Comment Resolution Sheet

Commentd AIL Commetned AIL Next

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Document Revision: Document Rev: Owner Discipline: Instrumentation
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks

Closed IN-01 3.2 At control room Noted and updated.

Closed IN-02 3.2 To be decided during Detail engineering Noted and updated.
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks
Following features are req. in control system

1Historian for data storage. Tag count upto 1000

2Historian provision provided by the Analytics platform
OEM
3Auto tag recognition, easy configurable tags and asset
mapping
4Real Time End to End Process Visualization (schematic
(Graphical) view)
5Customizable graphical dashboard for any process
performance & monitoring
6BI dashboards for a production line showing production
waste, product quality or heat maps, energy consumption
etc
7Real time Asset performance & monitoring (APM)
8Heat and Mass balance for equipment specific & overall Same shall be incoprorate in Control System
Closed IN-03 3.2 process block. specification.
9Validation & compute yield, norms & selectivity
10Creation of Soft Tag for Creating new KPI
11Basic Alarm / Alert management for anomaly and
deviation
12Customized and Standard Reports with drilldown option
13Superimposing of trends for multiple parameters of
units (distillation column, exchanger, reactor) or bad batch
production.
14failure analysis of units (distillation column, exchanger,
reactor) or bad batch production.
15Basic model creation (identification of similar pattern,
Fingerprinting) capability and alert for the same
16Inbuilt Data cleaning
17Internal Collaboration for trend/event analysis
18Exposure to chemical industry
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks
ELV design basis is separate document hence
ELV system Design Basis not mentioned . The same to be
Closed IN-04 3.2 mentioned
not covered here. Document has already
submitted.

Review for consideration of temp Class as per IPDS Temp. Class T4 has considered as per IPDS
Closed IN-05 3.2 requirement. Requirement.

Following requirement to be added.

Closed IN-06 3.2 1). Terminal Server Noted and Incorporated.
2). SMS/Email. Server

Closed IN-07 3.2 This option to be selected(Required) To be selected Noted and updated.

Closed IN-08 3.2 Req. for IS signals Noted and Incorporated.

30% (20% for Future requirement & 10% for

Commissioning)installed and wired spare for all types of
I/Os at controller level.
20% free slots in I/O rack for I/O card installation in future
requirements
20% free space in the system cabinet/marshalling cabinet
Closed IN-09 3.4 (relays/TBs/Barriers) for node expansion in future
Noted and spare philosophy has updated.
requirements.
50% Spare Tags (IOs) Software Licence (i.e- DST(Data
Storage Tags) Tags )
30% of Total AIs and AOs (Present Value + Output + Set
value) shall be considered for the History Package .
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks

Closed IN-10 3.3 Communication card with Bus Noted and Incorporated.

Closed IN-11 3.2 Dual Monitor to be considered. Noted and Incorporated.

Closed IN-12 3.2 Review availability of IP54 for cabinet with system vendors. IP rating for cabinet shall be IP-42.

For AI, AO and DI(non MCC/ Namur) Knife edge TBs to be

Closed IN-13 3.2 considered
Noted and Incorporated.

Closed IN-14 3.6 not required. 230VAC fans to be considered Noted and Incorporated.

Control room are safe and enclosed building hence IP-

IP 54 42 is comply for equipments installed in control
room.
Closed IN-15 3.9
Kindly Note that, due to Fans and filter installation in
Not Acceptable. It must be IP54 as per AIL design code.
Panel IP42 comply instead of IP54

1/4" : SS304 tube with PVC coating

Closed IN-16 3.11 1/2" : SS304
Noted and Incorporated.

Closed IN-17 3.7 F&G to be considered Noted and Incorporated.

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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks
Modbus TCP-IP is preferable. If it is not available with
Closed IN-18 3.8 package vendor then other protocol can be used after Noted and updated.
alignment with AIL and Mott.

Closed IN-19 3.11 1/4" tube to be considered here. Noted and Incorporated.

Closed IN-20 3.12 for armored Modbus cable Gray color to be considered Noted and Incorporated.

Closed IN-21 3.14 Please confirm Load cell output Confirmed

Closed IN-22 3.15 Tick to be removed here. Noted and updated.

This is installation activity to be taken care in Hook up

Closed IN-23 3.17.1.1 In line instrument installation shall be horizontal preferably.
drawing. No action requird for design basis.

Closed IN-24 3.17.1.4 1/2" to be considered. Noted and Incorporated.

Closed IN-25 3.19 Provide details of Power cable from UPS to PDB panel Noted and Incorporated.

Closed IN-26 3.19 1 Sqmm to be considered for RTD cable Noted and Incorporated.
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks

Closed IN-27 3.20 Nickel Plated Brass to be considered instead of SS304 Noted and Incorporated.

Closed IN-28 3.22 2 Nos. req. Noted and Incorporated.

Closed IN-29 3.23 Hinged door type to be considered Noted and Incorporated.

Closed IN-30 3.25 Update Spare philosophy. Noted and Incorporated.

Closed IN-31 3.26 LT Radar Connection - 3" Noted and Incorporated.

Closed IN-32 4.1.1 To be decided by Control valve vendor Noted and modified.

Vendor sizing sheet of instruments to be verified through

Noted and confirm. Sizing sheet shall be share with
Software like InstruCalc. Outcome the same to be shared to
AIL Team,
AIL

Closed IN-33 4.0 Comment is not relevant to Design basis. MM Ensure

Not incorporated in document. please include in design same and separate sizing sheet of software output as
basis as per given comments. verification of instrument sizing.Technical detail
related to procurment are part of design basis.
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Document Revision: Document Rev: Owner Discipline: Instrumentation
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks

Closed IN-34 4.1.7 To be discussed as AIL dont have bypass policy for CV. Updated as per discussed during join meeting.

Closed IN-35 4.2.6 Correct to stelliting Noted and corrected

Closed IN-36 4.2.1 Correct to cavitation Noted and corrected

Closed IN-37 4.4.3 SS316 Body req. Noted and updated.

Closed IN-38 4.4.3 IP67 req Noted and updated.

Closed IN-39 4.4.3 SIL 2 Certified req. Noted and updated.

Closed IN-40 4.4.3 Manual Override Not req. Noted and deleted.

Thermocouple K type if used for highr temperature

Closed IN-41 4.5.2 Need to clarify
measurement (above 250 degree )

Closed IN-42 4.5.2 IEC60751 Noted and updated.

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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks

Closed IN-43 4.7.6 2 Wire type is req. Noted and updated.

150mm dial with tricolor indication. Yellow/Green/Red for

Closed IN-44 4.10.1
Min/Oper/Max value
Noted and updated.

130% over reange instrumentation protection from

Closed IN-45 4.10.3 Need to clarify
full scale Value.

Closed IN-46 4.12.1 Pressure switch to be procure with RD from vendor. Noted and updated.

Closed IN-47 4.14 IP65 protection to be considered Noted and updated.

Gas detector will be connected to its separate Panel.

Closed IN-48 4.14
Repeat signal will come to DCS.
Noted and updated.

ITP will be shared to instrument vendor along with MR. Noted.

Closed IN-49 6.1

Comment is not relevant to Design basis. MM Ensure
Not included in design basis. please include ITP
ITP will share while issue RFI/RFQ. Hence not required
requirement in design basis as per given comment.
to add in design basis.

