11v02-acc-spc-m-0001-v2-part-c

SPECFICATION FOR AIR COOLED CONDENSER

PROJECT 1 x 300 MW COAL BASED THERMAL

POWER PLANT, CHHATTISGARH, INDIA

Doc. No. 11V02-201-SPC-M-0001, REV.R0

Date: 04-11-2011 VOL-II PART-C of 39

VOLUME-II

PART-C

CONTROL & INSTRUMENTATION




Doc. No. 11V02-201-SPC-M-0001, REV.R0


VOLUME-II, PART-C CONTROL & INSTRUMENTATION

I N D E X

CLAUSE NO. DESCRIPTION

1.00.00 INTRODUCTION

2.00.00 CONTROL & INSTRUMENTATION SYSTEM PHILOSOPHY

3.00.00 GENERAL TECHNICAL REQUIREMENTS

4.00.00 DATA SHEETS FOR FIELD INSTRUMENTS AND CABLES

5.00.00 UTILITIES

6.00.00 CODES AND STANDARDS

7.00.00 INSTRUMENT INSTALLATION

ANNEXURE-1 DRIVE CONTROL INTERFACE




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VOLUME-II, PART-C CONTROL & INSTRUMENTATION

1.00.00 INTRODUCTION 1.01.00 This specification is intended to cover all aspects of the design, engineering

manufacture, assembly, testing & inspection at manufacturer's works, delivery at site and erection & commissioning of the complete Control & Instrumentation System of Air cooled Condensor (ACC) package for 1 x 300 MW coal based thermal power plant at village - Bandakhar, Tehsil - Pali, Korba district in state of Chhattisgarh.

1.02.00 The Control & Instrumentation for the unit shall comprise equipment

described and specified in this section and other part/section of this specification document. In general only the major C & I systems and conceptual guideline for the plant C & I have been indicated.

1.03.00 It is not the intent or purpose of this specification to give details of every single item that might be required for completeness and/or proper integration of the overall system. The bidder shall be responsible for providing all materials, equipment and services, specified or otherwise which are required to fulfill the intent of ensuring functional completeness, safety of plant and personnel, operability, maintainability and reliability of the total work covered under this specification, during any stage of execution of the contract and the operating life of the plant; within the quoted price and without any further commercial implication to the Purchaser/Owner.

1.04.00 In the event of any conflict between the requirements of any two (2) clauses or documents forming a part of this contract the more stringent requirements shall supply unless otherwise confirmed by the Owner in writing. The decision of the Owner shall be final and binding in all such cases.

2.00.00 CONTROL & INSTRUMENTATION SYSTEM PHILOSOPHY 2.01.00 The Control & Instrumentation System shall mainly realize the following

functions in order to assist the operator to perform safe start up/shutdown and normal/emergency operation of the plant.

1. Closed loop modulating control of parameters for optimized

operation of turbine, boiler and balance of the plant.

2. Open loop control for automatic sequential operation,

interlock and protection of various drives.

3. Continuous supervision of system parameters and equipment operating conditions




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2.02.00 State-of-the-art-practices prevailing in the field of Control & Instrumentation shall be considered to ensure safe, efficient and smooth operation of the air cooled condenser with minimum interference of the operating personnel during normal working of the plant.

2.03.00 The system design shall be such that no single point failure will result in total

system paralysis under any operational eventuality. Redundancy shall be provided at appropriate levels for critical control system functions.

2.04.00 In the event of loss of a major plant item, activities of binary and analog

controls shall be coordinated to ensure that the plant is automatically brought to a safe holding condition consistent with maintaining maximum generation permissible under reduced plant availability.

2.05.00 The C & I System shall be configured to perform the following basic functions: -

a) Automatic sequencing of the start-up and shutdown of major

equipment and auxiliaries including group/plant level start-up to minimize operator’s intervention under normal operating conditions.

b) Regulation functions for various valves and dampers to achieve guaranteed performance and to achieve the most fuel-efficient operation.

c) Protection of plant equipment and monitoring of equipment life.

d) Acquisition, display and archiving of plant data and

generation of reports.

2.06.00 The entire operation of the air cooled condenser system will be through DCS from central control room.

Sequence control of ACC fan will be implemented in DCS. Bidder to optimise the % of VFD fans required for operation of the power plant meeting design performance and without under cooling for complete year operation at various temperatures. This system shall enable the operator for cold/warm/hot start-up and safe shutdown and carryout normal operation from control room. Hotwell control & CEP minimum recirculation control will be implemented in DCS by CWPC. The signals required for operation of ACC fans and associated valves will be cabled to DCS.




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Bidder shall consider all necessary field instruments, cable supply, cable laying including cable trays and cable termination in DCS cabinet/DCS remote I/O cabinets(supplied by BTG Vendor). Bidder shall prepare I/O list, ACC logics and graphic screens for implementation in DCS.

3.00.00 GENERAL TECHNICAL REQUIREMENTS 3.01.00 All equipment, system and associated accessories shall be from the latest

proven product range of qualified manufacturers. All materials and equipment furnished for permanent installation shall conform to applicable local and international codes and standards Specifications and shall be new, unused and undamaged.

3.02.00 The equipment and systems shall be designed and constructed to meet

specification requirements, and shall perform accurately and safety under the environmental and operating conditions described or implied in this specification without undue heating, vibration, wear, corrosion or other operating troubles during the continuous service life of the plant. It will be the responsibility of bidder to fully acquaint himself with the functional requirements and operating conditions for equipment, system/sub-system/ assemblies and accessories offered for this project. Additional features shall be provided where required to meet service conditions, functional/descriptive or parametric requirements for equipments/systems/assemblies/ accessories.

3.03.00 The design of the Control & Instrumentation system shall be such that

isolation of any piece of defective equipment/accessories should be possible without shutting down the main equipment and should result in minimum disturbance to the process.

3.04.00 The design of control systems and related equipment shall adhere to the

principle of “fail safe” operation at all system levels. “Fail-safe Operation” means that loss of signal, loss of power supply/air supply or failure of any component shall not cause a hazardous condition while at the same time prevent occurrence of false trips.

The following types of failure as a minimum shall be taken into account:

a) Failure of sensors or transmitters, producing high or low signal.

b) Failure of controller during automatic operation.

c) Loss of motive power to final control element actuators.

d) Loss of control power.

e) Loss of instrument air supply.




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3.03.00 The instrument material specifications shall be consistent with the operating

parameters like temperature, pressure, corrosion conditions and other process conditions. The instruments shall meet the brief technical requirements as specified elsewhere.

3.06.00 To ensure safe operation of C & I equipments located in hazardous areas,

based on area classification requirement, transmitters shall be intrinsically safe and JB/Switch shall have ex-proof enclosures.

3.07.00 Safety earthing and C & I system earthing shall be separate. Safety earthing bus shall be connected to main plant earthing pit. Separate earth pits shall be provided for C&I system earthing (electronic earth) to achieve less than 0.5 ohm resistance to ground. Separate earthing shall be provided for intrinsically safe system.

3.08.00 All field mounted instruments shall have waterproof enclosures conforming to

IP-65. All panels/cabinets shall have protection class IP-54 in ventilated areas and IP-42 in Air-conditioned area.

3.09.00 All field instruments shall be located in accessible/vibration free locations and

clearly visible range for all readable instruments. Access platforms with ladders shall be provided for measuring instruments located at high or difficult places.

