level gauge with top and bottom connections and when both the nozzles are from the side shall be 300 mm with/without standpipe.

• In general, the visible length of the level gauges shall be selected from the following. Visible length (mm) Centre to Centre Length (mm) 220 470 470 720 720 970 980 1230

• The maximum visibility length shall not exceed 1500 mm for a single gauge. Multiple gauges with overlapping range shall be used for such cases. For a given section, the visible length shall not be less than 90% of the total length of section.

• Float operated magnetically coupled gauges with 2" (50 mm) flanged end connections shall be used, for level gauging in very viscous liquids, liquids with crystals, sour services, toxic services and shall be of Bi-Color rolling cylinders/Balls.

• Bi-color type level gauges shall be used on steam drums. Larger chamber gauge glasses and an expansion loop between the top of the gauge and the top gauge valve shall be used. Level gauges on steam / boiler drums shall be in accordance with the latest requirements of the IBR code.

3.3.4.2 Level Transmitter





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• In general, differential pressure and/or RADAR type level transmitters shall be used for level measurement.

• In general Remote seal DP transmitters shall be used for all tank levels, KO drum levels and all tower level applications. Displacer type of level transmitter shall be used only for interface application. DP transmitters with diaphragm seals are envisaged, where condensing lag is required to be filled in normal DP transmitters, at all those locations, remote seal type DP transmitters are to be used. GNFC discourages the use of simple DP transmitters with lag filling. Also, wherever there is a control and interlock on level measurement, one transmitter shall be remote seal type diaphragm and one will be radar type level transmitter as per ITB. In general Remote seal DP transmitters shall be used for all tank levels, KO drum levels and all tower level applications.

• The process connection shall be 2” and irrespective of design pressure of vessel, the minimum rating for the flange shall be 300#.

• All types of level transmitters shall be 2-wire, 24 VDC, 4-20 mA output with LCD type local display.

• Irrespective of plant’s hazardous area classification, the level transmitter shall be intrinsically safe, i.e Explosion proof to EEx-i(a) and suitable for Zone-0, Gas group IIC/T6 and weatherproof to IP67. Transmitter shall have remote mount facilities as an option, in case of excess heat in the surrounding area.

• Transmitters shall have ½” NPT(F) electrical cable entry.

• The standard materials for Displacer and displacer chamber shall be SS316 and Torque tube shall be Inconel, as a minimum. Based on process fluid better options shall be selected.

• Finned torque tube extensions shall be provided as necessary for temperature service conditions.

• Differential pressure transmitter shall be used for level measurement above 1500 mm for services requiring purge or where liquid might boil in external portion.

• Differential pressure transmitters for use on corrosive or fouling service shall be diaphragm wafer with extended filled capillary type. The length of capillary shall be 5 mtr. with SS armored in PVC sheath.

• The process connection size shall be 2” Flanged for remote seal diaphragm type Level Transmitters. Irrespective of design pressure, the min. pressure rating shall be 300#

• Flush or extended diaphragm type differential pressure transmitter shall be considered for special applications only. Transmitters for closed vessel shall have correction for suppression or elevation.

• Diaphragm material shall normally be SS316L or better to suite process condition. Stainless steel.

• Dip Tube type level transmitters may be used on corrosive, congealing, slurry services, where suitable diaphragm seal type transmitter is difficult to obtain or where accuracy is not of prime importance.

• Diff. pressure type transmitters shall also be used in Level measurement applications. The specifications of the same can be found in section 4.4 of this document, at pressure measurement instruments specifications.

3.3.4.3 Tank Level Instruments





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• There shall be NO Mechanical float type gauges, Servo controlled level gauges or Ultra Sonic type level transmitters/switches for any of the level measurement/trip/alarm application. For all type of tank level instruments, a 2 wire RADAR instrument shall be used. Measurement accuracy shall be +/- 5mm or better for these RADAR type level instruments. There shall be one no. of 3" x 300# flanged RADAR type level transmitter on each tank in addition to normal / remote seal type DP transmitters.

• If the tank is for product storage, stock / inventory calculation purpose, a better accuracy RADAR with +/- 1mm accuracy along with inventory management software system shall be used.

• All RADAR type instruments shall have Flanged process connections and min. nozzle height for process connection shall be 150mm.

• Irrespective of pressure rating, the minimum pressure rating for RADAR flange shall be 300#.

• RADAR type transmitter shall be standard 2 wire, 24 V DC, 4-20 ma, SMART with HART protocol type with Local LCD display.

• Flange and wetted part MOC for RADAR shall be min. SS316.

• Wherever, the range can not be covered with 2 wire, 24 V DC type RADAR, a 4 wire transmitter with 110 V AC supply may be used. However, the RADAR transmitter shall be SMART with all other specifications same as above.

• Irrespective of plants hazardous area classification, all the RADAR type level transmitters shall be intrinsically safe, i.e. Explosion proof to EEx-i(a) and suitable for Zone-0, Gas group IIC/T6 as per CENELEC/ATEX and weatherproof to IP67.

• RADAR shall be with various software features like empty tank spectrum, dynamic error corrections, false echo filtering, Programmable range from 0-100%, throughout out the tank height, SPAN/ZERO elevation/suppression, programmable blocking window distance, etc.

• Hydrostatic tank gauging system can be used for high accuracy measurement if an application calls for same.

• For high-pressure steam drum application, conductivity type (Hydrostatic or equivalent level) instrument shall be preferred. Steam drum, Hydrastep is acceptable. However DP transmitters shall be with compensating column type only. If control and trip both are involved, there shall be additionally one no. of level switch also. This will facilitate 2 out of 3 trip voting ( 2 transmitters and 1 Level switch) and one transmitter for control purpose.

• For solid level measurement, type of instrument shall be RADAR or Ultrasonic type level transmitter.

• Standpipe shall be used for clean, non-viscous and non-crystallizing service if more than 4 nozzles are required for level instruments, e.g. one displacer instrument and one level gauge can be mounted directly on the equipment. The size of Standpipe shall be 2" NB minimum and valve at the instrument connections.

• Trip level switches should be directly mounted on vessel/column and not with the standpipes.

• Connection of standpipe from the bottom of vessel must be avoided.

• On horizontal vessels with boot, a separate standpipe shall be used for boot interface level measurement in addition to standpipe used for horizontal vessel.

• Level co-ordination sketches shall be produced showing all pertinent details including nozzle locations, alarm levels, controlled level zones, shutdown level, interface line, etc.





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• All displacer and float type instruments shall have provisions for on-site calibration simulation check.

3.3.5 Flow Instruments 3.3.5.1 Orifice Plate

• Orifice plate shall be the standard flow measurement device except for following conditions - where required accuracy is not obtained - where flow rate varies in wide range - where allowable pressure drop is limited - where other type of more accurate devices are required. Like mass flow meters for custody

transfers, etc.

• Flow measurement shall be normally carried out using thin, square edge, concentric orifice plate mounted between a pair of weld neck flanges of minimum 300# rating, for line size 2" and above.

• Flange taps shall be used for line sizes up to 12”. D-D/2 taps shall be used for line sizes 14" and above. For line sizes 1 ½” and below and for conical entrance orifices, corner taps shall be used. ( In case of fouling of tapping points w.r.t. to welding of flanges, flange tapings are to be used)

• The material of the orifice plates shall be normally SS 316, as a min. Flange, gaskets, bolts & nuts material shall be as per the relevant Piping specifications.

• Quadrant edge or quarter circle orifice plates shall be used for highly viscous fluids for pipe Reynolds number below 10,000. The Beta Ratio for these plates shall not exceed 0.6.

• Conical entrance type of orifice plates shall preferably be used for highly viscous fluid up to throat Reynolds number of 250. These shall be fabricated as per BS1042 part I. The Beta Ratio for these plates shall not exceed 0.3.

• Eccentric orifice plates shall be used for fluids containing two phases. Eccentric orifice plates shall have bottom of the orifice bore flush with the bottom I.D. of the pipe. Eccentric or segmental orifice plates shall be used in horizontal run only.

• Vent and drain hole shall be provided for orifices where bore diameter is more than 25 mm

• Plate dimensions and machining tolerances shall be as per BS 1042 and Sizing of orifice plates shall be carried out in accordance with ISO 5167. Other methods like AGA Report No.3, BS-1042, 'Flow measurement, R. W. Miller shall be used when specified.

• Honed metering runs in accordance with AGA tolerances or integral orifice type transmitter shall be used in lines with 1 ½” (40 mm) nominal diameter.

• Integral flow assembly shall be supplied as an integral assembly consisting of upstream and downstream straight pipes, integral orifice of 316 SS (as a minimum) installed along with manifold and SMART , 2 wire 24 V DC , DP transmitters. End flanges shall be as per piping specifications. Upstream and downstream pipes shall be honed from inside to achieve smooth surface. Integral orifice meters, when used, shall be installed with block and bypass valves.

• Upstream and downstream straight length shall be provided based on maximum d/D ratio of 0.75, in general. Where it is difficult to meet this requirement, the actual d/D can be considered for reducing the straight length as permitted by ' recommended practice shall be as per API-MPMS Recommended Practices and AGA Report No.3. The piping layout, where possible, shall be arranged such that straightening vanes are not required.





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• Orifice plates shall be installed on horizontal lines when practical. Vertical meter runs may be used for down flow of vapour and up flow of liquids.

• Meter taps shall be horizontal for liquids, condensable vapors and steam. The tap shall be on top for gas, non-condensable vapor, or liquids, which boils at maximum design ambient temperature at operating pressure.

• Where piping clearance are a factor, taps may be located up to 45” below the horizontal centre line for liquid and up to 45” above the horizontal centre line for condensable vapor and may be located up to 60° from vertical for gas and non condensable vapor.

• Each orifice plate shall be provided with a tab that is clearly visible in position. The tab will be stamped, or deep engraved, on the upstream with the tag number, orifice plate material, measured bore, I.D. of the pipe, flange size and rating. The tab shall also be in line with the Drain or Vent hole and shall indicate the direction of flow

• Flanges shall be as per ANSI B16.36 and shall generally be of weld-neck type only. Irrespective of pressure, the minimum flange rating shall be ANSI 300#.

• Flanges larger than 3" shall have a pair of jack-screws. The mating flanged shall be aligned in such a way that jack-screws will be diametrically opposite.

• Orifice flanges used at pressure ratings up to 600 Ib. shall be tapped ½” NPT(F) tap for 900 # above ¾” NPT(F). Orifice connections for Vena contracta taps or pipe taps ½” socket with schedule/MOC as per piping specs.

• The Meter Range flow shall be equal to the 1.5 times of normal flow or 1.3 times of the maximum flow.

• Differential ranges for all liquid flow meters shall not exceed 5000 mm water. Typical ranges for gas, steam or vapor meters are as follows:

Static Pressure Diff. Range (in Kg/Cm2g) (in mmwc) 0.35 to 2.5 500-1200 2.6 to 6 1250-2500 Above 6 2500-5000

• Where compressible fluids are measured using differential pressure producing devices, the selected differential in mm of water shall be preferably not numerically exceed 5.5 times the upstream static absolute pressure in kg/cm2 x 100.

• Though it is preferable to select diameter ratio between 0.5 to 0.65, The diameter ratio of orifice plates shall be as follows:

Type Beta Ratio Corner Tap 0.23 to 0.8 Flange Tap 0.2 to 0.75

• Orifice bore with diameter less than 0.125” shall be avoided.

• Orifice plates with RTJ flange connections above 2” shall be supplied with Carrier rings.

3.3.5.2 Venturimeters and Flow nozzles

• Venturi meter & flow nozzles may be considered for gas/air flow measurement in large size pipes / ducts, where high accuracy is required with less permanent pressure loss

• For high velocity steam or similar fluid, flow nozzles may be used in place of orifice plates to avoid problems due to erosion.





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• Irrespective of pressure, the minimum flange rating shall be ANSI 300#.

3.3.5.3 Variable Area Flow meters

• Variable Area Flow meters or Rota meters shall be as per ISA-RP 16.1. 16.2, 16.3 16.5 and 16.6 and shall be used for viscous or corrosive services or where rangeability of required flow precludes the use of an orifice.

• Metal tube rotameter shall be used for all fluids. The devices for indicating or transmitting shall be magnetically coupled with float or extension. Magnetic coupling shall be glandless type.

• The tube and flange be SS316 as a minimum. Flange connections shall be as per piping specifications. Irrespective of pressure, the minimum flange rating shall be ANSI 300#.

• Rota transmitter shall be 24 V DC, 2 wire, 4-20 ma, SMART with local display type.

• Irrespective of plant’s hazardous area classifications, all the Rota transmitter shall be intrinsically safe i.e. Explosion proof to EEx-i(a) suitable for Zone-0, Gas group IIC/T6 as per CENELEC/ATEX and Weather proof to IP67.

• Glass tube rotameter shall be used for low pressure utility services for local and where line size is 1-1/2" (40 mm) or less. Glass tube rotameter shall not be used if an outlet line is connected to a line or vessel containing hazardous or toxic fluid unless a check valve is installed at the downstream side of rotameter.

• Glass tube meters mechanically protected and (may only be used on non-hazardous fluid service up to temperatures of 130°C, and on fluids always above freezing.

• Linearity should be better than 5% for indication-only rotameter and better then 1% for rotameter transmitter. Accuracy shall be 2% (or better) of full scale for general and metal tube rotameter.

• Variable Area Flow meters (purge rotameter) fitted with a constant flow regulators shall only be used for fixed rate flows such as flushing or purging.

• For low cost measurement of high flow rates generally 2" and larger size, a by-pass rotameter shall be used.

3.3.5.4 Ultrasonic Flowmeters,Thermal Mass Flowmeter, Positive Displacement Type Flowmeters

• No Ultrasonic Flow Meters, Thermal Mass Flow meters or Turbine & Positive Displacement meters shall be used throughout the complete project.

3.3.6 Valves 3.3.6.1 Control /On-Off Valves

The control valves shall be designed based on following guide lines, as a minimum.

• Control valve type / design selection shall be made with considering the following conditions

o Pressure drops, which exceed 10 bars. o Flashing or cavitating liquids. o Steam service where pressure drop exceeds 5 bar. o Corrosive fluids. o Control valves on erosive services (slurries).