This shall be in AIL procurement not in erection vendor

Noted and updated.
supply.
Closed IN-50 7.0
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Status Comment No. Section AIL Comments Resolution by DEC/Vendor Acceptance / Remarks
Closed IN-50 7.0
Please update scope table as per given comments in
Noted and updated.
document.

Closed IN-51 14.0 False Ceiling Anti-Static Required Noted and updated.

Closed IN-52 3.22 Motor/Agitator- 2 Nos. Command Noted and updated.

Also include '' vendor sizing reports of valves/Instruments to

Closed IN-53 4.1.10 be varified by DEC through software like conval/Instrucalc Refer Reply of Comment IN-33
and outcome shall be shared with AIL.

Please include ''Indicative ITP of each items shall be shared

Closed IN-54 6.10
to vendor along with RFQ.
Refer Reply of Comment IN-49
Design Basis Instrumentation
AIL Pilot Plant
07-03-2022
Confidential
Mott MacDonald
A/301, 3rd Floor, Block A
Westgate Business Bay
Makarba
SG Highway
Ahmedabad
380 051
Gujarat
India

T +91 (0)79 4911 1600

mottmac.com

Design Basis Instrumentation

Aarti Industries Limited,
3M,PLOT NO. 41/2,
GIDC Jhagadia, Dist:-
Bharuch.
Gujarat, India AIL Pilot Plant
07-03-2022
Confidential

Mott MacDonald Private Limited.

Registered office: 101, Nomura,
Hiranandani Gardens, Powai, Mumbai 400
076, Maharashtra, India. CIN
U74210MH1970PTC014650
Mott MacDonald | Confidential | Design Basis Instrumentation
AIL Pilot Plant

Issue and Revision Record

Revision Suitabil Date Originator Checker Approver Description

ity
Code
C01 A2 31-01-22 HM AK TS For Review and approval
C02 A2 25-02-22 HM AK TS For Review and approval
C03 A5 07-03-22 HM AK TS Issued for Engineering

Document reference: 425124 | 425124-MMD-00-XX-RP-IN-0001 | C03-A5

AIL Reference : PIN-050-MMD-PC1-IN02-0001 | 00

Information class: Standard

This document is issued for the party which commissioned it and for specific purposes connected with the above-
captioned project only. It should not be relied upon by any other party or used for any other purpose.

We accept no responsibility for the consequences of this document being relied upon by any other party, or being
used for any other purpose, or containing any error or omission which is due to an error or omission in data supplied
to us by other parties.

This document contains confidential information and proprietary intellectual property. It should not be shown to other
parties without consent from us and from the party which commissioned it.

425124 | 425124-MMD-00-XX-RP-IN-0001 | C03-A5 | 07-03-2022

Mott MacDonald | Confidential | Design Basis Instrumentation
AIL Pilot Plant

Contents

1 Introduction 1

2 Purpose 2

3 Design Criteria 7

4 Field Instruments 18

5 Environmental Conditions and Erection 28

6 Approvals 29

7 Procurement Philosophy 30

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Mott MacDonald | Confidential | Design Basis Instrumentation 1
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1 Introduction

1.1 The Client

Aarti Industries limited is a leading Indian manufacturer of Speciality Chemicals and Pharmaceuticals with a
global footprint. Aarti started business in 1984, and now frontrunners in the chemical and pharmaceutical
industries.

Chemicals manufactured by Aarti are used in the downstream manufacture of Pharmaceuticals,

Agrochemicals, Polymers, Additives, Surfactants, Pigments, Dyes, etc.

Aarti Industries has 17 manufacturing units, mostly located near the large ports of western India. Aarti’s Head
Office is in the largest city of the region, and India’s commercial capital, Mumbai.

Visit Aarti Industries Limited at www.aarti-industries.com

1.2 About project

CLIENT is planning to set up Pilot plant facility in their 3M Plot area, in Jhagadia, in the state of Gujarat.

The proposed Pilot plant shall be executed in phased manner (Phase – I and II). For current proposal, scope
of work, equipment and services description are for Phase – I of Pilot plant only. Consolidated area demarcation
in plot plan for Pilot plant phase – II.

It is conveyed that there are certain temporary structures/ buildings shall be developed to cater utility and
electrical system requirement of Pilot plant.

1.3 Project Site Details

Particulars Description

Project Pilot Plant at Zone-4

Site address Aarti Industries Limited, Plot,

3M,PLOT NO. 41/2,
GIDC Jhagadia, Dist:- Bharuch, Gujarat

Nearest Railway Station Bharuch

Nearest Airport Surat

Design Max. Temperature 45° C

Design Min. Temperature 10° C

Yearly Rainfall 100 mm

Rain Intensity 75 mm

Seismic Zone Zone-III

Wind Speed 44 m/sec

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2 Purpose

Purpose of this specification is to define the general criteria and the guideline to carry out design,
specification, drawing of the instrumentation.

2.1 Reference
a. AIL Design Code
b. BEP Documents
c. Technical Discussion / Kick Of Meeting 17th & 18th Jan., 2022.
d. Query List shared by MM.

2.2 Codes & Standards

Design shall be carried out as per ISA-IEC-NBC-BSS-ASME codes and to this specification. If changes on
the same shall be agreed upon from time to time.

Codes Description
ASME B1.20.1 Pipe Threads, General Purpose (inch)
ANSI/ ASME B16.5 Pipe flanges & flanged fittings
ASME B 46.1 Flange Surface Finish
ANSI/ ASME B1.1 UNC Bolts
ANSI B 16.104/ FCI 70.2 Control Valve seat leakage
ANSI/ ISA-75-01 For Control Valve Sizing
ANSI/ ISA S 75.04 Face to face dimension for flangeless control valve body.
ANSI B 16.37 Hydrostatic testing
ANSI/ ISA S 75.03 Face to face dimensions of flanged globe style control valve bodies (ANSI
classes 150,300,600).
ANSI/ ISA S 75.16 Face to face dimensions of flanged globe style control valve
bodies (ANSI classes 900, 1500, 2500).
ANSI/ ISA S 18.1 Annunciation sequences and specifications
ASTM Material for control valves and instruments
ASTM A 269-98 Impulse Tubing
ASTM B 68/ ASTM B 75 Copper Tubing
API RP 520 Sizing, Selection and installation of pressure, relieving devices
in Refineries: Part 1: Sizing and Selection. Part 2: Installation
API RP 551 Process Measurement Instrumentation
API RP 550 Manual on installation of Refinery instruments and control
systems-Part 1: Process Control and Instrumentation
API RP 556 Instrumentation and control systems for Fired Heaters

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

API 670 Vibration, axial position and bearing temperature monitoring systems
BS 3643 ISO Metric Screw Threads: Part 1: Principles and Basic Data.
Part 2: Specifications for selected limits of size.
IEC 61508 :1-7 Functional safety of electrical / Electronic/ Programmable
Electronic safety related systems (For manufacturer)
IEC 61511 :1-3 Functional safety – Safety instrumented systems for the
process industry sector
ISO 5167 Orifice Plates : Measurement of Fluid flow by means of Pressure Differential
Devices.
ANSI B 16.36 Orifice Flanges
ANSI B 16.20 Gaskets
ANSI B 16.5 Process Connection Flange for meter run and integral orifice.
API RP 521 Guide for pressure relieving and depressuring systems
API RP 526 Flanged steel safety relief valves.
API RP 527 Seat tightness of pressure relief valves.
API RP 552 Transmission system
API RP 554 Process instrumentation & control
API RP 555 Process analyzers
IEC 60529 Degrees of Protection provided by Enclosures (IP Code)
IEC 60751 Industrial Platinum Resistance Thermometer Sensors (RTD)
IEC 60584 :1-3 /
Thermocouple Sensors
ANSI MC96.1
ANSI PTC 19.3 Part 3 Power Test Code Thermowell Strength Calculations
IEC 60757 Code for Designation of Colors
IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment.
IEC 60902 Industrial Process Measurement and control terms and
definitions.
ISA S51.1 Process Instrumentation Technology
ISA S5.1 Instrument Symbols on P&ID
ISA S5.2 Binary logic diagrams for process operations
ISA 5.3 Graphic symbols for Distributed control/shared display
instrumentation logic and computer system
ISA S7.3 Quality standards for instrument air

