Full Specifications For Off Shore Platforms

LIST OF FUNCTIONAL SPECIFICATIONS – INSTRUMENTATION
(As applicable for Sagar Laxmi Modification Project)
S.No. FS # Description Rev Date Revision
1. 3100 Level Gauge 04-05-2011 4
2. 3101 Level Switch (Pneumatic) 18.02.2008 3
3. 3102 Level Switch (Electrical) 18.02.2008 3
4. 3103 Level Transmitter 30.03.2011 4a
5. 3200 Flow Switch 18.02.2008 2
6. 3201 Flow Totalizer 31.03.2011 4a
7. 3202 Electronic Flow Transmitter 30.03.2011 5a
8. 3203 Orifice Plate Assembly 31.08.2009 4
9. 3204 Restriction Orifice Assembly 18.02.2008 3
10. 3205 Senior Orifice Assembly 27.08.2009 3
11. 3206 Rotameter 18.02.2008 3
12. 3207 Turbine Flow Meter 26.08.2009 4
13. 3208 Coriolis Meter 31.03.2011 4a
14. 3209 MPFM 16.12.2010 4
15. 3210 Gas Flow Computer 18.02.2008 3
16. 3211 Liquid Flow Computer 28.09.2009 4
17. 3212 Ultrasonic Flow Meter 03.05.2010 1a
18. 3213 Electro Magnetic Flow Meter 09.02.2009 1
19. 3300 Temperature Gauge 18.02.2008 4
20. 3301 Temperature Switch (Electrical) 18.02.2008 2
21. 3302 Temperature Transmitter (Electronic) 16.07.2010 3
22. 3400 Differential Pressure Gauge 30.09.2011 5
23. 3401 Pressure Gauge 31.03.2011 5b
24. 3402 Pressure Switch (Electrical) 18.02.2008 2
25. 3403 Pressure Transmitter (Electronic) 30.03.2011 4a
26 3404 Current to Pneumatic Convertor 21.12.2010 0
27. 3500 Fire & Gas Detection System 13.12.2011 4
28. 3501 Shut Down Panel (Pneumatic) 23.09.2010 4
Page 1 of 2
LIST OF FUNCTIONAL SPECIFICATIONS – INSTRUMENTATION
(As applicable for Sagar Laxmi Modification Project)
S.No. FS # Description Rev Date Revision
29. 3502 Telemetry Interface Cabinet 31.03.2011 3
30. 3503 Instrumentation for Equipment Package 28.03.2007 1
31. 3506 Hydraulic Power Unit Cum Panel 16.06.2008 1
32. 3507 Bulk item requirements for interfacing 15.05.2008 1
33. 3508 Instt Cables 02-05-2011 2
34. 3509 Sub Sea Intervention Valve Actuator 28.07.2008 1
35. 3510 Sub Sea Umbilical 05.09.2011 1
36. 3511 Electro Hydraulic System (Marginal Fields) 08.12.2011 0
37. 3600 Hi-Lo Pilot Switch 18.02.2008 4
38. 3601 Pressure Indicating Controller 31.03.2011 4a
39. 3602 P / I Converter 18.02.2008 2
40. 3603 Recorder (Electronic) 18.02.2008 2
41. 3604 Recorder (Pneumatic) 18.02.2008 2
42. 3605 Portable Calibrator 18.02.2008 3
43 3606 Filter Regulator 18.02.2008 3
44 3700 Control Valve 23.02.2010 4
45 3701 Safety Relief Valve 14.12.2010 3

Self Actuated Pressure Control Valve
46 3702 15.12.2010 4
(SAPCV)
47 3703 Deluge Valve 18.02.2008 3
48 C100 Distributed Control System 11.07.2007 3
49 C101 Programmable Logic Controller 28.03.2007 1
50 C102 Integrated Control System 06.12.2006 0
51 C103 Telecom System 07.12.2006 0
52 C104 HIPPS 15.06.2010 2
Page 2 of 2
Spec. No. 3100
Offshore Design Section FUNCTIONAL
Rev. No. 04
Engineering Services SPECIFICATION FOR
Discipline Instt
ISO – 9001:2008 “LEVEL GAUGE” Page: 2 OF 11
CONTENTS
Clause No. ITEM Page No.

1.0 Scope of This Document 3
2.0 Codes and Standards 3
2.1 Reference specifications 3
3.0 Scope of Supply 3
4.0 Level gauge 3
4.1 Gauge type 3
4.2 Material 5
4.3 Accuracy 5
4.4 Reading scales 5
4.5 Enclosure class 5
4.6 Miscellaneous 5
Annexure I Material Selection Chart for Level Gauge 6
Annexure II Hook-up drawing 7-10
Annexure III Data Sheet Format for LG 11
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 to 015 03 00 21.07.2010
Spec. No. 3100
Rev. No. 04
Discipline Instt
1.0 SCOPE OF THIS DOCUMENT:

1.1 This functional specification describes the essential design considerations for the
selection of Level Gauge for the intended service.
2.0 CODES & STANDARDS:
2.1 Reference Documents and Specifications:
a) Instrumentation Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) Process Design Criteria / Instrument Process Data Sheets / Instrument List with
Process Parameters
3.0 SCOPE OF SUPPLY:
3.1 The quantity to be supplied and installed shall be as per the requirements indicated
in the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Level gauge suitable for its
intended application, its procurement, tagging, packing, testing & calibration,
preparation for shipment, along with accessories, spares, and assistance where
required for its installation & commissioning at site. This FS shall be read in
conjunction with the Instrument Design Criteria.
4.0 LEVEL GAUGE:
4.1 GAUGE TYPE:
4.1.1 The Level Gauge may be transparent type / Reflex type / Magnetic Float type
depending on the nature of process fluid, for physical measurement of the level
in the vessel / tanks.
4.1.2 General:
4.1.2.1 Level indicator in hydrocarbon services shall be a transparent type for turbid /
dirty Liquids and Reflex type for clear liquids.
4.1.2.2 For level measurement greater than two meter, a differential type pressure
instrument shall be used.
4.1.2.3 Process connections shall be side and side or top and bottom ¾”NPT as per
process requirement. LG bottom connection shall not be located at the bottom of
the vessel on or near the exit / drain of the vessel / equipment, as it may cause
erroneous display of level on account of the velocity of the draining liquid.
4.1.2.4 Level instruments for pressure and non- pressure storage tanks, Large vessels
where measurement is not for accounting purpose, may be by differential head
measurement or by a float type level gauge with local indication at grade level(
for tank level gauge) and provision for remote indication and alarms.
Spec. No. 3100
Rev. No. 04
Discipline Instt
4.1.2.5 All flanges on the level instrument pressure retaining parts shall be of the same
type and rating as the process flanges, and shall be in accordance with the vessel
trim specification.
4.1.2.6 Float type level gauges shall comprise of a simple float magnetically coupled
with the indicator assembly.
4.1.2.7 The drain valve from all level instruments shall be piped / tubed into the platform
drains system. All level instruments in toxic and hydrocarbon service shall have
blow down connections to closed drain / safe venting place.
4.1.2.8 Each Level gauge shall be hydro tested to a pressure of 1.5 times the design/max/
process pressure. The manufacturer before shipment shall perform calibration and
alignment of all instruments.
4.1.3 Gauge Glasses
4.1.3.1 Gauge Glasses shall be provided on all vessels except product storage tanks, to
cover the complete operating range of level including the spans of level
transmitters and level alarm switches.
4.1.3.2 Reflex gauge glasses of the high-pressure type shall be used for gas-liquid
interfaces where the liquid is clean and colorless.
4.1.3.3 Transparent or thru vision gauges shall be used for liquid-liquid interfaces,
distillates heavier than 250 API gravity, all-crude and residues. Interface gauges
shall be connected directly to the vessel without gauge columns. Transparent
gauge glasses shall be back-lighted with gauge illuminators. Each Illuminator
shall have power isolation switch.
4.1.3.4 Gauge glasses shall have one or more sections of approximately 302 mm (11-
7/8") visible length with top and bottom connection. A maximum of five sections
shall be used for a single gauge. Where more than one gauge is required, they
shall overlap a minimum of 25 mm (1") of visible length.
4.1.3.5 Standard velocity check gauge-cocks shall be furnished with all gauge glasses.
They shall be the offset type with bolted bonnet, ¾” male unions at valve seat-and
gauge connections. Stem shall have hand wheels and quick closing thread with
double seated plunger to permit repacking cock in service and with tip on plunger
to unseat ball check before cock is closed.
4.1.3.6 Gauge glass assemblies shall be chosen for the design pressure and temperature
of the respective vessel.
4.1.3.7 Multiple gauge glasses installation may be mounted on a single pipe column with
block valves at the vessel. Multiple gauge glasses installations shall be
adequately supported so as to prevent strain on gauge valves and nozzles.
4.1.3.8 A block valves shall be installed between the gauge valve and source of fluid to
permit removal of the gauge glass.
Spec. No. 3100
Rev. No. 04
Discipline Instt
4.2 Material:
4.2.1 The material requirements for Level Gauge shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided in
Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid
and ambient conditions to which they are exposed.
4.2.3Body and cover plate shall be SS316. Bolts and nuts shall be SS316. The glass shall
be toughened borosilicate (Klinger or equivalent) which is resistant to thermal and
mechanical shocks. Ball checks plunger seat and valve stem shall be type SS 316.
Drain connection shall be ½” NPT and shall be provided with a SS 316 drain valve.
Wherever necessary, higher-grade material suitable to the process conditions shall be
used. Vent connection shall be ½” NPT on top of each gauge glass. Vent valve with
blind flange shall be provided with top connection. Drain connections shall be piped to
drip pans or deck drains.
4.3 Resolution: “Resolution of the markings on the gage shall be ±2mm.
4.4 Reading Scales: Units for level indicating scales shall be 0-100 percent. (For tanks,
it can be the measure of the height of the tank in the resolution desired) suitable least
count
4.5 Enclosure Class: The level gauge shall be weather proof to IP 65 for electrical
enclosure.
4.6 Miscellaneous:
Nameplate: In addition to the requirements mentioned in the Instrument Design
Criteria 3.6.6.1, the level gauge shall have “stamped” on its SS name plate the
following details:
• Tag Number
• Manufacturer’s Name and Trade Mark
• Gauge type and Model Number
• Material of construction and Pressure Rating
• C/C distance / Measuring range.
Spec. No. 3100
Rev. No. 04
Discipline Instt
ANNEXURE – I
Material Selection Chart for Level Gauge.
CHAMBER
COCK COCK
S. No. Piping Class &HAND
BODY TRIM
WHEEL.
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1,
PE1, PXF1, PF1, A2, B2, D2, E2, XG1, A1H,
1 A3, B3, A8 SS316 SS316 SS316
2 A4, A6, A9, B9, D9, E9 SS316 SS316 SS316
3 A5 MONEL MONEL MONEL

K 500 K 500 K 500
4 A7 Titanium Titanium Titanium.
A1N, B1N, D1N, E1N, F1N, XF1N, PA1N, SS316L SS316L SS316L
5
PB1N, PD1N, PF1N, XG1N (NACE) (NACE) (NACE)
6 A10, B10, D10, E10, F10 SS316L SS316L SS316L
A11, B11, D11, E11, F11, PA11, PB11, PD11, MONEL-

7 MONEL- 400 MONEL-400
PE11, PF11 400
Spec. No. 3100
Rev. No. 04
Discipline Instt
ANNEXURE – II
HOOK UP DRAWING
LEVEL GAUGE CONNECTION TOP AND BOTTOM
Spec. No. 3100
Rev. No. 04
Discipline Instt
(Hook Up Drawing)
LEVEL GAUGE ( ON STAND PIPE)
Spec. No. 3100
Rev. No. 04
Discipline Instt
LIST OF ITEMS.
CODE DESCRIPTION SIZE ENDS QTY UNIT
7 NIPPLE ½” THXPL 02 Nos
10 NIPPLE ¾” THXPL 02 Nos
39 GLOBE VALVE ½” SW 01 No
46 FLANGE ¾” TH 04 Nos
For ¾”FL
62 GASKET 02 Nos
½”
51 CAP TH 02 Nos
72 STUDS &NUTS For ¾”FL 02 Set.
DISPLACER LEVEL INSTRUMENT
Spec. No. 3100
Rev. No. 04
Discipline Instt
(SIDE -SIDE CONNECTION)
LIST OF ITEMS.
CODE DESCRIPTION SIZE ENDS QTY UNIT
7 NIPPLE ½” THXPL 2 Nos
17 SWAGE ¾” X ½” THXPL 2 Nos

NIPPLE
½”
39 GLOBE SW 2 Nos
VALVE
½”
51 CAP TH 2 Nos
Spec. No. 3100
Rev. No. 04
Discipline Instt
ANNEXURE – III (Typical Data sheet format)

UNITS: Flow→ Liquid M3/Hr Gas→ M3/Hr Steam → Kg/Hr Pressure → Kg/Cm2 G Temp→ 0C Level / Length→ MM
1 ITEM NUMBER
2 TAG NUMBER
GENERAL
3 SERVICE
4 UPPER FLUID
5 LOWER FLUID
SERVICE COND 6 PRESS - OPER / MAX
7 TEMP - OPER / MAX
8 TYPE
9 VISIBLE LENGTH mm
10 NOS. OF SECTIONS
11 CENTRE TO CENTRE DISTANCE mm
LEVEL GAUGE 12 CONNECTION SIZE & RATING
13 CONNECTION LOCATION
14 BODY MATERIAL
15 CHAMBER BODY MATERIAL
16 GLASS TYPE
17 BODY MATERIAL
18 TRIM MATERIAL
19 VESSEL CONN & TYPE
20 GAUGE CONN & TYPE
21 TYPE
22 BALL CHECK
GAUGE COCK
23 RENEWABLE SEATS
24 BONNET
25 SCREW - INSIDE / OUTSIDE
26 CLOSING - PLAIN / QUICK
27 MINIMUM RATING
28 ILLUMINATORS
29 ILLUMINATOR D ETAILS
30 MICA SHIELD
31 HEATING CHAMBER
ACCESS-ORIES 32 COOLING CHAMBER
33 NON-FROSTING TYPE
34 CALIBRATED SCALE
35 GAUGE - VENT
36 GAUGE - DRAIN
37 IBR CERTIFICATION
MISC. 38 MODEL NUMBER
39 MANUFACTURER
Notes :
□ DEVIATION □ NO DEVIATION
VENDOR’S SIGNATURE WITH SEAL
Design Division Spec # 3101
Functional Specifications
Engineering Services Rev # 3
11 - High, Mumbai LEVEL SWITCH Discipline Instt.
ISO 9001: 2000 (Pneumatic) Page # 1 of 8
FUNCTIONAL SPECIFICATION
FOR LEVEL SWITCH
(PNEUMATIC)
TOTAL
REVIEWED APPROVED
PREPARED No. OF DATE REV. No.
BY BY
PAGES
VS RS GRP 8 18.02.2008 3
ET RS GRP 12 28.03.2007 2
ET MC RK 12 23.06.2005 1
AK MC AC 12 17.04.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Level Switch (Pneumatic) 3
4.1 Switch type 3
4.2 Material 4
4.3 Enclosure 4
4.4 Miscellaneous 4
Annexure I Material Selection Chart for Level Switch 5
Annexure II Hook-up drawing 6
Annexure III Data Sheet Format 8
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Level Switch (Pneumatic) for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Level Switch suitable for
its intended application, its procurement, tagging, packing, testing & calibration,
4.0 LEVEL SWITCH:
4.1 Level switch may be externally mounted float or displacer type.
4.1.1 General:
4.1.1.1 All level instruments in toxic and hydrocarbon service shall have blow down
connections to closed drain.
4.1.1.2 Rotatable heads shall be provided with displacer/float type instruments.
Shutdown devices may be externally mounted float or displacer type.
4.1.1.3 External float or displacer level cages to have 1 ½ " connections. The float or
displacer shall be removable / replaceable. Liquid interface level switches shall
be displacer type.
4.1.1.4 Top-mounted/side-mounted internal displacer instruments shall have stilling well
of same diameter as the vessel nozzle, in order to restrict horizontal movement of
the displacer.
4.1.1.5 Air filter regulator shall be provided for each level switch. Regulator shall be
provided with an output gauge having 0-6 Kg/cm2 range.
4.1.1.6 All shutdown and alarm switches shall be fail safe and abnormal condition shall
cause a loss in output signals for pneumatic instruments.
4.1.1.7 Out put shall remain at 3.5 Kg/Cm2 between High and Low settings and 0
otherwise. Process connection shall be as per the approved P&ID.
4.1.1.8 The switch element shall be selected in such a way that it can withstand an over-
range pressure of 1.5 times maximum range without loss of calibration.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.1.1.9 Connection for air or gas supply, transmission and control signals shall normally
be internally threaded ¼” NPT.
4.1.1.10 Level switches, float or displacer-operated, shall be actuated mechanically for
switch operation. Head or pressure operated level switches shall be calibrated as
required. Each switch shall be hydro tested to a pressure of 1.5 times the max
process pressure. The manufacturer before shipment shall perform calibration
and alignment of all instruments.
4.1.1.11 External Cage Type Instruments:
4.1.1.11.1 External cage level instruments shall have pressure ratings equal to or greater
than the relevant piping classification for flanged valves.
4.1.1.11.2 Connection for external cages shall be minimum DN50 flanged.
4.1.1.11.3 A positive seal shall be used in transferring float / displacer motion to the
external mechanism where a float or displacer element is employed.
4.1.1.11.4 All external cage instruments shall be designed to permit rotation of the head,
torque tube and transmitter or switch case in relation to the cage / well portion.
4.1.1.11.5 The standard configuration for external cages shall be side and side.
4.1.1.11.6 All external cages shall be fitted with vent and drain and test connections
normally of ¾” NPTF.
4.1.1.12 Displacement Type Instruments:
4.1.1.12.1 Displacement type level instruments shall be of the externally mounted type.
4.1.1.12.2 Displacer chambers for external displacers shall have minimum DN50 ANSI
300 RF flanged vessel connections.
4.1.1.12.3 ‘Side and Bottom’ connections shall be used with ring type joints or similar
connections. Side and top connections shall be used only in cases where this
would avoid a pocket in the connecting piping (on small vessels).
4.1.1.12.4 Connection for internal displacer shall be DN 100 flanged, unless otherwise
specified and approved by the Company.
4.2 Material:
4.2.1 The material requirements for Level switch shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided
in Annexure I of this specification.
4.3 Enclosure Class: The Level switch shall be weather proof to IP 65 or better.
4.4 Miscellaneous: For Level Instruments, especially Switches, the bottom connection
shall not be located at the bottom of the vessel, on or near the exit / drain of the
vessel / equipment, as it may cause erroneous signals of “LSLL/LSL” on account
of the velocity of the draining liquid.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I
Material Selection Chart for level switch
S. No. Piping Class BODY DISPL/FLOAT
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 CS SS316
(EXCEPT WAT. INJ. SERVICE)
2 INJECTION WATER SERVICE CS MONEL
3 A4, A6, A9, B9, D9, E9 SS316 SS316
4 A5 MONEL MONEL
5 A7 CS SOLID TEFLON
A1N, B1N, D1N, E1N, F1N, XF1N, PA1N,

6 PB1N, PD1N, PF1N, XG1N
SS316 SS316
7 A10, B10, D10, E10, F10 SS316L SS316L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
MONEL-400 MONEL 400
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II
(Hook Up Drawing)
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II
(Hook Up Drawing)
ANNEXURE – II (Contd.)
LEVEL SWITCH (PNEUMATIC

DETAIL - 2
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – III: TYPICAL DATA SHEET

o
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> C Level/Length-> mm
1. Tag. No.
General 2. Quantity
3. Service
4. Area Classification
5. Internal / external
6. Interface
7. Case Material
8. C/C – Distance
9. Conn. Size & Rating
10. Location Upper
11. Location Lower
Cage
12. Case Orientation
13. Rotatable Head
14. Finned Extension
Drain Conn.
15. Vent
Size
Case to head flange size &
16.
rating
17. Displacer or Float
18. Diameter Length mm.
19. Insertion Depth mm.
20. Displacer Extension mm
Displacer Or Float 21. Displacer or Float Material
Displacer or Float Stem
22.
Material
23. Spring/Torque Tube Material
24. Function
25. Output
26. Control Modes
27. Differential
28. Controller Action
29. Elect. Area Classification
30. Enclosure Material
Functional Data 32. Power Supply
33. Switch Type
34. Qty. Form
35. Contact Rating
36. On Level Inc. O/P
37. On Level Dec. Contact
38. Cable Entry
39. Upper Liquid
40. Lower Liquid
41. Sp. Gr. Upper Lower
Service Conditions 42. Press. Nor. Max.
43. Viscosity-Upper Lower
44. Temp. C Nor. Max.
45 Manufacturer
46. Model No.
Others
47. P & ID No.
48. IBR Certification
NOTE :-
VENDOR SEAL AND SIGNATURE
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division Functional Specifications Spec No : 3102
For Rev. No : 3
Engg. Services
LEVEL SWITCH Discipline: Instrumentation
ISO – 9001:2000
(ELECTRICAL) Page: 1 of 8
FOR
LEVEL SWITCH
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
VS RS GRP 9 18.02.2008 3
ET RS GRP 12 28.03.2007 2
ET MC RK 12 23.06.2005 1
AK MC AC 12 17.04.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000
CONTENTS

4.0 Level Switch (Electrical) 3
4.1 Switch type 3
4.2 Material 5
4.3 Accuracy 5
4.6 Miscellaneous 5
Annexure I Material Selection Chart 6
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000

selection of Level Switch for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.1 The quantity to be supplied and installed shall be as per the requirements indicated in
the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Level Switch suitable for its
preparation for shipment, along with accessories, spares, and assistance where required
for its installation & commissioning at site. This FS shall be read in conjunction with
the Instrument Design Criteria.
4.0 LEVEL SWITCH (ELECTRICAL):
4.1 Switch Type:
4.1.1 Electrical type.
4.1.2 General:
4.1.2.1 The switch mechanism shall be a hermetically sealed micro-switch of 2 x SPDT, snap
action type. DPDT may be considered instead of 2 X SPDT.
4.1.2.2 Dual magnetic systems shall be used for all level switches, which use magnetic switch
mechanisms.
4.1.2.3 The switch shall be provided with 2Nos. ½”NPT (F) cable entries. One cable entry
shall be plugged with suitable explosion-proof plug.
4.1.2.4 Arcing during making or breaking of switch contacts shall be minimum. The switch
contacts shall have long life and minimum wear. The material chosen for switch
contact shall have good thermal conductivity for dissipating heat.
4.1.2.5 There shall be minimum bounce during making and breaking of switch contacts and
switch mechanism shall be designed to minimize the vibration.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000
4.1.2.6 The switch element shall be selected in such a way that it can withstand an over-range
pressure of 1.5 times maximum range without loss of calibration.
4.1.2.7 Level switches shall be heavy duty, with user adjustable set point . Adjustments shall
be tamper-proof.
4.1.2.8 The Level-sensing element shall be designed to meet a service life of one million
switching cycles.
4.1.2.9 Vendor shall ensure that set point falls between 35% and 70% of adjustable range of
the selected model in general.
4.1.2.10 The primary type of level instrument for level switches shall be float type. Level
displacer and float instruments shall be external chamber type. Solid displacers are
preferred to hollow displacers, especially in high-pressure services.
4.1.2.11 The drain valve from all level instruments shall be piped into the platform drains
system.
4.1.2.12 All flanges on the level instrument pressure retaining parts shall be of the same type
and rating as the process flanges, and shall be in accordance with the vessel trim
specification.
4.1.2.13 The collapse pressure of hollow displacers and floats shall be entered on the
instrument data sheet, and marked on the instrument nameplate.
4.1.2.14 The primary type of level instrument for remote transmission shall be displacer type.
4.1.2.15 All switches shall be Ex d.
4.1.2.16 External Cage Type Instruments:
4.1.2.1.15.1 External cage level instruments shall have pressure ratings equal to or greater than
the relevant piping classification for flanged valves.
4.1.2.1.15.2 Connection for external cages shall be minimum DN50 flanged.
4.1.2.1.15.3 A positive seal shall be used in transferring float / displacer motion to the external
mechanism where a float or displacer element is employed.
4.1.2.1.15.4 All external cage instruments shall be designed to permit rotation of the head, torque
tube and transmitter or switch case in relation to the cage / well portion.
4.1.2.1.15.5 The standard configuration for external cages shall be side and side.
4.1.2.1.15.6 All external cages shall be fitted with vent and drain and test connections normally
of ¾” NPTF.
4.1.2.17 Displacement Type Instruments:
4.1.2.17.1 Displacement type level instruments shall be of the externally mounted type.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000
4.1.2.17.2 Displacer chambers for external displacers shall have minimum DN50 ANSI 300
RF flanged vessel connections.
4.1.2.17.3 ‘Side and Bottom’ connections shall be used with ring type joints or similar
connections. Side and top connections shall be used only in cases where this would
avoid a pocket in the connecting piping (on small vessels).
4.1.2.17.4 Connection for internal displacer shall be DN 100 flanged, unless otherwise
specified and approved by the Company.
4.2 Material:
4.2.1 The material requirements for Level switch shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided in
Annexure I of this specification.
4.2.2 Instrument parts shall be resistant to the corrosive properties of the process fluid and
ambient conditions to which they are exposed.
4.3 Accuracy: The maximum error shall not exceed 1% of the span. Repeatability shall be
±1%.
4.4 Reading Scales: Units for level switch shall be in mm.
4.5 Enclosure Class: In addition to weatherproof, the switch enclosure shall be explosion-
proof to NEMA-7 and certified by third party agencies like UL/FM/BASEEFA or equal
for use in hazardous area (CL 1,DIV.1, GR.D). A warning label which reads
(EXPLOSION PROOF INSTRUMENT, ISOLATE ELSEWHERE BEFORE
OPENING”, shall be affixed on pressure switches which are certified as explosion
proof.
4.6 Miscellaneous:
The switches shall be provided with SS name plate indicating the following:
• Tag Number
• Manufacturer’s Name and Model Number
• Adjustable range
• Element material
• Enclosure classification.
4.6.1 For Level Instruments, especially Switches, the bottom connection shall not be
located at the bottom of the vessel on or near the exit / drain of the vessel / equipment,
as it may cause erroneous display of level on account of the velocity of the draining
liquid.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000
ANNEXURE – I
MATERIAL SELCTION CHART
Level Instrument
S. No. Piping Class
Body Displacer / Float
A1, B1, D1, E1, F1, XF1, F1, PA1,

PB1, PD1, PE1, PXF1, PF1, A2, B2,
1 CARBON STEEL SS 316
D2, E2, XG1, A1H, A3, B3, A8
2 INJECTION WATER SERVICE CARBON STEEL MONEL
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
4 A5 MONEL MONEL
5 A7 CARBON STEEL SOLID TEFLON
A1N, B1N, D1N, E1N, F1N, XF1N,

6 SS 316 SS 316
PA1N, PB1N, PD1N, PF1N, XG1N
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
A11, B11, D11, E11, F11, PA11,

8 MONEL 400 MONEL 400
PB11, PD11, PE11, PF11
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
For Rev. No : 3
Engg. Services
ISO – 9001:2000
ANNEXURE – II
(Hook Up Drawing)
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9000: 2000 (Electrical) Page # 8 of 8
ANNEXURE – III
(TYPICAL DATA SHEET FOR LEVEL SWITCH –Electrical Type)
o
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> C
Level/Length-> mm
1. Tag. No.
General 2. Quantity
3. Service
5. Internal / external
6. Interface
7. Case Material
8. C/C – Distance
9. Conn. Size & Rating
10. Location Upper
11. Location Lower
Case 12. Case Orientation
13. Rotatable Head
15. Vent Drain Conn. Size
16. Case to head flange size & rating
18. Diameter Length mm.
20. Displacer Extension mm
Displacer
Or Float 21. Displacer or Float Material
22. Displacer or Float Stem Material
23. Spring/Torque Tube Material
24. Function
25. Output
26. Control Modes
27. Differential
29. Elect. Area Classification
30. Enclosure Material
Functional 32. Power Supply
Data 33. Switch Type
34. Qty. Form
35. Contact Rating
36. On Level Inc. O/P
38. Cable Entry
39. Upper Liquid
40. Lower Liquid
41. Sp. Gr. Upper Lower
Service
42. Press. Nor. Max.
Conditions
43. Viscosity-Upper Lower
44. Temp. C Nor. Max.
45 Model No.
Others 46. P & ID No.
NOTE:-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
FUNCTIONAL Spec. No. 3103
Offshore Design Section Rev. No. 4A
SPECIFICATION FOR
Engineering Services Discipline Instt.
ISO – 9001:2008 LEVEL TRANSMITTER
(ELECTRONIC) Page: 2 OF 11
CONTENTS

2.0 Reference Documents and Specifications 3
4.0 Level Transmitter 3
4.1 General 3
4.2 Displacement Type Level Transmitter 3
Differential Pressure Type Level
4.3 4
Transmitter
Radar Type Level Transmitter for
4.4 4
Separator
4.5 Material 4
4.6 Accuracy 5
4.7 Output Signal 5
4.9 Display 5
4.10 Enclosure Class 5
Annexure II Hook-up drawing (2 Sheets) 7
Annexure III Data Sheets (3 Sheets) 9
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR

This functional specification describes the essential design considerations for the
selection of Level Transmitter for the intended service.
a) Instrumentation & Process Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) Instrument & Process Data Sheets
3.1 The quantity to be supplied and installed shall be as per the requirements
indicated in the Basic Bid Work and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Level Transmitter suitable
for its intended application, its procurement, tagging, packing, testing &
calibration, preparation for shipment, along with accessories, spares, and
assistance where required for its installation & commissioning at site.
4.0 SMART TYPE LEVEL TRANSMITTERS:
4.1 General:
4.1.1 The Level transmitter shall be intrinsically safe and certified by statutory body
like UL/FM/BASEEFA/CMRI/DGMS or equivalent.
4.1.2 All level instruments shall be provided with piping isolation valves
4.1.3 ‘Universal Hand Held Configurator’ shall be supplied for transmitters’
calibration. The number of the calibrator shall be two per Process platform & one
per Well platform. For Radar type level transmitter separate
configurator/calibrator shall be provided.
4.1.4 All vent and drains of the transmitter/tubing/valve manifolds shall be routed to
open drain header. If the instrument is on sour service and harmful fluids like
chemical etc. then it will be routed to close drain header.
4.2 Displacement Type Level Transmitter:
4.2.1 Displacement type level instruments shall be used for all process control
applications where level variation in the vessel is not beyond 1219 mm (48").
Displacer length shall be selected to fully utilize the surge capacity of the vessel.
External displacer cages, segregated from the vessel by two block valves, shall be
used. External cage level instruments shall have pressure ratings equal to or
greater than the relevant piping classification requirements for flanged block
valves on the vessel.
4.2.2 External displacer cages shall be supplied with side/side connections. Where this
is not possible top/bottom or side/bottom connections may be provided. Side / top
connections shall be used only in cases where this would avoid a pocket in the
connecting pipe. Connections for external cages shall be 2” ANSI flanged.
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
4.2.3 Rotatable heads shall be provided with displacer type instruments.