3.10.00 Separate cable trays shall be provided for control cables and instrumentation

(signal) cables and separated from power cable trays by at least 600 mm.All cable entry points to instruments, junction boxes of panel shall be provided with suitable dust and watertight double compression type glands. All cables from field to junction box shall be through flexible conduit upto main tray/sub-tray.

3.12.00 Bidder to provide necessary provision in HT motors for vibration sensor as

per API 670 4.00.00 DATA SHEETS FOR FIELD INSTRUMENTS AND CABLES 4.01.00 PRESSURE GAUGE (PG)

01. Quantity : As per Service Requirement

02. Make : As per approved vendor list 03. Sensing Element : Bourdon Tube 04. MOC sensing & socket : AISI – 316 SS 05. Movement material : AISI – 304 SS 06. Case material : Stainless steel casing bayonet type. 07. Accuracy : ± 1.0% of span or better.




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08. Dial size : 150mm 09. Adjustment : Micrometer screw of zero

adjustment. Internal micro meter screw for range adjustment 10. Scale : Black lettering on white background in 270º arc 11. Window : Shatterproof toughened glass 12. Process connection : ½” NPTM, Bottom entry 13. Element connection : Argon welding 14. Safety device : Blow out disc/Diaphragm at the back 15. Enclosure class : IP 65 16. Ambient temperature : 0 – 50º C 17. Over range protection : 130 % of max range by internal stop. 18. Nameplate : Tag number, service engraved in SS plate. 19. Application standard : IS – 3624 / 1996 20. Accessories : a) Snubbers for pulsating fluid application b) Syphons for steam services c) For viscous & corrosive

services, Remote Seal with Silicon Oil Filled diaphragm seal adapter flanges with nuts, bolts and gasket

4.02.00 PRESSURE SWITCH (PS) 01. Quantity : As per Service Requirement 02. Range & Set Pressure : As per Service Requirement 03. Make : As per approved vendor list 04. Type : Seal Diaphragm 05. Sensing element material : SS316 diaphragm 06. Case material : Die-cast aluminum with neoprene gaskets. 07. Performance : a) Accuracy±1.0% b) Accuracy of setting indicator of ± 1.5% c) Repeatability ±1% of span 08. Over range : 150% of maximum

pressure 09. Switch configuration : Two (2) Nos. SPDT type




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10. Switch type : Snap acting, shock & vibration proof 11. Switch rating : 240 V, 5A AC / 220 V, 0.5A DC 12. Ambient temperature : 0- 50ºC 13. Adjustability : a) Set point adjustable over span range b) Differential adjustable by 10% span 14. Cable Entry : 3/4" ET 15. Enclosure class : IP 65 16. Process connection : 1/2” NPT (M) bottom connected. 17. Name plate : Tag number, service engraved in SS tag plate 18. Accessories : a) Snubbers for pulsating fluid application

b) For viscous & corrosive services, Remote Seal with Silicon Oil Filled diaphragm Seal adapter flanges with nuts, bolts and gasket 4.03.00 PRESSURE TRANSMITTER (PT) 01. Quantity : As per Service Requirement 02. Make : As per approved vendor list 03. Principle : Smart 04. Type : 2 – Wire Microprocessor based Transmitter 05. Output signal : 4 – 20 mA DC with HART Protocol 06. Signal processing : Silicon solid state electronic circuitry 07. Measuring element : Diaphragm 08. Measuring element material : AISI – 316 (Stainless steel) Diaphragm 09. Static pressure : 150% of maximum span continuously without affecting the calibration. 10. Operating voltage : 24 V DC 11. Ambient temperature : 0-50 ºC 12. Performance a) Accuracy : ± 0.1% of span or better b) Repeatability : ± 0.1% of span or better 13. Turn-down ratio : Minimum 40:1 14. Load impedance : 600 Ohm min at 24V DC 15. Response Time : 100 msec or better 16. Span / zero adjustment : Locally adjustable, non- interacting facility for




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Elevation & Suppression by 100% 17. Enclosure class : IP-65 18. Output Indicator : LCD type in % and engineering unit. 19. Cable Entry : ¾” ET 20. Process Connection : ½” NPT

21. Nameplate : Tag number, service engraved in SS tag plate. 22. Body : Forged Carbon steel (SS for DM Water). 23. Accessories : a) Universal mounting bracket suitable for 2’’ pipe and wall mounting. b) Condensate pot for Steam services. c) High tensile carbon steel U bolts.

d) Installation accessories e) 2 –way SS manifold,

constructed from SS316 bar stock.

f) Reverse polarity protection required.

4.04.00 DIFFERENTIAL PRESSURE SWITCH (DPS)

01. Quantity : As per Service Requirement 02. Make, Model : As per Approved Vendor List 03. Type : Sealed diaphragm, piston actuated type for high pressure & diaphragm bellow and torque tube for low pressure.

04. Sensing element material : AISI SS-316 diaphragm / piston. All other wetted part SS316. 05. Case material : Epoxy coated steel plate or die- cast aluminum alloy with neoprene gasket and clear glass where applicable. 06. Scale : Black graduation on white linear scale. 0 – 100% with red pointer for set point.

07. Performance : a) Accuracy±1.0% b) Accuracy of setting Indicator of ± 1.5%

08. Over range : Static pressure on any one side, the other side being open to atmosphere.




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09. Switch configuration : Two (2) Nos, SPDT type 10. Switch type : Snap acting, shock & vibration proof

11. Switch rating : 240 V, 5A AC / 220, 0.5A V DC 12. Ambient temperature : 0 - 50ºC

13. Adjustability : a) Set point adjustable over span range b) Differential adjustable by 10% span 14. Cable connection : 3/4" ET compression gland

15. Enclosure class : IP 65 16. Process connection : 1/2” NPT (M) bottom connected. 17. Name plate : Tag number, service engraved is SS tag plate

18. Accessories : a) Snubbers for pulsating fluid application

b) Retention ring & screw for surface mounting

c) 1/2" NPT 5-way valve SS- 316 manifold constructed from bar stock.

d) 3/4" ET cable gland. 4.05.00 TEMPERATURE GAUGE (TG)

01. Quantity : As per Service Requirement 02. Range : As per Service Requirement 03. Make : As per approved vendor list 04. Type : Mercury filled, rigid stem type 05. Sensing element material : Bourdon – AISI – 316 SS 06. Movement material : AISI – 304 SS 07. Bulb diameter and length : 11/70mm 08. Bulb material : AISI 316 09. Case material : Stainless steel casing bayonet

type 10. Accuracy : ± 1.0% of full scale deflection or

better. 11. Dial size : 150mm 12. Scale : Black lettering on white

background in 270º Arc 13. Window : Shatterproof toughened glass 14. Process connection : 1/2"NPT (M)

15. Mounting : Surface 16. Enclosure class : IP 65 17. Over range protection : 130 % of max range by internal stop. 18. Zero Adjuster : Micro adjustable from front 19. Nameplate : Tag number, service engraved in




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SS tag plate. 20. Compensation : Case compensation 21. Thermowell : a. Standard : ASME - PTC 19.3 b. Body MOC : Stainless Steel - Barstock c. Process Connection : M33 X 2 Screwed d. Element Connection : ½” NPTF

e. Extension length : As per Service Requirement f. Insertion Length “U” : As per Service Requirement 22. Accessories : a) Installation accessories as required.