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ISA S5.4 Instrument loop diagrams

ISA 5.5 Graphic Symbols for Process Displays
RP 60.8 Electrical guide for control centres
BS 1042 Measurement of fluid flow in closed conduits
BS 6121 Mechanical cable glands
BS 7244 Breather valves
ICS-6 Enclosures for industrial control and systems
ISO/IEC 17025 General requirements for the competence of testing and
calibration laboratories
NFPA - 70 National Electric Code
ANSI/ISA - 60079-1 Electrical apparatus for explosive gas atmospheres
EEMUA 191 Alarm systems - a guide to design, management and
procurement
EEMUA 178 A Design Guide for the Electrical Safety of Instruments,
Instrument/Control Panels and Control Systems
IEC 60381-1 Analogue signals for process control systems. Part 1: Direct
current signals
IEC 60381-2 Analogue signals for process control systems. Part 2: Direct
voltage signals
IEC 60770 : 1-3 Transmitters for use in industrial-process control systems
IEC 61131 : 1- 5 Programmable controllers
IEC 61000 Electromagnetic compatibility (EMC)
IEC 61300-3-31 Fibre optic interconnecting devices and passive components
IEC TR 61158-1 Digital data communications for measurement and control
IEC 61326 EMC for Programmable Systems
IEC 61512 Batch Control Systems
IEC 61850 Commutation networks and systems in substations
IEC 62424 Representation of process control engineering requests in P&I
diagrams and data exchange between P&ID tools and PCE-CAE tools
IEEE 730 Software Quality Assurance Plans
IEEE 802.3 Carrier Sense Multiple Access With Collision Detection
(CSMA/CD) Access Method and Physical Layer Specifications
IEEE 802.4 Token Bus Access Method
IEEE 802.5 Token Ring Access Method
IEEE 518 Guide for the Installation of Electrical Equipment to Minimize

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Electrical Noise Inputs to Controllers from External Sources

IEEE 488.1 Standard for Higher Performance Protocol for the Standard
Digital Interface for Programmable Instrumentation.
IEEE 488.2 Standard Codes, Formats, Protocols, and Common
Commands for use with IEEE-488.1
ISA 5.06.01 Functional Requirements Documentation for Control Software
Applications
ISA 7.0.01 Quality Standard for Instrument Air
ISO 8573 Air Quality Classifications
ISA 12.13.01 Performance Requirements for Combustible Gas Detectors
ISA 12.13.02 Explosive atmospheres - Part 29-2: Gas detectors - Selection,
installation, use and maintenance of detectors for flammable gases and
oxygen
ISA 12.21.01 Use of Fiber Optic Systems in Class I Hazardous (Classified)
Locations
IEC 60204 Safety of Machinery
IEC 60721 Environmental conditions
ISA S71.01 Environmental Conditions for Process Measurement and
Control Systems, Temperature and Humidity
ISA S71.04 Environmental Conditions for Process Measurement and
Control Systems: Airborne Contaminants
IEC 61010 Electrical Safety
IEC 62026 Actuator/Sensor-Interface
IEC 62305 Protection against lightning
ISO 11064 :1-3 Ergonomic design of control centres
ISO 15663 Life Cycle Costing
NEC National Electric Code
NFPA National Fire protection Association
NFPA 72 National Fire Alarm and Signaling Code
NFPA 70E Standard for Electrical Safety in the Workplace
NFPA 70B Recommended Practice for Electrical Equipment Maintenance
IS 1554 : 1-2 PVC insulated heavy duty cables.
IS 7098 : 1-2 Crosslinked polyethylene PVC insulated Cable (XLPE)
IS 8130 Conductor for electrical cables
IS 5831 PVC insulation & Sheath for electrical cable

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IS 3975 Armouring for electrical cables

IS 694 Flexible & house wiring cable
IEC 332 : 1-3 FRLS - test for cable
IS 8784 Thermocouple compensating cable
IS 5571 Guide for Selection and installation of Electrical Equipment for
Hazardous Areas (other than mines)
IS 5572 Classification of hazardous areas (other than mines) having
flammable gases and vapours for electrical installation
IEC 62040: 1-3 Uninterruptible power systems (UPS)
IS 3043 / IEC 60364 Code of practice for earthing
IEC6
0079 Explosive Atmospheres

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3 Design Criteria

3.1 Haz. Area Classification

a. Process Plant  Zone-1  Zone-2  Safe

b. Utility  Zone-1  Zone-2  Safe

c. MCC & Control Room Area  Zone-1  Zone-2  Safe

d. Temp. Class  T3 / T4  T5 / T6  T4 Preferred

3.2 Control System

a. Mode of plant operation  Plant Wise-Standalone Dedicated for Pilot Plant

b. Controller assignment  Plant-wise

c. Type of hardware  DCS  PLC  BMS  Local

 Finalized during details engineering.

d. Operator Room Location  At Control Room

e. Marshalling Room Location  At one location above MCC room.

f. Inst. Tag Nos.  As per P&ID & AIL design code

g. Logic Representation  As per ISA

h. shutdown system  Not Required  Required
Plant safe and Emergency shutdown logic to be made to make plant safe in case of
any emergency. Requirement shall be finalized during engineering based on process
hazardous & Risk assessment.

i. Batch Server  Not Required  Required – Will be decide later based on

process.

j. Historian/OPC Server  Not Required  Required

k. Terminal Server  Not Required  Required

l. SMS/Email Server  Not Required  Required

m. Barriers  Not Required  Required for IS signal.

n. Relays  Not Required for iMCC

 Required-230VAC / 24VDC for MCC of Package Items.
o. Relays Boards  Not Required for IS signals.
 Required-24VDC for on-off valves NON-IS I/O

p. Valve Feedback  2 Nos.  1 No. only

q. Switch [Valve Feedback]  Micro-2 Wire  Proximity 2 Wire IS

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r. Operator Station  Required  Not Required

s. Engineering station  Required  Not Required

t. Monitor Screen Size  24’’ LED(Dual Screen)  32’’ LED

u. Network Printer A4 Colour  Required  Not Required

v. HMI in field [7’’ Display]  Required  Not Required

Shall be finalized at the time of system specification after discussion
over process operation.
w. IP Rating for Cabinet  IP-42 (For inside control room)

x. TBs in Panel  Knife edge for AI, AO AND DI (non MCC/ NAMUR)
Fused TB with LED indication for DI(MCC) & DO to be
consider.