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• Control valves shall normally be globe type, top guided (up to 10 Kg/Cm2 Delta P) or cage guided (more than 10 Kg/Cm2 Delta P), single seated, non-pressure balanced type only. Other valves like butterfly, ball, rotary, angle or 3 way valves shall be selected based on application. All control valves shall be flanged end type only the control valve Body material and Body rating shall be as per piping specifications. However vendor to ensure that the irrespective of pressure rating, the minimum pressure rating of end connection flanges shall be 300#. Pressure balanced design control valves shall be acceptable only for clean gas services, with prior approval of L&T. Also, this shall be considered only for those gas service valves, where spring opposed diaphragm actuators with unbalanced valve design is not available (due to technical limitation of required thrust requirement) from any of the control valve vendors, specified in vendor list.

• Valve bodies and other pressure parts, except diaphragm and housing shall be of forged or cast type conforming to ASTM standards, unless otherwise specified.

• The Minimum control valve body size shall be 1" in general. Body size shall be limited to 1", 1-1/2", 2", 3", 4", 6", 8'”, and 12”. Higher size may be used if required. The flanged connection dimensions and pressure temperature ratings shall be as per ANSI B16.5.

• The accessories like Air Filter Regulator, Solenoid Valve, Limit switches, Positioners, etc. shall be pre-tubed with actuator so that they can be removed easily for maintenance purpose.

• The max. allowable noise shall be 85 DB SPL ( Sound Pressure Level). Control valves, exceeding this limit will be provided with special precautions.

• Leakage class VI shall be considered, where tight shutoff is specified. All control and ON-OFF valves in vent, drain and shut off services shall have class VI and others shall have min. Class IV. For Steam and high temperature application, where soft seating is not permitted, Leakage Class V is acceptable.

• For all interlock/shutdown valves, the minimum leakage class shall be Class VI as per ANSI B16.104.

• Control valve sizing shall be carried out as per ISA S75.01. The selected CV shall permit up to 150% of normal flow or 110 % of maximum flow, whichever is higher. In general, control valves shall be sized so that the valve opening is as mentioned below.

At Max. Flow :- 80% Open

At Normal Flow :- 70% open

At Min. Flow :- 20% open

• Equal % control valve shall be sized for 60% to 80% opening for normal flow. For two phase flow, both phase CV is to be considered with relevant process condition while sizing the valve.

• Flanged bolted type gland packing boxes shall be used, unless other specified. Gland packing shall normally be self-lubricating type. Packing shall be PTFE type up to 200”C. For temperature above 200 “ C, grafoil is to be used. Usage of asbestos is not allowed in any part.

• Bellows seals shall be used wherever gland leakage is not permissible like toxic / hazardous product like carbon monoxide gas, etc.

• As a minimum, trim MOC shall be SS316. By default, all Guide MOC shall be hardened stainless steel like 440 C, 17.4 PH. For erosion service, high pressure drop, cavitating service hard surfacing of plug and seat material, stellite shall be used as specified in above





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point 6.7.1.12. Special cases valve may require 17.4PH seat and 440C solid plugs or other material like Hastelloy, Monel, Zirconia, etc.

• Where tight shutoff is required, fire safe type soft seat trims shall be used, provided pressure/temperature of service permits the use of this. For temperature above 300°C stellited facing shall be used for guide and guide bushing shall always be harder by a minimum of 125 Brinnel than that of the guide.

• Trim characteristics shall be equal percentage, unless otherwise specified. For high erosion service or in steam service where, the delta P is higher than 5 Kg/Cm2, hardened trim with stelliting shall be used. When this is not sufficient, in such cases, special Anti-cavitating trim or shall be selected

• The allowed stroking time shall be governed by process requirement. Generally, for control valves, equipped with positioner, max. stroke time shall be 10 seconds up to control valve size 4” or smaller. And shall be max. 15 second for control valve with size 6” and above. For critical control valves, like anti surge control valve, stroke time may be in the range of 2-5 seconds. For interlock valves, this could be in the range of 1 to 2 seconds. If the inherent stroke times as above are not achievable, with the help of higher size of Herion make volume boosters/quick exhaust relays, the same shall be achieved.

• PCV shall be used only when load is constant and precise control is not required.

• All shutdown valves shall be floating ball design with full bore design, unless otherwise specified.

• All valves with flow tends to open design, shall be used.

• Oxygen service valves shall be de-greased completely and certified for oxygen service use. MOC for body shall be Monel and trim shall be Inconel 600 only.

• For all steam service valve, vendor to ensure submission of IBR FORM IIIC certificate in original. (if sourced from abroad, then IBR authorized agency’s certificate is necessary)

• For all shutdown valves on fire safe applications, air volume tank shall be supplied for the storage of air volume for minimum 3 stroke operation.

• All shutdown related on-off valves, for which the position switches are used in interlocks shall be with 2oo3 philosophy.

3.3.6.2 Actuators

• Generally all actuators shall be single acting, spring return, diaphragm type only. Use of double acting piston actuator is not allowed. If thrust requirement is more, a spring return piston actuator shall be used. Also the usage of Hydraulic or Motorized actuators is not acceptable.

• All actuators shall be designed with max. 4 kg/cm2g air pressure availability only. The actuator shall be sized in such a way that it should be able to open the valve when full static upstream pressure is acting on upstream in valve full closed condition and down stream pressure is atmospheric pressure. Actuator shall be oversized to 125% of the thrust required for DP Shut off, as specified above. In short, actuator shall be able to with stand max. shut off static pressure with down stream atmospheric pressure, when available instrument air pressure to actuator diaphragm is minimum specified. Spring shall be painted with corrosion resistant paint. All actuator open/vent port shall be provided with breathers. Paint shall be min. epoxy type.





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• Actuator case MOC shall be Steel and Yoke MOC shall be high tensile ductile iron as a minimum. Diaphragm shall be of nylon reinforced neoprene or Buna N rubber. Extended bonnet shall be selected based on high temperature or cryogenic services.

3.3.6.3 Positioners

• By default, all the control valves’ positioners shall be Smart Electro-pneumatic type, accepting 2 wire, 4-20 m amp input signals from central DCS system.

• The make shall be ABB only and model shall be TZID-C200. All the positioner shall be supplied with isolated 4-20 ma continuous position feedback. In general it is preferred that all Control valves will be supplied with ABB make TZID-C200 or later version, SMART, Digital, electro-pneumatic positioners with isolated position feed back as 4-20 ma output with dual entry positioner enclosure. However, equivalent type of Positioners from the control valve vendors as specified in GNFC vendor list are also acceptable. However all positioners shall be SMART Digital valve positioners with HART protocol, local display/push buttons for AUTOSTROKE, separate 4-20 ma isolated analog output for position feed back with dual entry enclosure. It is to be noted that though all control valve positioners shall have analog position feedback output by default, only those analog position signals shall be wired to up to control room as ESD/system inputs which are required for interlock/logic and for all the valves which are on flare/vent lines. For rest of the valves, this analog position signal need not be wired up to control room as it shall be used as and when required.

• Irrespective of plants hazardous area classifications, all the positioner shall be intrinsically safe, i.e. Explosion proof to EEx-i(a), suitable for Zone-0, Gas group IIC/T6 as per CENELEC/ATEX only and weatherproof to IP65.

• There shall be min. two ½” NPT(F) cable entries in each SMART positioner, from where input signal and position output feedback signal wires can be terminated separately.

• Air consumption of the SMART positioner shall not be more than 0.3 NM3/Hr.

• Positioner shall be mounted on control valve so that it can be removed with ease during the maintenance.

• Positioner feedback link with control valve shall be fixed with 100% secure mechanism so that there is no backlash in motions, resulting hysteresis or chance of dis-engagement of the link while the control valve is installed with severs pipe vibrations.

3.3.6.4 Other accessories

• Hand wheels shall be provided if required.

• Valve stem position indicators shall be fitted as standard, showing incremental stroke positions.

• Direction of flow indication shall be engraved or embossed on the body.

• Limit switches, shall be 2 wire, NAMUR sensor, proximity type and P+F make only. This shall be installed in weatherproof IP65 box. No flying lead type connections are acceptable.

• All Solenoid Valves used in the whole plant (including those being supplied by package unit vendors) shall be of HERION make only.

• It shall be HERION make only and 24 V DC, Direct operated, Universal, 3/2 way ( 5/2 way depending on application as special case), ½” NPT(F) or ¼” NPT(F) process connections based on Kv/Flow requirement of control valve actuator and stroke speed requirement, SS 316 MOC body, intrinsically safe, i.e. Explosion proof to EEx- i(a), suitable for Zone-0 area,





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Gas group IIC/T6, as per CENELEC/ATEX irrespective of plant’s hazardous area classification and weatherproof to IP67 with ½” NPT(F) cable entry. The active barriers shall for SOV and all Digital output shall also be of P+F/MTL make. Model nos. shall be provided by GNFC. There shall not be any other type, make and model or different voltage level for SOV in the whole plant/project.

• The max. working pressure for all Solenoid valve shall be 10 kg/cm2g. There shall be only two types of common models of Solenoid valves shall be used (½” and ¼” Process connections) through out the complete plant design to maintain fewer inventories and have interchangeability at any time.

• All solenoid valves shall be supplied with ½” NPT, SS304 MOC, double compression Cables glands, which must be weather proof to IP65 with PVC hood.

• All control valves stroke time/required stroke speed shall be realized with larger size Herion make volume boosters/quick exhaust relays etc.

3.3.6.5 Limit switches / position switches

• All type of limit switches shall be 2 wire, proximity type, and NAMUR sensors only. These shall be intrinsically safe to EEx-i(a) suitable for Zone-0, Gas group IIC/T6 area, irrespective of plant’s hazardous area classification. The intrinsically safe isolation amplifiers to convert these NAMUR contact to pot-free contacts shall be installed in central cabinet room marshalling rack. These shall be P+F/MTL make, powered DIN rail mounted isolation amplifier with LB monitoring. The model number of isolation amplifiers shall be given by GNFC.

• The make shall be P+F only. The sensor shall be generally cylindrical NAMUR sensor type proximity switch. The diameter and sensing range shall be selected based on application.

• The MOC of sensor shall be SS316. Krastin type probes shall not be used, unless surrounding atmosphere heat permits the use of the same under worst condition.

• All limit switches sensor shall be adjustable with the threaded length and check nut arrangement.

• Flying lead type loose connections for NAMUR sensors are not acceptable. All these NAMUR sensors installed on any instruments to sense the position shall be housed in a closed box certified for weatherproof to IP67. The gland size shall be ½” NPT(F).

• All ON-OFF type application valves taking in part in interlock/shutdown shall be provided with Open and Close type NAMUR sensor as limit switches. The sensors along with enclosure shall be installed in control valve in such a way that it can be removed with ease for maintenance.

• Limit switches shall not be used for Control Valves. All controls valves shall be equipped with SMART positioner, from where the analog output for continuous position is available, which shall be used for interlock/control purpose.

3.3.6.6 Inspection & testing

Test Procedure shall cover the following test as minimum, but not limited to:

• Dimensional /Physical Test

• Hydrostatic Body Test. - Duration 3 min. (including all parts in assembled condition like body, gland, all joints)

• Seat leakage as per ANSI B16.104/FCI 70.2





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• Diaphragm head test

• Complete actuator leak test

• Helium leak test for control valve with below seals

• Stroke calibration

• Stroke speed test 3.3.6.7 Documents / test certificates

Vendor to ensure the delivery of the following documents as a minimum along with the valves

• MOC certificate for control valve, all accessories and other bought out items

• GA Drawings, including all accessories

• Dimensional Cross sectional drawings of complete control valve/accessories

• All type of tests certificate like Hydrotest / seal leakage test certificates

• Radiography test

• IGC test as per ASTM A262, Practice A, Fig. 1

• DP Test

• Stroke calibration and stroke time test certificates

• Operation and Maintenance manual of control valve and all accessories

• Product catalog of control valve and all accessories

• Functional test certificates for all accessories

3.3.6.8 Tag plate

Each valve shall be provided with SS MOC tag plate indicating the following details as a minimum

• Instrument Tag Number

• Vendor's Name

• Valve Model Number

• Order/Requisition Number

• Body & Trim Material

• Stem Packing

• Material Body Size and Rating

• Design CV (For Control valve and Regulator)

• Trim Characteristic or Cam Code/type as necessary

• Air-Fail Action

• Hazardous Area Class

• Actuator size





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• spring range

• Air supply pressure

3.3.6.9 The following standards/documents shall be used as design/test criteria.

• ANSIB16.10 - Control valve dimension

• ANSI / ISA S75.C1 - Flow equation for sizing of control valves

• ANSI / ISA S75.02 - Control valve capacity test procedure

• ANSI / ISA S75.03 - Face to Face dimension for flanged type control valve

• ANSI / ISA S75.04 - Face to Face dimension for flange less control valve

• ANSI / ISA S75.05 - Control Valve Terminology

• ANSI / ISA S75.11 - Flow Characteristic and rangeability

• API Std. 598 ISA - Test procedure.

3.3.7 Safety Relief Valve

• Pressure-relieving devices protecting pipes, vessels and equipment shall normally be sized in accordance with API RP 520 and/or API RP 521. ASME Code, Section I shall apply for steam drum and super-heater valves. Relieving devices protecting atmospheric or low- pressure storage tanks shall be sized according to API STD 2000.

• The following guidelines shall be applied for safety valve selection and line sizing: o Valve selection will be based on maximum operating temperature and relief

valve set pressure. o Conventional type relief valves shall be used for the cases where the built-

up back pressure and the variable superimposed backpressure doesn't exceed 10% of the set pressure. For the cases, where it exceeds 10%, but is below 30 % of the set pressure, balanced bellow type relief valves shall be used. For the cases, where the total back pressure is between 30 & 50% of the set pressure, the balanced bellow type relief valves may be used subject to confirmation from the manufacturer that there is no decrease in the capacity of the pressure safety valve due to high back pressure.

o Relieving device discharge lines shall be Sized based on the back pressure data. The sizing shall be done so as to limit the maximum back pressure at the discharge of a PSV up to 30% of its set pressure. However, if it exceeds 30% but is below 50% of the set pressure, necessary confirmation, as defined above, from manufacturer must be obtained.

o The discharge velocities shall not exceed 0.5 mach no. o PSV discharge shall be free draining to flare header. PSV inlet shall be free

draining towards the source. The inlet lines to safety devices shall be sloped back to the protected equipment and the discharge lines from safety devices shall be sloped towards the respective knock out drum. These lines shall be without pockets.

o Pilot operated relief valves shall be used for the systems where maximum set point accuracy is required. Such relief valves shall be installed in equipment, which operate very close to the set pressure.

o Pressure drop in a PSV inlet line must not exceed 3% of the set pressure of the PSV.