b) Adjustable nipple union nipple with thermo well connection

4.06.00 THERMOCOUPLES (T/C)


02. Range : As per Service Requirement 03. Make : As per approved vendor list 04. Type : Duplex, ungrounded 05. Element : Type-K (Chromel / Alumel). 16

AWG Wire 06. Protecting Tube: i) O.D : 8 mm (approx) ii) Material : 316 SS Seamless iii) Filling : Magnesium Oxide (Purity above 99.4%)

iv) Length : As per Service Requirement 07. Response time : < 20 seconds for measurement. 08. Head i) Type : IP-65 universal screwed type ii) Material : Die cast aluminum or better iii) Terminal blocks : Nickel plated brass screw type/silver plated iv) Cable connection : 3/4" ET v) Process Connection : ½” NPTF vi) Others : Terminal head cover with SS chain and suitable gasket. 09. Standard : ANSI – MC 94.1 10. Thermowell : a. Standard : ASME - PTC 19.3 b. Body MOC : Stainless Steel - Barstock c. Process Connection : M33 X 2 Screwed d. Element Connection : ½” NPTF e. Extension length : As per Service Requirement f. Insertion Length “U” : As per Service Requirement 11. Accessories : a) Adjustable nipple-union-




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nipple with thermo well connection 12. Nameplate : Tag number, service engraved in SS tag plate

4.07.00 RESISTANCE TEMPERATURE DETECTOR (RTD)

01. Quantity : As per Service Requirement 02. Range : As per Service Requirement

03. Make : As per approved vendor list 04. Type : 3 wire, Duplex, ungrounded

05. Element : Pt-100 ± 0.1/100 0hm at 0ºC, 06. Protecting Tube: i) O.D : 8 mm

ii) Material : 316 SS Seamless iii) Filling : Magnesium Oxide (Purity above 99.4%) iv) Length : As per Service Requirement

07. Response time : < 20 seconds for measurement. 08. Head

i) Type : IP-65 universal screwed type ii) Material : Die cast aluminum or better iii) Terminal blocks : Nickel plated brass screw type/silver plated iv) Cable Entry : ¾” ET v) Process Connection : ½” NPTF vi) Others : Terminal head cover with SS chain and suitable gasket 09. Standard : Standard DIN 43760 10. Thermowell : a. Standard : ASME - PTC 19.3 b. Body MOC : Stainless Steel – Bar stock c. Process Connection : M33 X 2 Screwed d. Element Connection : ½” NPTF e. Extension length : As per Service Requirement f. Insertion Length “U” : As per Service Requirement 11. Accessories : a) Adjustable nipple-union- nipple with thermo well connection 12. Nameplate : Tag number, service engraved in SS tag plate

4.08.00 TEMPERATURE TRANSMITTER (TT) 01. Quantity : As per Service Requirement

02. Make : As per approved vendor list 03. Principle : Smart with HART Protocol 04. Type : 2 – Wire




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05. Input : Thermocouple / RTD 06. Range : As per Service Requirement

07. Output signal : 4 -20 mA DC with HART Protocol 08. Signal Processing circuitry : Microprocessor based solid state electronic 09. Output indicator : LCD type 10. Body : Die Cast aluminum 11. Operating Voltage : 24 V DC 12. Ambient Temperature : 0 – 50 ºC 13. Performance : a) Accuracy : ± 0.2% of span or better b) Repeatability : ± 0.05% of span or better c) Cold Junction Compensation : Built-in 14. Load impedance : 600 Ohm min at 24V DC 15. Span / zero adjustment : Locally adjustable, non- interacting 16. Calibration : As Per N.I.S.T Monograph 125 for T/C 16. Enclosure class : IP-65 17. Cable connection : 3/4” ET 18. Nameplate : Tag number, service engraved on metallic tag plate rigidly fixed to the body. 19. Accessories : a) Universal mounting

bracket suitable for 2” pipe and wall mounting.

b) High tensile carbon steel U bolts.

4.09.00 TEMPERATURE SWITCH (TS)

01. Type : Mercury filled – in 02. Sensing element material : Bellow / Bourdon AISI SS-316 03. Bulb Material : AISI SS – 316 04. Capillary : Stainless steel armored 05. Movement Material : AISI SS - 304 06. Case Material : Epoxy coated steel plate or die-

cast aluminum alloy with neoprene gasket and clear glass where applicable conforming to IP65.

07. Scale : Black lettering n white background. 08. Over range protection : 120 % 09. Instrument connection : Bottom

10. Switch configuration : Two SPDT Lead wires (3+3 Nos.) are to be brought externally to the male connector wherein




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the female pug Connector will be inserted to connect the control room cables for easy removal & re - calibration.

11. Switch rating : 240 V, 5A AC / 220, 0.5A V DC 12. Switch Type : Snap acting, shock & vibration

proof 13. Adjustability : a) Internal Set point

adjustable over span range

b) Differential adjustable by 10% span (min)

14. Cable Connection : 3/4" ET compression gland 15. Compensation : a) Capillary compensation

with invar wire throughout the capillary length.

b) Case compensation 16. Performance i) Accuracy : ±1.0% of full scale ii) Repeatability : < 0.5% of full scale iii) Response time : < 40 seconds with thermo well 17. Capillary length : 5 meters (local) /15 meters (local

panel) 18. Name plate : Tag number, service engraved is

SS tag plate 19. Accessories : a) Mounting accessories,

b) 3/4'” ET cable gland.

4.10.00 LEVEL GAUGE (LG) – FLOAT & BOARD

01. Make : As per approved vendor list 02. Service : As per Service requirement 03. Type : Float & Board type 04. Float material : SS-304 / 316 05. Float Wire : SS-304 / 316

06. Tank Height : As per Tank Height 08. Range : As per Tank Height 09. Scale : 4” broad Aluminium (in inches) 10. Accuracy : ± 2% of FSD 11. Bolts and nuts : Rust proof alloy steel

12. Process a. Operating temperature: As per Service Requirement b. Operating Pressure : As per Service Requirement

13. Accessories : a) Counter flange, nuts & bolts,

suitable gasket etc. b) Wire Rope, Nylon Roller,




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Mounting brackets & all other required fittings.

4.11.00 LEVEL GAUGE WITH SWITCH – FLOAT & BOARD

01. Make : As per approved vendor list 02. Service : As per Process 03. Type : Float & Board Gauge with Low

Level Switch 04. Float & Wet material : SS-316 05. Float Wire : SS-316

06. Tank Height : As Required 07. Range : As Required

08. Scale : 4” broad Aluminium (in inches) 09. Accuracy : ± 2% of FSD 10. Bolts and nuts : Rust proof alloy steel

11. Process a. Operating Temp. : As per Service Requirement

b. Operating Pressure : As per Service Requirement 12. Switch configuration : Micro, SPDT type (2 Nos.) 13. Switch type : Snap acting, 2 NO+ 2 NC 13. Switch rating : 240 V AC, 5A / 220, 0.5A V DC 14. Adjustability : Set point adjustable over span range 15. Cable connection : 3/4" ET 16. Enclosure class : IP 65

17. Accessories : a) Counter flange, nuts & bolts, suitable gasket etc. b) Wire Rope, Nylon Roller, Mounting brackets & all other required fittings.