3.3 REDUNDANCY PHILOSOPHY

a. Controller  Redundant  Non-Redundant

b. Power Supply  Redundant  Non-Redundant

c. Dedicated for  Rack  Controller

d. Communication  Redundant at communication level  non-Redundant

e. I/O Cards  Redundant  Non-Redundant

Few Critical I/O’s may need redundancy in I/O’s. AIL will share the same during process engineering.

3.4 PROCESSOR LOADING PHILOSOPHY

Control processor < 60% (including required spares philosophy)
Note: 60% system loading includes Process Control, foreign devices and installed Spare tags.

3.5 POWER SUPPLY – UPS

a. DCS Incoming  24VDC  230VAC  110VAC

b. Solenoid valves  24VDC  230VAC  110VAC

c. 4 Wire Instruments  24VDC  230VAC  110VAC

3.6 POWER SUPPLY – Non-UPS

a. Cabinet Lighting  24VDC  230VAC  110VAC

b. Cabinet Fan  24VDC  230VAC  110VAC

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3.7 POWER SUPPLY – UPS

230 V AC, 50Hz from UPS for Distributed Control System. Location of UPS shall be near to control room.
UPS will be parallel redundant with 30 minutes battery backup time & SCVS Controller. Three phase input and
single-phase output.
UPS Should be < 40% on each UPS (of the total rated UPS capacity). As this UPS works on load sharing basis
so during maintenance of anyone UPS the complete load can be transferred to another UPS.
Rectifier-Inverter Type: SCR-IGBT or IGBT-IGBT (Preferred is SCR-IGBT due to robustness).

3.7.1 Dedicated UPS required for Instrumentation

a. Control System(DCS/PLC & FGS) & Field Instrument
b. ELV systems such as Fire Alarm, CCTV, PA, EPABx and Access Control
c. OSBL area ELV system such as permitter CCTV, etc.

3.8 TRANSMISSION AND CONTROL SIGNAL TOPOLOGY

a. Electronic  4-20mA for transmitter and Control Valves
 Digital for On-Off valves and switches
b. iMCC  Profibus-DP

c. Third Party Integration  Modbus TCP-IP(Preferable) OR Modbus-RS485 OR Profibus-DPs

d. If Remote I/O  Profibus-DP

3.9 EXPLOSION PROTECTED METHOD & CONSTRUCTION

Explosion class and ignition Group: Ex- proof to Gr IIA IIB or IIC / Gr. IIIA/IIIB as per HAC
a. Flame/Explosion proof  Ex ‘’ia’’ and Ex-d (to suit specified hazardous area)

b. Weatherproof class  IP- 65 / 67 for field instruments / junction boxes

 IP- 42 for control room mounted equipment
Field Electronic Instruments which are open to atmosphere shall have FRP canopy of minimum 4 mm
thickness.

3.10 INSTRUMENT AIR SUPPLY

a. Supply from  Instrument air receiver and through Air dryer

b. Operating pressures  Minimum: 4 kg/cm2g  Normal: 5 kg/cm2g

 Maximum 7 kg/cm2g

3.11 INSTRUMENT AIR SUPPLY PIPING

with 1",150# main incoming Isolation valve from Header. 1/2" NPTF Ball valve with drain plug of Header
 12 way OR 08 Way OR 06 Way to be decided during detail engineering

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 Through SS-316 Air header, SS-316 pipe, SS-316 air manifold & SS tube (if 1/4" size : SS304 tube with
PVC coating and if 1/2" : SS304 tube)
 ¼” Tube size for the valve upto 80NB.
 ½’’ Air piping direct for the valve 100NB and Above.
Permanent tagging plate to be provided to each tapping.

3.12 COLOUR CODING

a. Field Transmitter  Mfg. Standard

b. Field Switch  Mfg. Standard

c. Control valves  Mfg. Standard

d. On-Off Valves  Mfg. Standard

e. Actuator-  RED – Fail to Open  GREEN – Fail to Close

f. Junction Box  Light Gray Equivalent to RAL7035

 Epoxy Light Gray Shade 631
 Epoxy Sky Blue Shade for IS signals
g. RIO Enclosure  SS-316L with corrosive resistance paint.

h. Instrument Panels  Light Gray Equivalent to RAL7035

i. Cables
Analog Signals  Sky Blue  Gray
24VDC & Pot. Free DI  Navy Blue  Gray  Black
Digital Signals-DO  Black  Gray
RTD/Thermocouple  Yellow
Power  Black
Earthing Cable  Green
FAS Cable  Red

CCTV Cable  Black

Telephone cable  Gray / Blue

Profibus Cable  Purple / Violet  Gray ( armored Modbus)
Modbus cable  Blue / Violet
Ethernet Cable  Gray
FO cable  Gray / Orange

3.13 Field Instrument Type

a. Transmitters  Smart type HART 4-20mA Output
 Foundation Field Bus  Wireless

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b. On-Off Valves, Switch  Traditional Digital

 Asi-Bus  Festo Concept

c. Load Cell  Smart type HART 4-20mA Output

 Ethernet IP  Profibus

d. Positioner  Pneumatic – SMART  Electric

3.14 MARSHALLING ROOM GENERAL REQUIREMENTS – at Above MCC Room

MCC Interface  Conventional  iMCC
UPS  Required  Not Required
Emergency Lighting  Required  Not Required
False Flooring Anti-Static  Required  Not Required
False Ceiling Anti-Static  Required  Not Required
Room Air Conditioning  Required  Not Required
Air Lock  Required  Not Required
Emergency Exit  Required  Not Required
Cable entry  Bottom  Top
Space for Future Expn.  Required  Not Required

3.15 OPERATING ROOM GENERAL REQUIREMENTS – at Safe Location

Emergency Lighting  Required  Not Required
False Flooring Anti-Static  Required  Not Required
False Ceiling Anti-Static  Required  Not Required
Room Air Conditioning  Required  Not Required
Air Lock  Required  Not Required
Emergency Exit  Required  Not Required
Cable entry  Bottom  Top
Space for Future Expn.  Required  Not Required

3.16 STANDARDS FOR INSTRUMENT CONNECTIONS, MATERIAL & ENCLOSURE

Instrument connections, material of construction and type of enclosure protections shall be as per following
codes & standards.
a. Flange  ANSI /ASTM

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b. Thread  NPT

c. Materia  ASTM

d. Engineering Unit  Metric Unit

3.17 INSTRUMENT PIPING AND WIRING

INSTALLATION / TUBING HOOK-UP

3.17.1.1 Instrument Installation

 Close coupled (with approach to instrument)

 Remote– conventional impulse tubing
(Where instruments are not accessible or for very high temperature service)

3.17.1.2 Material of Tubing and fittings

 SS 304 stainless steel (minimum)
 SS 304 stainless steel with PVC Insulated in case of highly corrosive atmosphere.