4.2.4 The torque tube material shall be Inconel. The cage to head connection shall be
flanged.
4.2.5 For external cages, block valves shall be installed in horizontal position of both
lines at the vessels. If a vertical nozzle is used the valve shall be arranged so that
no sediment pockets are present. A valve shall be installed to permit draining
each displacer cage and piped to drip pans or deck drains.
4.2.6 A positive seal shall be used in transferring float / displacer motion to the external
mechanism where a float or displacer element is employed.
4.3 Differential Pressure Type Level Transmitters:
4.3.1 Differential pressure type level transmitters may be used in case of fluid of
constant Specific Gravity.
4.3.2 Differential pressure type level measurement is acceptable for remote level
indication. For level range of 1219 mm (48") and above, this type of transmitter
shall be used for all services; seals shall be provided as required. These
instruments shall have zero elevation/ suppression adjustment wherever required.
4.4 Radar Type Level Transmitters for Separator:
4.4.1 As per the Scope of Work requirement Guided Wave Radar Type Level
Transmitter shall be used for Separator.
4.4.2 Principle of the measurement of the transmitter shall be TDR (Time Domain
Reflectometry).
4.4.3 The Transmitter shall be with microprocessor based electronics
4.4.4 The level measurement shall be independent of density, conductivity, viscosity,
temperature, pressure, turbulence, vibration, bubbling etc.
4.4.5 Response Time:<1 Sec
4.4.6 The probe (dimension, material, installation criteria) shall be suitably selected as
per the process condition (dielectric constant, upper product thickness etc.).
4.4.7 For the interface measurement coaxial type probe shall be used in bypass/ stilling
well.
4.4.8 It shall have the zero span adjustment facility
4.4.9 It shall have 1/2” NPT cable entry.
4.4.10 The LT shall cover the full range of measurement.
4.4.11 Detail drawing (GAD) including the fitment and installation of the transmitter
with the separator and the technical specification shall be submitted as a part of
PS.
4.5 Material:
4.5.1 The material requirements for level transmitters / instruments shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria , the material
selection chart provided in Annexure I of this specification and FS-2004A for
Piping Design (2008) & Piping Material Specification.
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
4.5.2 All wetted parts shall be suitable for intended process application.
4.5.3 The cage material shall be compatible with the vessel material, and shall be
Carbon Steel as a minimum. Flange material for external cages shall be Carbon
Steel as a minimum.
4.5.4 All flanges on the level instrument pressure retaining parts shall be of the same
type and rating as the process flanges and shall be in accordance with the vessel
trim specification.
4.5.5 Torque tube when used shall be of Inconel / Monel minimum, with nylon bushing
type bearings. All other wetted parts shall be SS 316 minimum, unless otherwise
specified.
4.6 Accuracy:
4.6.1 For Displacer Type / DP Type Level Transmitter: The maximum error shall not
exceed ±0.5% of the span .
4.6.2 For Radar Type Level Transmitter: ± 3mm(Liquid Level) and ± 10mm(Interface
measurement) or better.
4.7 Output Signal:
4.7.1 Output signal shall be 2 wired 4-20 mA DC, and capable of delivering the rated
current signal into external load of around 600 ohms when powered with nominal
24V DC (negative earthed).
4.7.2 Transmitters shall have HART protocol for communication for remote calibration
and diagnostics from HART maintenance system
4.8 Reading Scales:
Units for level indicating scales shall be 0 – 100 percent.
4.9 Display:
LCD Type, Local/ Integral with the transmitter head or Remote Display. The
Transmitter shall be configurable in engineering units.
4.10 Enclosure Class:
The transmitter shall be weatherproof (IP 65 or better). In addition the LT
enclosure shall be as per Clause no 3.6.4.4.5 of Instrument Design Criteria.
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – I
Material Selection Chart for Level Transmitters
Level Instrument
S. No. Piping Class
Body Displacer / Float
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 CARBON STEEL SS 316
2 INJECTION WATER SERVICE CARBON STEEL MONEL
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
4 A5 MONEL MONEL
CARBON STEEL
SOLID TEFLON
5 A7 TEFLON LINED
** A1N, B1N, D1N, E1N, F1N, XF1N,

6 PA1N, PB1N, PD1N, PF1N, XG1N
SS 316 SS 316
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
MONEL 400 MONEL 400
[** All Process wetted parts shall be NACE MR-01-75 (Latest Edition ) as minimum ]
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – II
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – II
(Hook Up Drawing)
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – III (Page 1)

DIFFERENTIAL PRESSURE TRANSMITTER (dP Type)
1. Function: - 24. Service: -
2. Type: - 25. Element: -
3. Case: - 26. Body Material: -
4. Mounting: - 27. --
5. Enclosure: - 28. Process Conn.: -
Enclosure Class: - Process Conn. Loch. : -
6. Elec. Area Class: - 29. Diaphragm Seal:
Type: -
7. Intrinsically Safe: - Wetted Parts Matl: -
Other Material: -
8. Air Supply: - Process Conn.: -
Size Rating: -
9. Power Supply: - Facing & Finish: -
Capillary Material: -
10. Cable Entry: - Armour Flexible: -
Armour Matl. -
11. Accuracy: - Capillary Length: -
12 Repeatability: - Flush Filling Conn with Plug
TRANSMITTER MISCELANEOUS
13 Output: - 30. Static Pressure Rating: -
14. Trans. Power Supply: - 31. Options: -
. CONTROLLER a) 3-Valve Manifold
15. Output: - b) Integral Orifice
16. A/M Switch: - No. of Position: - c) Air Filter Regulator
17. Set Point Adjustment: - d) Intrinsically safe output meter
18. Manual Regulator: - e) Mounting Bracket for 2” N.B. Pipe mounting
control racks .
19. Node: -
RECORDER CONTROL NODES
20. Chart: - P : Proportional %
21. Chart Drive: - I : Integral rep/min
22. Moving Parts Matl.: - D : Derivative rep/min
23. Chart Speed: -
Diff. Range Zero
Zero ELEV. Max. Max. Control Options
Tag No. ELEV. Service
Span Set Mm H2O Press. Temp. Action
Mm H2O
NOTES:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE-III ( Page 2)
DISPLACER TYPE LEVEL TRANSMITTER
1. Tag No.
2. Service
General 3. Internal / External
4. Interface
5. Body or Cage Material
6. Flange Material
7. Conn. Size Type & Rating
8. Flange Facing & Finish
9. Location Upper
Body / Cage 10. Location Upper
11. Case Orientation
12. Rotatable Head
14. Vent Drain Conn. Size
15.
17. Diameter Or Length mm.
Displacer or 19. Displacer Extension mm.
Float 20. Displacer Or Float Material
21. Spring / Torque Tube Material
22.
23. Function
24. Output
25. Control Modes
26. Differential
28. Elec. Area Classification
Trans. / 29. Elec. Power Or Air Supply
Controller / 30. Switch Type
Switch 31. Qty. Form
32. Contact Rating
33. On Level Inc. Contact
35. Cable Entry Single / Dual
36. Enclosure
37. Intrinsically Safe
38. Filter Regulator with Gauge
39. Jacketing – Medium Conn.
Option 40. -Temp. C Press
41. Torque Tube Flushing Conn.
42. Intrinsically. Safe Weather Pr. / Pmete
43.
44. Upper Liquid
45. Lower Liquid
Service 46. Sp. Gr. Upper Lower
Conditions 47. Press. Nor Max.
48. Temp. C – Nor. Max.
49. Model No.
50.
NOTES:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE-III (Page 3)
RADAR TYPE LEVEL TRANSMITTER
1. Tag No.
2. Service
GENERAL 3. Line Number/ Equipment No.
4. P&ID No.
6. Upper Fluid
7. Lower Fluid
8. Density: (Kg/m3) Upper Lower
9. Pressure: Op. Max.
10. Temperature: Op. Max.
SERVICE COND. 11. Design Pressure
12. Design Temperature
13. Die Electric Constant Upper Lower
14. Type
EQUIPMENT 15. Internal Diameter / Height
16. Type
17. Principle
18. Range
SENSOR 19. Probe Type
20. Probe Length
21. Probe Material
22. Probe Submerging Cond. Fully/ Partially
23. Mounting
24. End Connection: Material
25. Internal/ External
26. Interface
27. Cage Material
28. Center to Center Distance: (mm)
29. End Connection: Size Rating
30. Location: Upper Lower
CAGE 31. Rotatable Head
32. Connection Size & Type: Vent Drain
33. Cage to Head : Flange Size Rating
34. Cable Entry Single / Dual
35. Location:
36. Type
37. Output
38. Accuracy
39. Repeatability
40. Resolution
TRANSMITTER &
INDICATOR 41. Housing Material
42. Enclosure
43. Environmental Protection
44. Galvanic Isolation
45. Power Supply
46. Cable Entry
47. Cable Gland
48. Set Point
49. Approvals/ Certifications
OPTIONS 50. LCD Display Location
51. Make
52. Model No.
NOTES:
ODS/SOF/007 ODS/SOP/017 01 00 21.07.2010
Engineering Services Functional Specifications Rev # 2
11 - High, Mumbai FLOW SWITCH Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FOR
FLOW SWITCH
TOTAL
PREPARED / REVIEWED REV.
APPROVED BY No. OF DATE
REVISED BY BY No.
PAGES
VS RS GRP 4 18.02.2008 2
ET RS GRP 6 28.03.2007 1
ET MC AC 6 13.05.2003 0
ISO -FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 2 of 4
CONTENTS

4.0 Flow Switch 3
4.1 General 3
4.2 Material 3
Annexure I Data Sheet Format 4
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 3 of 4

selection of Flow Switch for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Flow Switch suitable for its
4.0 FLOW SWITCH:
4.1 General:
4.1.1 The flow switch shall be Differential Pressure type / Thermal Dispersion type
suitable for Class I, Division I, Group D, T3 class.
4.1.2 The flow switch shall actuate a relay when activated or when shutdown is reached.
The contact rating shall in general be 24 V DC, 2 A. Flow Switches shall have a
repeatability of ±0.2%.
4.1.3 The flow switch shall have either internal / external set point adjustment with
locking mechanism to avoid tampering.
4.1.4 Cable entry to the flow switch shall be ¾” NPTF. Two numbers of cable entry
shall be provided. One cable entry shall be plugged with a plug suitable for the
area classification.
4.1.5 In case Insertion type flow switches are used, the immersion length for probe shall
be 250 mm from flange top face. The projection of flange nozzle from pipe top
face shall be 200 mm.
4.1.6 Plastic bags shall be provided for Flow Switches to protect them during handling,
installation and commissioning.
4.1.7 All switches shall be Ex d.
4.2 Material:
4.2.1 The material requirements for Flow Switches shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria.
4.2.2 The flow switch sensor material shall be suitable for the process conditions and
shall be minimum SS 316. For water service, the sensor material shall be Monel.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 4 of 4
ANNEXURE – I
Typical Data Sheet For Flow Switches
FLOW SWTICHES
3 3
UNITS: Flow Liquid – M /HR. Gas – NM /HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Line Number
GENERAL 3 Line Size & Schedule
4 Service
5
6 Switch Type
7
8 End Connection – Size & Rating
9 End Connection – Facing & Finish
10 Material – Body & Flange
11 Material – Element
BODY
12 Range
13
14
15
16
17
18 Type – Electric / Pneumatic
19 Output Type
20 Contact Rating
21 Load Type
22 Enclosure Class
23 Area Class
24 On flow increase – O/p Contact
SWITCH
25 On flow decrease – O/p Contact
26 Accuracy
27 Repeatability
28 Set Point
29 Difference – Fixed / Adjustable
30 Set Point Adjustment – Internal / External
31
32
OPTIONS 33
34
35 Fluid State
36 Flow Min. Maximum
37 Flow Normal
38 Inlet Pressure Operating Maximum
39 Temperature Operating Maximum
SERVICE 40 Sp. Gr. At Oper. Temp.
CONDITIONS 41
42 Molecular Weight
43 Operating Viscosity (Cp)
44 Allowable pressure drop
45 Corrosive Content
46
47 IBR Certification
48 Manufacturer
ITEM DETAILS
49 Model Number
50 Remarks
NOTES:
Vendor’s Seal and Signature
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3201
Offshore Design Section FUNCTIONAL Rev. No. 04 (a)
Engineering Services SPECIFICATION FOR Disciplin
Instrumentation
ISO – 9001:2008 FLOW TOTALIZER e
Page: 2 OF 4
CONTENTS
4.0 Flow Totalizer 3
4.1 Flow Totalizer type 3
4.2 Accuracy 4
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
Spec. No. 3201
Instrumentation
Page: 3 OF 4

1.1 This functional specification describes the essential design considerations for the selection of Flow
Totalizer for the intended service.
a) Basic Bid Work

b) Design Criteria - Process & Instrumentation
c) Project P & IDs
d) Process Data Sheets for Instruments

3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic Bid
Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Flow Totalizer suitable for its intended application,
its procurement, tagging, packing, testing & calibration, preparation for shipment, along with accessories,
spares, and assistance where required for its installation & commissioning at site.
4.0 FLOW TOTALIZER:

4.1 General:
The Flow totalizer shall be microprocessor based and shall have user-friendly interface for easy
programming with Passwords for configuration. The totalizer shall be capable of displaying the readings
when requested. The totalizer may either be field mounted or control room mounted as per process
requirement. It shall have flow display using square root or linear signal processing.
4.1.1 The Flow totalizer shall have 2-line display. The top line shall display the instantaneous flow rate while the
second line shall display the totalized flow. LCD type display shall be provided in the Flow totalizer.
Display range for rate shall be 6 digit display or better and for cumulative flow (Total) shall be 8 –digit
display or better. Rate / total display decimal point shall be selectable.
4.1.2 The input power supply to the Flow totalizer shall be 24 V DC. The device shall have two analogue output
for alarms. It shall have capability of processing analogue mA & VDC signal as its input.
4.1.3 It shall have Keypad for process programming and calibration. All programming and total values are
stored in non-volatile memory and can be retrieved even if the power is removed from the unit. The
totalizer shall have provision to save accumulated total flow even if the power is lost.
4.1.4 When Flow totalizer and other devices are grouped and mounted on a gauge board or instrument stand it
should be in such a manner that removal of each instrument shall be possible without the need to
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
Spec. No. 3201
Instrumentation
Page: 4 OF 4
disconnect, dismantle or remove any other instruments or tubing. Mountings accessories required for
Flow totalizer shall be 316SS or better.
4.2 Accuracy: The accuracy shall be ±0.25%. Repeatability shall be ±0.25%
4.3 Reading Scales: Units for Flow in totalizer shall be set in M3/HR for liquids and SM3 /HR for gases. In
addition, other selectable engineering units ( m3/sec, m3/day, etc) shall be available in the device.
4.4 Enclosure Class: Where specified for field mounting, the flow totalizer enclosure shall be Weather proof
to IP 65 and shall conform to Area Classification. In control room, it shall be housed n general purpose
enclosure to IP 42.
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008 FLOW TRANSMITTER
CONTENTS

4.0 SMART Type Flow Transmitter 3
4.1 General 3
4.2 Sensor Type 4
4.3 Material 4
4.4 Accuracy 4
4.5 Output Signal 4
4.6 Repeatability 4
4.7 Enclosure Class 5
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR

This functional specification describes the essential design considerations for the selection
of Electronic Flow Transmitter for the intended service.
2.0 REFERENCE DOCUMENTS AND SPECIFICATIONS:
a) Instrumentation / Process Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) Instrument / Process Data Sheets
3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the
Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Flow Transmitter suitable for
measurement range, accuracy, MoC & standard accessories for its intended application.
3.3 The procurement, tagging, packing, testing & calibration, preparation for shipment, along
with accessories, spares, and assistance where required for its installation & commissioning
at site shall be come under vendor’s responsibility.
4.0 SMART TYPE FLOW TRANSMITTERS:
4.1 General:
4.1.1 Flow Transmitters shall be of differential pressure type
4.1.2 The transmitter shall be mounted local, on a yoke. All mounting accessories required for
2” pipe shall be provided.
4.1.3 Cable entry to the transmitter shall be ½” NPTF.
4.1.4 The flow transmitter shall be provided with a 5-valve manifold.
4.1.5 The transmitter shall have 130% (static pressure) over-range protection.
4.1.6 The Flow transmitter shall be intrinsically safe and certified by statutory body like
UL/FM/BASEEFA/CMRI/DGMS or equivalent.
4.1.7 The transmitter should have Digital output meter (with engineering units). Flow
Transmitter shall be easily visible from grade. Where this is not possible, a separate loop-
powered indicator shall be provided for easy visibility. The output meter shall be suitable
for use in the hazardous area.
4.1.8 Flow Transmitters shall have a means for calibration that permits adjustment of the zero
output and span output.
4.1.9 Flow Transmitters shall be five- (5) point bench calibrated using a hydraulic or dead weight
tester or precision pneumatic calibrator prior to installation as well as after installation at
site. All calibration shall be carried out with certified master calibrators (valid and proved
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
by reputed accredited testing labs) or with calibrators tested and traceable to the standard
labs for calibration.
4.1.10 ‘Universal Hand Held Configurator’ shall be supplied for transmitters’ calibration. The
number of calibrator shall be two per process platform & one per well platform.
4.1.11 All vent and drains of the transmitter/tubing/valve manifolds shall be routed to the Drain
Header. If the meter is on the sour service and harmful fluids like chemicals etc, then it will
be routed to close drain header.
4.1.12 Transmitters shall be immune to Radio frequency interference due to walkie-talkie, paging
system, communication system etc. All electronic modules shall be designed for short
circuit protection.
4.2 Sensor Type:
4.2.1 The pressure element in the measuring unit shall be Diaphragm / Delta cell Type.
4.2.2 For measurement at slurries, viscous & corrosive fluid Diaphragm Seals shall be used.
Wherever Diaphragm seals are required they shall be “Liquid Filled System” type with a
1½” Flanged process connection and flexible armor. The diaphragm seal shall also have a
flushing filling connection with plug.
4.2.3 The process connection of the transmitter shall be ½” NPTF.
4.3 Material:
4.3.1 The material requirements for Flow Transmitters shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria. Material Selection Chart provided in Annexure
– I of this document .and FS-2004A for Piping Design (2008) & Piping Material
Specification
4.3.2 The element material of the measuring unit shall be suitable for the process conditions.
The Wetted parts of the diaphragm seal shall be same as that of the element material. The
capillary material shall be SS 316 and the armour material shall be SS 304.
4.4 Accuracy:
4.4.1 Flow Transmitters shall have an accuracy of ±0.1 % of span or better.
4.5 Output Signal:

4.5.1 Output signal shall be 2 wired 4-20 mA DC, and capable of delivering the rated current
signal into external load of around 600 ohms when powered with nominal 24V DC
(negative earthed).
4.5.2 Transmitters shall have HART protocol for communication for remote calibration and
diagnostics from HART maintenance system
4.6 Repeatability:
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
4.6.1 Flow Transmitters shall have a repeatability of ±0.1%.

The transmitter shall be weatherproof (IP 65 or better). In addition the FT enclosure shall
be as per Clause no 3.6.4.4.5 of Instrument Design Criteria
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – I
Flow Transmitter – Material Selection Chart
Flow Transmitter
S. No. Piping Class Valve
Body Sensor
Manifold
A1, B1, D1, E1, F1, XF1, F1,

PA1, PB1, PD1, PE1, PXF1,
PF1, A2, B2, D2, E2, XG1, CARBON
1 SS 316 SS 316
A1H, A3, B3, A8 STEEL
(EXCEPT WAT. INJ.
SERVICE)
INJECTION WATER CARBON

2 MONEL SS 316
SERVICE STEEL
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316 SS 316
HASTALLOY
5 A7 TITANIUM TITANIUM
C
** A1N, B1N, D1N, E1N, F1N,

6 XF1N, PA1N, PB1N, PD1N, SS 316 SS 316 SS 316
PF1N, XG1N
HASTALLOY
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
C
A11, B11, D11, E11, F11, PA11, HASTALLOY HASTALLOY

8 -
PB11, PD11, PE11, PF11 C C
[** All Process wetted parts shall be NACE MR-01-75 (Latest Edition ) as minimum ]
ANNEXURE – II
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
(Hook Up Drawing)
FLOW TRANSMITTER ( ELECTRONIC ) GAS SERVICE
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
CONDENSABLE LIQUID /VAPOUR SERVICE

NOTE :- TAPPING SHALL BE HORIZONTAL
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – III
Typical Data Sheet For Flow Transmitter
FLOW (D.P.) TRANSMITTER
Units : Flow →→Liquid-M /Hr, Gas → Kg/Hr, Steam → Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C, Level/ Length →→mm
3
GENERAL MEASURING UNIT

1 Function 24 Service
25 Element
2 Type 26 Body Material
3 Case 27 Element Material
4 Mounting 28 Process Connection
5 Electrical area Proc. connection. location
Classification 29 Temperature Element
6 Enclosure - Type
Enclosure Class - Leads
7 Intrinsically safe - Sheath OD / Material
8 Power supply Nipple & Union Material
9 Cable entry - Cable Entry
10 Accuracy - Enclosure
Thermo well as per
11 Repeatability 30
drawing
12 TRANSMITTER - Pressure Element
Output 31
13 Trans. Power supply MISCELLANEOUS
14 CONTROLLER 32 Over range protection
Output a OPTIONS
15 A/M Switch b Out put Meter
16 No. of positions c Air filter regulator
Set point adjustment d Mounting accessories
5 - Way Valve Manifold
17 Manual Regulator e
for Tx
18 Mode f Integral Orifice
19 33 SS Tag Plate
34 Load driving capability
Proportional
Derivative
Integral
Range
Sl. Max. Oper./ Zero
Tag. No. Zero Super Service Control Options
No Press. Max. Temp. SPAN SET Elev.
S:
1. Over range protection shall be 130% of maximum static pressure.
2. Local digital Integral output meter shall be intrinsically safe and to be calibrated in engineering unit.
3. Environmental protection cover to be provided for each transmitter
4. For Extended Diaphragm seal with fill in liquid, data sheet shall be suitably filled up.
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
Spec. No. 3203
Rev. No. 04
Discipline Instrumentation
ISO – 9001:2000 ORIFICE PLATE ASSEMBLY Page: 1 OF 8
FOR
ORIFICE PLATE ASSEMBLY
Spec. No. 3203
Rev. No. 04
CONTENTS
2.1 Applicable Codes & Standards 3
2.2 Reference Specifications 3
4.0 Orifice Plates 3
4.1 Application 3
4.2 General 3
4.3 Material 4
4.4 Range 4
4.5 Scales 4
4.6 Flanges 4
4.7 Meter Runs 5
4.8 Orifice Plate Sizing 5
4.9 Miscellaneous 5
ODS/SOF/004B ODS/SOP/008 to 015 03 00 02.12.2008
Spec. No. 3203
Rev. No. 04

1.1 This functional specification describes the essential design considerations for the selection of Orifice
Plates for the intended service.

2.1 Applicable Codes & Standards: Latest editions of applicable codes & standards as enlisted in Cl.
3.6.3.1, Instrumentation Design Criteria
2.2 Applicable Documents and Specifications:

a) Basic Bid Work
c) Project P & IDs
d) Process Data Sheets for Instruments

3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic Bid
Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Orifice Plates & Meters suitable for its intended
application, its procurement, tagging, packing, testing & calibration, preparation for shipment, along with
accessories, spares, and assistance where required for its installation & commissioning at site. This FS
shall be read in conjunction with the Instrument Design Criteria.
4.0 ORIFICE FLOW METERS:
4.1 Application:
4.1.1 Orifice Plates shall be used as the flow-measuring element wherever dictated by the process
requirements.
4.1.2 For a standard orifice meter, only one fixed Orifice Plate shall be designed for the rangeability of 3:1 or
less.
In case of flow rangeability higher than 3:1, senior orifice meter with two or more orifice plates shall be
required to cover the entire flow range and the each plate shall be sized for the range of 3:1 or less.
4.2 General:
4.2.1 Fabrication of the orifice plate shall be in accordance with AGA – Gas Measurement Committee, Report
No. 3, latest edition for gas measurement.
4.2.2 The Orifice meter shall in general comprise of a concentric square edged orifice plate designed for flange
tap except for particular process requirements. (Eccentric, segmental or quadrant edged orifices may be
used for special services such as slurry, wet gas or highly viscous service).
4.2.3 Where the orifice plate flow element is coupled with a force balanced or bellows type meter, the meter
shall be with a built-in adjustable dampening device.
Spec. No. 3203
Rev. No. 04
4.2.4 The Orifice Plate Assembly shall be capable of withstanding differential pressure equal to full line
pressure without zero or calibration change.
4.2.5 Orifice plate beta ratio (orifice diameter/ inside pipe diameter) in general shall be between 0.2 and 0.75.
4.3 Material:
4.3.1 The material requirements for orifice plates shall in general be according to clause 3.6.4.5 of
Instrumentation Design Criteria and the material selection chart provided in Annexure I of this
specification.
4.4 Range:
4.4.1 Differential ranges for orifice flow meters shall not exceed 5000 mm (200 inches) of water. Typical meter
ranges for gas, steam, or vapor, streams shall be as follows:
STATIC PRESSURE DIFFERENTIAL PRESSURE

2
(Kg / cm g (PSIG)) (mm of Water (inches))
0.35 to 2.5 (5-35) 500 - 1250 (20 - 50)
2.5 to 6 (35 - 85) 1250 - 2500 (50 - 100)
Above 6 (Above 85) As per AGA-3 guidelines.
4.4.2 The range 2500 mmwc (100 inches WC) is desirable wherever possible in line with AGA-3 guidelines in
case of static pressure of 6 Kg/cm2g and above.
4.4.3 Orifice meter ranges shall preferably be chosen such that the normal flow is between 60% and 80% of the
meter range.
4.5 Scales:
4.5.1 Scales for orifice metering system shall be 0 - 10 square root with multiplication factor to suit rate of flow
requirements for DP (Bellows ) type Pneumatic flow meter.
Orifice flow meter with totaliser (with or without pressure correction) shall be provided with a proper
multiplication factor in line with the flow calculation as per AGA-3 with AGA-8 (for gas). Linear scale of
DPT shall be combined with the Square root scale of Totaliser.
In case of orifice meter with MVT ( with integrated flow computer / separate Flow computer at site) and
FT with panel ( at CCR) mounted flow computer, the range of process parameters like Pressure,
Temperature, Diff. Pressure, Flow etc shall be as per the Basic Bid Work / approved P & IDs of the
respective projects.
4.6 Flanges:
4.6.1 Orifice flanges and fittings shall be installed according to AGA - Gas Measurement Committee Report No.
3.
4.6.2 Orifice flanges shall be in accordance with the standard ANSI B 16.36 with a minimum flange rating of
300# ANSI and a minimum of 1½-inch pipe size.
4.6.3 Two pairs of flange taps located diametrically opposite shall be provided. Location of taps & Tap sizes
shall be in accordance with the AGA-3 standard, latest edition. The spare tappings shall be plugged with
SS 316 as a minimum.
Spec. No. 3203
Rev. No. 04
4.6.4 Unless otherwise specified, Orifice flange shall be RF, weld neck type for low pressure application (< 600
# rating). For high pressure application ( > or = ANSI # 600), flanges shall be of RTJ type. Based on
process requirement, final material and selection of flanges shall be in accordance with the standard
ANSI B-16.36 & AGA-3.
4.7 Meter Runs:

4.7.1 All meter runs (Upstream & Downstream) shall be designed for flange tap differential measurement
unless otherwise specified as per AGA - Gas measurement committee report No. 3, latest edition.
4.7.2 Orifice meter runs shall not be for less than 1 - ½” nominal pipe size. Where required, the piping dia shall
be blown up to the required size for installing the meter run / orifice, in line with the applicable standards.
4.7.3 The straight length of upstream & downstream pipe works shall be in accordance with the standard AGA-
3. No connections shall be made in either the upstream or downstream straight pipe work, other than the
orifice flange tappings. In case sufficient straight run is not available for the given piping geometry, meter
runs with straightening vanes may be used. These straightening vanes shall be as per AGA 3. The
straightening vane material shall be 316 SS or better to suit the process conditions. The location of
Temperature sensor (on the downstream only) shall be within 5 to 20 D internal diameter of the pipe run.
4.8 Orifice Plate Sizing:

Orifice plate sizing shall be based on AGA 3 with AGA-8 standards for gas application & ISO-5167 for
liquid application. Sizing calculations shall be submitted to Company for approvals.
4.9 Miscellaneous:
4.9.1 Orifice meter design and installation shall be in accordance with the AGA - Gas Measurement Committee
Report No. 3. It is preferred that metering orifices be located in horizontal lines.
4.9.2 Orifice flanges or meter tubes shall be installed horizontally near the deck or platform for ease of
accessibility and safe changing of the orifice plate.
4.9.3 Orifice plates shall be installed after line flushing is completed, before hydro testing.
4.9.4 Prior to installing the orifice plate, it shall be checked against the Instrument Specification sheet and
inspected by the Company’s representative.
4.9.5 The static pressure element shall be connected to the upstream pressure tap on gas flow measurement.
4.9.6 Piping and equipment shall be arranged so that flashing does not occur at or upstream of orifice plates.
4.9.7 The piping layout shall always be arranged such that straightening vanes are not required and gas meter
runs are self-draining.
4.9.8 Upstream elbows in more than one plane shall be avoided to minimize vorticity.
4.9.9 Orifice plate shall be checked for correct alignment, and correct orientation with respect to the process
flow.
4.9.10 Orifice Plates shall be checked visually for nameplate data and for an upstream sharp edge. Bore shall
be callipered to check for compliance with specifications.
4.9.11 All socket-weldings shall be 100% Dye penetration / Magnetic particle tested. All other welding shall be
100% radio graphed.
4.9.12 The orifice plates shall be suitably marked with tag. Nos., bore size & direction of mounting.
Spec. No. 3203
Rev. No. 04
ANNEXURE – I
Material Selection Chart for Orifice Plates
Orifice Assembly
S.
Piping Class Flange /
No. Plate
Body
A1, B1, D1, E1, F1,
XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1,
A2, B2, D2, E2, XG1, CARBON
1 STEEL
SS 316
A1H, A3, B3, A8
(EXCEPT WAT. INJ.
SERVICE)
INJECTION WATER CARBON

2 SERVICE STEEL
MONEL
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
90-10 Cu
4 A5 Ni / MONEL
MONEL
A1N, B1N, D1N, E1N,

F1N, XF1N, PA1N, CARBON
6 PB1N, PD1N, PF1N, STEEL
SS 316
XG1N
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
A11, B11, D11, E11,

DUPLEX INCONEL
8 F11, PA11, PB11, PD11,
SS 625
PE11, PF11
Spec. No. 3203
Rev. No. 04
ANNEXURE – II (Hook-Up Drawing, typical, for Gas application)
Slope : 1:12,
upwards
96
ORIFICE PLATES FLANGE CONNECTIONS
Spec. No. 3203
Rev. No. 04
ANNEXURE – III - Typical Data Sheet For Orifice Plates
ORIFICE PLATES (With FLANGES)

3 3
1 Tag Number
2 Line Number
4 Service
5 Inlet Line ID Outlet Line ID
6 Diff Range In mm H2O
METER
7 Meter Maximum
8 Type
9 Sizing As Per
10 Material
11 Thickness “W” In Mm
PLATE
12 Beta Ratio d/D
13 Bore Dia. ‘d’
14 Vent / Drain
15 Center Distance ‘R’
16 Type
17 Tap Type Size
18 Number Of Taps Per Flange
19 Material
20 Size & Rating
21 Facing & Finish
22 Line ID / OD
FLANGES
23 Gasket Thickness Mm
24 Gasket Material
25 Plate Holder
26 Plate Holder Material
27 Stud Bolt Material
28 Nut Material
29 Wetted Part Material
30 Straightening Vanes
OPTIONS 31 Connection
32 Material
33 Fluid State
35 Flow Normal
Inlet Pressure
36 Maximum
Operating
Temperature
37 Maximum
SERVICE CONDITIONS Operating
38 Sp. Gr. At Oper. Temp. 15 OC
39 Molecular Weight Cp / Cv
41 Compressibility Factor
42 Pipe Reynolds Number
44 Manufacturer
ITEM DETAILS
45 Model Number
NOTE:-
1. Orifice assembly must include supply of plates, flanges, stud, bolts, nuts, jack screw, gasket / plate, holder & plugs.
Functional Specifications Spec No : 3204
Design Division
For Rev. No :3
Engg. Services
RESTRICTION Discipline: Instrumentation
ISO – 9001:2000
ORIFICE ASSEMBLY Page : 1 of 5
FOR
RESTRICTION ORIFICE ASSEMBLY
TOTAL
PREPARED / REVIEWED
REVISED BY BY
PAGES
VS SRS GRP 5 18.02.2008 3
ET RS GRP 7 28.03.2007 2
AK MC RK 7 22.07.2005 1
ET MC AC 7 13.05.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
For Rev. No :3
Engg. Services
ISO – 9001:2000
CONTENTS