4.12.00 LEVEL SWITCH– RF TYPE

01. Quantity : As per Service Requirement 02. Service : Coal Bunker 03. Height : As per Service Requirement

04. Make/Model : As per approved vendor list 05. Type : RF type 06. Mounting : Side mounted 07. Supply voltage : 230 V AC

08. Contact type : Snap acting, 2 NO+ 2 NC 09. Contact rating : 240 V AC, 5A / 220 V, 0.5A DC 10. Adjustability : Set point adjustable over span range 11. Performance :




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a. Accuracy : ±5% of FSR b. Dead band : ±2% of FSR 12. Cable connection : 3/4" ET

13. Response time : less than 1 sec 14. Sensing element : SS 316 14. Coat guard shield : SS 316 15. Insulation : PTFE

4.13.00 RADAR LEVEL TRANSMITTER

01. a) Type : Guided wave Radar type

transmitter b) Probe : Coaxial c) Probe material : SS 316 / SS 316L

02. Calibration Range : As per application 03. Process medium : As per application 04. Process temperature : As per application 05. Static pressure : Capable of working in vacuum

also 06. Power supply : Range to be specified by the bid

(loop power Available =24V DC) 07. Reverse polarity protection : Required 08. Output : 4 to 20 mA, 2Wire & HART 09. Accuracy : ±10mm or better 10. Stability : As per process application 11. Communication : Communication / configuration

shall be possible either through integral key pad and display or through hand communicator. If integral key pad is not available, one number hand held communicator common for all the transmitters shall be supplied

12. Load limitation : Max 600 ohm at 24V 13. Span & Zero : Adjustable 14. Flange Mounting : Yes 15. Environmental protection : IP 66 or better 16. Process connection : Traditional flange with ¼” - 18

NPT on flange with process adapters

17. Electronic housing : Aluminum alloy 18. Electrical connection : Preferably ½:” – 14 NPT with

gland 4.14.00 ULTRASONIC LEVEL TRANSMITTER

01. Type of transmitter : Non contact Microprocessor

based 2 wire type, HART protocol




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Compatible 02. Output Signal : Galvanically isolated 4 – 20 mA

DC along with superimposed digital signal (HART protocol)

03. Sensor Accuracy : ± 0.5% of calibrated span 04. Sensor Repeatability : 3 mm or better 05. Power Supply : 18 - 36V DC

06. Temperature Compensation : To be provided within transducer 07. Configuration : Sensor and electronic unit are

separate. Electronic unit all be possible to mount on the accessible location near the transducer. All cables, weather proof fittings for connection between transducer and electronic unit.

08. Housing : IP 55 with durable corrosion resistant Epoxy coating

09. Calibration : Through HART communicator

10. Zero and Span adjustment : Continuous, Tamper proof, Remote as well as manual adjustability. Provision to

calibrate the instrument without any level in the tank or sump etc.

11. Sensor Material : Corrosion resistant application to suit the individual

12. False signal tolerance : Facility to be provided. Shall have adjustable damping circuitry.

13. Range : To be decided during detail Engineering, with a facility to take care of frequency attenuation due to different obstructions (Surface, vapor)

14. Display : Minimum 4 character display with integral key pad, access

protected features. 15. Diagnostics : Loss of echo alarm 16. Load impedance : 500 Ώ minimum or as per vendor

spec. 17. Electrical connection : Plug and socket 18. Accessories : Canopy for protection sunlight and Rain Mounting hardware’s

4.15.00 DISPLACER TYPE LEVEL TRANSMITTER

01. Type : Smart




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02. Float movement : Vertical 03. Stages of operation : Continuous 04. Material a) Displacer/Float : AISI 316 SS/304 S b) Wire rope, sleeve pipe: AISI 304 SS/316 SS c) Torque tube : AISI 304 SS/316 SS/ Inconel 05. Transmission : 2-wire 06. Output Signal : 4-20 mA Protocol HART 07. Signal processing : Solid-state electronic circuitry

08. Static/overload pressure : Maximum static pressure without permanent deformation or loss of accuracy.

09. Turn-down ratio : 100: 1 minimum 10. Zero & Span : Easily accessible (local zero &

span adjustment and non-interactive type)

11. Zero Suppression / elevation : i) Suppression = 150 % of span (min.)

ii) Elevation = 50 % of span (min.).

12. Enclosure class : IP-65 (explosion proof for NEC class-1)

13. Body/Cage : Forged Carbon Steel or Stainless Steel depending upon fluid condition

14. Output Indicator : LCD type 15. Output Ripple : < 0.25% of span 16. Operating voltage : 16 – 48 V DC 17. Nameplate : Tag number and service

engraved in SS tag plate 18. Ambient Temperature : 0 - 50ºC 19. Load Impedance : 600 Ohms at 24 Volts (minimum) 20. Process connection : 50 NB ANSI RF Companion

flange with nuts, bolts and gaskets

21. Performance a) Accuracy : ±0.5 % of span or better

b) Repeatability : ±0.05 % of span or better c) Sensitivity : 0.1 % of span or better d) Hysteresis : ± 0.05 5 of span or better e) Temperature : < ± 0.5 % of span / 50ºC

regardless of rate of calibration change.

f) Power supply effect : ± 0.005 % / volt 22. Accessories : i) ANSI RF Counter

Flange; rating as per process pressure.




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Necessary nuts, bolts, gaskets etc.

ii) Vent and drain plugs iii) Stilling chamber v) 3/4" ET cable gland

23. Preferred Features : a) Test plug connection and cutout terminal physically separated from other electronics.

b) Electronic Damping facility (adjustable)

4.16.00 DP TRANSMITTER (LT & FT)

01. Quantity : As per Service Requirement 02. Make : As per approved vendor list

03. Principle : Smart with HART Protocol 04. Type : 2 – Wire Microprocessor based Transmitter 05. Output signal : 4 – 20 mA DC with HART

Protocol 06. Signal processing : Silicon solid state electronic circuitry 07. Measuring element : Diaphragm 08. Measuring element material : AISI – 316 (Stainless steel) Diaphragm 09. Static pressure : 150% of maximum span continuously without affecting the calibration. 10. Operating voltage : 24 V DC 11. Ambient temperature : 0-50 ºC 12. Performance a) Accuracy : ± 0.05% of span or better b) Repeatability : ± 0.05% of span or better 13. Turn-down ratio : 100:1 14. Load impedance : 600 Ohm min at 24V DC 15. Response Time : 100 msec or better 16. Span / zero adjustment : Locally adjustable, non- interacting facility for Elevation & Suppression by 100% 17. Enclosure class : IP-65 18. Output Indicator : LCD type in % and engineering unit. 19. Cable Entry : ¾” ET 20. Process Connection : ½” NPT 21. Nameplate : Tag number, service engraved in

SS tag plate. 22. Accessories : a) Universal mounting




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bracket suitable for 2” pipe and

wall mounting.

b) High tensile carbon steel U bolts.

c) Installation accessories d) Condensate Pot for steam service e) 5 - way SS manifold, constructed from SS316 bar stock.

f) Reverse polarity protection required.