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o PSV inlet and outlet line sizes shall be equal or greater than the PSV nozzle sizes.

o Inlet and outlet isolation valves of PSVs shall be full port. o All relief valves, which are susceptible to plugging, shall be steam traced

and have a rupture disc installed under them. o Staggered pressure setting may be specified to minimize losses. o For atmospheric relief, the open end of discharge will be located 30m from

any source of ignition. Discharge shall be 3m higher than any equipment or manholes (ladder, platform etc.) within 15m radius, or 2 meters above the top most technological platform, which ever is higher.

o The relief valves on storage tanks shall be as per API codes to take care of over filling also.

o Thermal Safety Valves (TSV) shall be provided for the protection of equipment and lines, where ever there is possibility of blocked liquid getting heated up on account of another heating medium or direct sun light. The discharge of TSVs shall be appropriately routed to local drain for cooling water and slop system for hydrocarbons (amine).

o The discharge line of all liquid safety valves discharging to atmosphere shall be routed to appropriate drain system.

o All drains on safety valves (wherever provided) for amine service shall be connected to the slop system.

o All safety valves shall normally have carbon steel body with stainless steel trim. Bronze or cast iron bodied valves shall not be used.

• Percentage Over-pressure, Accumulation and Blow-down used in the calculation of orifice sizes of relieving devices shall be as follows:

• Over-pressure: o 3%- Steam service where ASME Power Boiler Code (Section I) applies. o 10% - Gas or vapour service. o 10%- For liquids o 21%- Fire exposure on unfired pressure vessels o 10%- For liquids (non-certified).

• Accumulation : o 6%- Steam service where ASME Power Boiler Code (Section I) applies. o 10%- Gas, vapour and liquid where ASME Pressure Vessel Code

(Section VIII) applies o 16% - Gas, vapour and liquid where ASME Pressure Vessel Code (Section

VIII) applies and the system is protected by means of multiple valves. o 21% - Fire exposure on unfired pressure vessels.

• Blow-down : o 4%- Maximum for steam service where ASME Power Boiler Code

(Section I) applies. o 5-7%- For vapour, gas and steam service. o 10-20%- For liquid service.

• Nomenclature shall be in accordance with API RP-520.

• Safety and Relief Valves shall generally be flanged, direct spring-loaded types with high lift, high-capacity and top-guided disc. Balanced bellow valves shall be furnished for relief into closed flare and blow-down systems if the sum of variable superimposed backpressure and the built-up back-pressure exceeds the allowable accumulation, or for toxic





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substances. Bellows shall also be specified for liquid relief valves in case of any variable back-pressure.

• Materials for Construction shall be selected in accordance with API STD 526, the process fluid characteristics and the Vessel and Piping Specifications.

• End Connections shall normally be flanged with facing and rating in accordance with the Piping Specification. However, where applicable API STD 526 sizes and ratings shall always govern. Centre-to-face dimensions shall be in accordance with API STD 526 where applicable.

• PSV design should be such that online testing is possible (i.e. On line testing arrangement can be fitted on it).

• Each valve shall have identification marking containing all data required by the applicable ASME code and / or API standard .

• The design temperature and pressure shown in the datasheet should be used for the design of pressure-retaining parts of the pressure safety valves and the operating temperature shown in the datasheet should be used for design of temperature sensitive materials e.g elastomeric components used in the pressure safety valves.

• The materials for nozzle, disc, body and Spring shall be compatible with process fluid. Supplier shall review and either confirm selection or offer alternate material based on the proven experience in similar conditions.

• The springs of relief valves shall be given a suitable coating to protect against general corrosion and/or sulfide stress corrosion cracking. Coatings of cadmium or zinc shall not be used due to the risk of liquid metal embrittlement during service and/ or hydrogen embrittlement during the galvanizing process. Suitable aluminum coatings may be used.

• The material to be used for the spring shall be selected according to the temperature and the fluid. Where “Fire case” is envisaged (as material/calculation selection criteria) the spring material shall be chosen considering the maximum anticipated service conditions.

• Material of bonnet, cap shall be as per the process requirement. The bonnet shall be of bolted type.

• An adjusting ring (Blowdown ring) shall be provided for the safety valves and the material of construction of gaskets and bolts/nuts shall be suitable for safety valve material and operating conditions.

• Nitrogen shall be provided in all dead ends of flare header for continuous purging. The permanent nitrogen connections shall be provided with double block valves (one isolation valve and one controlling), spectacle blind, rotameter and a bleeder (with valve and blind).

• Double safety valves shall be provided with isolation valves, such that on-stream isolation and maintenance of a safety valve is possible without affecting unit operational safety requirements. This shall be considered for all operation failure cases (guided or no-guided).

• All isolation valves of pressure safety valves shall be lock open/close type.

• All pressure safety valves shall be provided with a bypass line with double block valve and a spectacle blind in between. No bypass is required, when depressurisation of the upstream equipment to flare is possible through accessible valves & suitable piping.

Test required:





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• All Safety relief valves shall be tested as below: o Function tested for the range as indicated in the data sheets. Safety relief

valves shall be tested in an apparatus as specified in API-RP-576. o Set pressure test . o Seat tightness shall be bubble tested at the vendor-specified percentage of

set pressure. o Hydrostatic test of 1.5 times the maximum operating pressure o The material test certificates, internal shop test reports, welding reports (as

applicable), etc. shall be verified during inspection o Radiography test of valves for rating ANSI 600# or above. o Helium leak test for hydrogen service. o Stress relieving reports (as applicable) o Calibration reports o Test certificate for safety valve set pressure and reseat pressure .

Certification required:

o Material certificates according to EN 10204 (2.2 or 3.1.B) are required for pressure retaining parts for on-line instruments.

o NACE certificates where applicable. o IBR form III C o Other conformance certificates as applicable.

3.4 BULK ITEMS 3.4.1 Instruments power / signal & control cables

In addition to various cable manufacturing standards like IS1554 part-I, BS/ IS5831 and IS694-Part-I standards, the following basic design criteria shall be followed as a minimum. All cables, color codes shall be strictly as follows. This philosophy applies to package unit instruments also.

• Single pair signal cable: ATC, Multi strand (Max 7 strands), 1 Pair, twisted pair, 0.75 sq. mm, white/black color, screened / armored/ FRLS cable, Outer Jacket color code: Blue (IS), Black (Non-IS). This shall be used for all 4-20 m amp. analog inputs/outputs signals.

• Power cable: - ATC, Multi strand (Max 7 strands), 1.5 sq. mm for 110 v ac, (2 core- Red / black, 3 core- Red / Black / Green,) armored/FRLS, Outer jacket color code: Black. This shall be used for 110 V AC power supply to field instruments, solenoid valves, etc. This shall be used for 110 V AC power supply as a minimum size. Vendor to ensure correct size (cross section area) for various requirements.

• Power cable: - ATC, Multi strand (Max 7 strands), 2.5 sq. mm for 24 V DC, (2 core- Red/blue) armored/FRLS, Outer jacket color code: Black. This shall be used for 24 V DC power supply as a minimum size for solenoid and other requirements. Vendor to ensure correct size (cross section area) for various requirements.

• Control Cable for DI - Single Pair:- ATC, Multi strand(Max 7 strands), 1.5 sq. mm, 2Cx1Pair, overall screened, Red/Blue, armored/FRLS cable, Outer Jacket Color code: Blue (IS), Black (Non-IS). This shall be used for all 24 V DC Digital input signals.

• Control Cable for DO - Single Pair:- ATC, Multi strand(Max 7 strands), 2.5 sq. mm, 2Cx1Pair, overall screened, Red/Black, armored/FRLS cable, Outer Jacket Color code: Blue (IS), Black (Non-IS). This shall be used for all 24 V DC Digital output signals.





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• Single Triad RTD cable ATC, Multi strand (Max 7 strands), 1 Triad, 1.3 sq. mm, red/white/black color, screened / armored/ FRLS cable, Outer Jacket color code: Blue. This shall be used for all RTD input signals.

• T/C single pair: 1 P x 18 AWG (Single) or 20 AWG (Duplex) as per IEC 60584-3, Special compensating cable for particular type of thermocouple

• The fiber optic cables shall be single mode, 6 core, jelly filled, armored type only, as a minimum. This shall be laid in overhead cable trays.

3.4.2 Field junction boxes

The following basic design criteria is to be followed for all type of junction boxes, through out the specifications, including those being supplied by package unit vendors.

• All the supplied junction boxes shall be of weatherproof to IP67 as per IEC529. If a field junction box is used for power supply distribution for 110 V AC/DC or any other level, which cannot be sourced from intrinsically safe circuit from control room, than these shall be FLAMEPROOF to EEx-d IIC/T6 as per CENELEC/ATEX .

• All the field junction box shall be made of die-cast aluminum LM-6 Material.

• There shall be diff. junction box for diff. type of I/O signals as well as dif. Destination like DCS and ESD systems. As a minimum the following segregation shall be maintained

• Signal Category wise segregation a. Analog Input and Analog output b. 24 V DC Digital Input / NAMUR sensors c. 24 V DC Digital output signals for SOLENOID valves and lamps d. 110 V AC power cables for field instrument power e. RTD signals f. T/C signals

• Destination Based Segregation a. DCS Junction Boxes b. ESD Junction Boxes c. Other systems

• The naming philosophy for junction box shall be adopted in such a way that from the tag number of the particular junction box, it shall be evident to decide type of signal and destination

• All junction box MOC shall be die-cast aluminum LM-6 and it shall be epoxy painted. Based on requirement, there shall be diff. insulated shield and earth bus bars are to be provided in the junction box. The individual branch cable shall be brought to central cabinet room panel instrument shield bus bar via insulated shield bus bars and multi pair shields from junction boxes.

• All junction boxes shall have branch and multi pair cable entries from bottom only.

• All junction boxes shall be weather proof to IP67 as a minimum. Generally 12 branch entries of ¾” ET and 1 no. of main multi pair cable entry type junction boxes shall be used in the total project.

• Each Junction box shall have 0.5 to 4.0 sqmm, screw less , WAGO make terminals inside them. These shall be DIN rail mounted. The color code shall be based on type of signals. The qty. shall be as required.

• Each junction box shall have engraved/embossed SS tag plate with tag number. This tag plate shall be screwed on the junction box.





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3.4.3 Canopy

• All electronic instruments and junction boxes in the field shall be provided with individual FRP or aluminum fabricated canopies of minimum 2 mm thickness.

3.4.4 Cable Trays

All the power/control and signal cables shall be through SS304 cable trays.

• On the main cable route, cable duct shall be used with clear separation of various low voltage signal cables (AI/AO/DI/DO with 24 V DC and lower voltage) and high voltage power cables (e.g. 110 V A.C. power supply cables to field instruments, etc.). On the trunk and branch route from main cable duct to field junction boxes and local panels, 300 mm(w) x 60mm (H) cable trays will be used. For other branch cables various sizes of perforated cable trays shall be used with the following general specifications.

o 300 mm (W) x 60 mm(H) cable trays o 200 mm (W) x 50 mm (H) cable trays o 100 mm (W) x 50 mm (H) cable trays o 50 mm (W) x 40 mm (H) cable trays

3.4.5 Instrument earthing

• All equipment for electric transmission, including the enclosures as well as the armoring, lead sheathing and screening of cables, shall be properly earthed for personnel safety reasons and to obtain the maximum possible rejection of interference.

• Instruments and associated equipment requiring electricity with a potential to earth greater than 50 V AC or 120 V DC shall be adequately earthed (refer to IEC 60364 part 4, protection of safety, section 41, and protection against electric shock.)

• All equipment in the control satellite building shall be connected either to the general plant earthing system or to the instrument earthing system.

• Unintentional interconnections between the two systems are not allowed to occur.

• All earth connections shall be protected against corrosion, which might adversely affect the earth resistance.

• With intrinsically safe philosophy, there shall be separate earth pits for IS and Non-IS earth in the whole plant.

• All metal enclosures housing instrument and/or instrument systems and all armoring of field cables shall be connected to the general earthing system.

3.4.6 Impulse Lines

• Except for steam service instrument impulse lines, all other location shall be ½” OD SS tubes. The thickness of impulse tube shall be 1.6 mm for ½” OD SS tubes and 1.0 mm for ¼” OD SS tubes, unless otherwise specified. All tube fittings shall have Swagelok make. For steam services, it shall be ½” CS/IBR pipes (Min. SCH160).

3.4.7 Field instrument connections :





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Instrument Type

Piping/Vessel Connection

Instrumentation Connections

DIP Flow Instruments

½” NPT

½” NPT

External Displacer ( Min. Rating ANSI 300#)

2" Flanged

2" Flanged

Internal Displacer ( Min. Rating ANSI 300#)

4" Flanged

4" Flanged

External Ball Float ( Min. Rating ANSI 300#)

2" Flanged

2" Flanged

Internal Ball Float ( Min. Rating ANSI 300#)

4” Flanged

4” flanged

Level Gauge ( Min. Rating ANSI 300#)

2” Flanged

2" Flanged

D/P Level

½” NPT

½” NPT

D/P Level with Remote Diaphragm Seal ( Min. Rating ANSI 300#)

2” Flanged

2” Flanged

D/P Level Direct Vessel Mounted ( Min. Rating ANSI 300#)

2” Flanged

2” Flanged

RADAR ( Min. Rating ANSI 300#)

3" flanged

3" flanged

Pressure Instruments

½” NPT ½” NPT

Press.Gauge

½” NPT ½” NPT

Pressure with diaphragm seal ( Min. Rating ANSI 300#)

2" Flanged

2" Flanged

Thermowell ( Min. Rating ANSI 300#)

1 ½” Flanged

1 ½” Flanged

Note:

i. There shall be a separate tapping for each of the instruments on any pipeline. No multiple instruments from one tapping is acceptable (for example PG and PT from single pipe line tapping with single or double mechanical isolation valves are not acceptable). However, as an exception to this, three transmitters on clean gas services from one orifice (with two pairs of tapping) is acceptable, where multiple (2 out of 3, etc.) transmitters are to be installed.

ii. All type of instrument tapping flange rating shall be minimum ANSI 300#, irrespective of minimum design pressure. However for pressure rating of 600# class and above, RTJ flange shall be used. At few locations, double isolation valves shall be used as per table given below.