1.0 Scope Of This Document 3
2.0 Standards And Specifications 3
2.2 Other Specifications to be followed 3
3.0 Scope Of Supply 3
4.0 Restriction Orifice Assembly 4
4.1 Application 4
4.2 General 4
4.3 Material 4
4.4 Range 4
4.5 Flanges 5
4.6 Meter Runs 5
Annexure I Typical Data Sheet – Restriction Orifice Plates 8
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
For Rev. No :3
Engg. Services
ISO – 9001:2000

selection of Orifice Plates for the intended service.
2.0 STANDARDS & SPECIFICATIONS:
2.1 Reference Specifications:
b) Basic Bid Work
c) Project P & IDs
Process Parameters
e) MR / OD / INST / FS / 3203: Functional Specification for Orifice Flow Meter.
2.2 Other Specifications To Be Followed:
a) ISA RP 3.2
b) API 2531
c) API Manual of Petroleum Measurement – Chapter 4
3.2 The vendor shall be responsible for the selection of the Orifice Plates suitable for its
intended application, its procurement, tagging, packing, testing & calibration, preparation
for shipment, along with accessories, spares, and assistance where required for its
installation & commissioning at site. This FS shall be read in conjunction with the
Instrument Design Criteria.
3.3 The Restriction Orifice Assembly shall include Orifice Plates complete with studs, bolts,
nuts, jackscrews, gaskets, plate holders and plugs and all other accessories necessary to
make the system complete.
4.0 RESTRICTION ORIFICE ASSEMBLLY:
4.1 Application:
4.1.1 Restriction Orifice Fittings shall be used wherever process requirements dictate pressure
reduction.
4.2 General:
4.2.1 Details of the Orifice Plates to be used in the Restriction Orifice Assembly shall in
general be as per Document No. MR / OD / INST / FS / 3203: Functional Specification
for Orifice Flow Meter.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
For Rev. No :3
Engg. Services
ISO – 9001:2000
4.2.2 The orifice plates shall be welded together to make ‘RO’ assembly. However, the last
plate shall not be welded and an arrangement shall be made to remove and replace the
last plate.
4.2.3 For the RO Assembly, certain overlaps shall be provided between successive plates.
4.2.4 The installation of Restriction Orifice Assembly shall in general be according to clause
3.6.4.6 of Instrumentation Design Criteria and as per clause 6.0 of FS 3203: Functional
Specification for Orifice Flow Meter.
4.2.5 Sizing calculations for restriction orifice assemblies shall be furnished along with the
purchase specification. These calculations shall include number of plates, bore diameter,
thickness of each plate, stress calculation, etc.
4.3 Material:
4.3.1 The material requirements for orifice plates to be used in the Restriction Orifice
Assembly shall in general be according to clause 4.3 of Document No. MR / OD / INST /
FS / 3203: Functional Specification for Orifice Flow Meter.
4.3.2 The material requirements for Restriction Orifice Assemblies shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria.
4.4 Range:
4.4.1 Range selection for Orifice Plates used in the Restriction Orifice Assembly shall in
general be according to clause 4.4 of Document No. MR / OD / INST / FS / 3203:
Functional Specification for Orifice Flow Meter.
4.5 Flanges:
4.5.1 Flange requirements for Orifice Plates used in the Restriction Orifice Assembly shall in
general be according to clause 4.6 of Document No. MR / OD / INST / FS / 3203:
Functional Specification for Orifice Flow Meter.
4.6 Meter Runs:
4.6.1 Meter runs required for Restriction Orifice Assembly shall in general be according to
clause 4.7 of Document No. MR / OD / INST / FS / 3203: Functional Specification for
Orifice Flow Meter.
4.7.1 Sizing for Orifice plate to be used in the Restriction Orifice assembly shall be based on
and AGA Report No. 3. Orifice plate sizing calculations shall be submitted to Company
for review.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
For Rev. No :3
Engg. Services
ISO – 9001:2000
ANNEXURE – I - TYPICAL DATA SHEET FOR RESTRICTION ORIFICE ASSEMBLY

UNITS: Flow Liquid – M3/HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Line Number
4 Service
5 Plate Only Assembly
6 Required Pressure Drop
7 Type Concentric Square edged
8 Single Stage Pressure Reduction
9 Multiple Stage Pressure Reduction
10
11 Material
PLATE
13 Beta Ratio d/D
15 Vent / Drain
17
18
19
20 Type
21 Material
22 Size & Rating
23 Facing & Finish
24 Line ID / OD
FLANGES
26 Gasket Material
27 Plate Holder
30 Nut Material
31 Welded Construction
32 Spool Piece Length
34 Material
35 Fluid State
37 Flow Normal
SERVICE
41
CONDITIONS
46
49 Manufacturer
ITEM DETAILS
50 Model Number
Notes
Vendor’s Sign and Seal
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3205
Offshore Design Section Functional Specifications
Rev. No. 3
Engineering Services
SENIOR ORIFICE Discipline Instt
ISO – 9001:2000
ASSEMBLY Page: 1 OF 5
FOR
SENIOR ORIFICE ASSEMBLY
Spec. No. 3205
Rev. No. 3
ISO – 9001:2000
CONTENTS

4.0 Senior Orifice Assembly 3
4.1 Application 3
4.2 General 3
4.3 Material 4
4.4 Range 4
4.5 Scales 4
4.6 Flanges 4
4.7 Meter Runs 4
4.9 Miscellaneous 4
Spec. No. 3205
Rev. No. 3
ISO – 9001:2000

selection of Senior Orifice Assembly for the intended service.
2.1 Applicable Codes & Standards : Latest editions of applicable codes &
standards as enlisted in Cl. 3.6.3.1, Instrumentation Design Criteria.
a) Basic Bid Work
c) Project P & IDs
d) Process Data Sheets for Instruments / Instrument List with Process Parameters
indicated in the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Senior Orifice Assembly
suitable for its intended application, its procurement, tagging, packing, testing &
assistance where required for its installation & commissioning at site. This FS
3.3 The Senior Orifice assembly shall include Orifice Plates, sliding valve, equalizer,
stuffing box, plate carrier, sealing unit, flanges, senior orifice fittings, studs, bolts,
nuts, hand wrench, plugs and all the accessories to make the system complete.
Chamber venting with vent valve shall be possible for senior orifice.
3.4 No. of Orifice plates to be supplied along with the Senior Orifice assembly shall
be as per the Process data sheet to cover the complete range and each plate shall
be sized for the range of 3:1 or less as per AGA 3 with AGA 8.
4.0 SENIOR ORIFICE ASSEMBLLY:
4.1 Application:
4.1.1 Senior Orifice Fittings shall be used as the flow-measuring element wherever
dictated by the process requirements.
4.1.2 On line retractable orifice fittings assembly shall be used to provide periodic
checking / changing of orifice plates without disturbing normal operation.
4.2 General:
4.2.1 Details of the Orifice Plates to be used in the Senior Orifice Assembly shall in
general be as per FS / 3203: Functional Specification for Orifice Plate Assembly.
Spec. No. 3205
Rev. No. 3
ISO – 9001:2000
4.2.2 The Senior Orifice Assembly shall be capable of withstanding differential

pressure equal to full line pressure without zero or calibration change.
4.3 Material:
4.3.1 The material requirements for Senior Orifice Assemblies shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria and clause 4.3 of
FS / 3203: Functional Specification for Orifice Plate Assembly.
4.4 Range:
4.4.1 Range selection for Orifice Plates used in the Senior Orifice Assembly shall in
general be according to clause 4.4 of FS / 3203: Functional Specification for
Orifice Plate Assembly.
4.5 Scales:
4.5.1 Scales for Orifice Plates used in the Senior Orifice Assembly shall in general be
according to clause 4.5 of FS / 3203: Functional Specification for Orifice Plate
Assembly.
4.6 Flanges:
4.6.1 Flange for Senior Orifice Assembly shall in general be according to clause 4.6 of
FS / 3203: Functional Specification for Orifice Plate Assembly. However,
referring to 4.6.4 of FS / 3203, “Senior Orifice fittings” shall be in general weld
neck in the upstream and Flanged in the downstream.
4.7 Meter Runs:
4.7.1 Meter runs required for Senior Orifice Assembly shall in general be according to
FS / 3203: Functional Specification for Orifice Plate Assembly.
4.8.1 Sizing for Orifice plate to be used in the Senior Orifice assembly shall be based
on AGA Report No. 3 & 8. Orifice plate sizing calculations shall be submitted to
Company for review.
4.9 MISCELLANEOUS :
4.9.1 The installation of Senior Orifice Assembly shall in general be according to
clause 3.6.4.6 of Instrumentation Design Criteria and as mentioned in the FS 3203
/ Functional Specification for Orifice Plate assembly.
4.9.2 Calibration, inspection and testing requirements shall in general be as per clause
3.6.4.7 of Instrumentation Design Criteria.
Spec. No. 3205
Rev. No. 3
ISO – 9001:2000
ANNEXURE – I - TYPICAL DATA SHEET FOR SENIOR ORIFICE ASSEMBLY

SENIOR ORIFICE ASSEMBLY
3
UNITS: Flow Liquid – M /HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – oC Level/Length - M
1 Tag Number
2 Line Number
4 Service
5 Inlet Line ID Outlet Line ID
6 Diff Range In mm H2O
METER 7 Meter Maximum
8
9 Type Conn. Square Edged
10 Sizing As Per AGA 3 & API RP 3.2
11 Material
PLATE 13 Beta Ratio d/D
15 Vent / Drain
17
Upstream : Weld Neck
18 Type
Down Stream : Flange
19 Tap Type Size Flanged ½” NPT
20 Number Of Taps Per Flange Two
21 Material
22 Size & Rating
23 Facing & Finish
24 Line ID / OD
FLANGES
26 Gasket Material
27 Plate Holder
30 Nut Material
31 Wetted Part Material Same As Plate
32
33 Straightening Vanes
35 Material
36 Fluid State
38 Flow Normal
SERVICE
42
CONDITIONS
47
49 Manufacturer
ITEM DETAILS
50 Model Number
11 - High, Mumbai ROTAMETERS Discipline Instt.
ISO 9001: 2000 Page # 1 of 6
FOR
ROTAMETERS
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 6 18.02.2008 3
ET RS GRP 9 28.03.2007 2
ET MC RK 9 23.06.2005 1
ET MC AC 9 10.03.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 2 of 6
CONTENTS

4.0 Rotameters 3
4.1 Application 3
4.2 General 3
4.3 Material 3
4.4 Range 4
4.5 Reading Scales 4
4.6 Accuracy 4
4.7 Transmitters 4
4.8 Miscellaneous 4
Annexure II Data Sheet Format 6
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 3 of 6

selection of Rotameters for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Rotameters suitable for its
3.3 The Rotameter Assembly shall include the meter, transmitter (where required) and
all other accessories necessary to make the system complete.
4.0 ROTAMETER:
4.1 Application:
4.1.1 Rotameter shall be used as the flow-measuring element wherever dictated by the
process requirements.
4.1.2 In general Rotameter shall be used when:
a) Linear flow rate signal characteristics are required.
b) Extremely low flow rate measurement is involved.
c) Rangeability is greater than 3 to 1.
4.2 General:
4.2.1 The Rotameter shall in general be metal tube type with bottom inlet and top outlet
connections.
4.2.2 The metering tube shall have self-guided floats, with top and bottom float stops.
4.2.3 The pressure drop across the Rotameter shall be minimum.
4.2.4 The Rotameter shall be provided with flanged end connections, the facing and
finish of which shall be as per the piping specifications.
4.2.5 Armoured meters shall have a metal tube with magnetically coupled integral
indicator.
4.3 Material:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 4 of 6
4.3.1 The material requirements for Rotameter shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and the material selection chart provided
in Annexure I of this specification.
4.3.2 The Rotameter tube, float and end fittings shall in general be SS 316, unless
otherwise mentioned.
4.3.3 The Contractor shall ensure that all wetted parts are compatible with the process
conditions.
4.4 Range:
4.4.1 The range of the Rotameter shall be selected such that the normal flow rate is
between 50% and 100% of the instrument range.
4.5 Reading Scales:
4.5.1 Scales for Rotameters shall be direct reading, marked for 10-100% of flow.
4.5.2 The flow rate shall be indicated by the vertical position of the float or magnetically
coupled pointer.
4.6 Accuracy:
4.6.1 Rotameter shall have an accuracy of +/- 2% or better.
4.7 Transmitter:
4.7.1 Wherever transmitters are to be provided, they shall be 2-wire magnetic type. The
transmitter shall operate on 24 V DC and shall give an output of 4 – 20 mA. The
transmitter shall be intrinsically safe with the enclosure class for Rotameter being
Weather proof to IP 65 or better
4.8 Miscellaneous
4.8.1 Rotameters shall be installed vertically with the outlet connection at the top and the
inlet connection at the bottom.
4.8.2 Rotameters shall be installed as received. A level plumb shall be used to check for
proper installation.
4.8.3 The Rotameter location shall be free from vibration.
4.8.4 The Rotameter shall be located with sufficient clearance for maintenance purposes,
including float removal, without dismantling the meter body from the pipeline.
4.8.5 Elbows, valves & other fittings shall not be closer than 5 pipe diameters upstream.
4.8.6 The meters shall be provided with two full-bore isolating valves and by-pass valve
for maintenance.
4.8.7 A check valve shall be installed downstream, where backflow may be expected in
gas service, or where there is the possibility of liquid hammer.
4.8.8 Rotameters shall be checked and tested after installation both at yard and at
offshore site to confirm that shipping stops have been removed.
4.8.9 The transmitting mechanism of the Rotameters shall be checked by mechanically
raising and lowering the float and then checking the output.
4.8.10 Rotameter calibration curve shall also be furnished along with the purchase
specification.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 5 of 6
ANNEXURE – I
Material Selection Chart for Rotameter
Rotameter
S. No. Piping Class
Body End Fitt. Float
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 SS 316 SS 316
2 INJECTION WATER SERVICE - -
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
4 A5 MONEL MONEL

SS 316 SS 316
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
- -
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 6 of 6
ANNEXURE – II - Typical Data Sheet For Rotameter

ROTAMETER
3 3
1 Tag Number
2 Line Number
3 Service
4 Type
5 Function
GENERAL 6 Mounting
7 Connection Type Size & Rating
8 Length & Finish
9 Connection Inlet Outlet
10 Enclosure Class
11 Tube Size Float Guide
12 Tube Material Float Material
13 Scale Length & Type
14 Scale Graduation
15 Range
METER 16 Meter Factor
17 End Fitting Material (FLG.)
18 Packing or O Ring Material
19 Accuracy
20
21
22 Extension Well Material
EXTENSION
23 Gasket Material
24 Type
25 Power Supply
26 Output
TRANSMITTER 27 Electrical Area Class
28 Scale Range
29 Enclosure
30 Cable Entry
31 Protective Shield with safety glass
32 Jacking – Medium Connection
33 - Temp. Pressure
34 Constant – Diff. Relay
OPTIONS 35 Needle valve
36 Flange to flange distance
37 Filter regulator with gauge
38
39
40 Fluid State
42 Flow Normal
SERVICE
45 Sp. Gr. At Oper. Temp. Mol. Wt.
CONDITIONS
46 System Pressure Drop
48 Max. Allowable pressure drop
49
50
51 Manufacturer Model No.
52 Tube Nos. Float No.
ITEM DETAILS
54 Remarks
NOTE:-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3207
Offshore Design Section
Functional Specifications Rev. No. 4
Discipline Instt
ISO – 9001:2000 TURBINE FLOW METER
Page: 1 OF 6
FOR
TURBINE FLOW METER
Spec. No. 3207
Discipline Instt
Page: 2 OF 6
CONTENTS
Cl. No. ITEM Page No.

4.0 Turbine Flow meter 3
4.1 Application 3
4.2 General 3
4.3 Material 4
4.4 Over speed Protection 4
4.5 Rangeability 4
4.6 Accuracy 4
4.7 Totalizer 4
4.8 Pre-Amplifier 5
4.9 Transmitter 5
4.10 Flow Conditioner 5
4.11 Miscellaneous 5
Annexure I Data Sheet 6
Spec. No. 3207
Discipline Instt
Page: 3 OF 6

1.1 This functional specification describes the essential design considerations for the selection of
Turbine Flow meter for the intended service/ application.
2.1 The following codes and standards (latest edition) are referenced to and make a part of this
specification.
Numbers Description
AGA Report - 7 Measurement of Natural Gas by Turbine Meters
API MPMS Chapter 4 Proving system
Chapter 5 Section 3
NACE MR-0175 Metals for Sulphide Stress Cracking and Stress corrosion
(Revision 2003 or later) Cracking Resistance in Sour Oilfield Environments

b) Basic Bid Work
c) Project P & IDs
d) Process Design Criteria / Instrument Process Data Sheets
3.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic
Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Turbine Flow meter suitable for its
intended application, its procurement, tagging, packing, testing & calibration, preparation for
shipment, along with accessories, spares, and assistance where required for its installation &
commissioning at site. This FS shall be read in conjunction with the Instrument Design Criteria.
3.3 Turbine Flow Meter Assembly shall include flow element, pre-amplifier, transmitter (if
required), flow conditioning elements , local flow indicator /Totalizer and all the accessories
necessary to make the system complete.
4.0 Turbine Flow Meters:
4.1 Application:
4.1.1 Turbine Flow Meters shall be used as the flow-measuring element wherever dictated by the
4.2 General:
4.2.1 The turbine flow meters shall be provided with flanged end connections, the facing and finish of
which shall be as per the piping specifications.
Spec. No. 3207
Discipline Instt
Page: 4 OF 6
4.2.2 The flow direction shall be clearly stamped or cast on the body.
4.2.3 Meter cable entry shall be ¾” NPTF.
4.2.4 The turbine meter shall have dual pick-ups with dual pre-amplifiers. Fidelity and Security of
Flow Measurement Pulsed-Data Transmission Systems shall be in accordance with API Manual
of Petroleum Measurement Standards, Chapter 5 Section 5. Any unused pick-up amplifier
combination shall be covered as per area classification requirement.
4.2.5 The Turbine Meter pick-up coil shall be hermetically sealed.
4.2.6 The enclosure for pre-amplifier /transmitter/ Totalizer shall be weather proof to minimum IP 65
and shall be certified for use in Class I, Division I, Group D, T3 hazardous area by a statutory
body.
4.3 Material:
4.3.1 The material requirements for Turbine Flow Meters shall in general be according to Cl. 3.6.4.5
of Instrumentation Design Criteria, FS- 2004A for Piping Design (2008) & Piping Material
Specification.
4.3.2 The Contractor shall ensure that all wetted parts are compatible with the process conditions.
Rotors shall be constructed from SS 316 as a minimum, unless otherwise mentioned.
4.3.3 All wetted parts of Turbine assemblies shall meet NACE MR-01-75 2003 or later for Sour
service.
4.3.4 Tube bundle material for flow conditioner if used shall be same as that of meter internals.
4.3.5 Bearing shall be of tungsten carbide and self lubricating type.
4.4 Over Speed Protection:
4.4.1 The turbine flow meter shall have an over-speed protection of 130% of maximum flow rate.
4.5 Rangeability
4.5.1 Rangeability shall be 10:1 for liquid service and better for Gas Service
4.6 Accuracy:
Turbine Flow Meter shall have accuracy of ±0.2% or better over the total flow range.
4.6.1 Linearity:
Turbine Flow Meters shall have a linearity of ±0.5% of rated flow range.
4.6.2 Repeatability:
Turbine Flow Meters shall have a repeatability of ±0.02% (Minimum Flow to Maximum Flow).
4.7 Totalizer:
4.7.1 The Totalizer shall have local indication for resettable totalized flow (batch), non resettable
cumulative flow and instantaneous flow rate indication.
4.7.2 The Totalizer will have in general, two displays of totalized flow on 6 digit (min) LCD backlit
screen. Resettable display will also toggle to display instantaneous flow rate. Totalizer shall
display flow rate, totalized flows in engineering units. It shall also have data logging facility for
minimum fifteen days
Spec. No. 3207
Discipline Instt
Page: 5 OF 6
4.7.3 Permanent batteries (Li-ion or equivalent) with life of minimum 3 years will be provided for
Totalizer .Battery change shall not cause any loss of data.
4.7.4 The Totalizer shall be capable of providing ‘low battery’ indication on the LCD screen.
4.7.5 Totalizer/ integral LCD meter provided with the Turbine flow meter shall be easily accessible
from grade level. Where this is not possible, Totalizer shall be remotely mounted for easy access
and mounting accessories for 2” stanchion shall be provided with the turbine flow meter.
4.8 Pre-Amplifier:
4.8.1 Pre-amplifier provided with the turbine flow meter shall be intrinsically safe, and shall be located
on the meter.
4.8.2 The pre-amplifier shall operate on 24 V DC signal.
4.8.3 The cable entry to the pre-amplifier shall be ¾” NPTF.
4.9 Transmitter:
4.9.1 The transmitter if provided with the turbine flow meter shall be SMART and intrinsically safe
and shall operate on 24 V DC power.
4.9.2 The cable entry to the transmitter shall be ¾” NPTF.
4.10 Flow conditioner:
4.10.1 Flow conditioner shall be used where adequate straight runs are not available. The flow
straighteners if used for Turbine Flow Meters may be of either tube type or vane type.
4.10.2 Construction of conditioning plates / straightener shall correspond in general to API MPMS
Chapter 5 Section 3.
4.10.3 Straightening vanes when used shall be of flange type.
4.11 Miscellaneous
4.11.1 Suitable strainers will be considered to provide adequate protection to the internals of the turbine
meter. Material of the constructions shall be minimum 316SS.
4.11.2 The Turbine Flow Meters shall be installed after hydro testing and line flushing.
4.11.3 Turbine Flow Meters shall be calibrated using mechanical displacement meter prover as per API
Manual of Petroleum Measurement Chapter 4.
4.11.4 All castings and welding (other than slip-on welds, which shall be Dye Penetration tested) shall
be 100% radio graphed.
4.11.5 For Custody transfer application, International Organization of Legal Metrology (OIML)
certification for Liquid Turbine Meter (Model Type) shall be submitted by vendor.
Spec. No. 3207
Discipline Instt
Page: 6 OF 6
ANNEXURE – I - Typical Data Sheet for Turbine Flow Meter

UNITS: Flow Liquid – M3/HR. Gas – NM3/HR. Pressure – Kg/cm2 Temperature – co Level/Length - M
1 Tag Number
2 Line Number
3 Line Size & Schedule
GENERAL
4 Service
5
6 End Connection Size & Rating
7 End Connection Facing & Finish
8 Pulses / m3
9 Flow Range
10 Enclosure
11 Cable Entry
12 K Factor - Cycles per volumetric unit.
13 Excitation
14 Maximum speed
METER
15 Minimum output voltage
16 Pick off type
17 Material – Body
18 - End Connection
19 - Rotor
20 - Bearing
21 - Other Wetted Parts
22 Accuracy Repeatability
23 Totalizer Type
24 Type – 2-wire / 3-wire
25 Pre-Amplifier Location
26 Power Supply Cable Entry
PRE-AMPLIFIER
27 Enclosure
28 Intrinsically Safe
29 Mounting
30 Power Supply Cable Entry
31 Enclosure
TRANSMITTER
32 Intrinsically Safe
33 Mounting
34 Compensation – Viscosity
35 Conditioner element
OPTIONS
36 End Connection Material
37 Eliminator
38 Strainer Size & Mesh
OPTIONS (GAS)
39 Pressure tap on meter body
40 Fluid State
42 Flow Normal
SERVICE
46 System Pressure Drop
CONDITIONS
51 Percent Solid & type
52 Back Pressure
53 Area Classification
54 EMI / RFI protection
55 Manufacturer
56 Material certificate
57 Calibration certificate
58 Signal retransmission
59 Meter Model Number
60 Transmitter Model Number
61 Pre-Amplifier Model Number
62 Remarks
FUNCTIONAL Spec. No. FS 3208
SPECIFICATION FOR Rev. No. 4a
Discipline Instt
ISO – 9001:2008 “CORIOLIS METER”
Page: 2 OF 6
CONTENTS

4.0 Coriolis Type Mass Flow Meter 4
4.1 Application 4
4.2 General 4
4.3 Material 5
4.4 Accuracy 5
4.5 Transmitter 5
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Discipline Instt
Page: 3 OF 6

selection of Coriolis type Mass Flow Meter for the intended service.
1.2 This functional specification shall be read in conjunction with the reference documents
and specifications attached with the Bid documents.
b) Basic Bid Work & P&IDs
c) Process Design Criteria / Instrument Process Data Sheets / Instrument List.
d) Relevant API / MPMS standards. (Chapter 5.6 – for Coriolis Meters)
2.2 This FS shall be guideline and specifications for the Coriolis meter, and shall not limit
the vendor /contractor/packager from providing the meter / system as per basic bid
work and P&IDs, with all the necessary hardware, electronic cards power supplies and
accessories for proper measurement & display at field / control room, for the intended
purpose. (Rev 4a)
the Basic Bid Work and approved P & IDs.
3.2 The vendor shall be responsible for the selection of the Coriolis type Mass Flow Meter
calibration, preparation for shipment, along with accessories, spares, and assistance
where required for its installation & commissioning at site.
3.3 The Coriolis type mass flow meter shall include the sensor, transmitter (with integral or
separate local indicator) and accessories necessary to make the measurement system
complete.
- Where Coriolis type mass flow Meter is a part of Custody type metering system, all
necessary signals shall be terminated / hooked up to a metering panel for metering,
calibration / proving, computation etc.
- Metering system shall be local skid mounted or in metering control room or in
centralized control room as indicated in basic bid work.
- Where DCS is part of the control system in the control room, metering panel may be
located at metering skid or in the equipment room with all necessary provisions for
accessing all metering data / parameters from DCS via serial link, including the
corrected values, process data, etc., as the case may be.
- Where this meter is for measurement only (and not for the custody type metering
system), the meter shall be capable of transmitting the mass flow and density values to
the flow computer / receiver / DCS, as the case may be, for the various display and / or
computation requirements in the control room .
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Discipline Instt
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- Necessary software (and hardware) as required in the control room for computation the
mass, volume flow rate shall be provided by the Vendor. Provision of manual input
/feed of density value shall be kept in the system so supplied.
- Water in oil calculations (Net oil Computations) shall be provided with all necessary
provision for manual entry of densities of oil and water. A separate meter for net oil
computation shall be provided by way of flow computer or Net oil computer, with
display of computed values.
- Necessary software for computation and / or provision to access the computed values
shall be provided, where computation and display in DCS is specified.
4.0 CORIOLIS TYPE MASS FLOW METER:
4.1 Application:
4.1.1 Coriolis type mass flow Meter shall be used as the flow-measuring element and / or
density-measuring element wherever dictated by the process requirements.
4.1.2 In general, Coriolis type mass flow Meters shall be used for direct measurement of
mass flow and / or density of liquids, and where very high turndown ratios are required.
Prototypes or meters with no proven track record in relevant oil and gas service shall
not be supplied.
(a) Typically, Coriolis type mass flow meters shall be used for measurement at the
downstream liquid outlet of conventional test separator for fairly accurate assessment of
the flow of liquid from individual wells
(b) Where precise / accurate measurement of oil flow in custody transfer application is
required Coriolis type mass flow meter may be used in typically low to medium flow
range condition, after which meter size may become a limitation on the availability of
space.
4.2 General:
4.2.1 The Coriolis type mass flow Meter shall be selected such that the nominal bore size of
the sensor is equal to or less than the line size.
4.2.2 The Coriolis type mass flow Meter shall have flanged end connections, with “rating”
and “type” suitable for the associated piping class.
4.2.3 Coriolis type mass flow meter(s) shall be preferably installed in horizontal
configuration (on horizontal piping) and avoid stresses on the piping on which it is
installed. 1” & 2” meters may be installed in flag configuration following the
manufacturer’s recommendations and with suitable supports, where the installation of
the meter on vertical piping becomes inevitable.
4.2.4 The Coriolis type mass flow Meter shall be provided with intrinsically safe local LCD
display (integral or separately mounted near the flow meter or as a part of the locally
mounted transmitter) irrespective of the requirement of display in control room or any
other remote display location mentioned in the basic bid work. In case the display is
not integral, all mounting accessories required for the display shall be provided by the
Contractor. The Contractor shall also provide interconnecting cable (between the
sensor and the local display unit) and the cable glands suitable for the enclosure type
provided. These interconnecting cables shall be kept as short as practicable.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
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4.2.5 Any special cable and / or hardware which is proprietary but required to make the
system complete shall be supplied by the Contractor. (Rev 4a)
4.2.6 All the welding and castings (if any) shall be 100% radiographed.
4.2.7 All the electronics shall have enclosure suitable for Class I, Div I, Group C & D
Temperature Class T3 applications, and, shall be Weather proof to IP 65 or better.
(Where instruments cannot be provided with enclosures suitable and certified for Class
I, Div I Group C & D by the meter manufacturers, enclosure suitable and certified for
the area classified as Class I, Div II may be accepted in areas approved as “Class I Div
II Group C & D”). Local Indicator, Transmitter, Input / output to peripheral devices like
laptop computers & networks, etc., shall be intrinsically safe. Enclosure type shall be
certified by recognized bodies like IEC / FM / UL / BASEEFA / CENELEC / CSA /
DGMS / PTB / CMRI etc.
4.2.8 Where intrinsically safe electronics / instruments are provided, suitable barriers shall be
recommended along with the instruments / electronics for use in the instrument loop.
4.2.9 Coriolis type mass flow meter shall not be mounted on piping / pipelines subject to
frequent & high vibrations. Suitable precautions shall be taken for locating the meter on
piping down-stream of ‘vibrating’ equipments.
4.2.10 The Coriolis type mass flow Meter Transmitter shall be ‘SMART’ type with 24 V DC
power supply and 2 numbers of 4 – 20 mA output, serial output/s with a local indicator.
4.2.11 On high temperature applications, the transmitter shall be mounted separately from but
local to the sensor. Sensor cables shall be kept as short as practicable.
4.2.12 OIML Certification (Weights & Measures) shall be furnished where the meter is used
for liquid custody transfer applications.
4.3 Material:
4.3.1 The material requirements for body and wetted parts of the Coriolis type mass flow
Meter shall in general be according to clause 3.6.4.5 of Instrumentation Design Criteria.
4.3.2 The Contractor shall however ensure that the sensor and all other wetted parts are
compatible with the process fluid conditions. The metal tubing (sensor element) shall
be made of SS 316L as a minimum for NACE applications and SS 316 as a minimum
for non NACE applications, unless the process conditions dictate the use of ‘alternate
materials’ / ‘higher corrosion resistant’ materials.
4.4 Accuracy:
4.4.1 Coriolis type mass flow Meters shall have an accuracy of + 0.2% of flow rate or better,
with repeatability of + 0.1 % or better.
4.4.2 Accuracy for density measurement shall be + 0.001 g/cc or better. Where the meter is
used for custody transfer, the accuracies shall follow the requirements of MPMS
standards for density measurements and computations. (API MPMS 14.6).
4.4.3 Where a Coriolis type mass flow meter is installed in a bypass line for ‘density
measurement’, the design shall ensure that the flow rate through the meter provides the
desired accuracy in measurements.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Discipline Instt
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ANNEXURE – I - Typical Data Sheet For Coriolis type mass flow Meter
CORIOLIS TYPE MASS FLOW METER
UNITS: Flow [ Liquid – (KG or M )/HR :: Gas – NM3/HR].:: Pressure – Kg/cm2 ::Temperature – oC::Level – Mtrs
3
1 Tag Number
2 Line Number
3 Service
GENERAL 4 Function
6 Enclosure Class
7 Sensor Material
8 End Connection & Face Finish
9 End Connection Flange Material
10 Sensor Spool Piece Material
11 Other Wetted Parts Material
12 Enclosure Material
13 Measuring Range
METER 14 Adjustable Range
15 Accuracy
16 Sensitivity
17 Repeatability
18 Effect of Temperature
19 Minimum Detection Limit
20 Cable Entry Connection
21 Local Display
22 Power Supply
23 Output
TRANSMITTER 24 Electrical Area Class
25 Enclosure
26 Cable Entry
27 Fluid State
29 Flow Normal
32 Sp. Gr. At Oper. Temp. Mol. Wt.
SERVICE 33 System Pressure Drop
CONDITIONS 34 Operating Viscosity (Cp)
Max. Allowable pressure drop across
35
meter
36 Density
Maximum
37 Water Content Normal
Minimum
38 Manufacturer
ITEM DETAILS 39 Model No.
40 Remarks
NOTE:-
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
11 - High, Mumbai GAS FLOW Discipline Instt.
ISO 9001: 2000 COMPUTER Page # 1 of 6
FOR
GAS FLOW COMPUTER
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 6 18.02.2008 3
AK BK GRP 9 28.03.2007 2
AK BK GRP 9 31.09.2006 1
ET MC AC 9 13.05.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Gas Flow Computer 3
4.1 Purpose 3
4.2 General requirements 3
4.3 Type of gas flow computer 5
4.4 Functional requirements 5
4.5 Materials 5
4.6 Accuracy 5
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Gas Flow Computer for the intended service.
b) Basic Bid Work
c) Project P & IDs
3.2 The vendor shall be responsible for the selection of the Gas Flow Computer
where required for its installation & commissioning at site. This FS shall be read in
4.0 GAS FLOW COMPUTER:
4.1 PURPOSE:
4.1.1 The purpose of a Gas Flow Computer is to perform flow calculations, data
archival, data retrieval and data transmission to the required destination.
4.2 GENERAL REQUIREMENTS:
4.2.1 The Gas Flow Computer shall be capable of reading and displaying, as a
minimum, the following: instantaneous flow, compensated flow, cumulative
flow and compensation parameters.
4.2.2 The Gas Flow Computer shall be capable of calculating flow in accordance
with the latest edition of AGA and API Standards. The Gas Flow Computer
shall use latest edition of AGA-3 for orifice flow calculations and latest edition
of AGA-8 for super compressibility calculations. The Gas Flow Computer
software shall be capable of volume correction as per API standards.
4.2.3 The Wall Mounted Gas Flow Computer shall be provided with a general
purpose enclosure suitable for use in safe area.
4.2.4 The Field Mounted Gas Flow Computer shall be provided with an enclosure
intrinsically safe to IP 65. Necessary certifications shall be attached with
Purchase Specification.
4.2.5 The Gas Flow Computer shall be furnished with all the necessary weather and
anti-corrosion protection to prevent damage from saline and corrosive process
atmosphere.
4.2.6 Mountings accessories required for Gas Flow Computer shall be 316SS or
better. All instrument supports shall be galvanized prior to installation.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.2.7 Power Supply:

4.2.7.1 The Gas Flow Computer shall operate on 24 V DC supply.
4.2.7.2 The Gas Flow Computer shall have sufficient battery back-up to retain data for
a minimum of 15 days. This back-up battery may be permanent type for field-
mounted units and shall be rechargeable type or permanent type for units
mounted in the safe area. In case the back-up battery is rechargeable type, a
battery charger that can operate on 24 V DC supply shall be provided. In case
the back-up battery in permanent type, the battery shall have a life of not less
than 2 years, in continuous service. Also one set of spare batteries shall be
provided for future requirement, provided, they have a shelf life of more than 2
years.
4.2.8 Inputs to the Gas Flow Computer:
4.2.8.1 The Gas Flow Computer shall be capable of accepting the following inputs as
required by the process / application:
• 4 – 20 mA signals
• Pulse inputs
• Digital inputs
• RTD inputs
• 0 – 5 V signals
The specific inputs that are to be connected to the Gas Flow Computer shall be
as per the P & IDs.
4.2.9 Outputs from the Gas Flow Computer:
4.2.9.1 The Gas Flow Computer shall be capable of generating the following outputs:
• 4 – 20 mA analog signals for communication with TIC
• Digital signals for communication with TIC
• RS–232 output port for communication with data logger, wherever provided
The specific outputs that are required from the Gas Flow Computer shall be as
per the P & IDs and the process requirements.
4.2.10 Display Requirements:
4.2.10.1 The Gas Flow Computer shall provide 2 lines of alphanumeric display with 16
characters per line as minimum. The display shall be LCD type.
4.2.10.2 The Gas Flow Computer unit shall have a user-friendly keypad for selection of
functions and displays. Calling up a function or a display shall not require
more than 3 key presses. The keypad shall suitable for performing simple
programming / customization of the Gas Flow Computer software. It shall be
possible to configure certain keys on the keypad for launching quick functions.
4.2.11 Self Diagnostics:
4.2.11.1 The Gas Flow Computer shall be capable of performing self-diagnostics of the
electronics and of the software. It shall also provide relevant error display.
4.3 TYPES OF GAS FLOW COMPUTERS:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.3.1 The Gas Flow Computer may be either Wall-Mounted or Field-Mounted.