4.17.00 ROTAMETER

01. Quantity : As per Service Requirement 02. Type : Online Reading

03. Process Parameter : As per Service Requirement 04. Accuracy : ±1% of FSD 05. Scale : Graduated-Engraved Black

lettering on white background, in m³/hr

06. Body : SS-316 07. Tube : Borosilicate glass 08. Float : SS-316 09. Stopper : SS-316 10. Gland packing : PTFE 11. End connection size/Type : As per Service / Flanged to ANSI

B16.5 CL150 12. Pressure drop : As per Requirement 13. Range : As per Requirement

4.18.00 FLOW ORIFICE

01. Quantity : As per Service Requirement 02. Service : Feed Water 03. Design Standard : BS- 1042 04. Flow element & type : Orifice / Concentric 05. Flow element material : SS 316 06. Flow element thickness : 3mm minimum 07. Pipe material : SA 106 GR B 08. Flange Material : SA 106 GR B 09. Type of tapping : Corner tapping 10. Number of tapings : Two pairs




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11. Beta ratio : 0.4 to 0.7 12. Pressure loss (meter max) : 0.7 Kg/Cm2 13. Process Parameter : As per Table 14. Service : Feed Water 15. Flow Rate (Nor/ Max.) TPH : As per Service Requirement 16. Pressure (Kg/Cm2) : As per Service Requirement 17. Temperature °C : As per Service Requirement 18. Density : 1 19. Pipe Size / MOC : As per Service Requirement 20. End Connection : As per Service Requirement 21. Accessories : SS316 Flanges, 1/2" root valves (Globe), 1/2" Nipple (2 nos. of Root valves if upstream pressure >40 Kg/cm2)

Note: The following Drawing / Document shall be submitted along with each instrument.

• GA drawing • Data Sheet • Flow orifice sizing calculation

• Flow Vs Differential pressure curve 4.19.00 FLOW NOZZLE

01. Quantity : As per Service Requirement 02. Service : As per Service Requirement 03. Design Standard : BS-1042 04. Flow element & type : Flow Nozzle/ Long Radius 05. Flow element material : Alloy Steel 06. Pipe material : SA 335 P22 07. Pipe size : As per Service Requirement 08. End connection : Butt Weld 09. Type of tapping : D and D/2 10. Number of tapings : Two pairs 11. Beta ratio : 0.5 to 0.7 12. Pressure loss (meter max) : 0.4 Kg/Cm2 13. Service : As Required 14. Flow Rate : As per Service Requirement 15. Flow Rate (Nor/ Max.) TPH : As per Service Requirement 16. Pressure (Kg/Cm2) : As per Service Requirement 17. Temperature °C : As per Service Requirement 18. Density : As per Service 19. Pipe Size / MOC : As per Service Requirement 20. End Connection : Butt Weld 21. Accessories : 1/2" root valves (Globe), 1/2" Nipple

Test: The Following test shall be carried out along with supply of instrument:




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• 100% Radio graphic.

• Hydro test.

• Calibration test.

• IBR test Certificate. Note:

Drawing/ Document shall be submitted along with supply of instrument:

• Fabrication & assembly drawing

• Data Sheet

• Flow Nozzle sizing Calculation

• Flow Vs Differential pressure curve

4.20.00 FLOW SWITCHES (FS)

01. Type : Flapper 02. Material of sensing element : PP / Die Cast Aluminum, stoved,

enameled With anticorrosive paint

03. Flow range and surge ratio : Later 04. Accuracy : ± 1 % 05. Contacts – type, rating : Two (2) Nos, SPDT type with

snap action

06. Enclosure class : IP 65 07. Connection – Instrument/ : As per process requirements / ¾”

NPT (F) Conduit 08. Accessories : Isolation valve, drain and vent

plug on external cage, Bolt/Nut and gaskets.

4.21.00 MASS FLOW METER

A. Sensor 01. Measuring principle : Coriolis Mass flow. 02. Primary Element : Flow tube of 316 SS or better 03. Heating Arrangement : Integral with Flow Element 04. Temp. control for heating : To be provided 05. Process connection : ANSI RF Flanged and rating as

per process required. 06. Drain : Self-draining facility 07. Accessories : Counter flanges, mounting nuts,

bolts, gaskets etc. B. Transmitter

01. Measured quantities : Mass Flow rate, Total Mass Flow, Density, Temperature as minimum

02. Input Signal Processing : Digital processing 03. Display : Digital Display (LCD).




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04. Output : 2 Nos. isolated output of 4-20mA DC selectable from four measured quantities.

05. Load : <750 ohms 06. Power supply : 240V AC, 50 HZ. 07. Turn Down : 100:1 08. Accuracy : ± 0.2% of measured value 09. Ambient Temperature : 85° 10. Repeatability : ± 0.05% 11. Housing : IP 65(Explosion proof for NEC

Class-1) 12. Hazardous duty version : FM Standards. 13. Nameplate : Tag number, service engraved in

SS tag plate 14. Accessories : a) As required for field

mounting b) Handheld configurator c) Mounting U-bolts, nuts,

prefab cable etc. d) ¾” ET cable gland.

4.22.00 MOTORISED VALVES

01. Quantity : As per Service Requirement 02. Valve service : Main Steam

03. Valve type : Gate Valve 04. Pipe size inlet / outlet : 250NB Sch 140 / 250NB Sch 140 05. Pipe MOC : SA-335 P22 06. Guiding : Later 07. Type of connection : Flanged

08. Material i) Valve body : Later ii) Stem : ANSI -316 SS

iii) Seat rings : ANSI -316 SS iv) Plug : ANSI -316 SS

v) Bonnet gasket : Later 09. Port size : Later

10. Plug type : Later 11. Plug characteristic : Later 12. Differential pressure : Later

13. Maximum flow capacity : a. Normal Flow in TPH : As per Service b. Maximum Flow in TPH: As per Service c. Operating Temp in OC : As per Service

d. Up steam Operating Pressure in Kg/cm2 : As per Service

e. Down steam Operating Pressure in Kg/cm2 : As per Service




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14. Valve stem packing : Later 15. Type of actuator : Motor operated 16. Actuator make / model : Later 17. Signal range : Later 18. Integral Bypass Valve : 25NB Motorized Integral Valve with All accessories 19. Accessories included : Electric motors, Position limit

switches & Torque limit switches, Hand wheel, gear train, mechanical position indicator, internal wiring, integral starters and terminal block etc.,

20. Noise ratio : < 85 db 21. Leakage class : Class IV

22. Minimum clearance required : As per standard for maintenance purposes

23. Integral Bypass Valve : 25NB Motorized Integral Gate Valve with all accessories

24. Make : As per approved vendor list.

4.23.00 CONTROL VALVE

01. Quantity : As per Service Requirement 02. Make : As per Approved Vendor List

03. Valve service : Later 04. Valve type & size : As per process requirement 05. Valve co-efficient : Later 06. Connection size inlet / outlet : As per process parameter 07. Guiding : Later

08. Type of connection : Later 09. Material

i) Valve body : Later ii) Stem : ANSI -316 SS iii) Seat rings : ANSI -316 SS iv) Plug : ANSI -316 SS v) Bonnet gasket : Later 10. Port size : Later 11. Plug type : Later 12. Plug characteristic : Later 13. Differential pressure : Later 14. Maximum flow capacity : Later 15. Valve stem packing : Later

16. Type of actuator : Pneumatic actuator 17. Actuator make & model : Later 18. Signal range : Later 19. Action on air failure : Fail to open or fail to close in a




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direction safe for the process 20. Accessories included : Hand wheel, Limit switches, I/P Converter, air lock relay, position transmitter and JB etc. 21. Noise ratio : < 85 db

22. Leakage class : IV 23. Min. clearance required : As per standard for maintenance

purposes 24. Process Parameters:

a) Process Pressure : Later b) Process Temperature : Later c) Process Flow : Later d) Line Size : Later

4.24.00 SOLENOID VALVE

01. Operating Principle : Electromagnetic (noiseless) Latch

/ release coil shall be used in the required application where the safety is to be ensured.