REVISION : 0


INSTALLATION PRESSURE TAPPINGS

LEVEL TAPPINGS

FLOW ELEMENTS

CONTROL VALVE

RATING 150 # / 300 # SINGLE SINGLE SINGLE SINGLE 600 # DOUBLE SINGLE DOUBLE SINGLE 900 # / 1500 # / 2500 # DOUBLE DOUBLE DOUBLE SINGLE

iii. Flanged instrument connections shall be in accordance with ASME B16.5.

iv. Flange surface finish shall be as per relevant piping specification and in accordance with ASME B46.1.

v. Screwed connections shall be in accordance with ASME B1.20.1 (NPT) or ISO 228 (parallel).

vi. Cable gland connections to be generally ½” NPT as a minimum in accordance with EN 60423.

vii. Standard instrument connection shall be ½” NPT female, except that pressure gauges and pressure switches shall have ½” NPT male connections. A parallel thread should be used in cases of a hazardous process fluid.

viii. Except for steam service instrument impulse lines, all other location shall be ½” OD SS tubes. The thickness of impulse tube shall be 1.6 mm for ½” OD SS tubes and 1.0 mm for ¼” OD SS tubes, unless otherwise specified. These thickness shall be followed as standard as a minimum, except special case requirements for vary high pressure and temperature services. For steam services, it shall be ½” CS/IBR pipes (Min. SCH160).

ix. All field transmitters including Gas and Liquid Analyzers shall be Microprocessor based and SMART with HART protocol, 24 V DC, loop powered. All field transmitters lower housing shall be SS316 and top house/enclosure shall be die cast aluminum with EPOXY paint. In addition, all mass flow meters shall also have RS485 communication interface links to remote engineering/HMI PCs and/or DCS.

3.5 Installation guidelines

• All instruments shall be mounted as close as possible to the process connection provided. Maintenance and accessibility requirements are to be taken into account. The length of the impulse line shall be minimal. The location of instruments shall be such that direct drainage of condensate, water or process fluids from adjacent equipment has no adverse effect.

• Instruments shall be mounted on a vibration free place. Special care shall be taken for heat expansion.

• Local converters, amplifiers, switches, etc., shall be installed near the corresponding instrument.

• Local indicating instruments shall be readable from where the related equipment is operated or from where the primary instruments are to be tested or calibrated.

• Pressure gauges shall be preferably installed direct mounted.

• Instruments shall not be direct mounted on handrails.

• Plates welded to structures, yokes and similar support arrangements shall be used for mounting of off-line instruments. Instrument supports attached to process piping or vessels shall not be allowed.





REVISION : 0


• On prefabricated skids, modules or packages, instrument cabling and/or tubing leaving or entering the unit, as well junction boxes, bulkheads or panel plates, shall terminate at a central location near the edge. All cables shall be protected in closed tray of aluminum MOC tray/cover.

• All instrument supports, cable ladders/trays, conduits and other iron supporting materials shall be hot dip galvanized.

• Fasteners such as bolts, nuts and washers shall at least be made of SS as a minimum. No copper/brass alloys are allowed in the whole plant.

• The interface connection between piping and instruments is always after first isolation valve provided by piping group. No instrument needle valves shall be used as first isolation valve.

• At the instrument side of the first block valve, using tubing with compression-type fittings shall make instrument connections. Piping shall provide reducing flanges with a ½” O.D. tube connector to accommodate the instrument connection requirements. All SS316 tubing shall be either ½” or ¼” OD, Seamless SS316 tube only and all instrument fittings shall be double compression, Swagelok type.

• For pipe classes above 600 # up to and including 2500 # piping shall provide a flange connector with a ½” compression-type fitting to accommodate the instrument tubing.

• Pressure gauges will be hooked-up by means of “pancake” flanges.

• Manifold shall be mounted closed coupled to the transmitter.

Service Type Manifold Type

Flow / Differential pressure -Block/Equalizing/Drain/Vent (3-valve manifold) Pressure Block/Drain/Vent -2-valve manifold Differential pressure Block/Drain/Vent -(3-valve manifold)

• Position of transmitters (based on API RP 551): Phase Under / Above tapping Liquid Under Gas Above Vapor Under Steam Under

Final orientation of tapping to be determined in conjunction with process conditions on the project.

• All pressure instruments, except for those fitted with diaphragm seals, shall have a block valve and a drain/vent facility, to provide the capability of depressurizing the impulse line. Diaphragm seal Pressure instrument shall have mechanical isolation/drain valve and flushing ring with drain/vent.

• Differential pressure instruments shall be located above the taps for gas and non-condensable fluids, and below the taps for liquids and condensable liquids. For steam service, pressure instruments shall be mounted with a steam siphon.

• When instrument supports have to be fixed to fireproofed plant structures, these supports shall be welded to the steel structure before the fireproofing is applied.

• Instrument process impulse lines shall generally be ½” OD. seamless, annealed, stainless steel Grade AISI-316, wall thickness of 0.065” as a minimum. Care shall be taken that selected fittings are compatible with the tubing size and its specifications.





REVISION : 0


• Where the above tubing and fittings are not suitable for the process fluid or the process conditions and/or specific project requirements, other materials conforming to the piping specification shall be used.

• Instrument and capillaries shall be plumb and level. Impulse lines which run at a slope shall be continuously sloped in not less than one (1) in ten (10) except where otherwise specified. Preferred direction of slope is downward from the process for liquid service and upward from the process for gas service. Tubing shall be supported and protected from vibration and physical damage.

• No mechanical stress shall be induced upon an instrument that will cause a malfunction or error in the readout. Tubing shall not be secured directly to machinery or pipes. Tubing clamps and miscellaneous hardware shall be 316 stainless steel.

• The sizing of instrument air supply sub header shall be in general as follows:

SIZE NUMBER OF USERS ½" Pipe according to ANSI 1-5 users * ¾" Pipe according to ANSI 6-12 users * 1" Pipe according to ANSI 13-20 users * 1½" Pipe according to ANSI 21-50 users *

* In case off large air consumers (on/off valves etc.) air consumption must be calculated and number of users shall be adjusted.

• Individual instrument air supply and pneumatic transmission lines to and from instruments shall be SS 316 tubing.

o Tubing shall be ¼” OD x 0.039” wall thickness soft annealed, seamless. o High-volume pneumatic actuators may require ½” OD x 0.065” tubing. o Fittings shall be SS double compression, Swagelok only. Care shall be taken that selected

fittings are compatible with the tubing size and its specifications. o Instrument tubing and fitting/ferrule hardness shall be selected such that proper crimping /

sealing is ensured.

• Individual tube runs shall be supported by existing structures and steelwork.

• All junction boxes shall have WAGO make, screw less, side entry, DIN rail mounted terminals with 0.5 to 4.0 sqmm size.

• Color of terminals shall be grey for non-Exi signals, color blue for Exi signals. Each junction box shall be tagged by means of a screwed SS tag plates with tag number engraved on it.

• Cable glands shall suit the selected instrument cable and shall be suitable for the area classification concerned, standard Ex-d IIC/T6 and weatherproof to IP65 as a minimum with PVC hood for all flameproof instruments and weatherproof to IP65 for all intrinsically safe instruments.

• The thread of cable gland shall be ISO metric in accordance with BS 3643/IEC 60423 and with the applicable classified area concerned.

• Cable glands shall be made of Stainless Steel (SS304) and double compression type only with PVC hood and WP to IP65. However for inside control room, cable glands shall be anodized aluminum MOC, single compression type with check nuts and without PVC hood.

• Maximum filling of Cable ladders/trays shall be 70%.

3.6 Other specifications for Package Unit Instrumentation





REVISION : 0


• There shall generally be no field mounted control panels. Local panels at package unit shall be used only for Local Push Buttons and a few clustered LED type Lamps for start/stop and health/running status indications of machine/peripherals and initial start up procedure only. The field mounted Local Panel shall be weather proof to IP55 as a minimum. If panel is installed in hazardous location, all push buttons/clustered LED type lamps etc. and all other sundry hardware installed inside the local panel shall be certified for Flameproof to Ex-d IIC/T6 as per CENELEC/ATEX, if not interfaced with intrinsically safe circuits/barriers from control room/cabinet room. Purged panels are not acceptable. The panel make shall be RITTAL only and color shed shall be RAL7032.

• A common field alarm hooter at each package unit / local control panel shall be generated from central control room control system to alert the machine trip condition. Complete control should be possible from control room for all the machines. Also emergency shutdown of this entire machine/package unit shall be governed by control room system only.

• If a package unit vendor wants to deviate from the approved vendor list, they have to obtain prior approval from GNFC. If a package unit item is a completely imported package, then for few erection hardware related to instrumentation like Junction boxes, cable/cable glands, cable trays, tube/fittings, etc., the package unit vendors’ sub-vendors shall be acceptable.

• The type of instruments shall be Explosionproof to EEx-i (a), irrespective of plant hazardous area classification, to maintain interchangeability. Hence all field instruments shall be intrinsically safe as per IEC6079-11, certified for EE-x i(a), suitable for IIC/T6, as per CENELEC/ATEX, irrespective of plant's hazardous area classifications. All field junction box shall be weatherproof to IP67 and all cable glands shall be of SS304 MOC, double compression type, weatherproof to IP65 with PVC hood. All instrument cables shall be IS type. All field junction box shall have min. 30% spares. All the field instruments shall be weatherproof to IP67.

• Through-out the complete project, only one philosophy of intrinsically safe field instruments shall be followed. Wherever intrinsically fail safe design is not available, only at those locations, only Flameproof to Ex-d IIC/T6 design shall be used with prior approval of GNFC.

• Package unit vendor to lay branch cables from individual instrument to skid mounted Junction box in closed aluminum perforated cable trays. Junction box segregation shall be maintained for various type of I/O signals like AI/AO can be combined in common junction boxes, Digital inputs shall be wired in separate junction boxes, Digital Output for lamps and Digital Output for Solenoid valves can be wired in same junction boxes, if they are from same system.

• All branch cables shall be FRLS type armored only. The broad specs, mentioned elsewhere in this specification shall be strictly followed as minimum. Other specs shall be as per IS1554 and shall be approved by GNFC.

• All cable glands shall be of double compression type, Flameproof to Ex-d IIC/T6 and weatherproof to IP65 with SS MOC and PVC hood, where Flameproof to Ex-d IIC/T6 execution is approved by GNFC, otherwise these shall be weatherproof to IP65.

• Package unit vendor shall maintain segregation of Electrical (all MCC related I/O) and Instrument signals in diff. junction boxes. Electrical and instrument interface junction boxes shall be a separate junction box in the package unit.

• Power supply shall be provided by L & T from UPS grade 110 V AC / 50 Hz power supply at one location only from PDB panel located in central cabinet room. Further distribution /





REVISION : 0


voltage level conversions, Fuse co-ordinations, etc. shall be performed by package unit vendors.

• Package unit vendor to supply all drawings/documents in 4 sets of hard copy and 2 sets in editable software like Microsoft Excel / AUTOCAD only. The drawing and documents includes, various panel drawings, panel GA/IA drawings, dimensional drawings, loop sheets, interlock and logic diagrams, wiring diagram, cable schedule, PDB SLDs, Junction box schedule, instrument list, Tag list, datasheets, sizing calculation sheets, etc.

• Training for operation and maintenance for any specialty package unit control system at sub-vendors’ works shall be imparted to GNFC engineers for 1 week for 2 persons for each of the different systems supplied within package unit.

4.0 NAMEPLATE & PAINTING

4.1 Nameplate

• All field-mounted instruments shall have tag number plates with punched or engraved tag numbers. A circular, stainless steel plate, 20-25 mm in diameter, 1-2 mm thick shall be used for tagging instruments.

• Besides the tag number, the name plate shall have information as per ISA or relevant IS e.g design / operating service conditions, range etc.

• Letters and figures shall be min. 4 mm in size. The plate shall be securely attached to the instrument with a soft stainless steel wire if it is impossible to screw the plate to the instrument body.

• Self-adhesive tape or signs are not allowed for the permanent marking of instruments or associated equipment. Panel-mounted instruments shall have permanent signs on the front and on the rear.

4.2 Painting

• Field Instruments sh all have colour coding/shade as per ISA or relevant IS unless otherwise specified.

• In general, all internal and external parts of the casing and all metal parts including the canopy (if applicable) likely to come in contact with the surrounding air shall be protected with anti-acid paint that will resist the specified environment conditions.

5.0 TESTS & INSPECTION

5.1 Inspection

• All instruments/ instrument systems shall undergo factory testing and inspection by purchasers authorised representatives, PMC, Owner / PMC, unless specified otherwise.

• Wherever inspection at vendor’s shop is waived by Owner/PMC because of any reason, the purchaser shall carry out the inspection at vendor/sub-vendor’s shop and forward the inspection reports for verification by owner/ PMC before dispatch. In no case, items shall be released without proper inspection / verification.

• The purchaser shall be free to request any specific test deemed necessary although not listed specifically .The cost of performing all tests shall be borne by the vendor.

5.2 Tests Vendor shall submit the following test reports for purchaser's review:





REVISION : 0


• Dimensional verification certificate

• Manufacturer's test reports as per relevant IS/ISA/IEC Codes.

• Functional and performance test reports viz.

Accuracy Repeatability Over Pressure Vacuum test ( if applicable) Calibration report

6.0 PACKING & DESPATCH

Packing and Despatch methodologies are Logistics issues. However from the engineering perspective following considerations are to be adhered.

All the instruments/instrument systems shall be segregated type wise /part wise / service wise as instructed, into several packing for protection and ease of handling during transportation and also for ready storage to follow installation sequence after delivery at the purchaser/owner’s facility. Special notations such as 'Fragile', 'This side up', 'Centre of gravity' , 'Weight', 'Owner's particulars',

The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rainfall and high ambient temperature, unless otherwise agreed.