4.3.2 The Wall Mounted Gas Flow Computer shall be mounted in the TIC room, i.e.
safe area.
4.3.3 The Field Mounted Gas Flow Computer shall generally be mounted as per the
approved area classification on the platform. The Field Mounted Gas Flow
Computer may be of the following types:
• With integral solar cells: This type of Field Mounted Gas Flow Computer
shall be provided where power availability is a constraint.
• Without integral solar cells: This type of Field Mounted Gas Flow Computer
shall be provided where power is available from the existing / new power
supply system.
4.3.4 In case the Field Mounted Gas Flow Computer has to cater to only one set of
flow parameters (i.e. 1 Differential Pressure value, 1 Upstream Pressure Value
and 1 Temperature value for compensation), then a Gas Flow Computer with
integral multi-variable sensor may be used. In this case, the temperature
transmitter shall not be in the scope of supply of the Gas Flow Computer
vendor. The maximum DP range of the Multi Variable Sensor shall be 150-
inch water column. The static pressure range shall be 500-psi maximum. The
process connection shall be 1/2” NPTF vertical plane bottom connection.
4.4 FUNCTIONAL REQUIREMENTS:
4.4.1 The Gas Flow Computer shall be capable of archiving data for a minimum of
15 (fifteen) days for a minimum of 15 (fifteen) points.
4.4.2 The time interval of data capturing / frequency of data logging shall be user-
programmable with standard 1 hour, 10 minutes and 1 minute intervals.
4.4.3 The Gas Flow Computer shall be capable of providing data of trends displays
over user selectable time base.
4.4.4 The Gas Flow Computer shall have facility for changing the range selection,
multiplication factor, etc.
4.5 MATERIAL:
4.5.1 The material requirements for Gas Flow Computer shall in general be
4.5.2 The enclosure material of the Gas Flow Computer shall be Manufacturer
standard. However, it shall be certified for use in classified area if the Gas
Flow Computer used in field-mounted type.
4.5.3 Wherever a multi-variable sensor type Gas Flow Computer is used, the material
of the sensor shall be compatible with the process fluid and shall be SS 316
minimum. Wherever the process demands NACE compliance, the same shall
be provided. The process flanges for the multivariable sensor shall be CS
minimum.
4.6 ACCURACY:
4.6.1 The accuracy of the Gas Flow Computer shall be ± 0.1% or better.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE –I TYPICAL DATA SHEET
GAS FLOW COMPUTER
1 Tag Number
2 Display Capability:
a) Instantaneous Flow Data Yes / No
b) Compensated Flow Data Yes / No
GENERAL
c) Cumulative Flow Data Yes / No
d) Compensation Parameters Yes / No
e) Others (Specify)
3 Wall Mounted Yes / No
4 Field Mounted Yes / No
TYPE OF GAS FLOW
a) With Integral Solar Cell Array Yes / No
COMPUTER b) Without Integral Solar Cell Array Yes / No
c) With Integral Multi Variable Sensor Yes / No
5 Display:
a) No. of lines of display
GAS FLOW
b) No. of characters per line
COMPUTER
c) Alphanumeric display Yes / No
CHARACTERISTICS
6 Programmable Keypad Yes / No
7 Self Diagnostics Yes / No
8 Power Supply
Rechargeable /
9 Battery Back-Up Type
POWER SUPPLY & Permanent
BATTERY BACK-UP 10 If Permanent Battery, life of battery
11 One set of spare battery provided Yes / No
12 If Rechargeable Battery, Battery Charger provided Yes / No
13 4 – 20 mA signal (mention quantity of such i/ps)
14 Pulse inputs (mention no. of such i/ps)
INPUT TO GAS 15 Digital inputs (mention no. of such i/ps)
FLOW COMPUTER 16 RTD inputs (mention no. of such i/ps)
17 0 – 5 V signal (mention no. of such i/ps)
18 Others, if any, with no. of such i/ps
19 4 – 20 mA signal (mention no. of such o/ps)
OUTPUT FROM GAS 20 Digital inputs (mention no. of such o/ps)
FLOW COMPUTER 21 RS-232 port
22 Others, if any, with no. of such o/ps
23 No. of days for which data can be stored
DATA ARCHIVING
24 Frequency of data logging permissible
25 Enclosure
MATERIAL
26 Multi Variable Sensor, if provided
ENCLOSURE 27 Rating
ACCURACY 28 Gas Flow Computer Accuracy
29 Fluid State
31 Flow Normal
SERVICE 33 Temperature Operating Maximum
CONDITIONS 34 Sp. Gr. At Oper. Temp.
35 Molecular Weight
39 IS Certification
40 Manufacturer
ITEM DETAILS
41 Model Number
42 Remarks
NOTE:-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3211
Discipline Instt
ISO – 9001:2000 FLOW COMPUTER
Page: 1 OF 7
FOR
FLOW COMPUTER
Spec. No. 3211
Discipline Instt
Page: 2 OF 7
CONTENTS
Sl.No. ITEM PAGE NO.
1 Scope of this Document 3
2 Codes & Standards 3
3 Scope Of Supply 4
4 Flow Computer 4
4.1 Purpose 4
4.2 General Requirements 4
4.3 Diagnostics 6
4.4 Accuracy 6
Annexure - I Data Sheet 7
Spec. No. 3211
Discipline Instt
Page: 3 OF 7
Flow Computer for the intended purpose.
2.1 The following codes and standards (latest edition) are referenced to and make a part of this
specification.
Numbers Description
AGA -3 Orifice Metering Of Natural Gas And Other Related Hydrocarbon
Fluids
AGA-Report 7 Report No. 7, Measurement of Gas by Turbine Meters,
AGA-8 Compressibility factor of Natural Gas and other related Hydrocarbon
Gases
AGA- Report 9 Measurement of Natural Gas by Ultrasonic Meter
AGA- Report 10 Speed of Sound in Natural Gas & other related Hydrocarbon Gas,
May2003
AGA-Report 11 Measurement of Natural Gas by Coriolis Meter
API MPMS 11.1 Physical Properties Data Section 1—Temperature and Pressure Volume
Correction Factors for Generalized Crude Oils, Refined Products, and
Lubricating Oils
API MPMS Manual of Petroleum Measurement Standards Chapter 12—Calculation
Chapter 12 of Petroleum Quantities
API MPMS 21.1 Flow measurement using electronic metering system section-1
Electronic gas measurement
API MPMS 21.2 Flow measurement using electronic metering system section-2 - Inferred
mass.
ASTM D 1250 Standard Guide for Use of the Petroleum Measurement Tables
ISO 5167 Measurement of fluid flow by means of pressure differential devices
ISO 5168: 1998 Measurement of fluid flow – Evaluation of Uncertainties.
ISO 6976 Natural gas - Calculation of calorific values, density, relative density
and Wobbe index from composition
ISO 10723 Natural Gas-Performance Evaluation for On-line Analytical Systems
Spec. No. 3211
Discipline Instt
Page: 4 OF 7

b) Basic Bid Work
c) Project P & IDs / Process Design Criteria / Process Instrumentation Data Sheets
Bid Work and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Flow Computer suitable for its
commissioning at site. This FS shall be read in conjunction with the Instrument Design
Criteria.
4.0 FLOW COMPUTER:
4.1 PURPOSE:
4.1.1 The purpose of Flow Computer is to perform flow calculations, data archival, data retrieval and
data transmission to the required destination.
4.1.2 For Gases, Flow Computer shall be used obtaining compensated flow, instantaneous flow,
cumulative flow and compensation parameters (Pressure and Temperature), Molecular
weight , & Totalized flow ( Mass / Volume ).
4.1.3 For Liquids , Flow Computer shall be used for obtaining uncompensated flow , Compensated
flow , Instantaneous Flow , Compensation Parameters (Temperature, Viscosity) , Density ,
Totalized flow ( Mass / Volume ) and Net Oil and water cut, wherever applicable.
4.2.1 Flow Computer shall be wall mounted or field mounted in case of Unmanned Platforms and
for Process Platform flow computer shall be Panel mounted in Central Control Room.
4.2.2 Wall Mounted Flow Computer shall be mounted in the TIC room on unmanned platforms. It
shall have an enclosure suitable for use in safe area with rating of IP 54.
4.2.3 Field Mounted Flow Computer shall be provided with an enclosure with NEMA 4 X or
equivalent rating and shall be certified for use in hazardous area by a statutory body as
defined in Clause 3.6.4.4.5 of Instrumentation Design criteria. Necessary certifications shall
be attached with Purchase Specification.
4.2.4 Field Mounted Flow Computer can be of the following types:
Spec. No. 3211
Discipline Instt
Page: 5 OF 7
• With integral solar cells: This type of Field Mounted Flow Computer shall be provided
where power availability is a constraint.
• Without integral solar cells: This type of Field Mounted Flow Computer shall be
provided where power is available from the existing / new power supply system.
4.2.5 In case the Field Mounted Flow Computer (for Gas application) has to cater to only one set
of flow parameters (i.e. 1 Differential Pressure value, 1 Upstream Pressure Value and 1
Temperature value for compensation), then MVT with flow computation capability can be
used. Separate RTD shall be provided for process temperature compensation.
4.2.6 Wherever Flow Computer with integral multi-variable sensors is used, material of sensors
shall be compatible with the process fluid and shall be SS 316 minimum. Wherever the
process demands NACE compliance, the same shall be provided.
4.2.7 For field mounting, mounting accessories required for Flow Computer shall be 316SS or
better. All Instrument supports for installation shall be galvanized.
4.2.8 Flow Computer shall be capable of archiving data for a minimum of 15 (fifteen) days for a
minimum of 10 (Ten) parameters.
4.2.9 The time interval of data capturing / frequency of data logging shall be user-programmable
with standard 1 hour, 10 minutes and 1 minute intervals.
4.2.10 Flow Computer shall be capable of providing data of trends displays over user selectable
time base.
4.2.11 Flow Computer shall have facility for changing the range selection, multiplication factor.
4.2.12 Necessary software shall be provided with the flow computer as per application.
4.2.13 Power Supply:
4.2.13.1 Flow Computer shall operate on 24 V DC supply.

4.2.13.2 Flow Computer shall have Li-ion or equivalent permanent battery back-up with battery life
for three years continuous operation of data archival etc.
4.2.14 Inputs to Flow Computer:
4.2.14.1 The Flow Computer shall be capable of accepting the following inputs:
• 4 – 20 mA signals ( HART)
• Pulse inputs
• Digital inputs
• RTD inputs
• 0 – 5 V signals
• Serial input (RS 232, RS 485, and Modbus) for gas molecular weight / liquid density
Spec. No. 3211
Discipline Instt
Page: 6 OF 7
Specific inputs that are to be connected to Flow Computer shall be as per P & IDs and
process requirement.
4.2.15 Outputs from Flow Computer:
4.2.15.1 Flow Computer shall be capable of generating following outputs:

• 4 – 20 mA analog signals
• Digital signals
• RS-232C / RS 485 Modbus or Ethernet TCP/IP protocol for RTU / DCS
The specific outputs that are required from Flow Computer shall be as per P & IDs and
4.2.16 Display Requirements:
4.2.16.1 Flow Computer shall have in general two displays with LCD backlit screens, one resettable
for indicating instantaneous flow, compensated flow and compensation parameters
(minimum 6 digit) and other non resettable ( min 8 digits).
4.2.16.2 Flow computer shall have facility to configure engineering units required for display as per
requirement. Flow Computer unit shall have a user-friendly keypad for selection of
functions and displays. Calling up a function or a display shall not require more than 3 key
presses. The keypad shall suitable for performing simple programming / customization of
Flow Computer software. It shall be possible to configure certain keys on keypad for
launching quick functions.
4.3 DIAGNOSTICS:
4.3.1 Flow Computer shall be capable of performing self-diagnostics of electronics and software.
It shall also provide relevant error display.
4.3.2 ‘Low battery’ indication shall be generated on LCD screen.
4.4 ACCURACY:
4.4.1 The accuracy of the Flow Computer shall be ± 0.025% or better.
Spec. No. 3211
Discipline Instt
Page: 7 OF 7
ANNEXURE – I : DATA SHEET FOR FLOW COMPUTER
FLOW COMPUTER
1 Tag Number
2 Display Capability:
a) Instantaneous Flow Data Yes / No
b) Compensated Flow Data Yes / No
GENERAL
c) Cumulative Flow Data Yes / No
d) Compensation Parameters Yes / No
e) Others (Specify)
3 Control Panel Mounted Yes / No
Wall Mounted
TYPE OF FLOW 4 Field Mounted Yes / No
a) With Integral Solar Cell Array Yes / No
COMPUTER b) Without Integral Solar Cell Array Yes / No
c) With Integral Multi Variable Sensor Yes / No
5 Display:
a) No. of lines of display
FLOW COMPUTER b) No. of characters per line
CHARACTERISTICS c) Alphanumeric display Yes / No
6 Programmable Keypad Yes / No
7 Diagnostics Yes / No
8 Power Supply
9 Battery Back-Up Type
POWER SUPPLY &
10 If Permanent Battery, life of battery
BATTERY BACK-UP
11
12
13 4 – 20 mA signal (mention quantity of such I/O)
14 Pulse inputs (mention no. of such I/O)
INPUT TO FLOW 15 Digital inputs (mention no. of such I/O)
COMPUTER 16 RTD inputs (mention no. of such I/O)
17 0 – 5 V signal (mention no. of such I/O)
18 Serial inputs/Others, if any, with comm., protocol
19 4 – 20 mA signal (mention no. of such I/O)
OUTPUT FROM FLOW 20 Digital outputs (mention no. of such I/O)
COMPUTER 21 Communication Port (i.e. RS-232, etc.)with protocol
22 Others, if any, with no. of such I/O
23 No. of days for which data can be stored
DATA ARCHIVING
24 Frequency of data logging permissible
25 Enclosure
MATERIAL
26 Multi Variable Sensor, if provided
ENCLOSURE 27 Rating
ACCURACY 28 Flow Computer Accuracy
29 Fluid State
31 Flow Normal
SERVICE CONDITIONS
34 Sp. Gr. at Oper. Temp.
35 Molecular Weight
36 Operating Viscosity (CP)
39 IS Certification
40 Manufacturer
ITEM DETAILS
41 Model Number
42 Remarks
Offshore Design Section Spec No. 3212
Engineering Services Rev. No. 01(a)
ISO 9001: 2008 ULTRASONIC FLOW Discipline Instrumentation
METER Page 2 of 11
CONTENTS

4.0 Multipath Ultrasonic Flow Meter 4
4.1 Meter body 4
4.2 Ultra sonic transducer 5
4.3 Accuracy & Repeatability 7
4.4 Output / input 8
4.5 Electrical safety design requirement 8
4.6 Calibration 8
4.7 Diagnostics 9
4.8 Miscellaneous 9
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selection of Multipath Ultrasonic Flow meter for the intended gas or Liquid
services.
a) Process & Instrumentation Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) The following codes and standards ( latest edition ) are referenced to and make
a part of this specification.
Number Description
AGA 8 Gas Transmission Measurement Committee Report No. 8, 1992 –

Compressibility Factors of Natural Gas and Other Related
Hydrocarbon Gases
Gas Transmission Measurement Committee Report No. 9,1998 -
AGA 9
Measurement of Gas by Multi-path Ultrasonic Meter
AGA 10 Speed of Sound in Natural Gas and Other Related Hydrocarbon
Gases, May 2003
API MPMS Chapter 1 Vocabulary

Chapter 4 Proving system
Chapter 5 Metering
IEC 529 Degree of protection provided by the enclosures
IEC 801 Electromagnetic compatibility of industrial process measurement

and control equipment
IEC 79 Electrical apparatus for explosive gas atmosphere.
ISO / TR Measurement of fluid flow – Evaluation of Uncertainties”

5168: 1998
ISO 10723 Natural gas ~ Performance Evaluation for On-line Analytical
Systems
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METER Page 4 of 11
3.2 The vendor shall be responsible for the selection of the Multipath Ultrasonic Flow
meter suitable for in line Gas /Liquid Measurement for the intended application,
its procurement, tagging, packing, testing & calibration, preparation for shipment,
along with accessories, spares, and assistance where required for its installation &
commissioning at site.
4.0 MULTIPATH ULTRASONIC FLOW METER:

GENERAL:
The meter shall be suitable for the intended application as described in the scope
of work like for the custody application (gas/liquid), process flow (gas/liquid) &
flare gas measurement. Wherever the meter is called for custody application, the
meter shall be ‘inline’ / multipath (minimum 04 path) meters as per AGA-9.
All electrical instruments shall be suitable for the Hazardous area classification
(Class I, Division I, Group D, T3 Hazardous Area) and certified by bodies such as
IEC / FM / UL / CENELEC / BASEEFA / CSA / DGMS / PTB / CMRI for use in
hazardous area specified. Clause 3.6.4.4.5 of Instrumentation design criteria shall
be followed for hazardous application.
4.1 METER BODY
4.1.1 MAXIMUM & MINIMUM OPERATING PRESSURE

The maximum operating pressure shall meet the requirement of the pipeline
flanges. The maximum design operating pressure of the meter should be the
lowest of the maximum design operating pressure of the following: meter body,
flanges, transducer connections, transducer assemblies.
For gas services, Meter at minimum operating line pressure shall meet the
requirement of a minimum gas density ( a function of pressure) for the proper
functioning of ultrasonic transducers .
4.1.2 CORROSION RESISTANCE

All wetted parts of the meter shall be compatible with process fluid; the wetted
parts shall be minimum of SS-316. All external parts shall be made up of
noncorrosive material or sealed with corrosion resistant material. MOC must be
selected based on the harsh offshore conditions.
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4.1.3 METER BODY LENGTHS AND BORES

The meter body lengths and bore shall be as per AGA-9 /API Ch 5.8 , Dowel
pins must be required on the upstream meter runs to ensure the USM is aligned
correctly to the upstream meter run, in the event the USM is removed for
maintenance. For bi-directional applications, both ends of the meter should be
considered “upstream.”
4.1.4 ULTRASONIC TRANSDUCER PORTS
Transducer ports shall be designed in a way that reduces the possibility of liquids
or solids accumulating in the transducer ports. It should be possible to replace the
ultrasonic transducers without depressurizing the meter run suitable proviosn
must be kept for the same.
4.1.5 PRESSURE TAP
At least one pressure tap shall be provided for measuring the static pressure in
the meter, other requirements shall be as per AGA-9/ API Ch 5.8 (for liquid).
4.1.6 MISCELLANEOUS
The straight length comprising the upstream and downstream meter tube pipe
sections shall be considered straight when the deviation from a straight line does
not exceed 0.4% over the length of the meter tube.
Steps in adjacent pipe sections, changes in the internal diameters and protrusions
upstream and downstream of the meter spool shall be avoided since these will
create local disturbances to the velocity profile. Profiler and spools used shall be
sized to meet the full bore flow in the meter.
The ultrasonic metering system shall be provided with full diagnostics and user
interface.
The Meter’s cross sectional area, the interior of the meter tube assembly shall be
clean at all times to avoid accumulation of deposits due to a mixture of dirt, mill
scale, liquids or lubricating oils shall. The vendor shall provide filter / filtration
system as per process requirements.
The meter should be designed in such a way that the body will not roll when
testing on a smooth surface with a slope up to 10%. This is to prevent any
damage to ultrasonic meter while it is dismounted for maintenance. The meter
should be designed to permit easy and safe handling of the meter during
transportation and installation. Hoisting eyes or clearance for lifting straps should
be provided.
4.2 ULTRASONIC TRANSDUCER:
4.2.1 The Ultrasonic meter shall be based on multipath technology using non reflective
type technology. The sizing shall be done for the given process conditions as per
AGA-9 (latest edition)/ API Ch 5.8 and full sizing calculations for the same
shall be submitted.
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Sizing shall be done including the minimum inlet operating pressure and gas
composition and other process conditions. Meter shall be inherently bidirectional,
however where application requires bidirectional meters, the downstream run shall
be identical to upstream run as per applicable standards. For custody transfer
application the meter shall be minimum ‘four path’.
4.2.2 It shall be possible to replace or relocate transducers in-situ under the line operating
conditions without a significant change in meter performance. After an exchange of
transducers and a possible change of the associated software constants, the resulting
shift in the meter's performance should not be more than the allowable repeatability
of the meter as per relevant standards.
4.2.3 For multi path meters, loss of one path (1 pair of transducers) shall generate an alarm
, but continue to operate , it should not result in shift of accuracy. During the
working of the meter with loss of one path or due to any component change the
overall accuracy shall be maintained within accuracies specified in the AGA-9.
Vendor to provide documentary evidence from certifying agency to substantiate the
same.
4.2.4 The vendor shall comprehensively advise the impact of transducer failure on the
performance & accuracy of the USM with documentation.
4.2.5 Electronics (signal processing unit etc.), computer programs (i.e. firmware, software,
diagnostic features etc.) shall be designed and tested as per relevant codes and
standards. Documentary proof for the same shall be submitted to the company for
review.
4.2.6 The Installation requirements and piping configuration shall be selected to meet the
performance requirements as mentioned in the AGA-9 and in this specification.
Algorithm used in their electronic for computation of average velocity and flow
profile/ wall roughness correction etc. for achieving the specified accuracy,
including the Ultrasonic Flow meter sizing velocity calculation shall be submitted to
company for review and approval.
4.2.7 The data sheets for the associated instrumentation used shall be submitted to the
company for review.
4.2.8 Ultrasonic flow meter and accessories operation shall be protected from
electromagnetic exposure / interference. The electromagnetic compatibility shall be
as per IEC-801.
4.2.9 Ultrasonic flow meter spool inside diameter to meet the specified I.D. and internal
surface roughness shall be as per relevant codes and standards.
4.2.10 External body shall be blast cleaned to near white metal as per international
standard and primed with inorganic zinc premier (two coats each of 40 micron
minimum dry film thickness) and the final coat epoxy paint of 40 micron dry film
thickness.
4.2.11 The transducer/ probes shall be of robust construction for uninterrupted long life
and accurate performance. The transducer / probe shall be hermetically sealed type,
electroplated with suitable material so as to perform under dirty gas condition also.
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4.3 ACCURACY & REPEATABILITY

4.3.1 Ultrasonic Flow meters shall meet the following requirements for Accuracy /
Repeatability / Uncertainties over and above the requirements mentioned in the relevant
codes and standards for the range 20% to 100% of the flow:
a) For Custody Transfer Applications:
I. Meter Repeatability shall be +/- 0.2% for the flow range as per the process
requirements.
II. Meter for custody transfer application shall have accuracy of +/- 0.3% or better
(including uncertainty) before any calibration adjustment.
III. Meter shall be supplied in (1+1) x100% each or in (2+1) x 50%.
IV. In addition to the configuration above, a Master Meter shall be provided in form of
Turbine Flow Meter / Ultrasonic Flow Meter for indirect proving of the ‘stream’ of
ultrasonic flow meters (meant for custody transfer application).
V. Stream Flow computer shall be provided with each meter run, capable of accepting data
from proving computer for calibration purposes. Master flow meter shall have proving
computer capable of providing all the data for all the meter runs associated with the
metering system.
VI. The total energy system uncertainty shall be less than +/- 0.7% of energy flow rate. The
accuracy should be total system uncertainty based on ISO / TR 5168: 1998
“Measurement of fluid flow – Evaluation of uncertainties”. The calculation including
both the systematic and random errors taking in to account the certified heating value of
GC calibration gas shall be submitted.
VII. The pressure and temperature uncertainties to be included in the calibration should
consist of the transmitter uncertainty and calibration / validation equipment
uncertainties. The uncertainty of the ultrasonic flow meter including both the meter
repeatability as well a laboratory uncertainty shall not exceed +/- 0.3% of the flow rate.
VIII. Calibration shall be done at reputed flow laboratories like NEL or equivalent. Complete
Metering System for Custody transfer shall be certified by NMI / PTB / CEESI /
TransCanada, and shall meet the statutory requirements of OIML.
b) For ‘measurement system’ involving ultrasonic flow meter for other than custody
transfer application, accuracy shall be +/- 0.5% or better including uncertainties.
Uncompensated and Compensated flow values shall be available in the flow computer
provided along with the meter.
c) For the ‘in line’ flare gas measurement, suitable ultrasonic type meters shall be
provided with an accuracy of +/- 3 % or better. ‘Turn down’ ratio for measurement in
the meter shall be as per the process requirements with a ratio of 1: 1000 as a minimum.
In case of loss of one path for Multipath insertion type ultrasonic meter for flare gas
measurement, system shall generate alarm for path failure and shall continue its
operation within the accuracy.
4.3.2 Vendor shall include wet flow calibration to achieve specified accuracy for custody transfer
applications. Vendor shall confirm with back-up test results/ documentation, the long-term
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METER Page 8 of 11
stability of measurement accuracy, duly taking into consideration that the pipe wall roughness
is expected to change over the period.
4.4 OUTPUT / INPUTS
4.4.1 The meter shall have at least one serial data interface (RS-232 / RS-485).
4.4.2 Standard Frequency output(s) representing flow rate at line conditions. (Frequency output
shall be electrically out of phase by 90 deg for pulse integrity check).
4.4.3 The meter shall have Analog (4-20mA, DC) output for flow rate at line conditions.
4.4.4 Flow should be scalable up to 120% of the meter’s maximum flow rate , a programmable
low cut off function shall be provided that sets the flow rate output to zero when the
indicated flow rate is below a minimum value ( not applicable to serial data output). Two
separate flow rate outputs and a bidirectional state output or serial data values should be
provided for bi-directional applications to facilitate the separate accumulation of volumes
by the associated flow computer , and provide bi directional state output signal.
4.4.5 All the outputs shall be isolated from the ground and have necessary voltage protection to
meet electronics design testing requirements as per relevant codes and standards.
4.5 ELECTRICAL SAFETY DESIGN REQUIREMNTS

4.5.1 The Ultrasonic Meter including the signal processing unit (SPU), shall be intrinsically safe
design and explosion proof enclosure design for use in Class I , Division I area and shall be
certified by an statutory authority .
4.6 CALIBRATION
4.6.1 The vendor shall test each transducer or pair of transducers and document the results as
part of the USMs quality assurance program. Each transducer shall be marked or tagged
with a permanent serial number and be provided with a transducer data pack. If the signal-
processing unit (SPU) requires specific transducer characterization parameters, each
transducer or transducer pair, shall also be provided with test documentation that contains
the specific calibration test data, calibration method used and characterization
parameter(s).
4.6.2 The calibration shall be made over a statistically significant number of runs and over a
range of flow velocities. As a minimum, calibration shall be carried out for at least 6
velocities, logarithmically spaced over the meter range, taking the mean of at least three
measurements, of 100 seconds, at each velocity. In the lower part of the range, the number
of measurements may be increased to 5 or 10. In determining the number of repeat points
at each flow condition, the variability of the instrument under test should be considered, so
that the random errors are sufficiently averaged and the remaining difference with respect
to the calibration standard is predominantly the bias of the instrument under test.
4.6.3 The ultrasonic meter must be flow calibrated in general as per the AGA 9. The flow
calibration shall be performed at the following test flow rates as a minimum : at Qmin ,
0.10 Qmax , 0.25 Qmax, 0.50 Qmax, 0.75 Qmax and at Qmax.
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A detailed report of the flow calibration test shall be submitted to the Company for
review.
4.6.4 The algorithms and data used for computation of average velocity and flow profile /
wall roughness correction etc. for achieving the specified accuracy shall be submitted to
the company.
4.7 DIAGNOSTICS
4.7.1 The Ultrasonic flow meter shall provide the following diagnostic requirements as a
minimum via RS-232 / RS-485 serial data interface from the meter to the Operator
Console / Flow Computer / Station Computer / etc., as specified in the Basic Bid Work :
• Average axial velocity through the meter.
• Gas / Liquid velocity for each acoustic path
• Corrected and uncorrected volumetric flow rate
• Speed of sound along each acoustic path
• Average speed of sound
• Velocity sampling intervals
• Average time intervals
• % of accepted pulses for each acoustic path
• Status and measurement quality indicators
• Alarm failure indictors & other Diagnostic data
4.8 MISCELLANEOUS
4.8.1 The vendor shall specify the flow rate limits for qmin, qt, and qmax, for the selected
USM size and type, as detailed in relevant codes and standard.
4.8.2 As a minimum, flow conditioners shall be 316 stainless steel of between-flanges.
These shall comply with the requirements as per relevant codes and standard.
4.8.3 Where flow conditioners are recommended, care must be taken to select flow
conditioners that do not generate acoustic noise with harmonic frequencies that
may interfere with the USM performance.
4.8.4 Cast body of the ultrasonic meter shall be preferred compared to the welded body
for better immunity from vibration, reduced corrosion and better internal surface
of the meter, as well as negligible impact due to pressure and temperature.
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4.8.5 All the meters shall be tested based on testing requirements mentioned in the
AGA-9 / relevant codes and standards. The certificates including the detailed test
report shall be submitted for company’s review along with purchase
specification.
4.8.6 In addition to the requirements mentioned in the instrument design criteria
3.6.6.1, the multipath ultrasonic flow meter shall have all the information tagged
as per AGA-9 on a Stainless steel tag plate.
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UNITS: Flow→ Liquid M3/Hr Gas→ M3/Hr Steam → Kg/Hr Pressure → Kg/Cm2 G Temp→ 0C Level / Length→ mm
1. Qty
2. Service
3. Manufacturer
4. PI & D No.
Service Conditions
1. Fluid
2. State
3. Minimum gas velocity
4. Flow Min/nom/max m3/h
5. Pressure (Min/ Nor/ Max) Bar
6. Temperature C Nor/ Des
7. Design Pressure Barg
8. SG or Density (Typical)
9. Area Electrical Classification
10. Line Size
Flow Meter/ Transducer
1. Tag No./Model No.
2. Type
3. Size & End Connection/Rating
4. Wetted Parts
5. Mounting
6. Pressure Drop @ Max Flow
7. Face to Face Dimension
8. Transducer Material
9. Transducer construction
10. Electrical protection
11. Pressure Tapping
12. Testing
Flow Transmitter
1. Tag No./Model No.
2. Type
3. Input Power
4. Calibration Range
5. Output Signal (Note 1)
6. Gross Volume Flow Accuracy (Note 2 & 3)
7. Input signal
8. Housing ( Enclosure class)
9. Direct connectivity with on-line Gas Chromatograph
10. Manual entry of gas composition
11. AGA- 8 Calculations
12. Serial Communication port
13. Communication Protocol
Accessories
1. Flow conditioner
2. Pressure transmitter
3. Temperature Probe/ transmitter
4. Flow computer
5. Third party certification
6. Flow Calibration
ODS/SOF/23 ODS/SOP/17 01 00 21.07.2010
11 - High, Mumbai ELECTRO-MAGNETIC Discipline Instt.
ISO 9001: 2000 FLOW METER Page # 1 of 6
FOR
ELECTRO-MAGNETICFLOW METER
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