02. Coil voltage rating : 240 V AC /110V AC / 24 V DC / 48

V DC / 220 V DC (As required). 03. Ways : 3 ways (NO + NC) [General], other Depending on requirement 04. Port size : 1/2" NPT / as per site requirement 05. Body : SS Bar Stock

06. Trim : AISI SS-316 07. Manual operator : In built 08. Duty : Suitable for continuous

energization 09. Sealing : Airtight and leak proof 10. Ambient temperature : 0 - 50O C 11. Fluid temperature : 0-150O C or as per application 12. Coil enclosure : Stainless Steel 13. Insulation : Class-H 14. Coil casing : IP-65 (Explosion proof for NEC

Class-1) 15. Mounting : On pipe or on panel 16. Cable connection : 3/4" ET Compression gland

17. Accessories : Mounting brackets, nuts and bolts 18. Pressure Rating : As per application 19. Special feature : i) Temperature operated fuse at explosion proof




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enclosure. ii) Solenoid valve directly

integral to actuator body shall have NAMOOR interface.

4.25.00 ELECTRO-PNEUMATIC CONVERTER (I/P)


02. Make : As per approved vendor list. 3. Type : Electro-Pneumatic Input 4. Input : 4-20 mA DC 5. Output : 0.2 to 1.0 kg/cm² 6. Direct/reverse action : Provided 7. Enclosure class : IP 65 8. Mounting : Field (Pipe& wall) mounting 9. Air filter regulator : Sintered bronze, 5 Microns, 10Kg/cm² 10. Output gauge : Provided 11. Connections : ¾” ET / ¼” NPT (Electrical/

Pneumatic) 4.26.00 AIR FILTER REGULATOR

01. Quantity : As per Service Requirement 02. Make : As per Approved Vendor List 03. Filter element : Sintered Bronze 04. Filter size : 5 microns 05. Input air : 10.0 Kg/Sq.cm (maximum) 06. Output : Adjustable from 0- 2.0 Kg / cm or 0 – 7.0 Kg/Sq.cm (continuous) as

applicable. 07. Effect of supply : Maximum 0.002 Kg/Sq. cm for a

change pressure variation in supply pressure of Kg / Sq.cm

08. Bowl material : Metallic cover around high Temperature Area / clear transparent polycarbonate with metallic cover for ordinary applications.

09. Accessories : 2" dial size output pressure gauge 10. Desirable feature : No perceptible drop of pressure on opening the drain port.

4.27.00 JUNCTION BOX

01. Quantity : As per Service Requirement 02. Make : As per Approved Vendor list 03. Type : Flame proof/weather proof




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04. Enclosure : IP-65 05. Material : Die cast aluminum with

protective coating 06. Cable entry : Bottom 07. Cable glands : Double compression type – Nickel plated brass with PVC hoods. 08. Mounting : Outdoor 09. No. of terminals : As required with standardization 10. Terminals : Phoenix/Wagon 11. Grounding : Two terminals for body and

shield ground

12. Door : Hinged, lockable type.

4.28.00 POSITIONER

01. Stroke Adjustment : Shall be possible. 02. Gauges : Supply, signal, output 03. Travel time of valve : < 10 seconds 04. Hysteresis : ±0.5% of F.S. 05. Linearity : ±1.0% of F.S. 06. Dead Band : ±0.5% of F.S.

4.29.00 LIMIT SWITCH (LS)

01. Type : Dust proof momentary spring

return 02. Operating head : Adjustable roller Lever (32-82.5

mm) with 19 mm Dia and 8 mm Dia Vide metal Roller.

03. Accuracy and differential : ± 0.2% of full scale 04. Differential–fixed/ adjustable : Adjustable 05. Contact Arrangement : SNAP Action 06. Number of contacts : 2 Normally Open (NO) & 2

Normally Closed (NC) 07. Contact rating : 5A, 240V/0.25A, 220V DC 08. Outlet Pressure gauge range : 50 mm diameter Range (0 -10) 09. Operating temperature range : Later 10. Cable Entry : 3/4" Double compression cable

gland 11. Enclosure class : IP 65 13. Accessories : Isolation valve, drain and vent plug on external cage




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4.30.00 Control &Instrumentation Cables 4.30.01 600V GRADE SINGLE PAIR TWISTED INSTRUMENTATION SIGNAL

CABLE

CONSTRUCTION a) Conductor: Each core shall be seven stranded annealed copper electrolyte grade conductor of cross section 1.0 mm2 generally complying to IS-8130. b) Insulation: Each core shall be provided with extruded HR PVC conforming to IS:5831 Type 'C'. Insulation thickness shall be >=0.8 mm and shall conform to relevant IS/other standard. Color of insulation shall be white and black in a pair.

c) Twist: Every 2 core shall be twisted to form a pair and number of twist shall be 20 twist per meter.

d) Shielding: The individual pair shall be shielded. Shield shall be Aluminium backed by Mylar tape bonded

together side down helically applied with either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.05mm Drain wire

shall be 0.5 sq mm multi stranded bare tinned annealed copper conductor. The drain wire shall be in continuous contact with aluminium side of the shield.

e) Inner sheath: Cables shall be provided with extruded HR PVC inner sheath as per IS 5831 type ST1. The

color shall be black and minimum thickness shall be >= 0.4 mm.

f) Armouring: Armouring applied over inner sheath shall be of galvanised steel wire 1.4 mm dia as per IS 1554 part I and IS 3975. g) Overall sheathing: The cable shall be sheathed with extruded HR

PVC type ST1 as per IS 5831 Color of sheath be Black. Thickness of the sheath shall be as per

IS 1554 Part. I and >= 1.24 mm. FRLS PVC outer sheath shall be provided.




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4.30.02 600V GRADE MULTIPAIR TWISTED INSTRUMENTATION SIGNAL CABLES

GENERAL

Multi pair twisted instrumentation cables shall be same as Single pair shielded cable.

Following additional features shall be applicable: - a) Conductor: Each core shall be seven stranded annealed copper electrolyte grade conductor of cross section 0.75 mm2 generally complying to IS-8130.

b) Shielding: In addition to individual shielding of pair, overall

shielding shall be provided. Overall shield shall be Aluminium backed mylar tape helically applied with metallic side down either side 25% overlap and 100% coverage. Shield thickness shall be 0.075 mm. Drain wire shall be similar to individual pair drain wire and shall be in continuous contact with the Aluminium side of the overall shield.

b) Twist: Overall twist of all pair shall be as per

manufacturer standard

c) Pair-Identification : Pairs shall be identified by printing pair numbers by black indelible ink on the white core

at interval not more than 250 mm. Conductor insulation shall be black and white for each pair.

4.30.03 600V GRADE SINGLE TRIAD SHIELDED CABLE

600V grade single triad cable shall be same as Single pair shielded cable.

4.30.04 600 GRADE MULTI TRIAD SHIELDED CABLE

600V grade multi triad cable shall be same as Multi triad shielded cable.