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_3.0

PROJECT : AMMONIA SYNGAS REVISION : 0GENERATION PLANT

CUSTOMER : GNFC , BHARUCH DATA SHEETS PAGE : 1 OF 1

TABLE OF CONTENTS

Note : Vendor to furnish applicable Datasheets in ISA format

SL NO. SECTION REMARKS PAGES

1.0 Package Control Systems Not Applicable

2.0 Special Instrument SystemsPH/Conductivity Analyser As per ISA formatOther Analysers( If Applicable)

3.0 Field Instruments3.1 Temperature Instruments As per ISA format

ThermocoupleRTDTemperature Transmitter

3.2 Pressure Instruments As per ISA formatPressure/ DP GaugePressure / DP Transmitter


PACKAGE

3.3 Flow Instruments As per ISA formatOrificeVenturi and Flow nozzleVariable Area Flow meter

3.4 Level Instruments As per ISA formatLevel GaugeRadar Level Transmitter

3.5 Control and Shut down Valves As per ISA format

3.6 Actuators As per ISA format

3.7 Positioners As per ISA format

3.8 Solenoid Valves As per ISA format

3.9 Limit Switches As per ISA format

3.10 3.3.10 Safety Relief Valve As per ISA format

4.1 Bulk ItemsCables As per ISA format



PACKAGE



REVISION : 0

CUSTOMER : GNFC, BHARUCH PAGE : 1 OF 1 DESIGN & ENGINEERING DATA

TABLE OF CONTENTS

SECTION REF Document No. PAGES

1.0 DESIGN

1.1

1.2

1.3

1.4

1.5

FORMAT FOR FUNCTIONAL

SPECIFICATION OF THE

PACKAGE UNIT

FORMAT FOR HARDWIRED

I/O SIGNAL EXCHANGE

BETWEEN DCS/ESD AND

PACKAGE UNIT ; I/O PIONT

DATABASE

FORMAT FOR PROCESS

CONTROL DIAGRAM

FORMAT FOR

INTERLOCKING LOGICS

FORMAT FOR CABLING

INTERCONNECTION

BETWEEN JB-FIELD

INSTRUMENTS

2.0 LISTS

2.1 FORMAT FOR INSTRUMENT

INDEX

FORMAT FOR CABLE LIST

3.0 LAYOUTS

3.1 SCHEMATIC INSTRUMENT &

JB LOCATION DRAWING

INSIDE BATTERY LIMIT

NOTE : Vendor formats shall be furnished with the offer. However, requirement of the Purchaser’s format need be adhered, which shall be furnished by the Purchaser at a later date, to successful Bidder.



SUB SUPPLIERS LISTCUSTOME: GNFC , BHARUCH PAGE : 1 OF X

INSTRUMENTATION REQUIREMENT FOR CPU PACKAGE

15

17

11

Magnetic Level Gauges

13

6

Level Guage Glass and cocks

Displacer Type Level

Turbine Flow meters

Level Guage, Hydrastep ( EWLI) Type

Level Switches, Displacer/Float type

10

8

14

1

16

Orifice Plates and Flanges Assly.

Temperature Elements and Thermowells

5

Field Instruments ( SMART Transmitters for Flow/Pressure/Dif. Pressure/Remote Seal PT/DPT/ Temperature Transmitters

Vortex Flow meter12

Flow elements (Venturi, Nozzle)

7

Averaging Pitot Tube ( Annubar)

9

EmersonABB Automation Ltd

Yokogawa India Ltd.Krohne

Veris Inc.Emerson Process Management Pte

Not to be used in this project

Technomatic India Pvt. Ltd.HydrastepYarway

Solatron Mobrey Ltd ( Formerly Megget Tokyo KeisoMagnetrol India / InternationalFisher Sanmar Ltd.

Variable Area Flow meters

Bliss Anand Pvt. Ltd.Chemtrol Engg(P) Ltd.

Rotameters and Purge rotameters (Both metal tube type only)

Rotameters ( Glass) - shall be used only in Analyser sampling handling systems only


Instrumentation Engineers(P) Ltd.

Brooks Emerson

Transducers & Control Pvt. Ltd.Placka Instrumnts & Controls (P) Ltd.


Pressure Switches - (Shall be used only for alarm purpose)

U.E. DeltaSORKDG Mobrey

Temperature Gauges

Barksdale Inc

2

3

4

Waaree Instruments Ltd.

Micro Precision Products Pvt. Ltd.

Emerson Process Management (FT, PT, DPT, DP type LT shall be of Emerson 3051 series)

Electrical & Electronics CorporationGeneral Instrument Consortium

A.N. Instruments Pvt. Ltd.

Pressure Gauges H. Guru instruments P. Ltd.WIKA Instruments India Pvt. Ltd.

Precision Industries Ltd.General Instrument Consortium

Baliga Lighting Equipments LimitedMicro Precision Products Pvt. Ltd.

Tempsens Ltd.Not to be used in this project

General Instrument Consortium

Pratolina Instruments Pvt. Ltd.

Minco(I) Pvt. Ltd.

DanielBaliga Lighting Equipments LimitedGeneral Instrument Consortium

Eureka Indl. Equip (P) Ltd.

Instrumentation Engineers(P) Ltd.

Transducers & Control Pvt. Ltd.

Detrive Instruments & Electronics Ltd

Pyro Electric Instruments Goa Pvt. Ltd.

SR. NO. SUB-SUPPLIER OFFERED BY VENDORITEM/COMPONENT

Krohne Marshall Pvt. Ltd.






On-Off Valve (Plug)

Level Instruments - Capacitance type

Level Instruments - Conductive ( Hydrastep)

Solenoid Valves

27

31

Junction Boxes & Cable Glands33

Transmitters ( SMART type only)

18

SMART Positioner

30

23

RADAR type level Transmitters

2928

24

25

22

19

20

21

Control Valve ( Globe/Angel Body)

Control Valve (Butterfly body)

E & H

E & H

Magnetrol IndiaVEGA GMBH

equivalent from control valve manufacturer,

HERION ( 24 v dc, EEx-i(a)/T6, IP65, SS body)

WAGO make, Side / Side entry, DIN RAIL mountable, Screwless type only.

(Isolators, 2 wire NAMUR sensors ( NJ or SJ

Solartron Mobrey Ltd.

Pressure Relief Valve(Conventional + Pilot+Thermal)

Magnetrol International (Steam Drum

Fisher Sanmar Ltd.Tuflin

Microfinish India ( For non-critical services Kitamura Valve Mfg. Co. Ltd.Metso automation ( Neles Design)

On-Off Valve (Ball)

Emerson Process management

35

34

Instrumentation Ltd.

SEBIM Valves India PVt. Ltd.Fainger LesserSempell Valves

Kent Introl India Ltd.(Formerly ABB Kent)

Magnetrol India

Associated Flexible & Wires (P) Ltd.

Baliga Lighting Equipments Limited

Fisher Sanmar Ltd.Instrumentation Ltd.

Fisher Sanmar Ltd.Tyco Valves & Controls

Thermo Cables- Hyderbad

Tyco Valves & ControlsVirgo ( For non-critical services only)

E & HMagnetrol India/International

Dresser India Ltd. (DML)

Dresser Valve India Pvt. Ltd.

Brooks International

Kent Introl India Ltd.(Formerly ABB Kent)

Level State System (Steam Drum Application)

Xomox Sanmar Ltd.Metso automation ( Neles Design)

Instrument Tube Fittings and Instrument valves

32

Shavo Norgren(I) Pvt. Ltd.Placka Instrumnts & Controls (P) Ltd.Air Filter Regulator

Associated Cables Pvt. Ltd.

Thermo couple Extn. Cables

Keystone

Terminals ( for DCS / PLC / Marshalling / Field Junction Box, etc. all locations)

Delton Cables

Flexpro Electricals

Exprotecta

Signal, Control and Power Cables for Instrumentation

Tyco Sanmar

ABB Kent ( Introl) Instrumentation Ltd

Proximity Switches /

Universal Cables

Same as Item No.-2

26

Metso automation -SingaporeMAPAGInstrumentation Ltd.






pH & Conductivity Analysers

38Emerson Process Management

ABB Automation LtdYokogawa India Limited

Density (Sp. Gravity) Analyser - Coriolis Type Mass flow meters only

42For any other item not specified here at Point No- 1 to 41 Vendor to seek prior approval before finalizing

the vendor.

Indiana GratingGlobe IndustriesSteelite

RITTAL - RAL7032 color shed, Model: as per ITB, size 1200 mm (W) x 800 mm( D) x 2100 mm ( H) or 600 mm (W) x 800 mm( D) x 2100 mm ( H) size as per ITB as a special case

Endress & Hauser

Instrument Manifolds for Pressure/Diff. pressure instruments and

36

40

39

37

Solatron

Emerson Process Management

Micro Precision Products Pvt. Ltd.Excell Hydra Pneumatic Pvt. Ltd.

Swaglok / Fluid Controls as an indian supplier of Swaglok make fittings only.ASTEC Instruments Pvt. Ltd.

(Non Critical)Swaglok / Fluid Controls as an indian supplier of Swaglok make fittings only.

Tube Fittings and Instrument Valves (Critical)

Cable Duct / Perforated aluminum Cable Trays

Control Panels ( All types of instrumentation panels in whole project)

41



CUSTOMER : GNFC , BHARUCH INSPECTION & TEST PLANS PAGE : 1 OF 1

TABLE OF CONTENTS

SL NO. SECTION REF DOC. PAGES

1.0 INSPECTION PROCEDURE L&T/GNFC/IP/002 12

2.0 INSPECTION & TEST PLAN

2.1 PACKAGE CONTROL SYSTEM

2.2 SPECIAL INSTRUMENT SYSTEMSANALYSERS GNFC-IITP-210 1

2.3 FIELD INSTRUMENTSTEMPERATURE INSTRUMENTS GNFC-IITP-218,219 1,1PRESSURE INSTRUMENTS GNFC-IITP-220 1FLOW INSTRUMENTS GNFC-IITP-208,222-227 1,6LEVEL INSTRUMENTS GNFC-IITP-207,221 1,1TRANSMITTERS GNFC-IITP-211 1CONTROL VALVES GNFC-IITP-203 1SHUTDOWN VALVES GNFC-IITP-204 1MOTORIZED OPERATED VALVES GNFC-IITP-206 1SAFETY RELIEF VALVES GNFC-IITP-209 1DESUPERHEATER GNFC-IITP-216 1


PACKAGE

DESUPERHEATER GNFC IITP 216 1BLOWDOWN VALVE GNFC-IITP-213 1PRESSURE REDUCTION VALVE GNFC-IITP-214 1

2.4 BULK ITEMSINSTRUMENT CABLES GNFC-IITP-215 1JUNCTION BOXES GNFC-IITP-230 1CABLE TRAYS & GLANDS GNFC-IITP-236,232 1,1INSTRUMENT FITTINGS GNFC-IITP-233 1INSTRUMENT TUBES GNFC-IITP-234 1INSTRUMENT AIR HEADER GNFC-IITP-235 1DAMPER ACTUATOR GNFC-IITP-237 1AIR FILTER REGULATOR GNFC-IITP-238 1RUPTURE DISC GNFC-IITP-239 1FLAME ARRESTOR & BREATHER VALVESGNFC-IITP-241 1SWITCES GNFC-IITP-240 1RUPTURE DISC GNFC-IITP-239 1BLANKETING SYSTEM GNFC-IITP-242 1SOLENOID VALVE GNFC-IITP-243 1SMART POSITIONER GNFC-IITP-244 1FO / COMMUNICATION CABLE GNFC-IITP-245 1GI CONDUITS GNFC-IITP-246 1SUNSHADE & CANOPIES GNFC-IITP-248 1INSTRUMENT PANELS SHALL BE FURNISHED LATER

3.0 POSITIVE MATERIAL IDENTIFICATION L&T/GNFC/IPMI/004 8

EQUIPMENT DESCRIPTION PROJECT

EQUIPMENT TAG NO :

TEST & INSPECTION AS PER : PR/PS NO :(CODES & SPECIFICATIONS)

1

2 Witness Inspection & / or Document review by PMC

3 Witness Inspection & / or Document review by L&T & / or Third Party / Statutory Authority

4 Witness Inspection & / or Document review by Vendor & Sub-vendor.

5 Certificates / Data to be Submitted by Vendor for Approval / review.

1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

6 W W H W X

7 H W X

8 R R X

9 R R X

10 H H W X

LEGENDS: H- Hold, W- Witness, R- Review, A- Approval, I- Information, X- Submit, PWHT- Post weld Heat Treatment.

PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification, NDT- Non destructive Testing.

TPI - Third Party Inspection, AI - Authorised Inspector,

Note: This is an Indicative Inspection & Test Plan identifying scope of inspection & review of documents by

L&T / TPI Agency / Client as a minimum requirement.

Detailed Quality Control Plan indicating all specified requirements after issue of PO / PR / PS to be

generated by Vendor & same duly approved by L&T / TPI agency to be submitted to Client for Approval.

___________CLIENT

Final Inspection Release Note

Model No., Tag Plate, Type of Mounting

Cable Entry Type & Size

Degree of Protection , Intrinsically safe, Area Classification & CCOE Certificate as Applicable

L&T

Detailed Inspection & Test Plan after issue of PO/PR/PS

Inspection & Test Procedure as applicable

Summary of All Supplementary Requirements as specified in the PO/PR/PS

Shop Calibration Records of 100% Instruments

Routine Checks (100% by vendor,L&T &TPI)

Visual check as per Tag No, Drgs & BOM

Any other requirements

ITP NO : L&T/IITP-210 Rev 0

ACTIVITY

: GNFC - Ammonia Syngas Generation Bharuch

CATEGORY : A

Witness Inspection & / or Document review by GNFC

: ANALYSER AND GAS CHROMATOGRAPHY

Communication Ports & Communication check

Review of Material Test Certificates for all Technical Components

Spares check (100% by vendor & L&T/TPI)

Functional Checks on Accessories As Applicable

Auto Calibration Mode Check

Response time check, Power supply variation check

Process Connection for Type, Size, Rating, Etc.

___________

Accessories

Dimensional Check

Performance Test (100% by vendor & at random by L&T/TPI)

Calibration check - Accuracy, Repeatability etc

LARSEN & TOUBRO LIMITEDSHEET 1 OF 1

E&C DIVISION, HMD - QA&I

Type Test Reports For

INDICATIVE INSPECTION AND TEST PLAN


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R R X

5 W W H W X

6 W W H W X

ACTIVITY

Dimensional check, Threading & surface finish, Contact of Temperature Element & Thermowell


Shop calibration records for 100% gauges, material test certificates for thermowells

Performance check for calibration, linearity, accuracy, hysterisis etc. As applicable ( 100 % by vendor & at random by TPIA )

Detailed inspection & test plan after issue of PO/PR/PS

Inspection & test procedures

Summary of all supplementary requirements as specified in the PO/PR/PS

Routine tests : ( 100 % by vendor & TPIA )

Visual check for range, Tag no, flange rating, marking etc

Continuity, polarity, grounding, T/C Wire identification

N2 Test, Response time





CATEGORY : B

: TEMPERATURE ELEMENTS WITH THERMOWELL


7 W W H W X

8 W W H W X

9 W W H W X

10 H W X

11 H W X

12 R R X

13 R R X

14 R H X

15 H H W X

LEGENDS: H- Hold, W- Witness, R- Review, A- Approval, I- Information, X- Submit, PWHT- Post weld Heat Treatment.PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification, NDT- Non destructive Testing.TPI - Third Party Inspection, AI - Authorised Inspector, Note: This is an Indicative Inspection & Test Plan identifying scope of inspection & review of documents by L&T / TPI Agency / Client as a minimum requirement. Detailed Quality Control Plan indicating all specified requirements after issue of PO / PR / PS to be generated by Vendor & same duly approved by L&T / TPI agency to be submitted to Client for Approval.