3.17.1.3 Instrument valve manifolds [3 Way] for

Flow Transmitters  Integral - Except High Temperature and steam Application

 Fabricated
DPT Transmitters  Integral  Fabricated

3.17.1.4 Impulse Line valves (After first isolation valve provided by piping)
Isolation Valves  Ball OR as per P&ID  Gate
Vent /Drain valves  Ball  Gate
Valves Material  As per Piping Specs.  SS-316/304
Impulse tube size  1/2”  ¼”

3.18 INSTRUMENT CABLE TRAY

Cable Tray Material  GI Hot dip galvanized  FRP  Wire mesh
Cable Tray Type  Perforated upto750mm  Ladder above 750mm

3.19 INSTRUMENT CABLING [ARMOURED TYPE]

For DC mA signals(1mm²)  Single pair with Screen  Multi-pair overall + individual screen
For RTD/TC cables (1mm²)  Single Triad with screen
For Power Supply(1.5mm²)  Two Core [24VDC] without screen

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For Power Cable from UPS  Three Core without screen – cable Size shall finalize during details
To PDB engineering as per load calculation.
For Control Cable((1mm²)  Two Core With overall shield  Multi-core with overall shield
[XV, Switch, Solenoids, etc.]
For Third Party Package  Modbus OR Rs-485 / Ethernet IP
For iMCC  Profibus DP OR FO

3.20 CABLE GLANDS WITH AND WITHOUT CHECKNUT

Double compression  Flameproof  Non-flameproof for safe area
Material  SS-304  Nickle Plated - Brass
Rubber Hood  Required  Not Required

3.21 INPUT / OUTPUT SIGNALS CONSIDERATIONS FOR FIELD INSTRUMENT

Transmitter  Analog Input - 1 No [Duel Output for Coriolis Mass Flow meter]
Control Valve  Analog Output - 2 No. [1 Analog Input for Valve Position Tx. For critical valves]
Solenoid Valve  Digital Output - 1 No.
On-Off Valve  Digital Output - 1 No.
Feed Back proximity switch  Digital Input - 2 Nos.

3.22 INPUT / OUTPUT SIGNALS CONSIDERATIONS FOR iMCC & Package MCC
Motor / Agitator  Digital Input - 3 Nos. Trip / Run Status / L/R Status
Motor / Agitator  Digital Output - 2 Nos. Start / Stop command
Motor / Agitator  Digital Output - 1 Nos. Safety Interlock
Motor / Agitator  Analog Input - 1 Nos. Current Indication- Critical Drives/ >25HP
VFD  Analog Input - 2 Nos. Current & Speed Indication
VFD  Analog Output - 1 No. Speed Control

3.23 JUNCTION BOX

No. of cable entry  16way/ 12Way or 06/04 ways to be decided during detailing.

Hazardous areas  Flame proof Ex ‘d’ & IP 67 / / EX"e" for IS signals

Non-hazardous areas  Flame proof Ex ‘d’ & IP 67 to maintain the similarity.
JB construction  Di-Cast Aluminium Alloy with Hinged door

Remote I/O  ATEX approval for Zone 1, Class IIA/IIB with

window, SS-316L with anti-corrosive paint

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3.24 GROUNDING
Control room mounted panels  Separate dedicated earth pit near to control room
Field instrumentation  Separate dedicated earth pit near to control room
UPS body earth  Electrical earth grid

3.25 SPARE PHILOSOPHY

In control system cabinet  30% (20% for Future requirement & 10% for Commissioning)
installed and wired spare for all types of I/Os at controller level.

 20% free slots in I/O rack for I/O card installation in future
Requirements

 20% free space in the system cabinet/marshalling cabinet

(relays/TBs/Barriers) for node expansion in future requirements.

 50% Spare Tags (IOs) Software Licence (i.e- DST(Data Storage

Tags) Tags)

 30% of Total AIs and AOs (Present Value + Output + Set value)
shall be considered for the History Package .

Spare instruments  10% or minimum one of each type of instrument.

Mandatory Spares  Required

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3.26 Nozzle Size Selection

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3.27 Instrument Straight Run Required

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3.28 Units of measurement shall be as follows:

Description Unit
Temperature : DegC
Flow - Liquid : m3/hr or Kg/hr
Flow - Gas : NM3/hr or Kg/hr at Normal conditions Flow - Steam
Mass : Kg/hr
Level - Process : % or mm
Level - Tank : % or mm or cm or meter
Pressure & Diff. Pressure : Kg/cm2 (gauge or absolute), mm of WC Vacuum
Weight : Kg or T
Density : Kg/m³
Velocity : m/s
Current : Ampere
Voltage : Volts / mV
Power : watt / KW / VA / KVA Energy
Frequency : Hertz
Thermal conductivity : W/m 0C
Plot plan dimension : m or mm
Equipment dimension : m or mm
Nozzle and flange sizes : inches
Vibration : Micron / mils
pH : pH
Speed : RPM
Analysis : % or PPM
Viscosity : cP
Conductivity : us/ cm

3.29 Graduations of scales and charts shall be as follows:

a. Differential pressure flow instruments:
i. Charts : 0-100% Square Root and Pressure & Temp. compensation for Gas
ii. Scales : 0-Full Calibrated flow value

b. Linear flow instruments :

i. Charts : 0-100% Linear
ii. Scales : 0-Full Calibrated flow value

c. Temperature and Pressure instruments:

i. Charts : 0-100% linear
ii. Scales : direct reading

d. Level Instruments:
i. Charts : 0-100 % linear
ii. Scales : 0-100 % linear

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4 Field Instruments

4.1 CONTROL VALVE

4.1.1 Control valves shall generally have spring and actuator suitable for 0.2 to 1 kg/cm²(g) if this is not
possible, they must be supplied complete with positioned and reducing filter for air supply, even if not
requested in specification. In any case signal to valve actuator shall not exceed 4 kg/cm² (g) Both the
positioned and reducing filter shall be complete with all the pneumatic connections with SS-304
forged fittings and tubes (8 mm O.D. minimum/STS ). Air filter regulator along with Pressure gauges
to be provided in all control valves. Valve Body Size upto 2 “ shall be manufactured with Investment
Casting Method only unless and until not specified explicitly in the Data sheet .Above 2” Size , Vendor
may go for Investment or Sand Casting.

4.1.2 Positioners and accessories shall comply with the requirements of this project. The pressure
gauges of positioner may comply with the Standard manufacture, if installed inside the positioner
case. If not, they shall be provided with connections and housing made of stainless steel or other
suitable material

4.1.3 Control valves shall generally be sized for capacity 130% of the maximum flow. A check shall be done
in order to ascertain a good operation of the valves over the whole expected operation range.

4.1.4 For lines up to 1”, the nominal diameter of the valve shall correspond to that of the line. For lines ≥ 1”
minimum valve diameter shall be 1”.

4.1.5 Valves shall generally have flanged connection and rating conforming to the piping specifications. All
valves shall have a trim as per process conditions.

4.1.6 Control valves shall be provided with air cooled bonnets or bonnet extensions for high (200 degree C
or more) or low temperature (-10 degree C & below) service respectively which are required to protect
the valve packing.

4.1.7 Hand wheels are to be provided only on critical valve. Drain valve( up and down stream) and by-pass
assemblies provision shall be consider as per P&ID.

4.1.8 The allowable maximum leakage through the vent control valves shall be 0.01% of maximum capacity
(class IV). For class IV leakage control valve soft seating shall not be used. Wherever process
demands leakage class of V & VI, soft seating shall be specified.

4.1.9 Continuously operating control valves and as well as vent control valves shall have < 70 dB (A) noise
level at 1 m distance.

4.1.10 Control valve shall be sized in accordance with the calculation method and formulae shown in
standard ISA: S.75.1 “Control Valve Sizing Equations”.

4.1.11 All control valves installed on steam service and boiler feed water are subjects to IBR
regulation/equivalent approved by IBR authorities. Pressure >3.4 Kg/cm2(g)

4.1.12 All control valves shall be supplied complete with tubing with SS-304 seamless tube.

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4.1.13 Air or power failure position of the valves shall be in accordance with the process requirement while
taking into consideration aspects of safety and overfill prevention.