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4.30.05 1100V GRADE 2 CORE CONTROL CABLE

CONSTRUCTION

a) Conductor: Each core shall be seven stranded annealed tinned copper conductor of cross section 1.5 mm2 generally complying to IS 8130.

b) Insulation: Each core shall be provided with extruded HR PVC

insulation conforming to IS 5831 Type 'C'. Insulation thickness shall be >= 0.8 mm. Color of core insulation shall be black with core numbers printed in white indelible ink at max. 150mm apart on each conductor.

c) Inner sheath: Cables shall be provided with extruded HR PVC

inner sheath as per IS 5831 type ST1. The color shall be black. Thickness of sheath shall be >= 0.3 mm.

d) Armouring : Armouring applied over inner sheath shall be of

galvanised steel wire 1.4 mm dia. as per IS 1554 part I and IS 3975.

e) Overall : The cable shall be sheathed with extruded HR PVC

sheathing type ST1 as per IS 5831. Colour of sheath shall be black. Thickness of the sheath shall be >= 1.24 mm as per IS 1554 part-I. FRLS PVC outer sheath shall be provided.

4.30.06 1100V GRADE Multi core control cables Multi core control cables shall be same as two core control cable except for

the following features. a) Conductor: Each core shall be seven stranded annealed tinned

copper conductor of cross section 0.75 mm2 generally complying to IS 8130.

The core identification can be done by numbers. In that case, the insulation of cores shall be of same color and number sequentially sorting with number 1 for inner layer. The number shall be printed in Hindu Arabic numerals on the outer surface of the cores. (All the numbers shall be of same color which shall contrast with the color of the insulation. The numerals shall be 1 eligible. Bidder may alternately offer color coded conductors).




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4.30.07 Fibre Optic Cable (Mono type)

i. Cable Type : Mono-mode with minimum 4 fibers

ii. Wavelength band optimized : 850nm / 1300nm / 1550nm iii. Mode field diameter : 9-10µm + 10% of nominal value iv. Cladding diameter : 125µm + 3

Non-concentricity core / Cladding : not more than 2µm Non-circularity of cladding : not more than 3µm

vii. Cut-off wavelength : 1200nm viii. Attenuation : 1. less than 0.3-0.4 dB/km at 1300nm

2. less than 0.15-0.25 dB/km at 1550nm

Fibre optic cables shall be Rodent proof type and shall be laid through 30 mm dia HDPE conduit

4.30.08 Fibre Optic Cable (Multi type)

i. Cable Type : Multi-mode with minimum 4 fibers ii. Core / cladding diameter : 62.5 / 125 µm iii. Jacketing Material : Halogen Free, Flame

Retardant, Low Toxicity iv. Attenuation @ 850 nm : Length (m) x 0.0035

db/m+2db maximum v. Outside Diameter : 8.10 mm (0.324 in) vi. Minimum Bend Radius : 12.5 cm (5 in) vii. Minimum Bend Radius : 7.5 cm (3 in) (Long term) viii. Cable Assembly : Tensile Load for attenuation

increase <0.5 db: 300 N (66 lb) maximum

ix. Tensile Load at Installation : 1776 N (400 lb) max. x. Connector Tensile Load MIC : 133 N (30lb) xi. Minimum Crush Resistance : 46 N /cm (250 lb /in) Fibre optic cables shall be Rodent proof type and will be laid through 30 mm dia HDPE conduit

5.00.00 CODES & STANDARDS 5.01.00 GENERAL 5.02.00 All equipment, systems and works covered under the Bidder’s scope shall

comply with all statutory regulations and safety codes as applicable internationally and in locality where the equipment will be installed.




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5.03.00 The Bidder’s scope of supply shall include some items such as thermowells,

control valves and other in-line devices for main steam, feedwater system, falling under the purview of Indian Boiler Regulation (IBR) Act. It shall be the responsibility of the Bidder to obtain the necessary approval of the concerned Inspecting Authority/Chief Inspector of Boilers for the design and design calculations, manufacturing and erection procedures as called for under the Indian Boiler Regulations Act.

5.04.00 The design, manufacture, inspection, testing and erection of the equipment covered under this Specification shall conform to the standards and codes (latest editions) including but not be limited to those mentioned below. Contractor shall refer to the latest revision of all codes and standards.

Bidder shall however, follow sound Engg. practice throughout. Temperature Measurement -ASME PTC 19.3 ANSI MC 96.1 IEC 751, IEC584.2 BS 1401 IS 2806

Pressure Measurement -ASME PTC 19.2 IEC 381 IS 3624 Flow Measurement -ASME PTC 19.5 BS 1042/ ISO 5167 Control Valves - ISA S 75.01-75.05 ANSI B16.34 ANSI B16.10 Sampling System -ASME PTC 19.11 ASTM D1198 ASTM A 269 Enclosures -IEC 529 IEC 79 (Hazardous) IS 2147/IS 13947 Annunciator - ISA S 19.1 Boiler Safety Interlocks - NFPA Section 85B/D/E/F/G Instrument Tubing, - ANSI B 16.11/B 31.1 Fitting




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Cables - IEEE 383 BS 6746 IS 5831 BS 5308 BS 6346 IS 10810 IS 1554 BS 6360 IS 694 IS 8130 BS 6500 6.00.00 INSTRUMENT INSTALLATION 6.01.00 General

a) Instrument process tubing and instrument air tubing to be designed in accordance with the instrument installation drawings.

b) All instruments, process connections, including isolation valves and

associated devices, shall be located in easily accessible locations for maintenance, calibration and replacement. All maintenance, calibration and replacement operations on a given device must be possible without interruption of service to adjacent equipment.

c) Instrument mounting height shall 4’ - 6” above equipment base or

platform. d) Instrument tubing installation are designed in accordance with ANSI

B31.1 “ Power Piping”. 6.02.00 Instrument Sensing Lines

a) All impulse pipe shall be of seamless type conforming to ANSI B36.10

for schedule numbers, sizes and dimensions etc b) Minimum bending radius of instrument sensing lines 3 times the tube

diameter. c) Instrument sensing lines are sloped in their horizontal runs, a minimum

of 1/2” per foot. In general, liquid and steam lines slope from their process tap connection down to the instrument. In general, gas and non-condensing vapor lines slope from their process tap connection upto the instrument.

d) Instrument sensing lines shall be routed as directly as practicable from

the process root valve to the instrument. The length of instrument tubing from the root valve to the instrument shall be limited to maximum of 12 meters for compressible fluids and 15 meters for non-compressible fluids.

e) Instrument sensing lines are grouped together as much as possible to

benefit from the use of common support members and to present a finished installation that is routed in a neat and orderly manner. Care is exercised to assure that spacing between adjacent tubes in the same




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group is maintained uniform and that tubes do not cross under or over one another at any point. Changes in direction of tubing is done by the use of tube bends and not tube fittings.

f) For connection to gauge or transmitter or switch compression tube

fittings will be used. g) A single blow down valve or double blow down valves (if the process

root valves are doubled) shall be installed to the sensing lines of all pressure transmitters that are tapped off liquid or steam process systems. These valves shall be located at the instrument and may be brought together to the header.

h) The maximum process temperature for all transmitters shall be limited to

80o

C. To dissipate the excess heat, a maximum of 1 meter of tubing for

each 30o

C of excess heat shall be installed to isolate the process media from the instrument. An additional isolation valve shall be used at the instrument for isolation on those instruments without valve manifolds.