CLIENT

Review of material test certificates for all technical components

Bore concentricity check ( 100 % by vendor & at random by TPIA )

Certificate of radiography/x-ray for welded joints as applicable. DP check will be done for joints where radiography is not applicable

Insulation resistance at 500 v dc ( 100% by vendor & at random by TPI)

Pressure test for thermowells as applicable ( Internal & External ) ( 100 % by vendor & at random TPIA )

Spares check ( 100 % by vendor & TPIA )

PMI Test for SS & AS Parts ( 100 % by vendor & TPIA ) ( as applicable )

Type test reports for:

Degree of protection, area classification & CCOE Certificate as applicable

)

L&T


Any other certificate as applicable


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R R X

5 W W H W X

6 W W H W X




Routine tests : ( 100 % by vendor & TPIA )

Check for general appearance / workmanship

Performance check for calibration, linearity, accuracy, hysterisis, over range protection, zero adjustment etc. As applicable ( 100 % by vendor & at random by TPIA )


ACTIVITY

CATEGORY : B

: TEMPERATURE GAUGES WITH THERMOWELL

Check for ranges, tag nos, flange rating & Case filling as applicable etc.

Shop calibration records for 100% gauges, material test certificates for thermowells

Check for process connection, mounting, Threading & Surface Finish

Dimensional check






7 W W H W X

8 W W H W X

10 H W X

11 H W X

12 R R X

13 R R X

14 R H X

15 H H W X

LEGENDS: H- Hold, W- Witness, R- Review, A- Approval, I- Information, X- Submit, PWHT- Post weld Heat Treatment.PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification, NDT- Non destructive Testing.TPI - Third Party Inspection, AI - Authorised Inspector, Note: This is an Indicative Inspection & Test Plan identifying scope of inspection & review of documents by L&T / TPI Agency / Client as a minimum requirement. Detailed Quality Control Plan indicating all specified requirements after issue of PO / PR / PS to be generated by Vendor & same duly approved by L&T / TPI agency to be submitted to Client for Approval.

___________CLIENT

Type test reports for:

Shatter proof Glass

Degree of protection, area classification Certificate as applicable

L&T


Bore concentricity check ( 100 % by vendor & at random by TPIA )

Certificate of radiography/x-ray for welded joints as applicable. DP check will be done for joints where radiography is not applicable


pp ( y y )

___________


Pressure test for thermowells as applicable ( Internal & External ) ( 100 % by vendor & at random TPIA )




EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 W W H W X

5 W W H W X

6 W W H W X

7 H W X

8 H W X

9 R W X

10 R W X

11 H H W X








___________CLIENT


Dimensional check including capillary length for diaphragm sealed gauges


Shatter proof Glass

Shop calibration records of 100% gauges and material test certificates for all wet components including for gauge savers, snubbers and other accessories


Functional check & hydro test on accessories like gauge savers, snubbers, Syphon etc.

Type test reports for :

Degree of protection, area classification

Check for type of mounting (flange rating etc. For flanged gauges / diaphragm gauges)

___________L&T



INDICATIVE INSPECTION AND TEST PLAN ITP NO : L&T/IITP-220 Rev 0

ACTIVITY




Performance check for calibration, linearity, accuracy , hysterisis, over range protection, Zero Adjustment, Blow out disc / Solid Front etc.


CATEGORY : B

: PRESSURE GAUGES WITH ACCESSORIES (SYPHON, SNUBBER, GAUGE SAVER ETC)


Routine tests consisting of :


Check for ranges, tag nos.



EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

6 W W H W X

7 H W X

8 H W X

9 R R X

10 R R X

11 H H W X








___________CLIENT


- Degree of Protection, Area Classification & CCOE Certificate As Applicable

: MASS FLOW METER ( CORIOLIS / VORTEX )

Dimensional Check & Accessories Check

Hydrostatic Test

PMI Test for SS & AS Parts (100 % by vendor & L&T/TPI) ( as applicable )

___________L&T




INDICATIVE INSPECTION AND TEST PLAN ITP NO.: LL&T/IITP-208 Rev 0

ACTIVITY


Shop Calibration Records of 100% Instruments

Type Test Reports For

Inspection & Test Procedure as appli.

Spares check (100 % by vendor & L&T/TPI)

HV Test & IR Test

Performance Test (100% by vendor & at random by L&T/TPI)

Calibration Check - Accuracy, Repeatability, Configuration Range etc

Any other certifcate as applicable

Review of Material Test Certificates for all Technical Components


CATEGORY : A

Routine Checks (100% by vendor & L&T/TPI)

Visual check - Model No., Tag Plate, Type of Mounting

Sensor details, accessories, power supply rating

Process Connection for Type, Size, Rating, etc.


Flow Density Cal Factor

EQUIPMENT DESCRIPTION : ORIFICE ASSEMBLY PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

6 H W X

Dimensional checks ( plates and flanges )

CATEGORY : B

NDT ( RT, UT, MT, DP etc ) as applicable

Check for general appearance, workmanship, surface finish, edge sharpness etc




PMI Test for SS & AS Parts ( 100 % by vendor & L&T / TPIA ) as applicable

Routine tests consists of

Check for type of mounting, flange rating / finishing, Tag No, Flow direction, end connection etc

ACTIVITY






7 H W X

8 R R X

9 R W X

10 H H W X








___________CLIENT


Spares check ( 100 % by vendor & L&T / TPIA )

Material test certificates for plates, flanges, nuts and bolts etc

L&T___________

IGC Test as applicable



EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 W W H W X

5 H W X

6 H W X

7 R W X







CATEGORY : B

: RESTRICTION ORIFICE PLATE






ACTIVITY

Routine tests consists of

- Check for general appearance, workmanship, surface finish, edge sharpness etc

- Check for type of mounting, Inlet direction etc

- Dimensional checks

8 R R X

9 H H W X








___________CLIENT


L&T

Material test certificates for plates as applicable

___________


EQUIPMENT DESCRIPTION : VENTURI METER PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

6 W W H W X

7 H W X

8 H W X

9 R R X

10 R R X

11 H H W X








___________CLIENT

___________L&T


Inspection & Test Procedure as applicable.


PMI Test for SS & AS Parts( 100 % by vendor & TPIA ) as applicable






CATEGORY : B

NDT ( RT, UT, MT, DP etc as applicable ) examination records

- Hydro Test as applicable

- Pneumatic Test

Review of Material Test Certificates For all Technical Components

- Check for type of Mounting, Flange Rating, etc.





Performance check

ACTIVITY

- Dimensional Checks

Routine Tests : ( 100 % by vendor & TPIA )

- Check for General Appearance /Workmanship & Surface Finish

EQUIPMENT DESCRIPTION : FLOW NOZZLE PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

6 W W H W X

7 H W X

8 H W X

9 R R X

10 R R X

11 H H W X








___________CLIENT

___________L&T


Inspection & Test Procedure as applicable.


Routine Tests : ( 100 % by vendor & L&T / TPIA )

- Check for General Appearance / Workmanship & Surface Finish

- Check for type of Mounting, Flange Rating, etc.

Pneumatic Test

Any other test as applicable


NDT ( RT, UT, MT, DP etc as applicable ) examination record

- Dimensional Checks

Review of Material Test Certificates For all Technical / wetted Components

PMI Test for SS & AS Parts ( 100 % by vendor & L&T / TPIA ) ( as applicable )



Performance Test :

Hydro Test

Calibration Check




ACTIVITY


CATEGORY : B


EQUIPMENT DESCRIPTION : PITOT TUBE PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X





Check for process connection, flange ratings, type of mounting etc

Dimensional check





ACTIVITY

Check for tag nos, Name Plate


CATEGORY : B


Routine tests : ( 100 % by vendor & L&T/TPIA )

6 W W H W X

7 H W X

8 H W X

9 R R X

10 R W X

10 R H X

11 H H W X








___________CLIENT

MTC for all technical & wetted components



Dimensional check

Spares check ( 100 % by vendor and L&T/TPIA )


PMI Test for SS & AS Parts ( 100 % by vendor and L&T/TPIA )

___________L&T

Shop calibration records for 100% items

Performance check & Hydro Test, Pneumatic Test as applicable ( 100 % by vendor and at random by L&T/TPIA )

EQUIPMENT DESCRIPTION : ROTAMETER PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X

Cable entry type & size

Accessories


ACTIVITY



CATEGORY : B



Model no., Tag plate, type of mounting


Dimensional check




Routine checks : (100% by vendor & L&T / TPI)

Visual / Workmanship

Process connection for type, size, rating, etc.

6 W W H W X

7 H W X

8 H W X

9 R R X

10 R W X

11 R R X

12 H H W X








___________CLIENT

Calibration check & hydro test

Functional checks on accessories as applicable

L&T___________


Dimensional check

Performance test (100% by vendor and at random by L&T / TPI)

Shop calibration records of 100% instruments and material TCs for all wet components



Degree o f protection & area classification, CCOE Certificate as applicable


Spares Check ( 100 % by vendor and L&T / TPIA )

PMI Test for SS & AS Parts (100 % by vendor & L&T / TPIA ) as applicable


EQUIPMENT TAG NO :


1





1 A A A R X Detailed Inspection & Test Plan after issue of PO/PR/PS

2 A R X Inspection & Test Procedure as applicable

3 R R X Summary of All Supplementary Requirements as specified in the PO/PR/PS

4 R W X Shop Calibration Records of 100% Instruments

5 W W H W X Routine Checks (100% by vendor & L&T/TPI)

- Workmanship

- Model No., Tag Plate, Type of Mounting

- Process Connection for Type, Size, Rating, Etc.

- Cable Entry Type & Size, Accessories etc

- Dimensional Check

6 W W H W X Performance Test (100% by vendor & at random by L&T/TPI)

- Calibration Check - Accuracy, Repeatability etc

- Communication with HART / FF Communicator

- Functional Checks on Accessories As Applicable and Hydrotest

7 H W X PMI Test for SS & AS Parts ( 100 % by vendor & TPIA ) ( as applicable )

8 H W X Spares check (100 % by vendor & L&T/TPI)

9 R R X Type Test Reports For


- Any other requirements

10 R R X Review of Material Test Certificates for all Technical Components

11 H H W X Final Inspection Release Note








___________CLIENT

CATEGORY : A

: RADAR TYPE LEVEL TRANSMITTER


ITP NO: L&T/IITP-207 Rev 0

ACTIVITY

___________L&T





EQUIPMENT DESCRIPTION : LEVEL GAGUES PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 W W H W X Routine tests : ( 100 % by vendor and TPIA )

Visual check - Tag No, Name Plate, Model No, Scale Calibration, Center to Center & Visible Distance etc

Check for type of mountings ( flange rating, etc)

Illuminator functional check as applicable

Dimensional check

Performance check as applicable

ACTIVITY



NDT ( RT, UT, MT, DP etc ) as applicable






CATEGORY : B


6 W W H W X

7 H W X

8 W W H W X

9 H W X

10 R W X

11 R H X

12 R R X

13 H H W X








CLIENT

Thermal shock for glasses

Helium Leak test as applicable (100 % by vendor and TPIA)

Ball seat leakage check for gauge cocks

PMI Test for SS & AS Parts (100 % by vendor and TPIA) as applicable

Spares check (100 % by vendor and TPIA)


Degree of protection & area classification, CCOE Certificate for Illuminator as applicable for accessories

Illuminator functional check as applicable

L&T

Shop calibration records for 100% gauges and material TCs for all wet components



Hydro test, Ball test as applicable (100 % by vendor and at random by TPIA)



EQUIPMENT TAG NO :


1










- Visual & Workmanship



- Cable Entry Type & Size

- Accessories

- Dimensional Check


Calibration Check - Accuracy, Repeatability, Hysterisis, Zero Adjustment etc

Power supply variation test

Hydrostatic test ( as applicable )

Over range protection test

Communication with Communicator ( HART / FF )

7 H W X PMI Test for SS & AS Parts (100 % by vendor & L&T/TPI) ( as applicable )














___________CLIENT

ACTIVITY

___________L&T





CATEGORY : B

: ELECTRONIC TRANSMITTER ( PRESSURE, DP, TEMPERATURE, FLOW ETC )




EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R R X

8 R W X

9 R R X

10 R R X

11 W W H W X

12 W W H W X

13 W W H W X

14 W W H W X

15 W W W W X

16 H W X

17 H W X

18 R R X

19 H H W X








___________CLIENT

: CONTROL VALVES WITH SMART POSITIONER


Spares check ( 100% by Vendor & L&T / TPIA )


ACTIVITY

Any othet certificate as applicable

Manufacturer's test certificates for valve body, stem components, actuator accessories, Positiner, Spares etc.