4.1.14 Below arrangement shall also be required based on service and Temperature
a. Bellow-seal design requirement
b. Extended bonnet design
c. Flashing Requirements.
d. SOV in case of any interlocks
e. Position transmitter in case of critical service.
f. PTFE/PFA lined valves, etc.

4.2 ON-OFF VALVE

4.2.1 On-off valve type / design selection shall be made with consideration of following conditions:
a. Flashing or cavitation liquids
b. Steam service where pressure drop exceeds 5 bar
c. Corrosive fluids
d. On-off valves on erosive services (slurries).
e. Pressure Drop

4.2.2 On-off valves shall normally ball type for line sizes up to 80 NB. Sizes 80 NB and above, Butterfly
Valve shall be considered. Wherein for process, to meet tight shut off ball valve shall be up to 150NB
and above 150NB Butterfly Valve to be consider.

4.2.3 Body material, body rating shall be as per piping specifications as a minimum. The flange rating shall
be 150# as a minimum or higher as per piping specifications. Valve bodies and other pressure parts,
except diaphragms and housings shall be of forged or cast carbon steel conforming to ASTM A182,
or BS 1503-161 Gr. B and ASTM A-216 or BS 1504-161 respectively, unless otherwise specified.
Valve bodies of carbon steel with equivalent or better physical properties will be acceptable provided
forged materials are not high manganese sulphur steels (free machining).

4.2.4 Flanged connections shall conform to the dimensions and pressure temperature ratings of ANSI
B16.5

4.2.5 The on-off valve shall be delivered complete with actuator and accessories pre-assembled.
Accessories such as air filter regulator and solenoid valve shall be securely pre-tubed and mounted
on the actuator such that they shall be removable for maintenance without disturbing other
components. Noise from on-off valve during operation shall be limited to OSHA specified level or
better. The maximum allowable noise is 70 dBA SPL (Sound Pressure Level).

4.2.6 Leakage Class-VI shall be considered wherever tight shut-off is specified depending upon the
availability with respect to temperature, pressure drop and stelliting requirement. If Class-VI is not

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available because of high temperature or pressure drop then stellated Class V is also acceptable.
On-off valve leakage shall conform to ANSI B16.104 or ANSI/FCI 70.2.

4.2.7 Flanged bolted type gland packing boxes shall be used, unless otherwise specified. Gland packing
shall normally be self-lubricating type. Packing shall be PTFE on liquid and gas service up to 160ºC
and Grafoil for 160ºC and above. Asbestos as wetted material, either in packing or seal is not allowed.

4.2.8 Bellows seal shall be used where it is required to isolate the packing from the process fluid or where
no leakage to atmosphere can be tolerated like toxic, explosive and precious fluids.

4.2.9 The allowed stroking time of the on-off valves shall be evaluated on the basis of the process on-off
requirements.

4.3 ACTUATOR

4.3.1 Actuator shall be selected & sized to suit the above mentioned failed condition of on-off valve.

4.3.2 Actuators shall be adequately sized to on-off with shut-off pressure differential applied. The maximum
differential pressure for actuator sizing shall be assumed as maximum upstream pressure with valve
fully closed and downstream atmosphere pressure where specifically not mentioned in the design
data sheet.

4.3.3 Valve actuator(s) shall be selected to ensure that they are capable of operating the valve(s) with out-
of-balance forces as would be caused by pressure equivalent to the full static pressure upstream and
normal atmospheric pressure downstream.

4.3.4 The actuator shall be designed considering 4 kg/cm2g air pressure to deliver 30% more force/torque
than the max. Torque requirement to operate the valve under all operating conditions including when
the valve is pressure balanced upstream and downstream with the body cavity vented.

4.3.5 The actuator shall be selected considering instruments air supply pressure of 4 Kg/cm2g as indicated
in engineering design basis and selected size shall be 150% of calculated size.

4.3.6 Piston type actuators may be used for very high shut off pressure requirements. Additional equipment
necessary to meet fail safe condition shall also be included, in case double acting piston type actuator
is selected Actuator shall be able to withstand maximum shut-off pressure with the minimum
instrument air pressure specified.

4.4 OTHER ACCESSORIES

4.4.1 Valve stem position indicators shall be fitted as standard showing open, closed positions. Direction
of flow indication shall be permanently indicated on the valve body and shall be clearly visible in the
final installed position.

4.4.2 The limit switches for on-off valve wherever applicable shall be suitable to area classified in data
sheet. The enclosure of limit switches shall be as per the respective area classification.

4.4.3 SIL-2 Solenoid valves, wherever used, shall be 3/2 way std. /universal type and shall be continues
rated type with class F coil insulation as per IEC 85/ IS 1271. These shall be of SS 316 body & trim

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with weatherproof IP 67 or Ex-proof or Ex ia enclosure as per the respective area classification. The
solenoid coil lead wires shall be nearly terminated on the solenoid valve terminal box. Flying leads
from the solenoid valve are not acceptable. Solenoid vents shall have bug screens. All pneumatic
tubing for interconnection of solenoid etc. shall be ¼” NPT (F) specifications. The solenoid valve shall
be suitable for specified area in data sheet. Manual override push and lock screw type to be provided.

4.5 TEMPERATURE MEASUREENTS

4.5.1 The type of thermocouple to be used shall be as follows:

4.5.2 In case of high temperature measurement Chrome Alumel (Type - K) thermocouple to be used. Pt100
shall used for temperature lower than 0ºC and for special cases such as control loop with range 0-
250ºC or less shall be used.

4.5.3 Resistance RTD shall be used upto 250 deg C and it shall comply with IEC 60751 Class A.

4.5.4 All thermocouple and RTD elements shall be of duplex type and all the elements shall be of high
purity MGO (99.9%) filled with SS sheathings.

4.6 FLOW MEASUREMENTS

4.6.1 Flow meters should be Pressure and Temperature compensation with appropriate accuracy.

4.6.2 The primary element shall usually be the orifice meter with “flange taps” connections and square edge
orifice calculated according to ISO-R-541 rules. The use of nozzle on steam, while venturi and Pitot
tubes for large diameters and multi variables DP are recommended, so that there will be Pressure
and Temperature compensation which give 1% accuracy.

4.6.3 For magnetic flow meters, the lining material shall be PFA. There shall be 2 sensing electrodes and
1 grounding electrode. The MOC of sensing electrodes shall be SS-316L as a minimum. The flow
meter shall be powered by 24VDC; this power supply shall be derived from a bulk power source
located in the control room.

4.6.4 For mass flow meter shall be based on the Coriolis Effect principle. The flow meter shall be powered
by 24VDC; this power supply shall be derived from a bulk power source located in the control room.

4.6.5 Flow transmitter (DP)- All shall be SMART type with HART protocol Electronic flow transmitters shall
be AISI316 body material. The sensing Element shall be capacitance type with digital local indication.
Wetted parts shall be as per process line spec’s requirements. Differential pressure calculation value
shall be normally not higher than 2500 mm H2O. In addition, the following range can be used 50,100
250 500, 625, 1250, 5000, 10, 000mm H2O.

4.6.6 Vortex flow meters are acceptable in clean Liquid, Vapour & Gas. It shall be used where high
rangeability is required, high accuracy is required, where mechanical vibration does not exist in the
pipe, in steam application. It shall not be recommended for flow measurement in high viscous and

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slurry service. Vortex meter shall be selected where the Reynolds number shall be above 20,000
under any normal or abnormal process condition.