2.1 Reference documents and Specifications 3
4.0 Electro-Magnetic Flow meter 3
4.1 Application 3
4.2 General 3
4.3 Material 5
4.4 Meter Selection 5
4.5 Miscellaneous 5
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Electro-Magnetic Flow Meter for the intended process application .
b) Basic Bid Work
c) Project P & IDs / Process Design Criteria / Instrument Process Data Sheets
in the Basic Bid Work and P & IDs.
3.2 The vendor shall be responsible for the selection of the Electro-Magnetic Flow
meter suitable for its intended application, its procurement, tagging, packing,
testing & calibration, preparation for shipment, along with accessories, spares, and
3.3 The Electro-Magnetic Flow Meter Assembly shall include sensors electrode sub
assembly, converters, pre-amplifier / transmitter, indicator, totalizer and all the
accessories necessary to make the measurement system complete.
4.0 ELECTRO-MAGNETIC FLOW METERS:
4.1 Application:
4.1.1 Electro-Magnetic Flow Meters shall be used as the flow-measuring system element
wherever dictated by the process requirements.
4.2 General:
4.2.1 The Electro-Magnetic flow meters shall be provided with flanged end connections
primarily as per ANSI B 16.5, the rating and facing of which shall be as per the
piping specifications.
4.2.2 The flow direction shall be clearly stamped or cast on the body to avoid polarity
errors. Meter shall have forward & reverse measurement functions and reverse
flow shall be confirmed by status output / indication.
4.2.3 Meter signal / power cable entry shall be ½” / ¾” NPTF respectively, as per ANSI
B 2.1.
4.2.4 As a minimum, Transmitter shall be ‘SMART’ type, 4 – 20 mA / HART output with a
local indicator. In addition, the meter shall be capable of providing the output in other
required form (pulse, serial, contact, etc.).
4.2.5 The meter’s enclosure housing the electrical parts, shall be suitable for the
hazardous area classification. Unless otherwise specified, the enclosure shall be
Explosion Proof (NEMA 7) & Weather proof to NEMA 4X /IP 65 or better. The
whole system shall be certified by a statutory body (like FM / UL / BASEEFA /
PTB / CMRI /DGMS). The vendor shall furnish certificate(s) for the same.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.2.6 The Electro-Magnetic Meter’s field coils shall be hermetically sealed. Coil
insulation shall be class F suitable for high temperature. Suitable grounding type
system and material shall be selected for the metering element.
4.2.7 Field coils may operate on the alternating supply voltage. Replaceable electrodes /
Frequency excitation methods are also acceptable where the magnetic flow meter
is operated on AC / DC voltages. Vendor shall indicate the power supply
requirements and furnish the power consumption for the meter (sensor, transmitter,
display, etc.) along with the sizing calculations for the selected meter. Standard
Signal types and communication protocols shall be offered. Appropriate EMI / RFI
protection for the meter shall be considered.
4.2.8 Meter shall not necessarily be of the line size indicated in the P&ID, but shall be
sized for range of flow regime and the conductivity /velocity requirement desired
for the meter. However, the meter shall be ‘Full bore’ meter with respect to its
meter run. Straight run requirement shall be sized as per the manufacturer’s
recommendations. Meeting the flow profile requirement for the meter by providing
necessary straighteners / flow conditioners etc., shall be vendor’s responsibility.
4.2.9 Magnetic Flow Meter shall be Microprocessor based system, in explosion proof
housing. Meter shall have a non-volatile memory for data access and data transfer
to remote controllers / indicators / DCS. There shall be no data loss upon the loss
of the power supply to the meter.
4.2.10 Where the process fluid may result in coating of the electrodes, suitable measures /
special installation requirements to minimize such coating shall be a part of the
design consideration in selection of meters. Monitoring of such adhesions
[Electrode scaling/ Electrode corrosion], Electrode leakage, Liner deformation, gas
bubbles and solid identification, shall be a part of the meter diagnostics. Meter
shall also have diagnostics features such as incorrect installation and partial filled
meter . Electrodes shall be replaceable type.
4.2.11 Where the fluid is having low conductivity / contain solids in the streams (like
slurries containing magnetic particles), vendor shall offer system with suitable
circuitry for compensating the signal changes so induced by the permeable solids.
4.2.12 The ‘minimum’ fluid conductivity shall be specified for which the meter
performance is within specified values.
4.2.13 The configuration capabilities of the meter shall be for LCD display of indication
of actual flow rate, forward, reverse, sum total flow indications, conductivity,
temperature, status indications. The same shall be available as user selectable
parameter on the LCD display of the meter.
4.2.14 The ‘local’ 2 line, 6 ½ (min.) digit alphanumeric backlit LCD display shall be
provided ‘integral’ with the meter / transmitter and shall be easily visible from
grade.
4.2.15 Software security shall be provided in the meter. Upscale / downscale alarms &
Engineering units shall be user selectable. Programming for range , alarms, display
settings shall be possible through front face of the meter and without opening the
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
transmitter housing in hazardous area. The programming method shall be touchpad

keys / magnetic keys / optical key.
4.2.16 Manual / Auto zeroing (nulling) facility shall be provided for the meter to offset
effects of nearby magnetic disturbances in ‘no-flow’ condition. This shall be done
from the meter front face display without opening the cover in the Hazardous area.
4.2.17 Wherever specified, a separate meter receiver with 2 line (min.) backlit LCD
indicator for instantaneous flow rate, flow totalizer and diagnostic functions shall
be shall be provided in the Control room
4.2.18 Calibration shall be 5 point ( min ) calibration unless otherwise specified and to be
carried out at an accredited lab as per Standard ISO 8316.
4.2.19 Vendor shall complete the data sheet enclosed at Annexure-I.
4.3 Material:
4.3.1 The material requirements for Electro-Magnetic Flow Meters shall in general be
according to clause 3.6.4.5 of Instrumentation Design Criteria Internals of the
meter shall be SS-316 minimum and HASTALLOY-C for piping class ( A11 ,
B11 , C11 , D11 , E 11, F11, PA11, PB11, PD11, PE11, PF11). As a minimum, the
meter flow tube, electrodes and coil housing should be SS 316. The housing should
be fully welded. Bolted coil housing with rubber or plastic gaskets is not
acceptable for offshore installation.
4.3.2 Tube liners shall be selected to meet the process requirement and shall be proven
for the application specified in the basic bid work.
4.3.3 The Contractor shall ensure that all wetted parts of Electro-Magnetic assemblies
shall meet NACE MR-01-75 (Latest Edition) and are compatible with the process
conditions.
4.3.4 Transmitter housing and mounting accessories required for meter shall be SS 316
or better. Meter enclosure shall be suitable for hazardous area. All instrument
supports shall be galvanized type for installation.
4.4 Meter Selection:
4.4.1 Over Range: Shall be designed for an over-range of at least 130% of Max flow.
4.4.2 Accuracy: ±0.5% of the reading or better.
4.4.3 Repeatability: ±0.1%
4.5 Miscellaneous
4.5.1 The Electro-Magnetic Flow Meters shall be installed after hydro testing and line
flushing.
4.5.2 All castings and weldings (other than slip-on welds, which shall be Dye
Penetration tested) shall be 100% radio graphed.
4.5.3 Inspection, testing & calibration shall be as per the Clause 3.6.4.7 of Design
Criteria.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I - Typical Data Sheet For Electro-Magnetic Flow Meter

MAGNETIC FLOWMETER
Units : Flow → Liquid-M /Hr Gas → NM3/Hr, Steam → Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C Level/ Length→ mm
3
1. Meter Tag No.

2. Service
3. Location
4. Line Size, Sched.
5. Line Material
CONN'S
6. Connection Type
7. Connection Mat'ls
8. Tube Material SS 316
9. Liner Material PTFE or Eq. suitable for process service
10. Electrode Type Burn off/ flush /MFR Design with PTR
11. Electrode Matl. SS 316 / Hastelloy
METER
12. Meter Casing SS 316
SENSOR
13. Power Supply Elect. Code 24 V DC from transmitter
14. Grounding, Type & Matl. *
15. Accuracy ± 0.5% of measured value
16. Enclosure Class IP65 / NEMA 4X
17. Mounting Integral / Field
18. Display *
METERING
ELEMENT
19. Display parameters *

20. Outputs 4-20mA HART / Pulse /serial/ Status
21. Communication output Serial
TRANS
22. Hazardous area Approval *
MITTER
23. Enclosure Class IP65 / NEMA 4X
24. Housing SS 316
25. Programming *
26. Cable entry *
27. Diagnostic features *
28. Fluid
29. Max, Flow, Units
30. Max, Velocity, Units
31. Maximum Viscosity
32. FLUID Norm. Flow M3/hr Min. Flow M3/hr
33. Max. Temp. °C Min. Temp °C.
34. Max.Press Kg/cm g Oper.PressKg/cm2
2
35. Min. Fluid Conductivity

36. Vacuum Possibility
INSTRUM
ASSOCIA
37. Instrument Tag Number

TED
ENT
38. Power Consumption

39. Transmitter Output *
TRANS.
40. RFI/EMI Protection *
41. Manufacturer
42. Meter Model Number
43. Instrument Model Number
44. Material Certificate
45. Calibration Certificate from Accredited Lab
• * By Vendor
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
11 - High, Mumbai TEMPERATURE Discipline Instt.
ISO 9001: 2000 GAUGE Page # 1 of 8
FOR
TEMPERATURE GAUGE
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 4
AK BK GRP 9 28.03.2007 3
AK BK GRP 9 31.09.06 2
AK MC RK 9 31.09.06 1
ET MC AC 9 25.08.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Temperature Gauge 3
4.1 Gauge type 3
4.2 Material 3
4.3 Accuracy 4
4.6 Thermocouple & Thermowell 4
4.7 Equipment protection 5
4.8 Miscellaneous 5
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Temperature Gauge for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Temperature gauge suitable
4.0 TEMPERATURE GAUGE:
4.1 General:
4.1.1 The temperature gauges shall be used for local indication. These local temperature
indicators shall in general be heavy duty, weatherproof, dial type bi-metal
thermometers with 100mm to 150 mm dial size, external zero adjustment, every
angle rotatable and rigid stems. Liquid filled casing shall be provided for dial
thermometers.
4.1.2 Filled system dial thermometers shall be used when the operating temperature is
between 0oC (32oF) and –45oC (-50oF).
4.1.3 The Bi-metal shall be adjustable union stem type with SS 316 material for the
stem. The Union size shall be ½” NPT and the diameter shall be suit the well
diameters.
4.1.4 Dial Thermometers shall be provided with separable stainless steel thermometer
wells.
4.1.5 Filled capillary instruments shall be fully compensated for ambient temperature
and shall not be used for measurements above 420 oC. Capillary and armour shall
be stainless steel. The armour shall be flexible.
4.2 Material:
4.2.1 The material requirements for temperature gauges and thermowells shall in general
be according to clause 3.6.4.5 of Instrumentation Design Criteria and as per
Anexure I of this document.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.2.2 Case material for all temperature gauges shall be SS 316. Capillary and Armour
shall be of stainless steel.
4.2.3 The Window material shall be Shatter proof glass.
4.3 Range:
The range shall be selected such that the normal operating temperature shall fall in
the middle third of the span.
4.4 Accuracy:
The accuracy shall be ±1% of the span.
4.5 Reading Scales:
Indicating scales and recorder charts shall read out in degrees Celsius.
4.6 THERMOCOUPLE & THERMOWELL:
4.6.1 Thermowell shall be installed for all temperature-sensing elements installed on
process lines or vessels.
4.6.2 The thermowell shall be suitable for the process media, generally 316 SS, or other
material as required by the project piping specification. The thermowell shall be
machined from drilled bar stock with minimum wall thickness of 4.8mm, and 6mm
bore. Bore shall be concentric with the outside diameter to within 10% of wall
thickness. The thermowell shall be provided with hexagonal head.
4.6.3 (The thermowell material requirement for various piping classes shall be as per
Annexure – I of this specification)
4.6.4 Thermowell flanges shall be of stainless steel and shall be rated one piping class
higher than the pipe to which it is connected.
4.6.5 Thermometer well shall have ½” NPT female thread for element and 1½” flanged
for vessel or piping connection.
4.6.6 Thermowells to be used as test wells shall be provided with a stainless steel
screwed plug and chain.
4.6.7 Wells for insulated vessels and lines shall have extension necks.
4.6.8 The Thermowell tip shall be at centerline of pipe but immersion length shall not
exceed 400 mm for higher size pipes.
4.6.9 Thermowell shall be designed to withstand vibration stresses caused by stream
velocity. Wake frequency at maximum flow velocity shall be less than 80% of the
natural frequency of the Thermowell. The Contractor shall provide calculations to
ASME performance Test Code 19.3, Part 3: Instruments and Apparatus
temperature Measurement.
4.6.10 A thermometer well shall be installed adjacent to all flow recorder, temperature
recorder and controller measuring elements.
4.6.11 Thermowell welding shall be full penetration type with ‘U’ length as follows:
4” to 6” lines - 280 mm
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Above 6” - 320 mm
Vessels - 400 mm
4.6.12 The typical thermowell installation shall be as per Annexure – II of this
specification.
4.7 EQUIPMENT PROTECTION:
In addition to clause no. 3.6.4.4 of Instrumentation Design Criteria Gauge
following protection requirements shall in general be as per.
4.7.1 Temperature Gauges: 130% of range shall be provided as Over-range protection
for the temperature gauge. The temperature gauge shall be weather proof to NEMA
4X / IP 66
4.7.2 Thermowells: Thermowells shall be designed to withstand vibration stresses
caused by stream velocity. Wake frequency at maximum flow velocity shall be less
than 80% of the natural frequency of the Thermowell. Temperature elements
having extended lengths shall be handled with care and suitably protected to
prevent damage.
4.8 Miscellaneous:
Thermowells shall not be installed in elbows. Lagging extensions shall be
provided on insulated piping and insulated vessels. Thermowells shall be oriented
so that gauge dials are clearly visible and readable from the deck or the appropriate
access platform. Where a thermowell location causes poor access or visibility, the
Contractor shall provide a remote-mounted capillary-gauge, located in an
accessible and readily visible location.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I
Material Selection Chart for Thermowells
Thermowell
S. No. Piping Class
Thermowell Flange
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1,
PE1, PXF1, PF1, A2, B2, D2, E2, XG1, A1H, A3,
1 B3, A8 SS 316 CARBON STEEL
2 INJECTION WATER SERVICE SS 316 CARBON STEEL
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
4 A5 MONEL MONEL

SS 316 SS 316
7 A10, B10, D10, E10, F10 SS 316 L SS 316 L
A11, B11, D11, E11, F11, PA11, PB11, PD11,

8 PE11, PF11
HASTALLOY C HASTALLOY C
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II
(Hook Up Drawing)
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – III – Typical data sheet Temperature Gauge
TEMPERATURE GUAGES
Units : Flow →Liquid-M3/Hr, Gas → Kg/Hr, Steam → Kg/Hr, Pressure → Kg/Cm2 G, Temperature → Deg C, Level/ Length →mm
1 Type :- Bimetal : Filled : Other : FILLED SYSTEM
2 Well :- Required : Not required : 14 SAMA Class :
3 Mounting :- Local : Surface : Flush : Compensation : Case : Full :
4 Dial Size :- 150 mm : Other : 15 Bulb type :
5 Colour :- White : With Black letters: Bulb Material :
6 Case Material :- Cast Aluminium : Other : 16 Bulb Union 1/2" NPT(M) : Other :
Threaded To :
7 Window Material :- Glass : Acrylic : Other : 17 Extension Type :- Rigid : Bendable: Angle :
8 Conn. Location :- Back : Bottom : 18 Bulb Dia :- Mfr. Std. : To suit well : Other :
Back Adjustable : All Angles Adjustable : 19 Capillary Material :
9 Accuracy : Armour Flexible :

10 Enclosure : Armour Material :
Enclosure Class : 20 Capillary Length :
11 Zero adj. : - Over range Protection :- 130% of range :
BIMETAL THERMOWELL
12 Stem : 21 Material : Other :
Type : Adj. Union : Threaded : 22 Construction : Driller bar Built up :
Stock
Material : Other :
Other : 23 Process Connection : 11/2" 1" NPT(M) :
flanged :
13 Stem Dia :- Mfr. Std. : Other :
Other : 24 Gauge Connection 1/2" NPT(F) Other :
To suit well : :
25 Thermowell As Per Drawing. :
26 Options : (a) SS tag plate
(b) Make / Model No. :
Tag Temp Deg C Range Well Dim Mm Flange Service Options
No. Deg C
Nor Max U T Material Rating,
face/fin.
NOTES :
1. Immersion lengths of thermo wells on vessels to be confirmed by respective vessel vendors.
□ VENDOR’S SIGNATURE WITH SEAL
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 SWITCHES Page # 1 of 8
FOR
TEMPERATURE SWITCHES
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 2
ET RS GRP 10 28.03.2007 1
AK MC AC 10 13.05.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Temperature switch 3
4.1 Switch type 3
4.2 Material 4
4.3 Accuracy 4
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Temperature Switch for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Temperature Switch
4.0 TEMPERATURE SWITCH:
4.1 SWITCH TYPE:
4.1.2 GENERAL:
4.1.2.1 The switch mechanism shall be a hermetically sealed micro-switch of SPDT,
snap action type.
4.1.2.2 The switch shall be provided with 2Nos. ½”NPT (F) cable entries. One cable
entry shall be plugged with suitable explosion-proof plug.
4.1.2.3 Temperature elements installed on process lines or vessels shall be installed in
thermo wells.
4.1.2.4 Thermo wells pressure/temperature rating shall be in accordance with ANSI B
16.5-1981.
4.1.2.5 Thermo wells shall have DN 40 RF Flange process connections for process lines
and DN50RF flange for connections to vessels. Sensor connection to thermo
wells shall be ½’’ NPT.
4.1.2.6 Stainless steel thermo well flanges shall be rated one piping class higher that the
pipe to which it is connected.
4.1.2.7 Arcing during making or breaking of switch contacts shall be minimum. The
switch contacts shall have long life and minimum wear. The material chosen for
switch contact shall have good thermal conductivity for dissipating heat.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.1.2.8 There shall be minimum bounce during making and breaking of switch contacts
and switch mechanism shall be designed to minimize the vibration.
4.1.2.10 Temperature switches shall be heavy duty, with user adjustable set point.
Adjustments shall be tamper-proof.
4.1.2.11 The thermo well shall be designed to withstand vibration stresses caused by
stream velocity. Wake frequency at maximum flow velocity shall be less than
80% of the natural frequency of the thermo well.
4.1.2.12 Vendor shall ensure that set point falls between 35% and 70% of adjustable
range of the selected model in general.
4.1.2.13 Thermowells shall not be installed in elbows. All Temperature instrument shall
be mounted as close as possible to sensing point. Mountings accessories required
for Temperature Instrument shall be 316SS or better. When switches and other
devices are grouped and mounted on a instrument stand it should be in such a
manner that removal of each instrument shall be possible without the need to
disconnect, dismantle or remove any other instruments or tubing.
4.1.2.14 Temperature switch shall have tamper-proof set point adjustment. Electrical
Temperature switches shall be calibrated for there set points.
4.1.2.15 All switches shall be Ex d.
4.2 Material:
4.2.1 The material requirements for Temperature switch shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and the material selection chart
provided in Annexure II of this specification.
4.3 Accuracy: The maximum error shall not exceed 1% of the span. Repeatability
shall be ±1%.
4.4 Reading Scales: Units for Temperature switch shall be in deg C.
4.5 Enclosure Class: In addition to weatherproof, the switch enclosure shall be
explosion-proof to NEMA-7 and certified by third party Statuary bodies like
UL/FM/BASEEFA or equal for use in hazardous area (CL 1, DIV.1, and GR.D).
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I
Material Selection Chart for Thermowell
S. No. Piping Class Well Flange
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 SS316 CS
2 INJECTION WATER SERVICE SS316 CS
3 A4, A6, A9, B9, D9, E9 SS316 SS316
4 A5 MONEL MONEL
5 A7 TITANUM TITANUM

SS316 SS316
7 A10, B10, D10, E10, F10 SS316L SS316L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
HASTC HASTC
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II CONT..
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE –III Typical data sheet for Temperature Switch
TEMPERATURE SWITCH
UNITS: - Flow Liquid – M3/HR Gas – NM3/HR Steam – Kg/hr Pressure – kg/cm2 Temperature – deg C Level/length -mm
1 Type MEASURING UNIT
2 Well 25 SAMA Class
3 Case material 25.1 Compensation
4 Mounting 26 Bulb Type
5 Enclosure 26.1 Bulb Material
Enclosure Class 26.2 Bulb Union Thread
6 Elec. Area Class 26.3 Bulb Extension Type
7 Intrinsically Safe 26.4 Bulb Dia
9 27 Capillary Materials
Power Supply for switch 28 Armour flexible
29 Armour Material
10 Accuracy 30 Capillary Length
31 Over Range protection
11 Repeatability THERMOWELL
SWITCH 32 Material
13 Electric contact 33 Construction
14 Qty. 34 Process Connection
15 FORM 35 Gauge Connection
16 TYPE 36 Thermo well as per
attached Drawing
17 Contact Rating OPTIONS
18 Load Type a) All mounting
accessories need to be
supplied.
19 Cable Entry b) Integral output meter
20 No. of Entries 37 Make
21 Set point Adj
22 Differential
TAG RANGE SET TEMPERAT WELL FLANGE SERVICE OPTIONS
No. POINT DIM.mm
NOR. MAX. U T MATERIAL #, FACE,
FINISH
NOTE:-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Offshore Design Section SPECIFICATION FOR Rev. No. 3
Engineering Services TEMPERATURE Discipline Instt.
ISO – 9001:2000 TRANSMITTER Page: 10 OF 10
(ELECTRONIC)
ANNEXURE – IV
TYPICAL DATA SHEET – TEMPERATURE TRANSMITTER
TEMPERATURE TRANSMITTERS
UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Steam – Kg/hr Pressure – kg/cm2 Temperature – deg C Level/length -mm
1 Function MEASURING UNIT
2 Type 15 SAMA Class
3 Case 15.1 Compensation
4 Mounting 16 Bulb Type
5 Enclosure 16.1 Bulb Material
Enclosure Class 16.2 Bulb Union Thread
6 Elec. Area Class 16.3 Bulb Extension Type
7 Intrinsically Safe 16.4 Bulb Dia
8 Power Supply 17 Capillary Materials
9 Power Supply for 18 Armour flexible
Transmitter
10 Cable Entry 19 Armour Material
11 Accuracy 20 Capillary Length

12 Repeatability 21 Over Range protection
THERMOWELL
TRANSMITTER 22 Material
13 Output 23 Construction
14 Trans Power Supply 24 Process Connection
25 Gauge Connection
26 Thermowell as per
Drawing
OPTIONS
a Mount Acc for 2”

pipe
b. Integral Output
meter
TAG No. RANGE TEMPERAT WELL FLANGE SERVICE OPTIONS
DIM
NOR. MAX. U T MATERIAL RATING,
FACE,
FINISH
AS PER
P& ID
NOTE:-
(ELECTRONIC)
CONTENTS

4.0 Temperature Transmitter 3
4.1 General 3
4.2 Thermo well 4
4.3 Accuracy 5
4.4 Repeatability 5
4.5 Output Signal 5
4.6 Material 5
Annexure II Hook-up drawing-Thermowell 8
Annexure III Temperature Transmitter W/ Thermo well 9
Annexure IV Data Sheet Format 10
(ELECTRONIC)

This functional specification describes the essential design considerations for the selection of
Temperature Transmitter (Electronic) for the intended service.
a) Instrumentation/ Process Design Criteria
b) Basic Bid Work
c) Project P & IDs
3.2 The vendor shall be responsible for the selection of the Temperature Transmitter suitable for
at site shall be under vendor’s responsibility.
4.0 TEMPERATURE TRANSMITTER
4.1 General:
4.1.1 Temperature transmitters shall be integral with the sensing element assembly.
4.1.2 The sensing element shall be RTD 3 wire type or thermo couple.
4.1.3 The RTD element length shall be selected to suit the Thermowell insertion length.
4.1.4 The thermocouple characteristics shall conform to IEC 584-1 and the RTD shall be
platinum 100 ohms at 0 centigrade to relevant standard IEC 751/DIN 43760 and complete
with a flanged thermowells.
4.1.5 Welding of flange well shall be full penetration type. Weld shall be dye penetrate checked
as per BS 5500.
4.1.6 Gasket contact surface finish for RTJ flanges shall be 63 RMS (MAX) and shall confirm to
ANSI B16.5.
4.1.7 For temperature up to 350 centigrade, measurement shall be by means of platinum
resistance temperature detectors, 100 ohm at 0 centigrade to BS 1904, with RTD/current
transmitters.
4.1.8 Transmitters shall include a Digital indicator scaled in engineering units, and shall be
mounted integrally in the head of the detecting element where access permits, otherwise
remotely mounted. Where the transmitter indicator is not readily visible a separate loop-
powered indicator shall be provided. The output meter shall be suitable for use in the
hazardous area.
(ELECTRONIC)
4.1.9 Thermocouples shall only be used above 350 centigrade, or when it can show that the
mechanical construction of an item does not permit the fitting of an RTD.
4.1.10 Surface metal temperatures shall be measured by thermocouples secured to the surface.
4.1.11 Thermocouples shall normally be the mineral-insulated metal- sheathed type, isolated from
earth. Characteristic of mV versus temperature shall conform to BS-4937.
4.1.12 Thermocouples shall be Type K (Chromel-Alumel) for the temperature range –20 degree
centigrade to 1000 degree centigrade. For temperature above 1000 degree centigrade, Type
R (Platinum/13 % Rhodium-Platinum) shall be used.
4.1.13 Transmitters shall be “SMART” type and use HART protocol for communication.
system, communication system etc. All electronic modules shall be designed for short
circuit protection.
4.1.15 Span shall be continuously adjustable over the transmitter range.
4.1.16 The TT shall be provided with ½”NPT (F) cable entries.
4.1.17 The change in out put due to change in ambient temperature should be very minimum.
4.1.18 The range shall be selected so that the normal operating temperature shall fall in the middle
third of the span.
4.1.19 Contractor shall submit wake frequency calculation as per PTC 19.3 for review. In case the
wake frequency exceeds 80% of natural frequency the recommended changes in length and
wall thickness of well, as per PTC 19.3 shall be submitted for approval.
4.1.20 TT shall have adjustable zero and span. Setting adjustment shall have locking
arrangement.
4.1.21 Over range protection shall be 130% of range.
4.1.22 All Transmitter instrument shall be mounted as close as possible to sensing point.
Mountings accessories required for Temperature Instrument shall be 316SS or better.
4.1.23 All the Temperature Transmitter shall be intrinsically safe and certified by statutory body
like UL/FM/BASEEFA/CMRI/DGMS or equivalent. The certificate for the same shall be
provided with the Purchase Specification.
4.1.24 TT Housing shall be Dual Compartment Type.
4.2 THERMOWELL:
4.2.1 Thermowell shall be installed for all temperature-sensing elements installed on process
lines or vessels.
(ELECTRONIC)
4.2.2 The thermowell shall be suitable for the process media, generally 316 SS, or other material
as required by the project piping specification. The thermowell shall be machined from
drilled bar stock with minimum wall thickness of 4.8mm, and 6mm bore. Bore shall be
concentric with the outside diameter to within 10% of wall thickness. The thermowell shall
be provided with hexagonal head.
4.2.3 (The thermowell material requirement for various piping classes shall be as per Annexure –
I of this specification)
4.2.4 Thermowell flanges shall be of stainless steel and shall be rated one piping class higher
than the pipe to which it is connected.
4.2.5 Thermometer well shall have ½” NPT female thread for element and 1½” flanged for
vessel or piping connection.
4.2.6 Thermowells to be used as test wells shall be provided with a stainless steel screwed plug
and chain.
4.2.7 Wells for insulated vessels and lines shall have extension necks.
4.2.8 The Thermowell tip shall be at centerline of pipe but immersion length shall not exceed
400 mm for higher size pipes.
4.2.9 Thermowell shall be designed to withstand vibration stresses caused by stream velocity.
Wake frequency at maximum flow velocity shall be less than 80% of the natural frequency
of the Thermowell. The Contractor shall provide calculations to ASME performance Test
Code 19.3, Part 3: Instruments and Apparatus temperature Measurement.
4.2.10 Thermowell welding shall be full penetration type with ‘U’ length as follows:
4” to 6” lines - 280 mm
Above 6” - 320 mm
Vessels - 400 mm
4.2.11 The typical thermowell installation shall be as per Annexure – II & III of this specification.
4.3 Accuracy : ±0.1%. Of FSD

4.4 Repeatability: ±0.1%.
4.5 Output Signal:
Output signal shall be 2 wired 4-20 mA DC, and capable of delivering the rated current
signal into external load of around 600 ohms when powered with 24V DC (negative
earthed).
4.6 Material:
4.6.1 The material requirements for TT shall in general be according to clause 3.6.4.5 of
Instrumentation Design Criteria, FS-2004A for Piping Design (2008) & Piping Material
Specification
(ELECTRONIC)
4.6.2 Transmitter body studs shall be high tensile stainless steel, or other corrosion-resistant
material for higher stress levels.
4.6.3 In general MOC for TW shall be as per Annexure I. T/W, rating class shall be one
class higher than Piping Class.
ambient conditions to which they are exposed

The Transmitter shall be weatherproof (IP 65 or better). In addition the TT enclosure shall
be as per Clause no 3.6.4.4.5 of Instrument Design Criteria
(ELECTRONIC)
ANNEXURE – I
Material Selection Chart for Thermowell
S. No. Piping Class Well Flange
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1, PD1, PE1,
1 PXF1, PF1, A2, B2, D2, E2, XG1, A1H, A3, B3, A8 SS316 CS
2 INJECTION WATER SERVICE SS316 CS
3 A4, A6, A9, B9, D9, E9 SS316 SS316
4 A5 MONEL MONEL
5 A7 TITANUM TITANUM
** A1N, B1N, D1N, E1N, F1N, XF1N, PA1N, PB1N,

6 PD1N, PF1N, XG1N
SS316 SS316
7 A10, B10, D10, E10, F10 SS316L SS316L
A11, B11, D11, E11, F11, PA11, PB11, PD11, PE11,

8 PF11
HASTC HASTC
[** All wetted parts of Thermowell shall conform to NACE MR-01-75 (Latest edition).]
(ELECTRONIC)
ANNEXURE – II
HOOK UP DRAWING – THERMOWELL
(ELECTRONIC)
Annexure-III
Temperature Transmitter W/Thermo well
VERTICAL MOUNTING
HORIZONTAL MOUNTING
(1)- FLANGE WITH GASKET (RF /RTJ) AS PER PIPING STANDARD

(2)- STUD BOLTS & NUTS ASTM A320 GR.L7M/A194 GR.7M WITH HOT DIPGALVANIZED TO
ASTM A153, AS PER THE REQUIREMENT
Offshore Design Section Rev. No. 5
SPECIFICATION FOR
Engineering Services Discipline Instt
ISO – 9001:2008
“DIFFERENTIAL PRESSURE
GAUGE” Page: 2 OF 7
CONTENTS