INDICATIVE INSPECTION AND TEST PLAN ITP NO.: L&T/IITP-203 Rev 0

Actuator pneumatic pressure test (100% by vendor & at random byL&T / TPIA)

Hardness Test / Corrosion Test / Fire Safe Test , as specificed

Hydro test for body and seat leakage test (100% by vendor & at random by L&T / TPIA agency)


CATEGORY : A


Inspection & test procedure including NDT procedures, PWHT procedure etc as applicable


Welding procedure specification and procedure qualification record for stelliting and casting repair procedure

Operational check for travel, calibration, accessories operation with Positioner ( 100% by vendor & at random by L&T / TPIA)

Valve casting repair procedure ( no weld repair to be carried out without the Client / L&T approval

NDT (RT, UT, MT, DP, etc as specified) examination records as applicable

Type test records for Capacity check, flow coefficient measurement, flow characteristics & operating time etc

Welders qualification / welder qualification record for stelliting and casting repair procedure

___________

Degree of protection, Area classification for accessories & spares & CCOE Certificate

PMI Test for SS & AS Parts, if specificed ( 100% by Vendor & L&T / TPIA ) ( as applicable )

Visual check of assembled valves including coating check

Dimensional check (100% by vendor & at random by L&T / TPIA)

L&T


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R R X

8 R W X

9 R R X

10 R R X

11 W W H W X

12 W W H W X

13 W W H W X

14 W W H W X

15 W W H W X

16 H W X

17 H W X

18 R R X

19 H H W X








___________CLIENT


Type test records for Capacity check, flow coefficient measurement, flow characteristics & operating time etc

___________L&T

Spares check ( 100% by Vendor & L&T / TPIA )




Degree of protection, Area classification for accessories & Spares & CCOE Certificate


: ON OFF VALVE WITH SOLENOID RESET

Operational check with Solenoid Reset for travel, static characteristic, ON OFF Time, accessories operation ( 100% by vendor & at random by L&T / TPIA)

Actuator pneumatic pressure test (100% by vendor & at random by L&T / TPIA)


PMI Test for SS & AS Parts, as specified ( 100% by Vendor & L&T / TPIA ) ( as applicable )

Manufacturer's test certificates for valve body, stem components, actuator accessories, Solenoid Valves etc


Hardness / Corrosion / Fire safe test , as specified




CATEGORY : A

Visual check of assembled valves

NDT (RT, UT, MT, DP, etc as specified) examination records as applicable

Inspection & test procedure including NDT procedures, PWHT procedure etc as applicable





ACTIVITY


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R W X

8 R R X

9 W W H W X

10 W W H W X

11 H W X

12 H W X

13 R W X

14 R W X

15 H H W X








___________CLIENT

ACTIVITY

Seat Leak Test ( Pneumatic )


___________L&T


Inspection & test procedure including NDT procedures, PWHT procedure , if specified




Performance test & acceptance test

Functional check of MOV / Accessories, limit switch

Manufacturer's test certificates for valve body, stem components, weeted parts, accessories etc

Routine tests ( 100% by vendor & at random by L&T / TPIA )


NDT Testng ( as applicable )




Type test & Routine Test Certificates for Motors

Hydro test for body, bonnet & seat


CATEGORY : A

: MOTOR OPERATED VALVES



Hand Wheel with Hand / Auto lockable lever shall be checked

Degree of protection, Area Classification for accessories & Spares & CCOE Certificate

Visual check & verification of marking, name plates & Tag No

Dimention check, end connection check

Integral Starter & control Transformer check as applicable



Physical check for PB's, Selector Switch, indication & control devices

EQUIPMENT DESCRIPTION : SAFETY VALVES PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A H X

5 R R X

6 R W X

7 W W H W X

8 R W X

9 H W X

10 H W X

11 R W X

12 H H W X








___________CLIENT

Cold bench set pressure test


CATEGORY : A

Hydro test for body and nozzle

Shell / body pneumatic test

Set pressure check (pressure change by minimum plus/ minus 5% by changing tension of spring and without effecting valve lift)

Dimensional check (100% by vendor & at random by TPI)

Seat leakage test





ACTIVITY

___________L&T


Inspection & test procedure



Manufacturer's test certificates for valve body, nozzle, trim components, accessories etc

NDT (RT, UT, MT, DP, etc as specified) examination records

Routine tests

Visual check of assembled valves, marking & name plate etc

Bellow integrity test


Helium Leak Test ( as applicable )

Blow down test

Any other test, as specified

Type test - capacity check




Valve lift check

EQUIPMENT DESCRIPTION : DESUPERHEATER PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R W X

5 R W X

6 W W H W X

7 H W X

8 H W X

9 R W X

10 R W X

11 H W X

12 H H W X








___________CLIENT

WPS / PQR, Welder qualification record

- Pneumatic Test for Assembly

Supplimentary requirement like hardness, impact test, IGC or any other as specified

Surface preparation, painting / pickling & passivation check


___________

- Any other test as applicable



L&T


Inspection & test procedure including NDT procedures, PWHT procedure




Verification of marking & review of vendor's final certificates

- Visual check & verification of marking, name plates, Tag No & mounting

- Dimensional check & nozzle check

- Hydro Test for Assembly





ACTIVITY


CATEGORY : B


EQUIPMENT DESCRIPTION : Blowdown Valves PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R R X

8 R W X

9 W W H W X

10 W W H W X

11 W W H W X

12 W W H W X

13 H W X

14 H W X

15 H W X

16 H H W X








___________CLIENT


Verification of marking & review of vendor's final certificates


CATEGORY : B

Visual check of assembled valves



Operational check ( 100% by vendor & at random by L&T / TPIA)


Manufacturer's test certificates for valve body, stem components, accessories etc





ACTIVITY



___________L&T


Inspection & test procedure including NDT procedures, PWHT procedure






�


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R R X

8 R W X

9 W W H W X

10 H W X

11 H W X

12 R W X

13 H H W X








___________CLIENT




CATEGORY : B

: Pressure Reduction Valves

PMI Test for SS & AS Parts, if specified ( 100 % by Vendor &L&T / TPIA ) ( as applicable )

Type Test - Bend Test as specified

Routine Tests (100% by vendor & at random by L&T / TPIA)

Set point calibration

Pneumatic Test for body & leakage test at gasket joints

Helium leak test ( as applicable )

NDT (RT, UT, MT, DP, etc as specified) examination records, as applicable


Manufacturer's test certificates for valve body,, accessories etc

Dimensional check, end connection




Witness Inspection & / or Document review by GNFCACTIVITY

___________L&T


Inspection & test procedure including NDT procedures, PWHT procedure as applicable



Spares check ( 100 % by Vendor & L&T / TPIA )


Hydro test for body and seat leakage test

Visual check of assembled valves & verification of marking & name plates

EQUIPMENT DESCRIPTION : INSTRUMENT CABLES PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 W W H W X


CATEGORY : B




ACTIVITY





Routine tests consisting of : (100% by vendor & L&T / TPI)

Check for colour, marking and general appearance

Dimensional check for size, length and outer sheath

Tensile & elongation test

Oxygen index, Temperature Index & drain wire resistance

Measurement of conductor resistance, inductance, capacitance, L/R ratio

Test for uniformity of galvanisation

Continuity Test

5 W W H W X

6 H H W X








___________CLIENT

Flame Retardent Test ( as applicable )

Smoke density test ( FRLS Cable )

Cable drum condition

Any other certificate / test as applicable

Physical test - Ageing, Hot deformation, Heat Shock, Shrinkage, Loss of Mass, Elongation, Tensile etc

Thermal stability test

___________L&T


Type test

HCL Gas emmision test ( FRLS Cable )

Water immersion test ( if applicable )

y

HV test & IR test (before and after HV test)

Spark Test ( if applicable )


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 R W X

7 H W X








___________CLIENT

Review of Documents

- Internal QA test report, Material test certificates for boughtout items


___________

HV Test / IR Test ( before & after HV )

- Degree of protection, Area classification & CCOE Certificate as applicable

Protective Coating for JBs ( Canopies as applicable )

Any other test as specified in the PR / PS / PO

- Any other certificate as applicable

L&T





Visual check, Dimensional check, Gasket check & Tag No, Nmae plate & surface finish etc

Mounting, cable entry, gland, plug etc

Functional test


Continuity check




ACTIVITY


CATEGORY : B

: JUNCTION BOX



EQUIPMENT TAG NO : CATEGORY : B


1





1 A A A R X Detailed inspection & test plan after the issue of PO/PR/PS.

2 R R X Summary of all supplementary requirements as specified in the PO/PR/PS.

3 H W X Final inspection - visual & dimensional, thickness inspection etc

( 100% by vendor & at random by L & T / TPI)

4 H W X Marking check & stamping -as applicable ( at random by L & T /TPI.).

5 R H X Review of manufacturer's test certificate / compliance certificate

Review of Test report for raw material , Nuts & Bolts .


6 H W X Final Inspection Release Note


PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification, NDT- Non destructive Testing,

TPI - Third Party Inspection, AI - Authorised Inspector.



Detailed Quality Control Plan indicating all specified requirements as per PO/PR/Data Sheets/Drawing/Indicative ITPs shall be

generated by vendor after issue of PO/ PS/PR.Same duly approved by L&T / TPI agency to be submitted to Client for approval

CLIENTL&T

ACTIVITY





: PERFORATED ALUMINIUM CABLE TRAYS



EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 R W X

7 H W X








___________CLIENT

- Internal QA test report


___________

- Material test certificate for boughtout items

- Any other test as specified in the PR / PS / PO


- Test Certificate for Measurement of Flame Path Joint

L&T





- Visual check, Dimensional check etc

- Quantity & marking Check


- Degree of protection, Area classification & CCOE Certificate as applicable

Review of Documents & Type test certificates




ACTIVITY


CATEGORY : B

: CABLE GLANDS WITH HOODS



EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 H W X

7 R W X

8 H W X








___________CLIENT

- Hydrostatic test as applicable

L&T

- Visual check, Dimensional check

- Marking check as applicable



___________

PMI Test for SS & AS Parts ( 100 % by vendor & L&T/TPIA ) as applicable



- Air leak test, Ferrule Hardness Test as applicable




ACTIVITY


CATEGORY : B

: INSTRUMENTATION TUBE FITTINGS


Spares check ( 100 % by vendor & L&T/TPIA )

Review of Documents






EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 R W X

7 H W X








___________CLIENT




ACTIVITY


CATEGORY : B

: INSTRUMENTATION TUBES


L&T







- Hydro Test & Pneumatic Test as applicable

Review of Documents



___________



- Tube hardness test, Eddy current test record, Flare test, Heat Treatment, IGC Test as applicable



EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 H W X

7 R W X

8 H W X








___________CLIENT


___________



L&T









ACTIVITY


CATEGORY : B

: INSTRUMENTATION AIR HEADER



Spares check ( 100 % by vendor & L&T/TPIA ) as applicable


- Hydro Test & Pneumatic Test as applicable

Review of Documents


- DP Test

EQUIPMENT DESCRIPTION : DAMPER ACTUATOR PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X


CATEGORY : B

Visual checks, Workmanship





Routine Test : ( 100 % by vendor & L&T / TPIA )



ACTIVITY


Model no., Tag plate, type of mounting, Name plate etc

Cable entry type & size

Accessories check

Dimensional check

Performance test ( 100 % by vendor and at random by L&T / TPIA )

Calibration check & Pneumatic Check

6 R R X

7 R W X

8 R R X

9 H W X








___________CLIENT

No load Operation test, Pressure resistance test, Stroking length & time

___________L&T


Degree o f protection & area classification, CCOE Certificate as applicable





Calibration check & Pneumatic Check

Functional checks / on accessories as applicable

Open & close time check, Air failure / signal failure position

EQUIPMENT DESCRIPTION : AIR FILTER REGULATOR PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

5 H W X

6 R R X


CATEGORY : B










ACTIVITY


Model no., Tag plate, type of mounting, Name plate etc

Presure Range & Vent

Dimensional check


Functional / Calibration check

6 R R X

7 R W X

8 R R X

9 H W X








___________CLIENT

___________L&T


Degree o f protection & area classification as applicable





EQUIPMENT DESCRIPTION : RUPTURE DISC PROJECT

EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R R X

5 H W X

6 H W X

Dimensional check


Burst Test as applicable




ACTIVITY


Model no., Tag plate, type of mounting etc

Presure Range & Vent





NDT Test ( RT / UT / MT / LPT - As applicable )


CATEGORY : B


7 H W X

8 H W X

9 R R X

10 H W X








___________CLIENT


Burst Test as applicable



___________L&T

Spares Check - ( 100 % by vendor & L&T / TPIA )

100 % PMI Test for SS & AS material ( as applicable )



EQUIPMENT TAG NO :


1














- Accessories

- Dimensional Check


- Calibration Check

- Set Point Check

- NO / NC Contact

- Functional Checks on Accessories and Hydrotest As Applicable

7 H W X PMI Test for SS & AS Parts (100 % by vendor & L&T/TPI) ( as applicable )














___________CLIENTL&T





CATEGORY : B

: ELECTRONIC SWITCHES ( LEVEL, PRESSURE, POSITION etc )



___________


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 R R X

5 W W H W X

6 W W H W X





NDT Test for casting ( RT / UT / MT / LPT - As applicable )


CATEGORY : B


ACTIVITY


Model no., Tag plate, type of mounting, marking etc


Dimensional check


Hydro Test

: FLAME ARRESTOR & BREATHER VALVES

Functional test ( Set Pressure, Set Vaccume etc ) & Seat Leakage test fro Breather Valves



7 H W X

8 H W X

9 R R X

10 R R X

11 H H W X








___________CLIENT

___________L&T

Spares Check - ( 100 % by vendor & L&T / TPIA )

100 % PMI Test for SS & AS material ( as applicable )





Detonation test & Flame Test

Type Test Certificates & Capacity Curve as applicable

Functional test ( Set Pressure, Set Vaccume etc ) & Seat Leakage test fro Breather Valves


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 A W X

5 A W X

6 A H X

7 R R X

8 R W X

9 H W X

10 H W X

11 H W X

12 R W X

13 H W X








___________CLIENT

Hydro test for body and seat leakage test

Visual check of assembled valves & verification of marking & name plates


___________L&T


Inspection & test procedure including NDT procedures, PWHT procedure as applicable



Spares check ( 100 % by Vendor & L&T / TPIA )


Set point calibration

NDT (RT, UT, MT, DP, etc as specified) examination records, as applicable


Manufacturer's test certificates for valve body,, accessories etc

Dimensional check, end connection







CATEGORY : B

: BLANKETING SYSTEM

PMI Test for SS & AS Parts, if specified ( 100 % by Vendor &L&T / TPIA ) ( as applicable )

Type Test - Bend Test as specified

Routine Tests (100% by vendor & at random by L&T / TPIA)

Any other test as specified

Pneumatic Test for assembled valve


EQUIPMENT TAG NO :


1









5 H W X Routine Checks (100% by vendor & L&T/TPI)





- Accessories

- Dimensional Check

6 H W X Performance Test (100% by vendor & at random by L&T/TPI)

- Operational check at max & min operational pressure of air / nitrogen

- External leak test , Seat leak test etc

- HV & IR Test for coil


8 R R X Type Test Reports

















CATEGORY : B

: SOLENOID VALVE



___________


EQUIPMENT TAG NO :


1









5 H W X Routine Checks (100% by vendor & L&T/TPI)





- Accessories

- Dimensional Check

6 H W X Performance Test (100% by vendor & at random by L&T/TPI)

- Calibration Check

- Communication Check

- Functional Checks on Accessories As Applicable



















CATEGORY : B

: VALVE POSITIONER



___________


EQUIPMENT TAG NO :


1





1 A A A R X

2 A R X

3 R R X

4 H W X

Measurement of conductor resistance, inductance, capacitance, IR ratio

Test for uniformity of galvanisation

Test for insulation and testing




Routine tests consisting of : (100% by vendor & L&T / TPI)

Check for colour, marking and general appearance

Dimensional check for size, length and outer sheath

Visual check for effects in outer sheath

Mechanical test - Tensile, crush, impact, bend, repeated bend, torsion test etc




ACTIVITY


: FIBRE OPTICS & OTHER COMMUNICATION CABLE


CATEGORY : B

5 H W X

6 H W X








___________CLIENT


Type test

HCL Gas emmision test ( FRLS Cable ) as applicable

Water penetration test

g

HV test

IR test (before and after HV test)

Drip Test

___________L&T

Flame Retardent Test ( as applicable )

Smoke density test ( FRLS Cable ) as applicable

Cable drum condition

Any other certificate / test as applicable


EQUIPMENT TAG NO : CATEGORY : C


1





1 I I A R X Detailed inspection & test plan after the issue of PO/PR/PS.


3 H W X Final inspection - visual, dimensional & thickness inspection ( after Galvanising).

( 100 % by vendor & at random by L&T / TPIA )

4 H W X Marking check & stamping as applicable ( 100 % by vendor & at random by L&T /TPIA)

5 R H X Review of manufacturer's test certificate / compliance certificate

Review of Test report for raw material , Nuts & Bolts .