4.6.7 The vortex flow meter shall have an electronic indicator with LCD display. For indicating face, shatter
proof glass shall be used. Transmitter shall have replaceable main electronic and display.

4.6.8 Vortex flow meter accuracy shall be ± 0.75% of reading for Liquid and ± 1.0% of reading for Gas and
Steam. Repeatability shall be ± 0.2% of reading.

4.6.9 ACCURACY AS PER AIL CODE

4.7 LEVEL MEASUREMENT

4.7.1 For local instrument, magnetic roto ball type level indicator shall be used. They shall have flanged
connections and rating as per line/vessel specifications (Minimum rating AISI 150 # for metallic end
blocks). The use of glass tube level indicators is allowed based on process requirement. Each level
indicator shall not be longer than 2.5 m. if more visibility is required; more level indicators shall be
foreseen, so as to cover the range. Level indicators shall include upper and lower quick acting shut-

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off valves with protection against glass breaking and lower drain. All level gauge valves shall be
offset design.

4.7.2 Displacement type will be used for local controllers with flanged connections. Float and internals shall
be made of AISI 316 as a minimum (Ranges: 14”, 32, & 48”). Where there is a chance of condensing
in the upper leg, capillary types DPT are to be provided.

4.7.3 Level switches shall be of the external float type and magnetic coupled switch, with flanged
connections (preferably side-side) and rating as per line/vessel specifications (Minimum rating ANSI
150# for metallic body). Float shall be made of AISI 316 as a minimum. Snap action micro-switch is
preferred.

4.7.4 Top mounted level switched on vessels shall have flange connection as per line specification.

4.7.5 Mechanical level gauges shall be used for local liquid level indication purpose. It shall be float
actuated level gauging system and shall utilise sturdy SS-304 indicator board. Process connection
shall be minimum AISI 150#. Minimum of 600 mm distance shall be maintained between equipment
& board.

4.7.6 Tuning fork type level switch Flanged connection. It will be 2 wire NAMUR type.

4.8 RADAR TYPE LEVEL TRANSMITTER

4.8.1 For level measurement in tank or vessel, the Non-Contact Radar type level transmitter shall be used
for dirty, corrosive and coating application, custody transfer application, higher accuracy requirement,
etc. It is based on Frequency Modulated Continuous Wave (FMCW).

4.8.2 Transmitter shall have an integral electronic indicator with LCD display. For indicating face, shatter
proof glass shall be used. Transmitter shall have external zero and span adjustment with cover plate.

4.8.3 The Non-contact type Radar shall be available with various type of the antenna like Horn, Parabolic,
etc.

4.8.4 Parabolic antenna shall be suitable when tank height is more, as free space available. Horn type
antenna shall be used with smaller tanks. The beam angle for parabolic antenna is lesser than horn
type antenna.

4.8.5 Vender shall select type and diameter of the antenna based on tank details and measurement range
of level mentioned in the data sheet.

4.8.6 The antenna shall have suitable coating in case of requirement specified in the data sheet. The wetted
parts shall be suitable to process requirement.

4.8.7 Accuracy (inclusive of linearity, repeatability and hysteresis) shall be better than ±3 mm, repeatability
shall be better than ±3.0 mm, Response time shall be better than 1 second.

4.8.8 Antenna MOC shall be PTFE or SS316 in general, however it may be of Alloy C-276, PFA lined, and
etc. depending upon the process fluid compatibility.

4.8.9 Contact Type Radar LT: Rope / Rode / C-axial shall be selected as per application & service.

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4.9 DP TYPE LEVEL TRANSMITTER

4.9.1 For DP type Level measurement, direct flanged or flush flanged type Chemical Diaphragm Seals
(Remote Seal) shall be used instead of standard diaphragm transmitter in the following application.
For Diaphragm seal transmitter, diaphragm seals shall be ordered as an integral part of the
instrument.
1. In viscous application (>200mm2/s or 200 cSt) applications (subject to the manufacturers
temperature limit on the diaphragm.
2. In waxy, sticky and plugging services.
3. If the fluid temperature at the instrument under any normal or abnormal operating condition
exceeds the maximum allowable temperature of the sensing element.
4. Where the impulse line fill fluid is not stable.
5. Process fluid having property of jamming.

4.9.2 Selection of Ranges: The ranges of the instruments shall be selected based on the following
philosophy indicated below:
1. For Level measurements, the maximum level shall be within 70 to 80% of the maximum scale
range.

2. The low-pressure connection shall be open to atmosphere or connected to a reference zero in

case of open or atmospheric tank.

4.9.3 Transmitter accuracy shall be ±0.06% of calibrated span for rangeability 100:1. The accuracy shall
include the combined effect of linearity, hysteresis and repeatability.

4.9.4 Over range protection shall be 150% of range or maximum design pressure whichever is higher.

4.9.5 Transmitters shall be capable of withstanding process static pressure of 100 kg/cm2g without
permanent damage or loss of calibration. All transmitters shall be capable to work for ambient
temperature of 0 to 70 0C

4.9.6 The MOC of isolating diaphragm which is in direct contact with the process fluids shall be made of
SS 316 as a minimum requirement unless otherwise specified. However, it may be of Alloy C-276,
Tantalum, gold plated, and etc. depending upon the process fluid compatibility.

4.9.7 Wetted O ring shall be suitable to maximum temperature limit, generally it should be of PTFE. Cover
O ring shall be Buna-N or suitable to process requirement.

4.9.8 Sensor fill fluid shall be used silicon DC 200 for temperature range -450C to 2050C. For higher
temperature suitable fluid shall be used.

4.10 PRESSURE MEASUREMENT

4.10.1 Local pressure gauges and those installed on local panel & shall have following characteristics:

150mm dial with tricolor indication. i.e. Yellow/Green/Red for

Dial (Direct/Receiver : Min/Oper/Max value
Sensitive element : Stainless steel
Movement Case : Stainless steel, with blow-out hole.
Connection size : ½” NPT M

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Pointer : Knife edge type with micrometer adjustment.

Accuracy : ± 1%
Range : 1.3 times operation pressure
Connection : Bottom (Direct) back (local panel mounted).

4.10.2 Glycerine filled case will be used for press. Gauges installed @ the outlet of pumps & any other
pulsating pressure measurement. So that glycerine will act as dampener as well as movement
lubricator.

4.10.3 For pressure D/P transmitters, and controllers, measuring elements shall be capacitance type, they
will be sized for over range of 30% min. of full scale value. All transmitters shall be of SMART type
with HART protocol. Body material shall be AISI 316 minimum (as per process line specifications
requirements).

4.11 PRESSURE TRANSMITTER EXTENDED DIAPHRAGM

4.11.1 Extended Diaphragm Seals are Suitable for corrosive, highly viscous, crystallizing or
hot pressure media.

4.11.2 Selection of Ranges: The ranges of the instruments shall be selected based on the following
philosophy indicated below:
For pressure and vacuum measurements, the maximum operating pressure shall be within 70 to 80%
of the maximum scale range.

All pump suction measurement shall cover the negative pressure range also and all vacuum
measurements shall cover the negative pressure as well as the positive pressure.

The normal pressure shall be read at not greater than 75 percent of the calibrated range for transmitters
reading steady pressures. For fluctuating services, the normal pressure shall be read at 60 percent of
the range.