2.1 Standards
3
2.2 Reference documents
4.0 Differential Pressure gauge 3
4.1 General 3
4.2 Material 4
4.3 Range 5
4.4 Accuracy 5
Annexure I Hook-up drawing 6
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008

selection of Differential Pressure Gauge for the intended service.
2.1 Standards :
a) ASME B 40 .100 – latest edition : Pressure gauges and gauge attachments
b) EN - 837 - latest edition: Pressure gauges Dimensions, metrology, requirements
and testing
2.2 Reference Documents :
b) Basic Bid Work
c) Project P & IDs
indicated in above reference documents.
3.2 The vendor shall be responsible for the selection of the Differential Pressure
gauge suitable for its intended application, its procurement, tagging, packing,
testing & calibration, preparation for shipment, along with accessories, spares,
and assistance where required for its installation & commissioning at site.
4.0 DIFFERENTIAL PRESSURE GAUGE:
4.1 General:
4.1.1 Differential Pressure gauges shall be used for local indication. Differential
Pressure Gauge may be Field mounted or Panel mounted based on the
requirements.
4.1.2 Dial size of Field mounted gauges shall not be less than 6” (150 mm). Process
connection for these gauges shall be ½ ” NPTM , generally with bottom entry .
4.1.3 Dial size of Panel mounted differential pressure gauges shall be of preferably
6”or 4” . Process connections for these gauges shall be ½ ” NPTM with back
entry .
4.1.4 Differential Pressure gauges shall in general be heavy duty, weatherproof , white
coloured dial with black numerals & markings and with black pointer.
4.1.5 Position of blowout disc shall be preferably rear mounted where ever not possible,
top mounted can be considered.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
4.1.6 Gauges that are 150 mm (6”) or larger diameter shall have micrometer pointers
for external or internal zero adjustment. Gauge pointers shall be adjustable
without removal from shaft.
4.1.7 Differential Pressure gauge measuring element shall generally be Bellows /
Diaphragm type. Diaphragm seals shall be used for measurement of slurries,
viscous and chemicals (effluent/ injection services etc.). Diaphragm seals with
capillary shall in general be 1 ½” flanged.
4.1.8 Additionally, where damping is required for gauges, differential pressure gauge
shall be liquid filled or any other proven (with PTR) advanced damping
technology can be used (without liquid filled damping) to arrest the process
fluctuations and vibrations due to installation. Glycerin / Silicone oil shall
generally be used for liquid filling. Liquid filled gauges (considering both
process and ambient temperature limits) shall have a small vapor space for
thermal expansion of liquid fill.
4.1.9 Differential Pressure gauge enclosure shall be weather proof to NEMA 4 / IP 65
or better. Over range protection of 130 % of maximum static pressure shall be
provided without affecting its calibration / accuracy.
4.1.10 Gauges located on lines subjected to pulsating pressures (such as all pumps,
compressors discharge service etc.) shall be provided with Snubber type pulsation
dampeners.
4.1.11 Gauge savers shall be provided wherever specified to prevent the gauge when
maximum working pressure exceeds 130% of maximum static pressure. Gauges
in vacuum service shall have over range protection to full vacuum. A visible Stop
Pin shall be used to restrict the upper limit of the pointer travel.
4.1.12 DPG shall be installed in such way that length of impulse lines is kept minimum.
4.1.13 Gauges shall be capable of passing Vibration Test , Fatigue Test , Endurance
cycle Test etc. as specified in International Standards (EN -837 etc.) .
4.2 Material:
4.2.1 Process connections and ‘Material of construction’ of all wetted parts shall be
compatible with the process fluid however it shall be SS 316 minimum . For Sour
service applications, MOC shall be compliant to NACE MR-01 75 requirements .
For raw seawater service, all wetted parts shall be of Monel material.
4.2.2 Material for Pointer shall be SS 316 or Aluminium.
4.2.3 Material for movement shall be SS 316 however for liquid filled gauges SS 304
can be acceptable.
4.2.4 Valve Manifold shall be SS 316 as minimum and compliant to NACE MR-01 75
wherever required. Superior material can be accepted.
4.2.5 Case material for all Differential Pressure gauges shall be SS 316 with a screwed
bezel / bayonet bezel retaining ring and weatherproof design.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
4.2.6 Window material shall be of Shatter-proof glass or ‘fully transparent’ acrylic

plastic.
4.2.7 Gauge saver and snubber when used shall be of the same material as that of the
pressure element.
4.3 Range :
4.3.1 Range shall be selected such that at zero differential pressure , pointer will be at
starting point of the scale however only for Vacuum applications, Pointer
position will be at the centre of the scale.
4.4 Accuracy :
4.4.1 Accuracy shall be +/- 1 % of the span or better. However for Low Static pressure
applications ( i.e 0 to 1 kg/cm2 ) accuracy can be +/- 1.6 % of FSD or better.
4.4.2 Change in process conditions shall not affect the accuracy of gauge.
4.5 Reading Scales:
4.5.1 Indicating scale shall be direct reading type . It shall have scale as ‘mm H2O’/
‘mm Hg’ / ‘PSI’ as per process requirements.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
ANNEXURE – I
(Hook Up Drawing)
BILL OF MATERIAL
ITEM QTY SIZE DESCRIPTION MATERIAL
17 2 ½” NPTF TEE , THKxTHKxTHK, SS316
73 2 ½” NPTM NIPPLE , 3” LONG , SS316

PL x THK x THK x THK,
96 2 ½” NPTM PLUG , SCRD SS316
107 A/R ½”OD x 0.065 THK TUBING SS316
138 2 ½” THK x ½” OD NPTM MALE CONNECTOR , SS316
143 6 ½” THK x ½” OD NPTM MALE CONNECTOR , SS316
5 VALVE MANIFOLD SS316 / better
200 - - VALVE - BY PIPING
201 - - NIPPLE - BY PIPING
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
ANNEXURE – II
TYPICAL DATA SHEET – DIFFERENTIAL PRESSRUE GAUGE
DIFFERENTIAL PRESSURE GAUGES

UNITS :- Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C Level/length -M
1 Type 15 Diaphragm Seal (wherever required)
2 Mounting a) Type
3 Dial Size/Colour b) Wetted Parts
4 Case Material c) Other Material
5 Bezel Ring d) Process Connection
6. Window Material e) Facing & Finish
7 Enclosure Class f) Capillary Material
8 Pressure Element g) Armour type
9 Element Material h) Armour Material
10 Socket Material i) Capillary Length
11 Accuracy j) Flushing Filling
Conn.
12 Zero Adjustment 16 Over range protection
13 Connection & Location 17 Blow out protection
14 Movement 18 Options
15 Diff Pressure Range & a) Snubber
Scale
b) Siphon
c) Gauge saver
d) Liquid filled casing
e) Vacuum protection
f) Space ring
g) Solid front
TAG RANGE OPER. MAX. OPER. MAX. FLUID

No. PRESSURE SERVICE TEMP SERVICE SERVICE OPTIONS
TEMP. TEMP.
NOTE:-
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt
ISO – 9001:2008 “PRESSURE GAUGE ” Page: 2 OF 7
CONTENTS

2.1 Standards
3
2.2 Reference documents
4.0 Pressure gauge 3
4.1 General 3
4.2 Material 4
4.3 Range 5
4.4 Accuracy 5
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt

selection of Pressure Gauge for the intended service.
2.1 Standards:
a) ASME B 40 .100 – latest edition : Pressure gauges and gauge attachments
b) EN - 837 - latest edition: Pressure gauges Dimensions, metrology,
requirements and testing
2.2 Reference Documents:
b) Basic Bid Work
c) Project P & IDs
indicated in the Basic Bid Work, Design Criteria and P & IDs.
3.2 The vendor shall be responsible for the selection of the Pressure gauge suitable
4.0 PRESSURE GAUGE:
4.1 General:
4.1.1 The pressure gauges shall be used for local indication. Pressure Gauge may be
Field mounted or Panel mounted based on requirements.
4.1.2 Dial size of field mounted gauges shall not be less than 6” (150 mm). Process
connection for these gauges shall be ½ ” NPTM with bottom entry.
4.1.3 Dial size of Panel Mounted Type Pressure gauges shall be of preferably 6”or 4”.
Process connection for these gauges shall be ½ ” NPTM with back entry .
4.1.4 Instrument air / gas supply gauges for instruments like positioners, smart
instruments etc, used as output gauge may have 2” (50 mm) dials.
4.1.5 Pressure gauges shall in general be heavy duty, weatherproof , with white
coloured dial with black numerals & markings and with black pointer.
4.1.6 Position of blowout disc shall be preferably rear mounted where ever not possible,
top mounted can be considered.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt
4.1.7 Gauges that are 6” (150 mm) or larger diameter shall have micrometer pointers
for external or internal zero adjustment .Gauge pointers shall be adjustable
without removal from shaft.
4.1.8 Pressure gauge measuring element shall generally be Bourdon / Bellows /
Diaphragm type. Diaphragm seals shall be used for measurement of slurries,
viscous and chemicals (effluent/ injection services etc.). Diaphragm seals with
capillary shall in general be 1 ½” flanged. For corrosive fluids, in lieu of
diaphragm seal , measuring element of suitable material can be considered for
such services .
4.1.9 Additionally, where damping is required for gauges, pressure gauge shall be
liquid filled or any other proven (with PTR) advanced damping technology can be
used (without liquid filled damping) to arrest the process fluctuations and
vibrations due to installation. Glycerin / Silicone oil shall generally be used for
liquid filling. Liquid filled gauges (considering both process and ambient
temperature limits) shall have a small vapor space for thermal expansion of liquid
fill.
4.1.10 Pressure gauge enclosure shall be weather proof to NEMA 4 / IP 65 or better.
Pressure gauge shall be capable of withstanding 130% of maximum range without
affecting its calibration / accuracy.
4.1.11 Gauges located on lines subjected to pulsating pressures (such as all pumps,
compressors discharge service etc.) shall be provided with Snubber type pulsation
dampeners.
4.1.12 Gauge savers shall be provided wherever specified to prevent the gauge when
maximum working pressure exceeds 130% of range. Gauges in vacuum service
shall have over range protection to full vacuum. A visible Stop Pin shall be used
to restrict the upper limit of the pointer travel.
4.1.13 Gauges shall be capable of passing Vibration Test , Fatigue Test , Endurance
cycle Test etc. as specified in International Standards (EN -837 etc.) .
4.2 Material:
4.2.1 Material requirements for pressure gauges shall in general be according to clause
4.2.2 Process connections and ‘Material of construction’ of all wetted parts shall be
compatible with the process fluid however it shall be SS 316 minimum . For Sour
gas applications , MOC shall be compliant to NACE MR-01 75 requirements.
However for raw seawater service, material for all wetted parts shall be Monel.
4.2.3 Material for Pointer shall be SS 316 or Aluminium. Movement material for liquid
filled gauges can be SS 316 or SS 304. For gauges with other proven technology
(without liquid filled damping) , movement material shall be SS 316.
4.2.4 Case material for all pressure gauges shall be SS 316 with a screwed bezel /
bayonet bezel retaining ring and weatherproof design.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt
4.2.5 Window material shall be of Shatter-proof glass or ‘fully transparent’ acrylic

plastic.
4.2.6 Gauge saver and snubber when used shall be of the same material as that of the
pressure element.
4.3 Range:
4.3.1 Range shall be selected such that the normal operating pressure lies
approximately in the middle third of full scale.
4.4 Accuracy:
4.4.1 Accuracy shall be +/- 1 % of the span or better.
4.4.2 Change in process conditions shall not affect the accuracy of gauge.
4.5 Reading Scales:
4.5.1 Indicating scale shall be direct reading type . Reading Scale used for 2 ” dial size
gauges shall be ‘PSI ’ and for other dial size gauges, it shall be Kg/cm2g unless
otherwise specified in bid documents .
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt
ANNEXURE – I
(Hook Up Drawing)
Note : For Sour Gas service drain valve shall be ball valve and drain connection shall be
connected to closed drain .
BILL OF MATERIAL
ITEM QUANTITY DESCRIPTION SIZE

NO
1 1 SWAGE NIPPLE , PL x TH ¾ ” X ½ ” NPTM
2 2 NEEDLE VALVE , SCRWD ½ ” NPT
3 1 PIPE NIPPLE ½ ” NPTM
4 1 3-WAY ,2-VALVE MANIFOLD
5 1 CAP ½” NPTF
6&7 2 MALE CONNECTOR ½” NPT
TUBINGS ½” NPTM
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3401
Rev. No. 5b
Discipline Instt
ANNEXURE – II
TYPICAL DATA SHEET – PRESSRUE GAUGE
PRESSURE GAUGES
1 Type 15 Diaphragm Seal (wherever required)
2 Mounting a) Type
3 Dial Size/Colour b) Wetted Parts
4 Case Material c) Other Material
5 Bezel Ring d) Process Connection
6. Window Material e) Facing & Finish
7 Enclosure Class f) Capillary Material
8 Pressure Element g) Armour type
9 Element Material h) Armour Material
10 Socket Material i) Capillary Length
11 Accuracy j) Flushing Filling
Conn.
12 Zero Adjustment 16 Over range protection
13 Connection & Location 17 Blow out protection
14 Movement 18 Options
a) Snubber
b) Siphon
c) Gauge saver
d) Liquid filled casing
e) Vacuum protection
f) Space ring
g) Solid front
TAG RANGE OPER. MAX. OPER. MAX. FLUID

No. PRESSURE SERVICE TEMP SERVICE SERVICE OPTIONS
TEMP. TEMP.
NOTE:-
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
11 - High, Mumbai PRESSURE SWITCH Discipline Instt.
ISO 9001: 2000 ELECTRICAL Page # 1 of 8
FOR
PRESSURE SWITCH
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 8 18.02.2008 2
AK SRS AC 9 28.03.2007 1
AK MC AC 9 25.08.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Pressure Switch (Electrical) 3
4.1 Switch type 3
4.2 Material 4
4.3 Accuracy 4
Annexure I Material Selection 5
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of pressure switch (electrical) for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the pressure switch (electrical)
4.0 PRESSURE SWITCH (ELECTRICAL):
4.1 Switch Type:
4.1.2 General:
4.1.2.1 The switch mechanism shall be a hermetically sealed micro-switch of SPDT,
snap action type.
4.1.2.2 The switch shall be provided with 2Nos. ½”NPT (F) cable entries. One cable
entry shall be plugged with suitable explosion-proof plug.
4.1.2.3 Arcing during making or breaking of switch contacts shall be minimum. The
switch contacts shall have long life and minimum wear. The material chosen for
switch contact shall have good thermal conductivity for dissipating heat.
4.1.2.4 There shall be minimum bounce during making and breaking of switch contacts
and switch mechanism shall be designed to minimize the vibration.
4.1.2.5 Process connection from bottom side, 316SS threaded ½” NPTF.
4.1.2.7 Pressure switches shall be heavy duty, with user adjustable set point.
Adjustments shall be tamper-proof.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
4.1.2.8 The pressure-sensing element shall be designed to meet a service life of one
million switching cycles.
4.1.2.9 Vendor shall ensure that set point falls between 35% and 70% of adjustable
range of the selected model in general.
4.1.2.10 Pressure switch shall have tamper-proof set point adjustment.
4.1.2.11 All pressure instrument shall be mounted as close as possible to sensing point.
4.1.2.12 Mountings accessories required for Pressure Instrument shall be 316SS or better.
When switches and other devices are grouped and mounted on a instrument stand
it should be in such a manner that removal of each instrument shall be possible
without the need to disconnect, dismantle or remove any other instruments or
tubing.
4.1.2.13 All the switches shall be Ex d .
4.2 Material:
4.2.1 The material requirements for Pressure switch shall in general be according to
provided in Annexure I of this specification.
4.3 Accuracy:
The maximum error shall not exceed 1% of the span. Repeatability shall be ±1%.
4.4 Reading Scales: Units for pressure switch shall be in kg/cm2.
In addition to weatherproof, the switch enclosure shall be explosion-proof to
NEMA-7 and certified by third party agencies like UL/FM/BASEEFA or equal for
use in hazardous area (CL 1,DIV.1, GR.D).
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I
Material Selection Chart for Pressure switch
S. No. Piping Class ELEMENT/SOCKET
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 SS316
2 INJECTION WATER SERVICE MONEL
3 A4, A6, A9, B9, D9, E9 SS316
4 A5 MONEL
5 A7

SS316
7 A10, B10, D10, E10, F10 SS316L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
MONEL 400
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – II
(Hook Up Drawing)
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE –II CONT..
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – III :- TYPICAL DATA SHEET
PRESSURE SWITCHES (ELECTRICAL)
UNITS: - Flow Liquid – M3/HR Gas – NM3/HR Pressure – kg/cm2 Temperature – deg C
Level/length -M
1 Type Pneumatic MEASURING UNIT
2 Function Indicate Pressure 26
Service
3 Mounting 27
Element Type
4 Case, Window 28
Element Material
5 Electrical Area Class - 29
Socket Material
6 Enclosure Class 30
Body Material
7 Intrinsically Safe 31
Connection location
8 Air Supply 32
DIAPHRAGM SEAL (Wherever
Required)
9 Power Supply Type
10 Cable entry Wetted Parts
11 Accuracy Other Material
12 Repeatability Process Connection
SWITCH Facing & Finish
13 Electric Capillary Material
14 Quantity Armour Material
15 Form Capillary Length
16 Type Flushing Filling conne.
17 Rating MISCELLANIOUS
18 Load Type 33 Over range protection
19 Cable Entry 34 Blow out protection -
20 No. Of Entries 35 Options
21 Pneumatic A Mounting accessories
22 Type B Air filter regulator with Gauge
C Intrinsically safe weather proof out put
meter
D Pressure gauges for supply, input and
output
E Snubber
F Gauge saver
G Air filter regulator
23 Signal H Vaccum protection
24 Set point adjustment 36 Pneumatic Connect.
25 Differential Load driving capability
TAG RANGE SET SET PRESSURE TEMP. FLUID SERVI OPTI
CE
No. POINT POINT OVER MAX OPER MAX ONS
1 2
NOTE:-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
SPECIFICATION FOR
ISO – 9001:2008 PRESSURE TRANSMITTER
CONTENTS
4.0 SMART Type Pressure transmitter 3
4.1 General 3
4.2 Material 4
4.3 Accuracy 4
4.4 Output Signal 4
4.5 Repeatability 4
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR

This functional specification describes the essential design considerations for the selection of
Pressure transmitter (electronic) for the intended service.
a) Instrumentation /Process Design Criteria
b) Basic Bid Work
c) Project P & IDs
3.2 The vendor shall be responsible for the selection of the Pressure Transmitter suitable for
at site shall be come under vendor’s responsibility.
4.0 SMART TYPE PRESSURE TRANSMITTER:

4.1 General:
system, communication system etc. All electronic modules shall be designed for short circuit
protection.
4.1.2 Span shall be continuously adjustable over the transmitter range. The PT shall be provided
with ½”NPT (F) cable entries.
4.1.3 All transmitters shall be provided with Digital integral output meters(with engineering units).
The output meter shall be suitable for use in the hazardous area.
4.1.4 PT shall have easily approachable zero and span adjustment facility.
4.1.5 Process connection of the transmitter shall be from the bottom side, 316SS threaded ½”
NPTF.
4.1.6 Over range protection shall be 130% of range or maximum pressure whichever is higher.
4.1.7 Transmitter shall be furnished with all necessary weather and anti-corrosion protection to
prevent damage from saline and corrosive process atmosphere.
4.1.8 All pressure instruments shall be mounted as close as possible to sensing point.
4.1.9 Transmitter shall be supplied with a 3 way valve manifold
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
4.1.10 The Pressure transmitter shall be intrinsically safe and certified by statutory body like
UL/FM/BASEEFA/CMRI/DGMS or equivalent.
4.1.11 ‘Universal Hand Held Configurator’ shall be supplied for transmitters’ calibration. The
number of calibrator shall be two per process platform & one per well platform.
4.1.12 All vent and drains of the transmitter/tubing/valve manifolds shall be routed to drain header .
If the meter is on sour service and harmful fluids like chemical etc. then it will be routed to
close drain header.
4.2 Material:
4.2.1 The material requirements for PT shall in general be according to clause 3.6.4.5 of
Instrumentation Design Criteria, FS-2004A for Piping Design (2008) & Piping Material
Specification.
4.2.3 Transmitter body studs shall be high tensile stainless steel, or other corrosion-resistant
material for higher stress levels.
4.3 Accuracy:
±0.1% of FSD or better.
4.4 Output Signal:

4.4.1 Output signal shall be 2 wired 4-20 mA DC, and capable of delivering the rated current
signal into external load of around 600 ohms when powered with nominal 24V DC (negative
earthed).
4.4.2 Transmitters shall have HART protocol for communication for remote calibration and
diagnostics from HART maintenance system
4.5 Repeatability:
4.5.1 Flow Transmitters shall have a repeatability of ±0.1%.

The transmitter shall be weatherproof (IP 65 or better). In addition the PT enclosure shall be
as per Clause no 3.6.4.4.5 of Instrument Design Criteria.
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE – I
(Hook Up Drawing)
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ANNEXURE-II :- Typical data sheet for Pressure Transmitter
PRESSURE TRANSMITTER (ELECTRONIC)
1 Type
DIAPHRAGM SEAL (Wherever Required)
2 Function 21 Type
3 Mounting 22 Wetted Parts
4 Case & Material 23 Other Material
5 Electrical Area Class 24 Process Connection
6 Enclosure Class 25 Facing & Finish

7 Intrinsically Safe 26 Capillary Material
8 Power Supply 27 Armour Material
9 Cable entry 28 Capillary Length
10 Accuracy 29 Flushing Filling conne.
11 Repeatability
MISCELLANIOUS
30 Over range protection

TRANSMITTER
12 Out put 31 Blow out protection
13 Power supply 32 Options
a) Mounting accessories 3 WAY
14 MEASURING UNIT VALVE MANIFOLD
15 Service
16 Pressure Element Type
17 Element Material 33 Load driving capability

18 Socket Material
19 Body Material
20 Connection location
TAG RANGE OPERATI PRESSURE TEMP. FLUID

No. NG OVER MAX OPER SERVIC OPTIONS
PRESSUR MAX E
E
Vendor Seal and Sign
ODS/SOF/023 ODS/SOP/017 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
“CURRENT TO PNEUMATIC
CONVERTER” Page: 2 OF 5
CONTENTS

2.1 3
Scope of Supply
3.0 General 3
4.0 P to I converter 3
4.1 Converter Type 3
4.2 Material 3
4.3 Accuracy 3
4.6 Hazardous area certifications 3
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008

selection of Current to Pressure converter for the intended service.
2.0 Reference Documents and Specifications

b) Basic Bid Work
c) Project P & IDs
d) Instrument Process Data Sheets
e)
indicated in the Basic Bid Work, and the P & IDs.
2.3 The vendor shall be responsible for the selection of the I to P converter suitable
3.0 Current to Pressure Converter:
3.1 General
A “current to pressure” converter (I/P) converts an analog signal (4 to 20 mA) to
a proportional linear pneumatic output (3 to 15 psig). Its purpose is to translate the
analog output from a control system into a precise, repeatable pressure value to
control pneumatic actuators/operators, pneumatic valves, dampers, vanes, etc.
3.1.1 The input signal shall be 4-20 mA, 2 wires.
3.1.1.1 The I/P converter shall be provided with two No. ½”NPT cable entries, with one
will be plugged.
3.1.1.2 The output signal shall be 3-15 psi. The output signal shall be linear in relation to
input signal.
3.1.1.3 The change in out put due to 10 degree Celsius change in ambient temperature
(Max-400C, Min-160C) should be very minimum.
3.1.1.4 I/P shall have externally adjustable zero and span.
3.2 Material:
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
3.2.2 Housing material -Die-cast low copper aluminum alloy body and cover, with
an epoxy powder finish.
3.2.3 Mounting accessories: shall be SS316.
3.3 Accuracy: better than ± 0.5% of span.
3.4 Reading Scales: Units for I/P converter shall be in PSI.
3.5 Enclosure Class: The I/P converter shall be weatherproof to NEMA-4X (IP-
65) and shall be intrinsically safe.
3.6 Hazardous area certifications: By third party agencies like
IEC/UL/ATEX/CMRE/FM/BASEEFA/CENELEC/CSA/PTB for use in
hazardous area (Class 1, Division.1, Groups C and D, T3).
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
ANNEXURE-I -TYPICAL DATA SHEET
CURRENT TO PNEUMATIC CONVERTER.

1 Type 10 Accuracy
2 Mounting 11 Actuation
3 Ambient Temperature 12 Housing Type
4 Electric Supply 13 Accessories
5 Input 14 Intrinsically safe
6 Out Put 15 Body material
7 Pneumatic connection
9 Conduit Connection
Electrical
Pneumatic
NOTE :-
VENDER SEAL AND SIGNATURE
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPEC. No. 3500
Design Division FUNCTIONAL 4
Rev. No.
ISO – 9001:2008 “FIRE & GAS Discipline: Instrumentation
DETECTION SYSTEM. Page 2 of 35
CONTENTS
Clause
ITEM Page No.
No.
- Title page 1
- Index of contents 2
4.0 Fire & Gas Detection System 4
4.1 General 4
4.2 System Requirements 6
4.2.1 Detectors and Field Devices 6
4.2.1.1 General 6
4.2.1.2 Gas Detectors 7
4.2.1.3 Fire Detectors 12
4.2.1.4 Manual Alarm Stations 15
4.2.1.5 Other Associated Field Devices 15
4.2.2 Control Devices 17
4.2.2.1 General 17
4.2.2.2 Fire & Gas detection system panel 17
4.3 Functional Requirements 25
4.3.1 Control Philosophy 25
4.4 Spares Philosophy 29
4.5 Material 29
5.0 Equipment Protection 29
6.0 Installation Requirement 30
7.0 Testing and Inspection 30
8.0 Quality Assurance 32
9.0 Documentation 33
10.0 Tagging & Nameplates 34
11.0 Review & Approval 35
12.0 Vendor Pre-Qualification Requirements 35
13.0 Preparation for Shipment 35
14.0 Receipt & Storage 35
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Rev. No.
1.0 SCOPE OF THIS DOCUMENT
1.1 This specification defines the minimum requirements for the design,
engineering, fabrication, inspection-testing, supply, installation and
commissioning of Fire & Gas Detection System for use on offshore platform.
1.2 This specification describes Fire & Gas Detection System with field detectors
and the functionality of the system as a whole. It does not cover the detailed
specifications of:
a) PLC: Functional Specifications of PLC are addressed in spec. no. MR /

OD / INST / FS / C101
b) Pneumatic Panel. Functional Specifications of Pneumatic Panel are
addressed in spec. no. MR / OD / INST / FS / 3501.
1.3 Any deviations from the requirements of this specification shall be stated in
‘Deviation List’ in contractor’s proposal. Unless specific deviations are stated,
it shall be understood that the Fire & Gas Detection system is in accordance
with the specification.
1.4 Contractor’s proposal shall also include revision status sheets, which shall
show revision status of each page of the proposal / purchase specification for
every submission.
1.5 Any ambiguity in this specification and the reference specifications pertaining
to the requirements of Fire & Gas Detection System shall be referred to the
company for clarification prior to finalization of Purchase Specification.
2.0 REFERENCE DOCUMENTS & SPECIFICATIONS
a) Basic Bid Work

b) Instrumentation Design Criteria
c) Spec. No. MR / OD / INST / FS / C101: Functional specification for
PLC.
d) Spec. No. MR / OD / INST / FS / 3501: Functional specification for
Shutdown Panel.
e) HSE -5102, OISD-189
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3.0 SCOPE OF SUPPLY
3.1 The Fire and Gas Detection System shall include the following equipment:
a) Field Detectors including thermal, smoke, point and open path type
Hydrocarbon gas detectors, Hydrogen gas detectors, toxic gas (H2S)
detectors, Triple IR (outdoor and GG-PT Enclosure) and UV/IR (indoor)
flame detectors, Fire loop system with Fusible plugs, ESD & FSD pull
stations (valves), manual alarm stations, flashing and audible alarm
beacons etc.
b) Accessories including mounting units, etc to make the system
operationally and functionally complete.
c) Interfaces to the field as well as Control Room for Alarm & initiation of
Fire Suppression actuating devices including Fire Water Pump control
panel, opening of Blow down valve for reducing hydro-carbon
inventory, deluge valves and for release of DCP/Clean Agent & other
Fire extinguishing agent.
d) Interfaces to other systems of the platform including DCS, ESD system,
Package equipment (such as Gas Turbines, Process gas compressors)
fire & gas detection system, Paging system, emergency generator,
pneumatic panel.
e) Fire and Gas Matrix panel, Critical alarms annunciation.
f) Other items including portable purge calibrators, calibration cylinders,
commissioning spares, special tools & tackles.
4.0 FIRE & GAS DETECTION SYTEM
4.1 GENERAL
4.1.1 The Fire & Gas Detection system is required to address the risk associated
with imminent or established fire and combustible/ toxic gas release.
4.1.2 Type approval by FM/UL/BASEEFA/CENELEC/CSA/IEC/DGMS/PTB/

CMRI/ATEX for use in Class I, Division I, Group C & D and T3 hazardous
area, of all Fire and Gas detectors shall be required.
4.1.3 Unless otherwise specified all contacts shall be volt free contacts which shall
be 2 X SPDT or DPDT type, rated 24 VDC – 2 amps.
4.1.4 The Fire & Gas Detection system scheme shall be one out of the following
two schemes (refer ‘Basic Bid Work’ for type of scheme to be followed for
the project)-
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a) Scheme – A : For Well-Head Platform

b) Scheme – B : For Process Platform
4.1.5 Scheme - A : Fire & Gas Detection system for Well-Head Platform shall
constitute the following :
a) Field detectors including point and open-path type hydrocarbon gas
detectors, Hydrogen gas detectors, H2S gas detectors, Smoke detectors,
Triple IR Flame detectors, Thermal detectors, Pneumatic Fire loops with
Fusible plugs, FSD & ESD pull stations (valves), Flashing & Audible
Alarm Beacons and Clean Agent System for Fire Suppression.
b) Each loop shall generate at least two independently adjustable volt free
contact outputs.
c) Accessories including mounting units, etc to make the system
d) Detectors controller / monitor card mounting unit with relays logics or
F&G PLC (SIL 3) (as per basic bid work) which shall be installed in
SAFE area.
e) Interface to the Electrical Rooms actuating devices as well as field
including ESD/FSD, deluge valve actuation logic, Clean Agent system,
Fire Water Pump etc.
f) Interfaces to other systems of the platform including pneumatic
shutdown Panel / PLC based SDP/ General Purpose Standalone PLC,
RTU etc..
g) Other items including portable purge calibrators, calibration cylinders,
4.1.6 Scheme – B : Fire & Gas Detection system for Process Platform shall
constitute the following :
a) Field devices including thermal, smoke, point and open-path type
Hydrocarbon gas detectors, Hydrogen gas detectors, toxic gas (H2S)
detectors, Triple-IR (outdoor & GG-PT enclosure) and UV/IR (indoor)
flame detectors, Pneumatic Fire loops with Fusible plugs, FSD & ESD
pull stations (valves), manual alarm stations, flashing and audible alarm
beacons for actuation of Fire suppression system.
b) Accessories including mounting units, etc to make the system
c) Interfaces to the field as well as Control Room actuating devices
including actuation of Clean Agent system, deluge valves & FWP
Control Panels, pneumatic solenoid & pilot valves, extinguishant
release, Blow-down valve open etc.
d) Interfaces to other systems of the platform including DCS, ESD system,
RTU, Package equipment (such as Gas Turbines, Process gas
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Rev. No.
compressors) Fire & Gas detection system, Paging system, Emergency

Generator, Pneumatic Shutdown panels.
e) Fire and Gas Matrix panel, Critical alarms annunciations.
f) Other items including portable purge calibrators, calibration cylinders,
For Building Modules, in the Enclosed areas like, Living Quarters, Control
Rooms, Switch Gear Rooms etc. all the F&G detectors shall be addressable
type and connected directly to the Addressable type F&G system which shall
be connected to a SIL 3 F&G PLC for execution of voting logic and actuation
of extinguishing agent. For open areas, all the F&G detectors shall be
addressable type and shall be either directly connected to SIL 3 F&G PLC
system or through Addressable interface unit. Fire Alarm Aspiration System
shall be provided for Control Rooms and Switch Gear Rooms and shall be
connected to SIL 3 F&G PLC (for SIL 3 PLC Refer Specification MR / OD /
INST / FS / C101).
4.2 SYSTEM REQUIREMENTS
The F&G system will be powered from a dedicated dual 24 VDC battery
back-up supply, which will provide stable supply, allowing orderly shutdown
and monitoring if power is lost. Power supply sizing shall also consider
requirement of installed spares & spare space in F&G system ‘Control
Devices’. The back-up system capacity shall allow continued monitoring by
the F&G system for a nominal period of minimum 24 hours for Process
Platform and 7 days for Well-Head Platform powered by Solar/Wind and 48
hours for Well-Head Platforms powered from Process Platform through Sub-
sea Cable. This period shall be confirmed by the contractor following project
risk assessments and HAZOP. A common power supply fault alarm shall be
provided for connection to RTU (for Scheme - A) / DCS (for Scheme - B).
Contacts shall be volt free contacts. The complete System shall be G3/GX
compliance with conformal protective coating as a minimum (ref. IDC rev6
Cl. No. 3.6.4.1.2.3). The F&G system shall have floating Ground power
supply. The F&G System shall be compatible to accommodate addressable
type detectors. The system shall have line monitoring system for all the
actuation loops.
4.2.1 DETECTORS AND FIELD DEVICES