Review of galvanizing report




PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification, NDT- Non destructive Testing,

TPI - Third Party Inspection, AI - Authorised Inspector.



Detailed Quality Control Plan indicating all specified requirements as per PO/PR/Data Sheets/Drawing/Indicative ITPs shall be

generated by vendor after issue of PO/ PS/PR.Same duly approved by L&T / TPI agency to be submitted to Client for approval

CLIENTL&T

ACTIVITY




: GNFC - Ammonia Syngas Generation Bharuch: GI CONDUITS


EQUIPMENT DESCRIPTION : CANOPIES & SUNSHADES PROJECT

EQUIPMENT TAG NO : CATEGORY : C


1





1 I I A R X Detailed inspection & test plan after the issue of PO/PR/PS.


3 H W X

4 R H X Review of manufacturer's test certificate / compliance certificate for materials.

Review of T.C. forTerminal block as applicable

Protective coating certificate for canopies if applicable.



LEGENDS: H- Hold, W- Witness, R- Review, A- Approval, I- Information, X- Submit,PO- Purchase Order, PR- Purchase Requisition, PS- Purchase Specification,TPI - Third Party Inspection, AI - Authorised Inspector.

Note: This is an Indicative Inspection & Test Plan identifying scope of inspection & review of documents by L&T / TPI Agency / Client as a minimum requirement. Detailed Quality Control Plan indicating all specified requirements as per PO/PR/Data Sheets/Drawing/Indicative ITPs shall be generated by vendor after issue of PO/ PR/PS.Same duly approved by L&T / TPI agency to be submitted to Client for approval

CLIENTL & T

ACTIVITY




Final inspection including visual ,Dimensional ,Mounting arrangement and Marking check ( 100 % by vendor and at random by L&T / TPIA)





CUSTOMER : GNFC , BHARUCH PAGE : 1 OF 1

TABLE OF CONTENTS

SL NO. SECTION PAGES

1.0 START UP & COMMISSIONING SPARES 1

2.0 MANDATORY SPARES 2

3.0 2 YEARS MAINTENANCE SPARES 1

SPARES LIST


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_7.1 (Form A)


CUSTOMER : GNFC , BHARUCH PAGE : 1 OF 1

SL NO.

EQUIPMENT PART NO.

COMMISSIONING SPARES LIST

SYSTEM / INSTRUMENT DESCRIPTION QTY UNIT PRICE


PACKAGE

REMARKS

Notes : Vendor to fill up & submit alongwith quotation . Spare price has to be furnished separately

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_7.2 (Form B)


CUSTOMER : GNFC , BHARUCH MANDATORY SPARES LIST PAGE : 1 OF X

SL NO.

1

1.1

1.2

1.3

1.4


Speed Probes, Speed Transmitters, Sensors of Gas Detectors

UNIT PRICE

10% of each type of instruments, subject to minimum 1 no. of each type, including all peripheral accessories

DESCRIPTION QTY REMARKS

Pressure Gauges,Differential Pressure Gauge, Draft Gauges, Field Indicators, RTD/T/C with Thermowells, welded thermowell, Skin Thermocuple Sets.

SYSTEM / INSTRUMENT

CATEGORY ITEM

10% of each type of instruments, subject to minimum 3 nos. of each type

Transmitters for Flow, Pressure, Level , Temperature Diff. Pressure application, Transmitter for LEL/GAS Detector System, including Magflow, Massflow, RADAR, etc.

10% of each type of instruments Head with Torque Tube Assembly and Transmitter, subject to minimum 1 no. of each type

10% of each type of instruments, subject to minimum 1 no. of each type

Displacer type Level Transmitters

Field Instruments

2

2.1

2.2

2.32.42.52.6

10% of each type of soft sets inlcuding diaphragms and 1 set of spring of each type. Min. soft sets shall be 2 set for each type and 1 set of spring of each type

Control Valve Spares

Soft part / actuator spares, including actuator diaphragm and spring sets, for each type of actuator

20% of each type of instruments, subject to minimum 5 nos. of each type

20% of each type of Proximity switches including enclosure

Solenoid valves

20% of each type of 10% of each type of

SMART PositionersOther accessories like Quick Exhaust relay, Volume Boosters, Air Filter

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_7.2 (Form B)


CUSTOMER : GNFC , BHARUCH MANDATORY SPARES LIST PAGE : 1 OF X

SL NO.


UNIT PRICEDESCRIPTION QTY REMARKSSYSTEM / INSTRUMENT

CATEGORY ITEM

3

3.1

3.2

3.33.43.53.63.7 1 set for each type

1 years normal ZERO/SPAN gas cylinders, various Career gases , etc.Filters/Orings and other consumable parts

1 type of each card as a 1 set of Sensor / Detectors

Electronic cards for Various AnalysersAnalyser Sensors / Detectors

1 Complete Set of Columns

1 set of each typeUV sources with lamps

Gaschromatograph Columns

Analysers

1 set of each typeInfrared Sources with lamps

5 Vendor to fill up & submit alongwith quotation Spare price has to be included in base offer

Notes :

1. The above spares do not include installed spares as well as commissioning spares or on-line installed spares in working systems. The above shall be purely ware house spares. Commissioning spares for each system is Vendor's responsibility and above spares shall not be used as commissioning spares.2. Wherever "Each Type" is specified, it is means "of the Type/make/model/size and exactly replaceble"3. Wherever "% qty." is specified, Vendor to quote in next higher rounded figure

4. Vendor to furnish optional quote / unit price for trims, complete actuator and complete unit spares for control valves along with offer with six months offer validity from placement of order. Based on the requirement, the order may be placed for few of the critical spares with these price.

5. Vendor to fill up & submit alongwith quotation . Spare price has to be included in base offer

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_7.3 (Form C)


CUSTOMER : GNFC , BHARUCH COMMISSIONING SPARES LIST PAGE : 1 OF 1

SL NO.

EQUIPMENT PART NO.

SYSTEM / INSTRUMENT DESCRIPTION QTY UNIT PRICE REMARKS


PACKAGE


PACKAGE



CUSTOMER : GNFC , BHARUCH COMPLIANCE FORMS PAGE : 1 OF 1

TABLE OF CONTENTS


1.0 DEVIATION LIST 1

2.0 COMPLIANCE STATEMENT 1

3.0 COMMENT RESOLUTION 1


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_8.1 (Form-D)


CUSTOMER : GNFC , BHARUCH DEVIATION LIST PAGE : 1 OF 1

SL NO.

CLAUSE REFERENCE SPECIFICATION REQUIREMENT DEVIATION WITH REASONS

Attachment Clause Ref Sheet no.

1.0 MR1.1 Attachemnt -1.01.2 Attachemnt -2.01.3 Attachemnt -3.01.4 Attachemnt -4.01.5 Attachemnt -5.01.6 Attachemnt -6.01.7 Attachemnt -7.01.8 Attachemnt -8.01.9 Attachemnt -9.01.10 Attachemnt -10.0

Vendor to fill up and submit , duly signed and stamped copy of this deviation list alongwith Quotation. Without this Deviation List , quotation will not be considered for Evaluation.


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_8.2 (Form-E)


CUSTOMER : GNFC , BHARUCH COMPLIANCE STATEMENT PAGE : 1 OF 1

SL NO.

COMPLIANCE STATEMENT BIDDER'S COMPLIANCE REMARKS

1.1 There are no deviations by Vendor to the enquiry document other than mentioned in deviation list. L&T presumes that Vendor is complying to L&T's Material Requisition in totality. Deviations/clarifications, if any, sorted out at later date will not be entertained & vendor shall comply the MR requirement without any time & cost impact to L&T

Complied / not complied

1.2 Confirm that the following has been enclosed along with bids: a. Deviation List (Form-D) b. Compliance Statement (Form-E) c. Spares List (Form-A, Form-B, Form-C)d. Catalogues Vendor to submit above documents, duly signed & stamped.

Confirmed / Not-Confirmed

1.3 Confirm that the offer meets all requirements of specifications in totality and all items are quoted.If not, confirm that item wise list of deviation is enclosed (Form-D). Please note that deviation given elsewhere will not be considered. Confirm compliance.


1.4 Confirm that documentation has been considered as per Attachment-10, Vendor Document Requirement


1.5 Confirm that items are certified for used in specified hazardous area.

Necessary statutory certification e.g. CMRI, CCOE, ATEX, IBR etc. are available


1.6 Confirm that PTR (past track record) is available for the offered items and enclosed alongwith offer


1.7 Confirm that Inpsection and testing is considered as per IITP and MR


Vendor to fill up and submit , duly signed and stamped copy of this deviation list alongwith Quotation. Without this Deviation List , quotation will not be considered for Evaluation.


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_8.3 (Form-F)

PROJ TEC : AMMONIA SYNGAS REVISION : 0GENERATION PLANT

CUSTOMER : GNFC , BHARUCH COMMENT RESOLUTION SHEET PAGE : 1 OF 1

SL NO.

REF. OWNER / PMC COMMENTS RESOLUTION STATUS

1.1 Open / Closed

1.2 Open / Closed

1.3 Open / Closed

1.4 Open / Closed

1.5 Open / Closed

1.6 Open / Closed

1.7 Open / Closed


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_9


CUSTOMER : GNFC , BHARUCH PROVEN TRACK RECORD PAGE : 1 OF 1

TABLE OF CONTENTS


1.0 PROVEN TRACK RECORD 1


PACKAGE

DOCUMENT NO.LARSEN & TOUBRO LIMITED ASGP-LTEM-IN-MR-2212E&C DIVISION, CHEM PLANTS Attachment_9.1 (Form-G)

PROJ TEC : AMMONIA SYNGAS REVISION : 0GENERATION PLANT

CUS MERTO : GNFC , BHARUCH PROVEN TRACK RECORD PAGE : 1 OF 1

SL NO.

CUSTOMER END USER INSTRUMENT/SYSTEM DETAILS APPLICATION DATE REMARKS





REVISION : 0

CUSTOMER : GNFC, BHARUCH PAGE : 1 OF 1 VENDOR DOCUMENT REQUIREMENT

TABLE OF CONTENTS

SECTION PAGE

1.0 VENDOR DOCUMENT REQUIREMENT (VDR) 2





REVISION : 0


1.0 VENDOR DOCUMENT REQUIREMENT

The purpose of this document is to consolidate the requirement for engineering documents to be furnished by vendor.

1.1 Documentation

Bidder shall submit the applicable documents /drawings as indicated in following table. SL. NO.

DOCUMENT APPL. WITH BID (Copies)

PROJECT MANAGEMENT (Copies)

AS-BUILT (Copies+1 CD)

SY

S

INS

T

BU

LK For

Approval after PO

After approval for information

Time (Weeks)

1 DESIGN 1.1 Package Control System 1.1.1 Package Functional

Specification √ 3 3 7

1.1.2 I/O point Database √ 3 3 7 1.1.3 I/O Summary √ 1 3 3 7 1.1.4 Process Control Diagrams √ 3 3 7 1.1.5 Interlocking and Logic

Diagram √ 3 3 7

1.1.6 Signal Exchange details & Interconnection Details between DCS/ESD System & the Package Unit/ Special Instrument Systems

√ 3 3 7

1.1.7 Serial I/O interface details between DCS/ESD system and Package Unit/ Special Instrument Systems

√ 3 3 7

1.2 Field Instruments 1.2.1 System/ Instrument

Design Documents √ √ 3 3 7

1.2.2 Utility Consumption requirement: Power Air Steam/Water

√ √ 1 3 3 7

1.2.3 Specification & Datasheet √ √ √ 1 3 3 7 2 LISTS 2.1 Instrument Index √ 1 3 3 7 2.2 Cable List √ 3 3 7 2.3 JB List √ 3 3 7 2.4 Spares List

(Recommended, 2 years Maintenance Spares, Mandatory Spares)

√ √ 1 3 3 7





REVISION : 0


SL. NO.

DOCUMENT APPL. WITH BID (Copies)

PROJECT MANAGEMENT (Copies)

AS-BUILT (Copies+1 CD)

SY

S

INS

T

BU

LK

For Approval after PO

After approval for information

Time (Weeks)

3 LAYOUTS 3.1 OGA/IGA & Assembly

Drawing √ √ 3 3 7

3.2 Installation Hook up Drawing

√ 3 3 7

3.3 Equipment/ Shelter & Routing Layout Drawings

√ 3 3 7

4 INSPECTION & TESTS Inspection Test Reports &

Certificates √ √ √ 3 3 7

FAT Reports √ 3 3 7 5 CATALOGS AND

MAINTENANCE MANUALS

Catalogs for Bought outs √ √ √ 1 3 3 7 Operation & Maintenance

Manuals √ √ √ 3 3 7

1.2 Guidelines All vendor documents shall be submitted in editable format (MS word, MS excel, AutoCAD, etc.)

SYS = Control System or Sub Control System or Special Inst System

INST=Field Instruments Bulk= Bulk Items

Time indicated for submission of documents from the date of LOI in weeks, unless otherwise

specified. Supplier to submit the Dwg / Document schedule indicating date of submission.

Supplier shall proceed with the manufacturing activities only after obtaining approval / written

clearance again the documents indicated in REVIEW category.

All “As-Built” drawings shall be duly certified by authorized inspection authority if applicable.

All drawing prepared by the supplier shall be on AutoCAD, Release 14

In addition to above, Supplier shall submit followings:

One Original set of all drawings to be submitted for record. All operating and maintenance instructions in electronic media or in scanned images converted in

electronic media.

26_ASGP LTEM in MR 2212 0 _Instrumentation Requirements for CPU

Documents

Transcript of 26_ASGP LTEM in MR 2212 0 _Instrumentation Requirements for CPU