6.03.00 Instrument Air Lines

a) Instrument air lines shall be of stainless steel.. b) Minimum bending radius of instrument air line tubing is 3 times the tube

diameter. c) All branch lines from the instrument air line header are made from the

top of the air header and shall not be smaller than 1/2 inch. Branch lines have a root valve at the process connection.

d) In areas with multiple air users, an instrument air manifold is used. The

branch from the air header to manifold is 1 inch, with a 1-inch isolation valve at the manifold. The manifold consists of a 3 inch pipe with a caps, 3/8 inch air takeoff connections with 3/8 inch shutoff valves, and a 1/2” drain valve. A six and eight air user, manifold design, will be used.

6.04.00 Instrument Mounting

a) Instrument mounting shall be in accordance to standard hook-up details

and mounting details. b) Spacing between multiple instruments mounted on the same support

shall be sufficient to allow ample clearance area in order to perform service, maintenance, calibration and testing.

6.05.00 Instrument Wiring




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6.05.01 General The two-wire system shall be employed for transmission of signals from electronic transmitting instruments. Electronic instrument wiring shall be done as per manufacturer’s standards and multicore cables shall be used wherever practical. Special, screened, shielded or co-axial cables shall be used as required and as such, these special cables shall be supplied by the Contractor.

6.05.02 Conduit

Compensating and screened cable shall, in general, be installed in rigid conduit. All special cable including compensating cables required for the plant shall be included in Contractor’s scope.

6.05.03 Terminal Box

Except for thermocouple cables terminal/junction boxes shall be used for the interconnection of control wiring and instrument signal wiring. Terminal boxes of a type approved for area classification shall be provided for terminating multicore control wiring. NEMA-3 standard type of better enclosures shall be used for junction boxes. 20 % spare terminals shall be provided in the junction box.

6.06.00 Wiring Practices 6.06.01 The signal cable shield shall not be used as a signal conductor. The signal

cable shall not be spliced. The cable shield shall be maintained at a fixed potential with respect to the circuit being protected.

6.06.02 Low level signal cable shall be terminated with short untwisted length of wire,

which should have as minimum area as practicable to be exposed for inductive pick-up. Low level signal cables should be separated (isolated) from noisy & power circuits by practicable large distance. Signal cables should not cross each others, if at all required, crossing shall be at right angles, and at a large practical distance.

6.06.03 Instrument cubicle/panel wiring shall be such that minimum crossing of signal

cables are encountered. Instrument/device located in left (and right) hand side of panel/cubicle should be terminated in left (& right) side terminal block respectively so as to minimise intercrossing of wires in panel/cubicles.

6.06.04 Unused shielded conductors in a low level signal cable shall be single end

grounded at the opposite end. 6.06.05 Earthing plate for all electronic instruments shall be away from common

electrical earthing point. A signal circuit shall be grounded either at the transmitter end or at the instrument end.




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6.06.06 All Cables to be terminated in Junction Box/Panel shall be through cable glands.

6.06.07 All instrument cables like signal cable, communication cable, supply cable

should have separate color code and cables should be distinguished from electrical cables. Signal cables and control cables should be put in cable trays separate from that of power cables.

6.06.08 All cables should have traceability from field to JB and JB to DCS/Panel with

identification ferrules. The cabling should be documented properly so that it can be useful for future maintenance.

7.00.00 DATA AND DOCUMENTS TO BE FURNISHED BY THE BIDDER ALONG

WITH BID Bidder shall furnish all required information/data sheet/drawing/document

required to facilitate full appreciation of bid which shall include but not limited to following :-

a) Proposed control philosophy along with Control system configuration diagram.

a) Filled up Technical Particular Sheets/Schedules.

b) Details of C & I and PLC System offered

c) Tentative I/O counts

d) Details of hardwired controls and indication (if any).

e) List of deviation from Specification document.

f) Vendor list of instrumentation items. DATA AND DOCUMENTS TO BE FURNISHED BY THE CONTRACTOR

a) Operational Philosophy.

b) Control system configuration diagram.

c) Description and write-up of control scheme and interlocking system.




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d) Complete Local Control room layout drawings with foundation, GA details of all panels, desks and consoles, wherever applicable.

e) Interconnection cable schedule (ICS) and cable schedule between instruments JB’s & I/O cabinets.

f) Cabinet / Panel wiring diagrams and internal layout drawings

g) Cabinet / Panel terminal details

h) Wiring diagrams for panel, local panel, junction boxes, actuators,etc

i) Proposed Graphics/Mimic displays and logs.

j) Control schemes/logic diagram.

k) Flow element and Control valve sizing calculations and dimensional drawings.

l) Interconnection Diagram of different PLCs / C & I systems and the DCS showing all hardware details.

m) Complete Instrument Schedule.

n) Junction Box Schedule

o) FAT procedure

p) Heat load, Power consumption and air consumption data

q) Calibration test & quality assurance test procedure and test certificates.

r) Shop and site Test Records.

s) Manuals & technical literature for instruments/ equipments.

t) Instrument installation diagram showing all erection hardware.

u) Power supply arrangement for field mounted instruments/panels/sub systems.

v) 'As built' status drawings.




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ANNEXURE-I-DRIVE CONTROL PHILOSOPHY Drive Control Philosophy: Control philosophy for interfacing of MCC/SWGR./Actuator with PLC/DCS is as follow:

a. Bi-directional drives (inching or open/close) -

All Motor operated valves/dampers are integral type. The following interface between PLC and valve integral starter:

i. Potential free On-Off commands from PLC to integral starter. ii. Speed output (For VFD Drives)

Feed backs from integral starter to PLC shall include:

i. Open limit switch feedback ii. Close limit switch feedback iii. Open torque switch feedback iv. Close torque switch feedback v. Integral Starter Disturbed (Loss of power/control supply, thermostat trip,

Thermal O/L, Torque open/close, Local/off/Remote S/S in Local or Off mode etc.)

vi. Position Transmitter Feedback (For Inching Type drive)

b. Unidirectional LT Drives –

LT drives like Pumps and Fans shall have the following interface with PLC and MCC:

i. Potential free On-Off commands from PLC to MCC. ii. Speed output (For VFD Drives)

Feed backs from MCC to PLC shall include:

i. On/Running ii. Off/stop iii. Switchgear/MCC Disturbance (when Thermal O/L, control power supply fails,

MCC power supply is isolated, EPB OPTD, S/S not in Remote). iv. Current Feedback for motor rated >30KW v. Speed (For VFD drives)

c. Unidirectional HT Drives –

HT Drives like pumps and fans shall have the following interface with PLC and MCC:

i. Potential free On-Off commands from DCS to MCC. ii. Speed output (in case of VFD)




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Feed backs from MCC to PLC shall include:

i. On/Running ii. Off/Stop iii. Switchgear/MCC Disturbance (Overload relay operated, control supply fail,

Emergency LPBS operated) iv. Switchgear/MCC Available (Breaker in service position, Switchgear in remote

& breaker spring charged, lockout relay reset) v. Breaker in test position vi. Current Feedback vii. Speed Feedback (in case of VFD)

d. Solenoid Drives –

Solenoid operated drives shall have the following interface with PLC: i. Energize ii. De-energize iii. Open limit switch feedback iv. Close limit switch feedback

e. Pneumatic Drive –

Pneumatic operated drives shall have the following interface with PLC:

i. Command to I/P converter ii. Position Transmitter Feedback iii. Open limit switch feedback iv. Close limit switch feedback v. Command to solenoid valve (Wherever Applicable)

11v02-acc-spc-m-0001-v2-part-c

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