4.11.3 Pressure transmitter accuracy shall be ±0.06% of calibrated span for rangeability 100:1. The accuracy
shall include the combined effect of linearity, hysteresis and repeatability.

4.11.4 Over range protection shall be 150% of range or maximum design pressure whichever is higher.

4.11.5 All pressure transmitters shall be capable of withstanding process static pressure of 100 kg/cm2g
without permanent damage or loss of calibration. All transmitter shall be capable to work for ambient
temperature of 0 to 70 0C. (as specified in the data sheet.)

4.11.6 The MOC of isolating diaphragm which is in direct contact with the process fluids shall be made of
Alloy C-276 as a minimum requirement unless otherwise specified. However, it may be of Tantalum,
gold plated, and etc. depending upon the process fluid compatibility.

4.11.7 Wetted O ring shall be suitable to maximum temperature limit, generally it should be of PTFE. Cover
O ring shall be Buna-N or suitable to process requirement.

4.11.8 Sensor fill fluid shall be used silicon DC 200 for temperature range -450C to 2050C. For higher
temperature suitable fluid shall be used.

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4.12 RUPTURE DISC

4.12.1 Rupture Disc is used in any application requiring over pressure protection where non-reclosing device
is suitable. Rupture Discs are used at upstream of pressure relief valve to seal the system, to meet
the emission standard, to provide corrosion protection for the valve, and to reduce the valve
maintenance.Rupture disc shall be designed in accordance with ASME Sec VIII and API RP520
unless otherwise specified in the datasheet. The Rupture disc shall be of adequate size to relieve
the capacity as specified on data sheet, at specified pressure and temperature conditions and fluid
physical properties regardless of any preliminary sizing calculations or orifice designations shown on
data sheet. Disc and holder material shall be compatible with the process fluid. Gasket & ‘O’ ring
material shall be suitable to process conditions mentioned in data sheet. When rupture disc is used
upstream of a pressure relief valve, a pressure switch shall provide on the downstream of the disc to
indicate any rupture of the disc in addition to an excess flow check valve, when specific requirement
by instrument Vendor.

4.13 SAFETY RELIEF VALVES

4.13.1 Safety relief valves must be in accordance with:

● API -520
● ASME Section-VIII for pressure vessels
● ASME Section- I for steam boilers
● All safety valves shall have a certificate stating the discharge coefficient.
● IBR certificate for steam service to be provided according to piping specification

4.13.2 Connections and rating shall generally be flanged as per line/vessel specifications, or threaded ¾”x1”
NPTF. Minimum rating for flanged connections <11/2” shall however as per Piping Specifications and
for threaded 3000#.

4.13.3 Material of Construction: Wetted Part Material list as per Service and process requirement. Nozzle
of PSV shall be from Bar stock. MOC of Spring shall be suitable to temperature and pressure of
process. Trim MOC shall be stellited for high temperature services > 150 deg C. Type of Bonnet
(Conventional or Bellow seal) based on service.

4.13.4 Basis of selection of bellows shall be as per process vapour type, Where Variable back pressure
exceeds 10% of the set pressure. Bonnet shall have ½” NPT F Vent connection wherever specified
in datasheet. Spring adjustment required to change the setting by +/- 10% of Set value. Blow down
adjustment up to 8 to 10% below Set value.

4.13.5 Basis of selection of pilot operated valves wherever large volumes are to be handled. Paint required
Epoxy coated with Blue colour. MOC of Stud Bolts / Nuts shall be as per piping specification. Use of
Silica or asbestos in the gasket, packing etc. is not permitted. Gasket MOC shall be as per piping
specification.

4.14 GAS DETECTORS

Gas Detection Type : Single Input or Multi Input (As per Datasheet)

Connected to : Dedicated Fire and gas system and repeat signal from FGS system to

DCS shall consider.

Power Supply : 24 V DC

Range & Alarms : As per Datasheet

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Output : 2 wire / 3 wire, 4 to 20 mA

Display : LCD with backlit.

IP Rating : IP-65

Mounting : Bracket 2" Pipe Mounted with U Clamp MOC: SS304

Enclosure : As per Hazardous Classification

Housing : Die cast aluminium with Epoxy painted corrosion resistance

Requirement for gas detection

Name of Gases Detection Method

Ammonia Electrochemical or Semiconductor
Benzene Catalytic Combustion or Infrared
Chlorine Electrochemical or Semiconductor
CO Electrochemical or Semiconductor
Hydrogen Electrochemical or Semiconductor
HCL Electrochemical or Semiconductor
Hydrogen
Sulfide Electrochemical or Semiconductor
SO2 Electrochemical or Semiconductor
DMS Electrochemical or Semiconductor
Methanol Electrochemical or Semiconductor

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5 Environmental Conditions and Erection

5.1 Instruments and accessories shall be suitable for installation in area at its ambient
temperature: 0 to 60ºC with humidity 95% at 40ºC. These environmental conditions shall be
taken into consideration in connection with:
● Transport, storage and operation of instruments are for outdoor installation.
● Transport and storage of equipment’s for indoor installation.

5.2 All erection material such as tubing, fittings, tube fittings, isolation valves, cables, etc. shall be
procured from mutually agreed vendors only for maintaining strict quality control.

5.3 All instrumentation erection shall be as per Hook-up drawings supplied to the erection
contractor. The erection material supply shall be as per specifications provided in erection
tender document.

5.4 All direct mounted instruments like level switch, RTD, Thermowell, Temperature Gauge, flow
switch, pressure gauge, pressure switch etc. shall be installed in such a way that they have
better readability and accessibility.

5.5 All capillary type instruments shall have the capillary tube supported properly and shall have
protection of capillary tube against mechanical damage.

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6 Approvals

6.1 Certifications
Supplier shall provide certifications (in original language and translation into English language) for
electrical/electronic equipment.
For all intrinsically safe/explosion proof / flameproof equipment’s / instruments / systems or
equipment’s with any other type of protection allowable as per this package which are manufactured
abroad and certified by any statutory authority like BASEEFA, FM, UL, PTB, LCIE, CENELEC etc.
should also have the approval of Chief Controller of Explosives (CCOE), Nagpur.
For all intrinsically safe equipment manufactured locally (indigenously), the testing shall be carried
out by any of the approved test house like CMRI/ERTL. Etc. The equipment shall in addition bear
the valid approval from Chief Controller of Explosives, Nagpur.
Cable test certificates to be given by supplier such as resistivity test, insulation test, physical
dimension test, elongation test, tensile test for insulation, sheath & conductor, high voltage test
applicable to National standards.
Calibration certificates to be supplied along with each measuring instruments applicable to National
standards. IBR certification for steam flow meters & Mechanical level gauge to be supplied by
vendor.

6.2 Vendor List

MM shall submit the vendor list for supply of instruments for review. Client may add or delete the
names of instrument suppliers on the basis of their past performance. Final list is to be made with
consent of Client..

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7 Procurement Philosophy

The following philosophy must be considered to execute the instrumentation, Client will decide the same at
later stage.

Item Description Client Supply Erection vendor supply

[ Free Issue to contractor]

Control system [DCS]  χ

Field instruments  χ

Instrument cables  χ

Junction Box / Panels  χ

Cable tray  χ

Erection fittings like Air header, χ 

tubes, nut-bolts, glands, connectors,
SS-304 with PVC insulated tubes for
air connection with SS-304 fittings,
etc.

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