4.2.1.1 GENERAL
4.2.1.1.1 The detectors and field devices shall be suitable for the offshore climate
including regular monsoonal rains and corrosive marine environment.
4.2.1.1.2 The atmospheric conditions that detectors and field devices will be subject to
are in general as per Instrumentation Design Criteria Cl. No. 3.6.4.4.1.
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4.2.1.1.3 Detector Location: The Contractor shall specify each type of detector and
their locations and mountings, to ensure the earliest response to imminent or
established fire or hydrocarbon release or toxic (H2S) gas release and
accumulation, with consideration to the following as a minimum:
a) Requirements of referenced standards, particularly API RP 14C, 14G,
ISA 12, ISA 92, NFPA 72 and SGDA (Smoke and Gas Dispersion
Analysis).
b) Equipment layouts: Placement of detectors shall not interfere with
process equipment maintenance.
c) Ease of Maintenance: The fire and gas detectors shall be installed in a
location accessible for calibration and maintenance, preferably from
deck or fixed platform, but not in frequently used access ways.
d) Certain areas shall be avoided, such as sample stations where spurious
alarms would negate the effectiveness of the detection system.
e) All the detectors shall be addressable type (in addition to having the
conventional outputs) for the Process platform.
4.2.1.2 GAS DETECTORS

4.2.1.2.1 For the purpose of selecting gas detectors following general factors shall be
considered-
a) Combustible Gas (HC & H2) Detectors shall be able to perform to the
temperature, humidity, air velocity and vibration specification
prescribed in ISA S 12.13.01 (Part I). Toxic Gas (H2S) Detectors shall
be able to perform to the specifications prescribed in ISA S 12.15.01
(Part I).
b) Temperature Effects: The detectors shall be calibrated at their mean
operating temperature. All components, including the sensor, shall be
designed for operation within the ambient temperature range for the
location of the installation. Where high temperatures are unavoidable,
high-temperature rated detectors with remote sensing heads shall be
employed.
c) Effects of Humidity: The detector housing shall be suitable for offshore
salt laden marine environment.
d) Air Velocity: Sensors shall be located away from prevailing winds,
heating and cooling system. Air circulation patterns and effects of other
equipment that affect circulation shall be taken into consideration while
finalizing the location of the detectors. Where widely varying wind
direction changes are expected, multiple detectors shall be installed to
provide the required coverage.
e) Vibration: Sensors shall be located away from vibration prone areas. If
this is not possible, the sensors shall be mounted on flexible mounts or
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Rev. No.
flexible conduit.
f) Combustible and toxic gas sensors shall be located in accordance with
the protection area limitations of the detector manufacturer.
g) Sensors shall be typically located approximately 1 m from the expected
emission point, and preferably in the direction of ignition sources and /
or populated areas.
h) Special consideration shall be given to the properties of the process gas
(refer Process Design Criteria for properties of process fluids),
specifically its vapour density and predominant component. For lighter-
than-air gases, the detectors shall be placed above the release point. For
heavier-than-air gases, the detectors shall be placed 300-450 mm above
the floor.
i) Detector locations shall take into account the possible flow pattern of the
leaking gas or vapour and ventilation system airflow.
j) The number of detectors shall be based on the number of potential
release sources.
k) Perimeter detection of releases shall be considered in areas containing
large amounts of light hydrocarbons (e.g. process areas or pressure
storage areas) to alert operations to initiate a manual response or to
actuate an automatic response (e.g. unit shutdown or firewater spray
system). These detectors shall be installed along a unit boundary
adjacent to an ignition source.
l) Indoor or partially enclosed installations that may require gas detection
(such as turbine enclosures, compressor stations, etc.) shall be protected
with open path or point detection system.
m) Where buildings are equipped with HVAC, pressurizing or a ventilation
system, a combustible-gas and / or toxic-gas detector shall be located in
the inlet to the system and also in air locks.
n) In high-temperature enclosures, such as enclosures for gas turbines, a
remote sampling head shall be used, with a standard detector located
outside the enclosure and the gas sample aspirated to the detector head.
o) Detectors shall be provided to detect presence of gas into engine air
intakes, and presence of gas in enclosure exhaust vents.
p) Sampling in indoor locations shall be accomplished by diffusion and
convection air currents.
q) No pump or other means of forced air movement shall be required for
normal application.
4.2.1.2.2 Fixed HC Detectors

4.2.1.2.2.1 Fixed Hydrocarbon (HC) Gas Detectors shall be based on Infrared Absorption
Technology. Catalytic HC detectors shall not be used.
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4.2.1.2.2.2 The detecting unit included in the sensor head shall provide adequate
sensitivity and stability, under all conditions, with ±5% accuracy (For Range
of 100 LEL).
4.2.1.2.2.3 The fixed HC gas detectors shall be powered from 24 V DC supply, with a 4-
20 mA signal loop to cover the calibrated range. Detector faults shall be
signaled by 4 mA signal.
Note: In Scheme-A, detector shall provide 2 nos. of volt free contact outputs
for Non-PLC Panel. These 2 nos. of contact outputs shall be independently
adjustable over entire range of gas detection.
4.2.1.2.2.4 Junction Boxes: Explosion proof junction boxes shall be provided with the
detectors for cable termination.
4.2.1.2.2.5 Detector system shall initiate responses at two different concentrations: for
warning alarms and for initiation of executive action. Typical values of these
set-points are:
• 20% and 60% LEL for general process areas
• 15% and 40% LEL for HVAC air intakes
• 5% and 10% LEL for turbine engine air intakes
4.2.1.2.2.6 The alarm condition shall not be resettable until the specific detector reading
has dropped below the warning alarm level as applicable (Manual-resettable
type).
4.2.1.2.2.7 Operator response shall be required to clear the audible and visual alarms.
4.2.1.2.2.8 HC detectors may be either Point Detectors, or Open Path Detectors or a

combination of both.
4.2.1.2.2.9 Point HC Detectors: Point HC Detectors shall be calibrated 0-100% LEL

(Lower Explosive Limit) of Methane in air. A single point detector may be
used for more than one release point, with due consideration to the
manufacturer’s specification of the sensing area.
4.2.1.2.2.10 Open Path HC Detectors: Open Path IR detectors shall be located where the
beam will provide a clear view over process equipment. The detectors shall
be selected for the correct path length with a separate transmitter and receiver.
The installation of transmitter and receiver shall be as per International Codes
and Standards. Combined transmitter and receiver with mirrors shall not be
used. Units shall not be affected by direct sunlight, fog or mist.
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Rev. No.
4.2.1.2.2.11 Combination of Open Path and Point IR Detectors: If multiple release

sources are present in a process unit, then both point and line-of-sight
detection may be used.
4.2.1.2.3 Portable HC Gas Detectors

4.2.1.2.3.1 The number of Portable HC Gas Detectors required per platform shall be as
per the Basic Bid Work.
4.2.1.2.3.2 The portable HC detectors shall be capable of detecting 0 – 100% LEL of HC

and shall have an accuracy of ±5% (For Range of 100 LEL).
4.2.1.2.3.3 The portable HC gas detector shall have an integral audio-visual alarm and
shall be factory calibrated for 20% and 60% LEL HC. Alarm shall be
adjustable over the entire detection range of gas detectors.
4.2.1.2.3.4 The portable HC detectors shall be standard size battery (AA/R6 or C/R14 or
D/R20) operated. The batteries shall not be rechargeable type.
4.2.1.2.3.5 The portable HC detector shall be capable of generating a “Battery Low”

Alarm.
4.2.1.2.3.6 The portable HC detectors shall also include accessories such as carrying
case, aspirator, calibration adaptor, etc.
4.2.1.2.3.7 The portable HC detector shall be suitable for Class I, Div I, Group B, C, D,
T3 hazardous area.
4.2.1.2.4 Fixed H2S Detectors

4.2.1.2.4.1 Fixed H2S Detectors shall be based on Electrochemical cell technology.
4.2.1.2.4.2 The fixed H2S gas detectors shall be powered from 24 V DC supply, with a 4-
Note: In Scheme-A, detector shall provide 2 nos. of volt free contact outputs
for Non-PLC Panel. These 2 nos. of contact outputs shall be independently
adjustable to over entire range of H2S gas detection.
4.2.1.2.4.3 The H2S detectors shall be capable of detecting 0 – 50 ppm of H2S and shall
have an accuracy of ±3 ppm.
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4.2.1.2.4.4 The fixed H2S detectors shall initiate responses at two different
concentrations: for warning alarms and for initiation of executive action.
4.2.1.2.4.5 Nominal system alarm settings shall be 10 ppm for “Alert” Level and 20 ppm
for “Danger” Level.
4.2.1.2.4.6 The alarm condition shall not be resettable until the specific detector reading
has dropped below the warning alarm level as applicable (Manual-resettable
type).
4.2.1.2.4.7 Two H2S detectors shall be installed at each ventilation air intake of control
rooms and normally manned buildings. For Living Quarters H2S detectors
shall have 0 to 10 ppm range with accuracy ±2 ppm. Nominal system alarm
settings shall be 3 ppm for “Alert” Level and 5 ppm for “Danger” Level.
4.2.1.2.4.8 Local display on the sensors and visual alarm indication shall be there.
4.2.1.2.5 Portable H2S Detectors
4.2.1.2.5.1 The number of Portable H2S Gas Detectors required per platform shall be as
per the Basic Bid Work.
4.2.1.2.5.2 The portable H2S detectors shall be capable of detecting 0 – 20ppm of H2S
and shall have an accuracy of ±3 ppm.
4.2.1.2.5.3 The portable H2S gas detector shall have an integral audio-visual alarm for
activation upon detection of 5 ppm and 10 ppm of H2S.
4.2.1.2.5.4 The portable HC detectors shall be standard size battery (AA/R6 or C/R14 or
D/R20) operated. The batteries shall not be rechargeable type.
4.2.1.2.5.5 The portable H2S gas detector shall be capable of generating a “Battery Low”
Alarm.
4.2.1.2.5.6 The portable H2S gas detectors shall also include accessories such as carrying
case, aspirator, calibration adaptor, etc.
4.2.1.2.5.7 The portable H2S detector shall be suitable for Class I, Div I, Group B, C, D,
T3 hazardous area.
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4.2.1.2.6 Fixed H2 Detectors
4.2.1.2.6.1 Fixed catalytic H2 Detectors shall be provided in the battery room and process
areas, which may see release of H2 gas. Minimum of two H2 detectors shall
be provided in an area.
4.2.1.2.6.2 The fixed H2 gas detectors shall be powered from 24 V DC supply, with a 4-
Typical set-points values for warning alarms and for initiation of executive
action are 20% and 60% LEL respectively.
Note: In Scheme-A, detector shall provide 2 nos. of volt free contacts /

outputs for non-PLC Panel. These 2 nos. of contact shall be independently
adjustable to over entire range of gas detectors.
4.2.1.2.6.3 The H2 detectors shall be capable of detecting 0 – 100% LEL of H2 and shall
have an accuracy of ±5% over the entire detection range.
4.2.1.2.6.4 The catalytic H2 detectors shall not be located in oxygen enriched or depleted
atmospheres.
4.2.1.3 FIRE DETECTORS
4.2.1.3.1 General
4.2.1.3.1.1 The fire detection system shall comprise a variety of fire detection devices
and sensors, including:
• Optical Flame Detectors
• Smoke Detectors
• Thermal Detectors
• Fusible Plug Loops
• Manual Alarm Stations
4.2.1.3.2 Optical Flame Detectors
4.2.1.3.2.1 Optical flame detectors shall be the Triple-IR type and shall make use of such
sensor, filters, and / or design to reject phenomena such as electric arcs,
heaters, artificial light sources, lightning and shall be completely “solar
blind”.
4.2.1.3.2.2 The detectors shall be able to detect all types of flaming fires.
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4.2.1.3.2.3 Detectors shall be powered from 24 V DC, with a 4-20 mA signal loop to
cover the calibrated range. Detector faults shall be signaled by a 4 mA signal.
Sufficient margin shall be allowed between fault, normal and alarm levels to
minimize spurious alarms.
4.2.1.3.2.4 Optical flame detectors shall have automatic, self-diagnostic circuitry that
continuously monitors the optical surfaces, sensor sensitivity and electronic
circuitry, and shall give fault status. Any detector malfunction shall be
alarmed on the Fire and Gas detection system panel and DCS.
4.2.1.3.3 Smoke Detectors
4.2.1.3.3.1 Smoke detectors shall be installed indoors in all rooms, including space above
false ceiling and below false flooring.
4.2.1.3.3.2 The smoke detectors shall incorporate an integral LED indicator for
confirmation that the unit is active.
4.2.1.3.3.3 Detectors those are not visible, such as above false ceiling or under false
flooring, shall be provided with remote LED’s located in the room being
monitored.
4.2.1.3.3.4 Two independent smoke detector loops in cross – zone concept shall be
installed in each area where executive action is required on detection of
smoke.
4.2.1.3.3.5 Photoelectric type smoke detectors shall be used to provide early response to
smoldering or flaming fires in their incipient stages. A detector base shall be
provided for connecting the individual detectors to the Fire and Gas (F&G)
control system.
4.2.1.3.3.6 Smoke detectors shall remain in alarm state until reset by the fire and gas
control system.
4.2.1.3.4 Thermal Detectors (Rate of rise & Fixed Heat Detectors)

4.2.1.3.4.1 Thermal detectors shall be used in all indoor spaces including all rooms and
equipment enclosures, including concealed floor and ceilings voids.
4.2.1.3.4.2 Rate of rise thermal detectors shall be used where an early warning of
smoldering fires is required, such as storerooms and equipment rooms where
air flow or high humidity may inhibit the response of smoke detectors.
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4.2.1.3.4.3 Fixed temperature or rate compensated type heat detectors shall be used
within areas unsuitable for smoke detection where a rapidly achieved high
temperature can be expected, such as machinery rooms or equipment
enclosures. These shall be set at approximately 12oC above maximum
ambient temperature within the area.
4.2.1.3.4.4 Thermal detectors shall remain in alarm state until reset by the fire and gas
control system.
4.2.1.3.4.5 All visible detectors shall incorporate an LED indicator as an integral part of
the detector head or its mounting base. Concealed thermal detectors shall be
provided with an LED “repeater” that is located in a visible location.
Normally, unmanned equipment rooms or offices shall have indicators in the
corridor. The detector circuitry shall cause the LED to remain illuminated
while the detector is the alarm condition.
4.2.1.3.5 Fusible Plug Loops, FSD (Fire Shutdown) valves & ESD (Emergency
Shutdown) valves.
4.2.1.3.5.1 Pneumatic Fire loop having Fusible plug shall be provided to initiate alarm in
F&G System and initiate opening of deluge valve and FSD system. The Fire
loop shall be laid out and segregated according to the fire zones.
4.2.1.3.5.2 Fusible plugs shall be selected to melt at 85oC. Each area covered shall have
independent loop.
4.2.1.3.5.3 Pneumatic Fire loops having fusible plug shall also be provided with
manually operated FSD valves installed at strategic locations all over the
platform as per API-RP-14C. FSD valves shall be RED in color. PSL shall be
provided to pick up the signal from each loop and communicate to F&G PLC
for further necessary action as per Cause and Effect diagram.
4.2.1.3.5.4 Each Fire loops having fusible plug and FSD valve loops shall be originated
from a field mounted Pneumatic Master Shutdown panel / Pneumatic
Charging Panel. Functional specifications of pneumatic panel are addressed in
Spec. no.- MR / OD / INST / FS / 3501.
4.2.1.3.5.5 Fusible plug / FSD valve loops shall be divided into independent group for
each deck corresponding to each fire water deluge networks. These sub-
groups of Fusible plug loops shall be provided with independent loop
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charging facility.
4.2.1.3.5.6 Manually operated ESD valves shall be provided on the pneumatic loop
generated from Pneumatic Shutdown Panel (Refer Spec. no.- MR / OD /
INST / FS / 3501). ESD valves shall be installed at strategic locations all over
the platform adjacent to each FSD valves. ESD valves shall be BLACK in
color.
4.2.1.4 MANUAL ALARM STATIONS

4.2.1.4.1 Manual alarm stations shall be provided for following functions:
a) Fire alarm.
b) Platform Abandonment.
4.2.1.4.2 Manual alarm stations for Fire alarm shall be located throughout all areas of
the platform, especially at exits and in the main equipment rooms. These
stations shall be located at easily accessible, well lighted, conspicuous areas
and located no more than 30 meters apart.
4.2.1.4.3 Manual alarm stations for Platform Abandonment shall be located in Control
Room and adjacent to each survival craft (exit Point).
4.2.1.4.4 All manual alarm stations shall require a double action to activate the alarm.
They shall be the break-glass, pushbutton type.
4.2.1.4.5 Each unit shall be surface mounted at a height of 1.4 meters and shall be
provided with a striker connected to the station by a chain.
4.2.1.4.6 Each unit shall be wired to the F&G control system in the Control Room.
4.2.1.4.7 The manual alarm stations- Fire alarm shall be red in colour & manual alarm
stations- Platform abandonment shall be black in colour.
4.2.1.4.8 Addressable type Manual Alarm Stations shall be provided.
4.2.1.5 OTHER ASSOCIATED FIELD DEVICES
4.2.1.5.1 Flashing Alarm Beacons
4.2.1.5.1.1 The Flashing alarm beacons shall be direct ignition, Xenon type. Flashing
alarm beacons shall be powered from 24 V DC, supply.
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4.2.1.5.1.2 The Flashing alarm beacons shall have flashing speed of 60 flashes per
minute.
4.2.1.5.1.3 For Scheme- A, following shall be considered-

a) Separate flashing alarm beacons shall be provided for visual indication
of confirmed HC-H2 gas release & H2S gas release.
b) Flashing alarm beacons shall be located at Helideck and Mezzanine
Deck for visibility to personnel approaching the platform via Helicopter
or sea.
4.2.1.5.1.4 For Scheme – B, following shall be considered-

a) Separate flashing alarm beacons shall be provided for visual indication
of confirmed Fire detection, HC-H2 gas release & H2S gas release.
Flashing alarm beacons shall be located at each deck covering all the
areas of the platform. In addition these beacons shall also be located
inside enclosures (such as Enclosure building of Gas Turbines, etc) with
high noise environment and shall be visible 3600.
4.2.1.5.2 Field Sounder
4.2.1.5.2.1 For Scheme- A :

4.2.1.5.2.1.1 Field sounder shall be electronic type, and shall be powered from a 24 V DC,
supply.
4.2.1.5.2.1.2 Field sounder shall be provided for audible alarm for confirmed HC-H2 / H2S
gas release.
4.2.1.5.2.1.3 Field sounder shall be located near personnel rest room on Main deck of the
platform.
4.2.1.5.2.1.4 Power Isolation switch for the Field Sounder & Flashing Alarm Beacons and
Remote Alarm Acknowledgement facility shall be provided to save Power.
4.2.1.5.2.2 For Scheme - B : Tone Generator

Different types of distinct tone for Fire, Gas, ESD, Abandon Platform and all
clear shall be provided with Fire & Gas System. Interfacing between Paging
system and F&G System shall be provided for alarm tone generation in public
address system during exigencies.
4.2.1.5.3 Portable Calibration Kit
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4.2.1.5.3.1 Complete calibration kit including Portable purge calibrators/calibration

cylinders with all accessories like pressure regulator, flexible hose, adaptor
cap (to fit on sensing heads) etc., as applicable shall be supplied to enable
calibration of the sensors in the field without dismantling them.
4.2.1.5.3.2 Methane, Hydrogen and Hydrogen Sulphide Calibration gas shall be supplied.
Sufficient quantity of calibration gas shall be supplied to enable complete
calibration, testing, inspection of all sensing heads during commissioning and
successive two time’s complete calibration during post-commissioning
period.
4.2.1.5.4 Extinguishant
4.2.1.5.4.1 Areas protected by extinguishant shall have warning lights and alarms, both
on the inside and outside of the enclosure that will be activated prior to and
during the release of extinguishant.
4.2.1.5.4.2 Two lights shall be provided apart from a blue flashing strobe. One of the
lights shall be used to indicate “Extinguishant release imminent” and the other
to indicate “Do Not Enter – Extinguishant Released”.
4.2.1.5.4.3 The release of the extinguishant shall be indicated on the F&G panel and the
DCS.
4.2.1.5.4.4 A manual release station and a lockable inhibit valve shall be provided at the
entrance to the protected area.
4.2.2 CONTROL DEVICES
4.2.2.1 GENERAL
4.2.2.1.1 The F&G Control components shall be located in safe area on the platform.
4.2.2.2 FIRE & GAS DETECTION SYSTEM PANEL
4.2.2.2.1 The Fire & Gas detection system panel for Scheme - A shall constitute the
following:
a) Controller / Monitor Cards, Control & other auxiliary components like
logic relays, auxiliary relays, power distribution for detectors-flashing
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alarm beacons-sounders, etc. or F&G SIL 3 PLC (as per Basic Bid
Work) shall be installed in the SAFE area and housed in Electrical /
RTU/Telemetry Interface Cabinet (TIC) Room. [PLC shall be provided
as per Functional Specification No. MR / OD / INST / FS / C101.]
b) For confirmed HC, H2 & H2S gas release separate SPDT volt free
contacts shall be provided for RTU connection.
c) Fire & Gas system panel shall be interfaced with Pneumatic Shutdown
panel to confirm to SAFE chart requirements.
d) Hooter shall be provided for alarms only.
e) The front panel mounted Gas/Fire detection controllers/monitors shall
be installed in mating cases or mounting bins recommended and
supplied by the manufacturer for panel mounting. All wiring to these
controllers shall be terminated on terminal blocks and/or multipin
connectors provided as an integral part of the case. Routing calibration
adjustments shall be accessible from the front of the panel without
having to remove any wiring or causing loss of the instrument function.
In addition total removal of the instrument and replacement with a spare
shall be possible from the front of the panel.
f) The modules shall be plug-in type permitting the removal of the
modules without disturbing the system wiring. Each module shall have
a maximum of 4 channels (one detector per channel) per modules.
Gas/Fire circuit shall be so designed that any channel can be put out of
service for repair, without affecting the other.
g) Each module shall have the following:

(i) Reset Button to acknowledge / reset alarm
(ii) Test button for Operation Check
(iii) Calibration switch, which when put in calibration mode shall
inhibit operation of alarm output, enable checks for alarm LED's
and reference level and also permit access to meter fine zero, meter
span and alarm level contacts.
(iv) Automatic malfunction detection in case of open circuit (sensor
element and line breaking), over range, short circuit and earth
fault.
(v) Indicator LEDs for the following: Malfunction warning for each
channel, Power on, Calibration mode, Test mode, Low alarm for
each channel, High alarm / trip for each channel.
(vi) Alarm Contact: For each detector, module shall be able to generate
minimum 2 independently adjustable (adjustable over entire range
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of detection) SPDT relays for each alarm level for the purpose of
alarming & logic solving.
4.2.2.2.2 The Fire & Gas detection system panel for Scheme- B shall constitute the
following:
a) Fire & Gas detection system panel for Scheme- B shall be SIL-3 PLC-
based providing independent automatic control. PLC shall be provided
as per Functional Specification No. MR / OD / INST / FS / C101.
b) Fire & Gas detection system panel shall be interfaced with the following
systems of the platform and confirm to Safety requirements:
- ESD system.
- Pneumatic Shutdown Panel / Charging Panel
- Central Control Panels for package items (such as Gas Turbines,
Process gas compressors, etc)
- Paging system for alarm tones
- Flashing Beacons & Sounders
- Extinguishant systems
- HVAC System
- Deluge panel
- Diesel and electric fire water pumps
- DCS for graphic displays
c) Besides PLC related cabinets other main components of Fire & Gas
Detection system panel shall be:
(i) Critical Annunciator Panel.
(ii) Matrix panel.
(iii) Common Facilities.
d) Critical Annunciator Panel: Annunciator Panel shall be provided for

critical alarms. The annunciation sequence shall be as per ISA-S18.1,
‘Annunciator sequences and specifications’. The annunciation lamps
shall be capable of removal and replacement from the panel front via
individual snap out windows or a swing out hinged door on which all
windows are mounted. Minimum critical alarms to be provided are
given below:
(i) Line monitoring fault.

(ii) Gas detection malfunction.
(iii) Fire detection malfunction.
(iv) Fire Water Pump (FWP) common alarm.
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(v) FWP- Start.

(vi) FWP- Failed to Start.
(vii) FWP- Off.
(viii) FWP- Shutdown.
(ix) FWP- On Manual.
(x) Fire water header Pressure- Low.
(xi) Diesel Generator- Running.
(xii) Diesel Generator- Fault.
(xiii) Diesel Centrifuge- Running.
(xiv) Diesel supply valve- Close.
(xv) Diesel supply valve- Open.
(xvi) Diesel storage tank level- Hi Hi.
(xvii) Gas Fault- Compressor.
(xviii) Instrument Air Pressure- Low Low.
(xix) FSD
(xx) ESD
(xxi) Confirmed H2S detection.
(xxii) Confirmed HC-H2 detection.
(xxiii) Confirmed Fire detection.
e) Matrix Panel: Matrix panel shall provide graphic status of Fire & Gas
Detection system & Fire suppression system area-wise for the entire
platform.
(i) Area-wise status indication shall include the following as minimum:
- Low HC
- High HC
- Low H2S
- High H2S
- Low H2
- High H2
- Flame
- Heat
- Smoke
- Manual Alarm Call point- Fire Alarm.
- Manual Alarm Call point- Platform abandonment.
- Fusible Plug
- Extinguishant- Inhibited.
- Extinguishant- Auto.
- Extinguishant- Manual.
- Extinguishant- Initiated.
- Extinguishant- Released.
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- Extinguishant- Pressure & Weight loss.

- Deluge- Valve open.
- Deluge- Valve closed.
- Deluge- Pressure.
- System Fault.
(ii) Area-wise control devices shall include the following:
- Extinguishant Auto-Manual-Inhibit 3-way selector switch.
- Extinguishant Manual release Pushbutton.
- Reset Pushbutton.
- Deluge- Open valve.
- Deluge- Close valve.
f) Common Facilities: This shall include F&G system related Shutdown-
alarm switches, Annunciator Pushbuttons, etc.
(i) Alarm & shutdown Pushbuttons shall include the following:
- Abandon platform.
- Gas alarm.
- Fire alarm.
- Manual ESD.
- Manual FSD (Separate for ‘Cellar’ deck and ‘Main’ deck).
- FWP: Start.
- FWP: Stop.
- Diesel Transfer Pump: Start.
- Diesel Transfer Pump: Stop.
- Diesel supply valve: Open.
- Diesel supply valve: Close.
(ii) Selector switches shall include the following:
- Auto / test
- On-Off-Manual (3-way selector switch)
- Lead / Lag (FWP selection sw)
(iii)Annunciator components shall include the following:
- Pushbutton- Lamp Test.
- Pushbutton- Mute.
- Pushbutton- Accept.
- Pushbutton- Reset.
- Buzzer.
(iv) All annunciator components except the alarm horn and auxiliary
contact relays shall be mounted integrally in a protective enclosure.
Mounting clamps which present a flat surface to the front panel face
shall be provided for panel mounting the assembly. All connections
(i.e. trouble contact, speaker, test, acknowledge and test-push-
buttons) shall be made on screw type terminals. Sufficient spares
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terminals shall be provided to accommodate all spares/future alarm

point in the display. Access shall be provided to allow checking
and/or changing the wiring to these terminal strips.
4.2.2.2.3 The Fire & Gas detection system panel shall be freestanding, self-supporting
cubicle type, fully enclosed construction made of CRCA sheet. The contractor
shall be responsible for matching this panel with the other panels of Control
room.
4.2.2.2.4 Plates shall be cut on Squaring shear to ensure tight flush joints when bolted
together. All sharp edges and corners shall be smoothened off to protect
personnel. The final assembly shall be free of buckles, warps, dents or blemishes.
Steel strips stock shall be edge welded to the back of the panel from face above
and below the cut-outs as required to ensure a rigid, self supporting structure. In
order to reduce the loading on the panel face, channel or equivalent support shall
be run horizontally beneath the module cases/shelves to provide rear support.
The finished panel frame work shall be of sufficient strength to allow
transportation and lifting by a crane, with all instrumentation installed without
causing buckling or deflection. Each panel section shall have four (4) removable
lifting lugs at the top of facilitate handling.
4.2.2.2.5 Hinges shall be full-length type. Doorframes shall be formed in the enclosure to
ensure that the doors fit tightly all around. Doors latches shall be the flush-
mounted, 3-point type with recessed chrome-plated handles. An installed
clearance will be maintained inside the panels to allow for door opening and
access the equipment. Doors shall open outwards of the panel.
4.2.2.2.6 The enclosure and its internal equipment arrangement shall be designed to
provide adequate cooling of panel hardware by natural convection alone. Louvers
shall be provided on the top of enclosures for air circulation purposes along with
exhaust fans, as required.
4.2.2.2.7 All sheet and structural steel shall be vapour degreased after shearing, cutting and
forming and prior to welding. Welded construction shall be used throughout,
except where specifically noted otherwise. All welds shall be continuous on the
pieces being joined. Skip welding is not acceptable.
4.2.2.2.8 Proper precautions shall be taken to prevent material wreckage during the
welding process. All welded surfaces shall be thoroughly brushed chipped and
ground to provide a clean, smooth surface.
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4.2.2.2.9 The entire steel structure is to be sand blasted, phosphatized and painted with two
coats of sealing primer on surfaces. The final finish shall be a minimum of three
coats of non-glossy Admiralty Grey epoxy paint on exterior surface and pale
cream on interior surface. The fabricator shall supply separately one (1)
Kilogram of paint for touch up.
4.2.2.2.10 Panel cutout sizes, instrument supports and stabilizers and panel reinforcements
shall be strictly in accordance with the instrument manufacturer's
recommendations. Cutouts shall not be made with flame production devices.
4.2.2.2.11 Sufficient access shall be provided for all instruments via cable duct/trays to
allow checking and/or changes to the wiring to the instrument case.
4.2.2.2.12 Auxiliary Equipment: All rear of panel equipment (terminal blocks, auxiliary
relays, solid state logic cards, etc.) shall be physically located off the exterior
walls of the panel by means of suitable mounting brackets/plates welded to the
wall prior to finishing and painting. Drilling and tapping the outside walls of the
enclosure for mounting internal equipment is prohibited. The auxiliary
equipment shall be located and arranged for easy access, for calibration and
maintenance. It shall not be necessary to remove any item in order to gain access
to check or remove any other item. All cable runs shall be grouped, routed and
secured to provide a neat appearance and prevent interference with the operation
and maintenance of auxiliary equipment. Auxiliary relays, if used shall be of the
plug-in enclosed type.
4.2.2.2.13 Electrical Construction: The installed electrical equipment component parts and
associated wiring in the panel shall be in accordance with the practices outlined in
NEC, latest edition, for non-hazardous area. The panel itself shall meet the
requirement for NEMA-1 (General purpose in door) electrical enclosure.
4.2.2.2.14 Cables from field shall enter through bottom of the panel through multi-cable
transits.
4.2.2.2.15 Cable glands are to be provided in panel to clamp the incoming/outgoing cables.
Glands shall be of Double Compression type and nickel-plated brass. Gland
plates shall be provided to facilitate cable gland installation.
4.2.2.2.16 The 24V DC main power supply feeder to the box shall be protected by a suitably
sized circuit breaker with manual trip lever. The breaker shall be housed in a
suitable surface mounted enclosure. All components shall be suitable for 24V DC
± 10%. Power distribution to controllers and associated group of auxiliary relays
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circuits shall be via fused terminals with a blown fuse indicator, and input/output
fuse status alarm.
4.2.2.2.17 Panel Ground and signal ground shall be separate. Signal ground shall be
provided for circuit grounds of Electronic instruments, Detector Circuit shields,
Drain wire of cable shields, I.S. Barrier earth etc. For this purpose an insulated
ground bus bar 25 mm wide x 6 mm thick of copper material shall be provided
which shall run along the entire panel length. Ground wiring shall be directly
connected to the ground bus bar by means of suitable wire lugs. Intermediate
terminals are not allowed. This ground bus bar shall be provided with grounding
terminals at both ends. Terminals shall be compression type suitable for AWG
No. 4 copper ground cable. The same shall be provided on each panel structure
for panel grounding.
4.2.2.2.18 The panel shall be designed such that field wiring from remote sensing head for
Fire & Gas may be terminated directly on the associated detection controller input
terminals, rather than interposing field wiring terminal blocks. All gas and fire
detection circuits shall be grounded as per recommendations of the manufacturer
and good engineering practices. All the detector circuit shields shall be grounded
at the same point as the signal circuit.
4.2.2.2.19 Terminals in a terminal block to be identified by their individual numbers located

integral with the terminal itself. Wiring at terminals shall be identified by the
terminal number and termination service at the other end of the wire. Wiring at
Instr. & accessories such as relays, push-buttons etc. shall be identified by item
tag no. and terminal service at the other end of wire.
4.2.2.2.20 Suitably sized Terminals shall be provided for terminating main power supply
cable. The size shall be decided by the Contractor.
4.2.2.2.21 Internal Fluorescent lighting, working on 110V AC, 50 Hz shall be installed

within the panel to provide adequate lighting for maintenance of equipments. An
On/Off control switch shall be provided for this purpose in a surface mounted
enclosure near both the panel doors. The lighting fixtures must not interfere with
doors or other equipment, which must be accessible and space shall be provided
for Fluorescent lamp replacement. Thermal insulation must be provided, if
necessary to prevent excessive temperature rise in the panel surface of mounted
equipment.
4.2.2.2.22 All major shut down alarms shall be repeated for output to a remote telemetry unit
(RTU). These outputs shall be in the form of SPDT volt free contacts and shall be
terminated separately in the panel at a convenient central location for further
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connection.
4.3 FUNCTIONAL REQUIREMENTS
4.3.1 CONTROL PHILOSOPHY
4.3.1.1 General
4.3.1.1.1 The Contractor shall produce a set of Cause and Effect diagrams during the
design stage reflecting the proposed location / action for review by the Company.
Cause and Effect diagram diagrams shall be as per API RP 14C requirements
together with the requirements of this specification.
4.3.1.1.2 All shutdown interlock and alarm circuits shall be designed to operate in a fail-
safe mode.
4.3.1.1.3 Fire & Gas logics shall be designed to de-energize to actuate gas / fire shutdown
interlock.
4.3.1.1.4 Alarms-
a) In addition to signaling on the F&G matrix and alarm annunciator, fire and
gas detection shall result in separate and distinct audible and visual alarms at
Control room / equipment enclosure room / field area. (Scheme- B)
b) Visual alarms shall be colour coded to the company’s requirements to
distinguish between fire, combustible gas release, and toxic gas. (All
Schemes).
c) For gas detection, distinct visual and audible alarms in the Control room shall
be provided for the two levels of detection. (Scheme- B)
d) Silencing of audible alarms shall not deactivate visual alarms until detection
falls below the alarm level.
e) Fire & Gas Detection system shall be suitably interfaced with platform DCS.
DCS shall have an over view graphic for each F&G zone. The graphic shall
display individual detector analogue value, alarm and fault status, and deluge
valve and extinguishant release status. A separate graphic will display the fire
water pumps run and fault status and fire water pressure. (Scheme- B)
4.3.1.1.5 Detector Voting: Confirmed fire or gas-release shall be indicated by the
following:
(i) 2ooN flame detector (N ≥ 2)
(ii) 1ooN thermal detector (N ≥ 2)
(iii) 2ooN gas detector 60% LEL (N ≥ 2)
(iv) 2ooN smoke detector in Cross Zone (N ≥ 2)
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‘N’ denotes the quantity of detectors required for covering an area as per the
requirements of this specification in general and clauses 4.2.1.1.3, 4.2.1.2 and
4.2.1.3 of this specification in particular. Each area, viz., each process component
area, each equipment area, each building module area, shall be covered
individually.
4.3.1.1.6 Distinct platform audio-alarm shall be provided for confirmed HC-H2 gas release,
confirmed H2S gas release, confirmed fire through paging system. Dry volt Free
Contacts shall be provided for the input signals.
4.3.1.1.7 Fire alarm shall be actuated by any of the following:

(i) Activation of Fire Detectors as defined above in ‘Detector voting’.
(ii) FSD loop activated pressure switch
(iii)Manual activation of extinguishant from Extinguishant Control cubicles /
stations.
(iv) Deluge valve activation push-button
4.3.1.1.8 All remote gas/fire alarm outputs shall be provided through paging system.
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4.3.1.2 Control Philosophy on Wellhead Platform (for Scheme - A)
4.3.1.2.1 The control actions to be initiated upon fire and / or gas detection on
wellhead- platform are as follows:
Location Fire Or Gas Detection Action
(See Below)
Process area Confirmed Fire (Fusible plugs) 1&4
Process area Confirmed Gas release 2&3
(HC or H2S detector)
Battery room Confirmed Gas release 2
(H2 detector)
RTU/Sw.Gr./VFD Room Confirmed Fire (Smoke, 1&4
Thermal etc.)
Transformer Area Confirmed Fire (Thermal, 1&4
Triple- IR etc.)
1. Alarm- Field Sounder.
2. Alarm- Flashing & Field Sounder
3. Initiate ESD.
4. Initiate FSD, open deluge.
Note: FSD (Fire Shut down) shall close all Shutdown valves including
SSSV and open deluge valves & activate fire water network.
ESD (Emergency Shut down) shall close all Shutdown valves.
4.3.1.3 Control Philosophy on Process Platform (for scheme- B)

4.3.1.3.1 The control actions to be initiated upon fire and / or gas detection on process
platform are as follows:
Location Fire Or Gas Detection Action

(See Below)
Process area Confirmed Fire 1&5
(Flame detectors or Fusible
plugs)
Process area Confirmed Gas release. 1&4
(HC detector or H2 detector or
H2S detector)
Generator enclosure Confirmed Fire. 1&6
(Flame detector or Thermal
detector or Smoke detector)
Generator enclosure Confirmed Gas release. 1&4
H2S detector)
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Turbo Compressor Confirmed Fire. 1&7

(Flame detector or Thermal
detector or Fusible Plugs)
Turbo Compressor Confirmed Gas release. 1&8
H2S detector)
Living rooms, Galley & Confirmed Fire. (Smoke 1&2
kitchen, Store rooms (LQ) detector or Thermal- fixed
detector or fusible sprinkler)
Emergency generator Confirmed Fire. 1&9
room (Smoke or Thermal-fixed or
Flame detector)
Switchgear rooms Confirmed Fire. 1&6
(Smoke or Thermal- Fixed
detector)
Battery room Confirmed Gas release. 1&3
(H2 detector)
Battery room Confirmed Fire. 1&2
(Smoke or Thermal- rate of rise
detector)
Control room / TG Confirmed Fire. 1 & 10
Control Room / Lab (Smoke or Thermal- rate of rise
detector)
Labs & Process store Confirmed Fire / Gas 1 & 11
rooms (Smoke or Thermal or HC/H2S
gas)
Switchgear rooms/ Smoke/Fumes Detected 1
Control room / TG (Aspiration Detection System)
Control Room
1. Alarm on DCS, Annuciators and Paging system, Indication on Fire & Gas
matrix.
2. Shutdown Power to Living Quarters, trip ventilation system and automatic
actuation of Fire Water spray system / Extinguishant system.
3. Shutdown Power to the concern area, trip ventilation system.
4. Initiate ESD and trip unit.
5. Initiate FSD and open deluge valve of the detected zone/area
6. Initiate FSD, trip unit, release extinguishant instantly.
7. Initiate FSD, Trip unit in ventilation mode, trip ventilation system, release
extinguishant instantly (GG-PT Enclosure) / open deluge valve
(Compressor area).
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8. Initiate ESD, Trip unit in ventilation mode and trip ventilation system.
9. Trip unit and ventilation system and release extinguishant instantly.
10. Initiate FSD, trip unit and release extinguishant after some time delay.
11. Shutdown Power to the concern area release extinguishant after some time
delay.
Note: i) FSD (Fire Shut Down) shall close all Shut Down Valves, shall
open blow down valves, shall start firewater pumps and open
deluge valves / Release extinguishant.
ii) ESD (Emergency Shut Down) shall close all Shut Down valves,
trip the main generator set and start the emergency generator.
4.4 SPARES PHILOSOPHY

This clause shall be read in conjunction with the IDC clause no. 3.6.4.8
(Instrument Spare Philosophy).
4.4.1 In Scheme- B, installed spares for PLC shall be as per Spec. no. MR / OD /
INST / FS / C101, ‘Functional specification for PLC’.
4.4.2 For installation, testing, commissioning of Fire & Gas detection system
vendor shall recommend and provide all the necessary spares. These spares
shall be properly & separately packaged with clear marking- ‘Commissioning
Spares’.
4.4.3 Vendor shall include along with the proposal a separate priced list of
recommended spare parts for one year normal operation and maintenance.
This list should take into account related factors of ‘Fire & Gas detection
system’ reliability, effect of downtime upon normal operation & safety and
availability of servicing facilities.
4.5 Material
4.5.1 Fire & Gas Detectors
4.5.1.2 The Fire & Gas detectors shall have SS 316 sensor body housing material.
4.5.1.3 Enclosure for sensor electronics shall be copper-free marine grade Aluminum
suitable for offshore marine environment.
4.5.2 For panels refer to 4.2.2.2 clause of this specifications.
5. EQUIPMENT PROTECTION
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5.1 The protection requirements for the components of the Fire and Gas Detection
System shall in general be as per clause no. 3.6.4.4 of Instrumentation Design
Criteria.
5.2 The fixed gas detectors shall be provided with manufacturer-approved rain
hoods. Shop fabricated rain hoods shall not be used.
6.0 INSTALLATION REQUIREMENTS
6.1 The installation requirements for the components of the Fire and Gas
Detection System shall in general be according to clause 3.6.4.6 of
Instrumentation Design Criteria.
6.2 All detectors shall be installed such that they are easily accessible from a
walkway or access platform for calibration and maintenance. Where this is
not possible, test tube connections for detector calibration shall be provided.
6.3 All field equipment shall be readily accessible without the need to move other
items or equipment, except ceiling and floor tiles in the case of concealed
detectors.
6.4 All components of the fire & gas detection system panel, which require
regular maintenance and / or monitoring, shall be easily accessible to the
operations and maintenance personnel with minimum wiring removal and no
special tools.
6.5 Maintenance space requirement shall be kept to a minimum without

compromising ease of maintenance.
7.0 TESTING & INSPECTION
7.1 Inspection category of Fire & Gas detection system is B. Equipment / items
shall be inspected by company representative only at final stages as per
project finalized documents viz. Purchase specification (s), applicable project
documents, vendor documents at vendor’s works, in addition to stage
inspection by contractor and / or third party inspection agency.
7.2 Calibration, inspection and testing requirements shall in general be as per

clause 3.6.4.7 of Instrumentation Design Criteria. However, for specific
requirements this specification shall also be followed.
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7.3 Prior to shipment from vendor’s works vendor shall carry out 100 percent
testing of hardware and software of Fire & Gas detection system in the
presence of company representative / Third Party Inspection Agency-
representative .
7.4 After finalisation of testing procedures Vendor / Contractor shall notify to the
company one month before the scheduled date of testing of Fire & Gas
detection system.
7.5 Vendor / contractor shall provide complete documentation and facilities

including consumables to allow testing of Fire & Gas detection system.
7.6 The minimum requirements for testing of Fire & Gas detection system shall
be:
a) Visual, dimensional, workmanship checks.
b) Internal inspection reports verification.
c) Test certificates, Material test certificates, Statutory certificates
verification.
d) Verification of components of Fire & Gas detection system (type, size,
configuration, ratings, etc).
e) Wiring check- visual check (type, size, segregation ferruling, etc),
continuity test, and insulation test.
f) Functional check: Gas detectors- Each detector shall be subjected to
calibration check. Inject test gas and check analogue readout and alarms
as per this spec requirement. Test filters shall be used wherever required.
g) Functional check: Heat detectors- Each detector shall be subjected to
calibration check.
h) Functional check: Flame detectors- Each detector shall be subjected to
testing and shall be powered for a minimum of 2 hrs before testing.
i) Functional check: Smoke detectors- Apply manufacturer approved test
fluid to each detector for testing.
j) Other field devices including Flashing beacons, sounder, etc shall be
tested for their functions.
k) Test all shutdowns in accordance with the ‘Cause and Effects diagrams’.
l) For ‘Loop testing / acceptance’ testing, ‘Panel’ inspection / testing, etc
refer to ‘Design Criteria- Instrumentation’.
m) Fire & Gas detection system shall be subjected to elaborate ‘Factory
Acceptance Test’ (FAT) at vendor’s works. After successful installation
system shall under-go ‘Site Acceptance Test’. For ‘Scheme- III’ vendor
/ contractor shall also refer to Spec. no. MR / OD / INST / FS / C101,
‘Functional Specifications for PLC’.
n) The Vendor shall demonstrate the design life and overall system
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availability. Full details of the operating design life of all major

components that will be subjected to planned maintenance / replacement
during the life of the package, shall be provided by the Vendor.
7.7 Responsibility of proper installation, site testing, commissioning of Fire &

Gas detection system shall be with the contractor. However, Fire & Gas
detection system vendor shall provide all the necessary assistance, supervision
services, etc for successful installation, site testing, commissioning of the
system.
7.8 Gas Detector Calibration- general considerations.
a) All fixed gas sensors shall be capable of direct calibration at the sensor
head from deck level or from a fixed platform, without the need to open
the detector enclosure.
b) A kit shall be provided for detector calibration and testing. Tubing to

conduct sample to the sensor head shall be provided.
c) Test filters shall be supplied for calibrating open-path detectors to 1, 3

and 5 LELm.
d) Calibration of all detectors shall be possible either from remote location

or via hand-held calibration tool, without disconnection of any
equipment or cables. On-line calibration of detectors shall be possible.
Methane calibration gas shall be supplied in sufficient quantity for
calibration of all sensing heads.
e) Gas detectors installed inside HVAC ducts shall be provided with

collecting cones and a facility to calibrate the gas detectors externally
from the ducts without disturbing the installation.
7.9 Fire / Heat / Flame Detectors
a) Kits for testing and calibrating the fire detectors shall be provided.
b) All fire sensors shall be capable of direct calibration at the sensor head
by one person from deck level or from a fixed platform.
8.0 QUALITY ASSURANCE

8.1 The Contractor shall submit complete QA / QC plans for the proposed Fire &
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Gas detection system for Company’s review.
8.2 The vendor, and his sub-vendor, shall operate a quality system satisfying the
applicable provisions of ISO 9000 (series). A detailed quality plan shall be
provided with the bid.
8.3 The company reserves the right to carry out quality and technical review at
both vendor’s and sub-vendor’s works.
9.0 DOCUMENTATION
9.1 The documentation requirements shall in general be according to clause

9.2 Specifically for Fire & Gas Detection system following minimum documents
shall be submitted:
Type of
S.N. Document Name
Document
Following documents shall be generated by the contractor and shall be included in
main DCI of the project. These documents shall be provided to the vendor to aid
design & engineering of Fire & Gas detection system.
1 F & G detectors, other field devices layouts. FR
2 Cause & Effect diagrams. FR
3 System I / O listing / point configuration database FI
Information for displaying all displays and reports FI
4
(For Scheme- III only)
5 F & G Cable schedule FI
6 Control room layout- F&G system details FR
Following documents shall be generated by the vendor. Before submitting the
documents for review / information to the company contractor shall verify &
confirm the documents in respect of approved PS requirements.
7 Package Schedule FI
8 Document index & schedule FI
9 System configuration drawings FR
10 Logic print-outs / diagrams FR
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Operator / Engg. station print-outs (Scheme- III FI

11
only)
Specifications & General Arrangement – Internal FI
12
Arrangement drawings of Panels / consoles
13 Power distribution plan FI
14 Grounding plan FI
15 Power consumption & heat dissipation details FI
16 PLC nest loading (Scheme- III only) FI
17 PLC wiring drawings (Scheme- III only) FI
18 Loop schematics FI
19 Factory test procedure FR
20 Site test procedure FR
21 PLC instruction manual (Scheme- III only) FI
22 Miscellaneous items catalogs / manual FI
23 Operation, Installation & Maintenance Manual FI
Following documents shall be sent along with the shipment of Fire & Gas
detection system.
24 Packaging list of Fire & Gas components FI
25 Factory test reports FR
26 Quality certificates. FR
Notes:
FR For ONGC Review
FI For ONGC Information
9.3 For other PLC related documents refer to Spec .no. MR / OD / INST / FS /
C101
9.4 Purchase specification shall cover all the details as indicated in ‘Design
Criteria- Instrumentation’. Beside these details indicative formats of the
documents 6, 7, 9, & 18 (typical only for each type of detector, field devices,
etc.) shall also be incorporated in the proposal / purchase specification.
10.0 TAGGING & NAMEPLATES
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10.1 Tagging & Nameplate requirements shall in general be according to clause

10.2 For the purpose of tagging field devices including detectors, manual alarm
stations, flashing beacons, sounders, etc following philosophy shall be used:
AAA – BBB – CCC
AAA :Type of Field Device.

BBB :Zone no.
CCC :Device Serial no. in the zone.
11.0 REVIEW & APPROVAL
11.1 Review and approval of purchase specification shall in general be according

to clause 3.6.6.3 of Instrumentation Design Criteria.
11.2 F & G detection system related detail engineering documents categorization

shall be as per Cl. No. 9 (including its sub-clauses) of this specifications.
12.0 VENDOR PRE-QUALIFICATION REQUIREMENTS
12.1 The Vendor pre-qualification requirements shall in general be according to

clause 3.6.6.4 of Instrumentation Design Criteria. Also, refer to Spec. no. MR
/ OD / INST / FS / C101
13.0 PREPARATION FOR SHIPMENT
13.1 The components of the Fire and Gas Detection System shall be prepared for
shipment in accordance to clause 3.6.6.5 of Instrumentation Design Criteria.
14.0 RECEIPT & STORAGE
14.1 Receipt and storage of the components of the Fire and Gas Detection System
shall be in accordance to clause 3.6.6.6 of Instrumentation Design Criteria.
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SPECIFICATION Rev. No : 4
Engineering Services Disc: Instrumentation
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SHUTDOWN PANEL
CONTENTS

4.0 Shut Down Panel 4
4.1 Purpose / Application 4
4.2 General 4
4.5 Material 14
7.0 Calibration, Inspection And Testing 15
10.0 Review And Approval 16
12.0 Preparation For Shipment 16
13.0 Receipt And Storage 16
Annexure I Typical Well Control Module (WCM) Layout 17
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1.1 This specification describes the essential considerations in the selection, design,
procurement, engineering, installation, calibration, testing and commissioning of Shut
Down Panel (SDP).
1.2 The Contractor shall be responsible for the design, engineering, procurement, packing,
calibration, testing at yard and offshore, shipment to yard and offshore site, installation
and commissioning at site of the Shut Down Panel (SDP).
1.3 The Contractor shall be responsible for the technical integrity of the Shut Down Panel
offered, including design, materials, manufacture, assembly, testing, performance and
specified engineering services. All activities shall be in accordance with the scope of
supply, functional specification, data sheets and interface information supplied by the
Company.

a) Specification No. 3.6: Instrumentation Design Criteria
b) Basic Bid Work
3.1 The scope of work shall include a Shut Down Panel (SDP) complete with SSV control
(pneumatic / hydraulic), SSSV control (hydraulic), ESD functions, FSD functions, Well
start-up system, Tele-metering functions and other components and / or functionality as
described in this document and in the scope of work. The number of Well Control
Modules required in the SDP, the type of SSV system i.e., pneumatic or hydraulic, etc
shall be as indicated in the Scope of Work.
3.2 The scope of supply shall also include commissioning spares and Mandatory Spares as a
part of the equipment as suggested by the Manufacturer & list of one years’ operational
spares along with other type of spares as indicated in clause 3.6.4.8 of Instrumentation
Design Criteria.
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4.0 SHUT DOWN PANEL:
4.1 Purpose / Application:
4.1.1 The purpose of the Shut Down Panel on offshore platforms is to control all safety
shutdown functions of the platform, and thereby ensure safety of personnel and
equipment.
4.2 General:
4.2.1 The Shut Down Panel shall perform platform safety functions such as shut-in of Surface
Safety Valve (SSV), shut-in of Sub-Surface Safety Valve (SSSV), Emergency Shut
Down (ESD) functions, Fire Shut Down (FSD) functions, well start-up functions, etc. as
described in the following document and in the basic bid work.
4.2.2 The SSV, ESD, FSD and well start-up systems shall in general be pneumatic and the
SSSV system shall in general be hydraulic. The functional requirements and system
requirements of these sub-systems shall be as given below in clause 4.3 and 4.4
respectively.
4.2.3 Pneumatic Supply:
4.2.3.1 Pneumatic supply to the panel shall in general be as per clause 3.6.4.2.1 of
4.2.4 Hydraulic Supply:
4.2.4.1 The hydraulic supply shall be as follows:

Hydraulic circuit design pressure: 350 Kg/cm2
SSSV / SSV Actuator swept volume: 1500 ml.
Approximate distance of SSSV header: 200 m
4.3 Functional Requirements:
4.3.1 The Shut Down Panel shall initiate shut-in of all Surface Safety Valves (SSV) under any
of the following conditions:
a) When any one of the points shown in the platform SAFE Chart / P&ID for SSV
shut-in receives an abnormal signal i.e. loss of holding signal.
b) When the associated wellhead pressure gives an abnormal signal i.e. loss of
holding signal.
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c) When the Common manual reset / shut-in button provided on the panel for each
SSV is activated.
The SSV control system shall be either pneumatic or hydraulic as indicated in the Scope
of Work. The control system required for performing this function shall be as per clause
4.4.1 of this document.
4.3.2 The Shut Down Panel shall initiate shut-in of all Sub-Surface Safety Valves (SSSV)
under the following conditions:
a) After respective Surface Safety Valves have shut-in and / or when any one of the
points shown in the SAFE table / P&ID for SSSV shut-in receives an abnormal
signal. A timing circuit shall be utilized to provide a time delay of 3 minutes
(which is adjustable) between SSV shut-in and SSSV shut-in. The time circuit
shall be of pneumatic type only.
b) When the Common manual reset / shut-in button provided on the panel for each
SSSV is activated.
The control system required for performing this function shall be as per clause 4.4.2 of
this document.
4.3.3 The Shut Down Panel shall initiate platform ESD and / or FSD as per the platform SAFE
charts. The system requirements for performing ESD and FSD functions shall be as per
clause 4.4.3 of this document.
4.3.4 The Shut Down Panel shall use the following control signals for the different shut down
circuits:
General Shut Down Circuit: 0 or 3.5 Kg/cm2 (Pneumatic)
SSV Shut Down Circuit: 0 or 7.0 Kg/cm2 (Pneumatic) or

105 to 210 Kg/cm2 (Hydraulic)
SSSV Shut Down Circuit: 200 to 300 Kg/cm2 (Hydraulic)
The well shut in pressure shall be as per process design criteria.
4.3.5 The Shut Down Panel shall be capable of telemetry and tele control of all parameters
shown in the platform SAFE Charts and P & IDs. The shutdown system shall be capable
of operation even when the telemetry system is not installed or communication failure
takes place. The system requirements for achieving this function shall be as per clause
4.4.4 of this document.
4.3.6 The SDP shall be capable of initiating remote opening of individual SSVs. Remote
opening of individual surface safety valves (SSV) shall be achieved only after initial
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start-up and commissioning and shall be effective only when all the conditions specified
in the platform Safe Table /P&ID are in healthy state. The opening of surface safety
valves (SSV) and any other valve through Telecontrol shall be accompanied by
automatic starting of an audible alarm with different tone. This audible alarm shall sound
for maximum time of three (3) minutes unless reset earlier. Visual indication for the
same shall be provided at the panel front on well control modules.
4.3.7 The SDP shall have a Well Start-up system for manual opening of individual wells since
pneumatic supply is generally not available on the platforms for initial start-up of the
wells. These operations shall be accomplished by operating hydraulic pumps manually.
4.3.8 The logics in the SDP shall take care that after tripping, the system is not be brought
back to normal, unless, “RESET” is actuated and tripping conditions have come back to
normal.
4.3.9 In case of shutdown, the air supply to the hydraulic pumps shall be cut off until
shutdown signal is normalized and the ESD is reset manually. Vendor shall ensure the
same in the logic.
4.3.10 It is the responsibility of vendor to design the logic in such a way that after tripping any
shutdown valve, the valve shall not open automatically until the signal causing the trip is
normalized and the operator opens the valve using manual reset of that particular valve.
4.4 System Requirements:
4.4.1 Surface Safety Valve (SSV) Control System:
4.4.1.1 The control signal for Surface Safety Valve (SSV) control system shall be as per clause
4.3.4 above and the supply for the SSV control system shall be either pneumatic or
hydraulic as per clause no. 4.2.3 or 4.2.4 above respectively.
4.4.1.2 Each SSV circuit shall have a permit circuit connected to its associated SSSV circuit, to
prevent the SSV opening before the SSSV as well as to shut the SSV, if the hydraulic
pressure to the SSSV is interrupted or decreased. This circuit shall consist of a high-
pressure hydraulic pilot, timing system and 3-way valve. This pilot shall be set at
approximately 200 kg/cm2g.
4.4.1.3 The bulkhead fittings to the individual SSV shall be suitable for 3/8” O.D. 6000#
tubings.
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4.4.2 Sub-Surface Safety Valve (SSSV) Control System:
4.4.2.1 The control signal for Sub-Surface Safety Valve (SSSV) control system shall be as per
clause 4.3.4 above and the hydraulic supply for the SSSV control system shall be as per
clause no. 4.2.4 above.
4.4.2.2 The SSSV control system shall comprise of SSSV equalize system and SSSV primary
system.
4.4.2.3 SSSV Equalize System:
4.4.2.3.1 The purpose of this system is to apply initial pressure to the SSSV, to enable the
difference in pressure between primary system and start-up system to equalize, without
applying unnecessary shock to the SSSV. A manual 3-way selector valve shall be
provided on the panel front to select primary / start up header.
4.4.2.3.2 The bulkhead fittings to the individual SSSV shall be suitable for 3/8" O.D. 316 SS
tubing and their rating shall be 6000#.
4.4.2.4 SSSV Primary System:
4.4.2.4.1 The SSSV primary loop shall be connected to SSSV start-up loop. The SSSV primary
loop shall not have entry to the SSSV till the SSSV equalize pressure is obtained. This
shall be automatically achieved by use of hydraulic pilot.
4.4.2.4.2 The SSSV's shall be provided with redundant return line connected to redundant return
header. This header shall be provided with relief valve and pilot valve. The pilot valve
shall operate from SSSV shutdown system with suitable adjustable time delay.
4.4.2.5 Hydraulic System for SSSV ( and for SSV system wherever applicable):
4.4.2.5.1 The hydraulic system shall consist of pumps, reservoir, accumulators, headers and other
accessories as required. The relief valve shall be provided in the system based on design
pressure given elsewhere. The reservoir and accumulator sizing is to be carried out by
the Vendor and all calculations are to be submitted to company for approval. Pump
exhaust shall be vented outside the panel through flame arresters in case instrument gas
is used.
4.4.2.5.2 The accumulator header shall be 1" XXX SS 316 with 6000# SS 316 fittings. The
hydraulic tubing shall be 316 SS 3/8" OD with 0.049" wall thickness.
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4.4.2.5.3 Pneumatic ( electrical type where PLC based SDP is asked in the scope of work)
pressure pilot shall sense low hydraulic pressure in the system and it shall cause
shutdown in the same way as defined for PSL on instrument air/gas header.
4.4.2.5.4 Hydraulics supply to header shall be through line size dual filters with necessary
isolation and differential pressure indication. Hydraulic fluid shall meet its functional
requirement in high pressure application as described in the scope of work.
4.4.2.5.5 All hydraulic pumps shall be gas/air driven as well as hand operated. Each pump
discharge shall be provided with relief valve and external check valves. Each pump-
suction shall have suction strainer and differential pressure gauges across it. The pump
for start up header shall have panel front mounted filter regulator.
4.4.2.5.6 Wherever regulators are used to derive a particular pressure level the same shall be
achieved using dual redundant isolation valves, regulators and relief valves.
4.4.2.5.7 The accumulators shall be provided to take care of leakage in the system and shall be
capable of one operation of all valves of one dual completion well in case of failure of
hydraulic pumps.
4.4.2.5.8 The accumulators shall be provided with isolation and drain valves.
4.4.2.5.9 Each pump exhaust shall be tube connected to the panel exterior with suitable exhaust
header.
4.4.2.6 Reservoir System for SSSV ( and for SSV system wherever applicable):
4.4.2.6.1 The reservoir shall have an oil volume of 75 litres minimum Vendor to check and
provide correct volume as required considering future requirements and adequate air
gap. The reservoir system components shall be in SS 316 material.
4.4.2.6.2 A relief tube, properly sized shall be placed between the hydraulic drain header and the
reservoir.
4.4.2.6.3 The reservoir shall have the following accessories:

i) Oil filter strainer for fill in connection
ii) Air filter/flame arrester
iii) Sight glass
iv) Drain plug
v) Clean out opening
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SHUTDOWN PANEL
vi) The common drain header shall be 3/4" Sch. 40 316 SS pipe.
vii) The reservoir system shall include pneumatic gas / air driven pumps with a
hand pump to keep the hydraulic system pressurized for opening SSVs /
SSSVs.
viii) Low level switch (potential free contacts)
4.4.3 ESD / FSD System:
4.4.3.1 The ESD and FSD Systems shall be pneumatic in general. The control signal for these
systems shall be as per clause no. 4.3.4 above.
4.4.3.2 The SDP shall accommodate the charging and detection system for ESD on the platform.
One manually actuated ESD valve shall be mounted on the panel to perform ESD
functions. Panel shall have provision for quick charging facility of ESD loop.
4.4.3.3 The SDP shall accommodate the charging and detection system for FSD and Fusible
Plug Loop on the platform. One manually actuated FSD valve shall be mounted on the
panel to perform FSD and Fusible Plug Loop functions. Panel shall have provision for
quick charging facility of FSD and Fusible Plug loop.
4.4.4 Telecontrol System:
4.4.4.1 Explosion-proof cum weatherproof pressure switches shall be provided in the panel for
telemetry of the required parameters.
4.4.4.2 Explosion-proof cum weatherproof solenoid valves shall be provided in the panel for
tele control of the required parameters. These solenoid valves shall be pulse operated,
magnetically latched type and shall not draw continuous power in both the open and
closed states.
4.4.4.3 RTU bypass valves shall be provided at the back of the panel with wire seal to prevent
inadvertent operation.
4.4.5 Components and Construction of the Shut Down Panel:
4.4.5.1 Panel Construction:
4.4.5.1.1 The Shut Down Panel shall be Removable Modular type, Skid-mounted and Free
standing. The Panel shall be of Welded construction.
4.4.5.1.2 The Panel front shall be smooth and flat. Stiffeners shall be provided wherever required
to prevent buckling due to weight while operating the switches.
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4.4.5.1.3 To ensure rain tightness, cracks around bolts, lifting eyes, panel-mounted instruments
etc. shall be sealed with suitable media.
4.4.5.1.4 The bulkhead fittings and electric conduit connections shall be located on the Left/ Right
side of the panel.
4.4.5.1.5 The panel shall have lifting eyes to facilitate handling during transportation and
installation.
4.4.5.1.6 All internal braces and supports shall be fabricated from stainless steel.
4.4.5.1.7 The panel shall be of welded construction all around and all buff welds are to be ground
smooth. Filter welds require no grinding provided they are neat in appearance.
4.4.5.1.8 The double door type panel shall have swing out rear doors hinged with a continuous
stainless steel hinge fully gasketted and held closed with a heavy T bar latch. The panel
door shall also have lock and key arrangement. The Back-side Door shall be opened
fully without any hindrance and latching mechanism to held the door open position for
O&M purposes.
4.4.5.1.9 The panel shall be self-standing with channel frame at the base to support all the heavy
items such as pumps, accumulator reservoir. A drip pan with ¾” drain valve shall be
provided covering entire base of panel.
4.4.5.1.10 The components mounted on the panel shall be easily accessible for routine maintenance
with minimum tubing removal. All panel front components required for operation and
operator's observations shall be mounted at 600 to 1800 mm elevation from grade.
4.4.5.1.11 Engraved name plates shall be fixed by SS 316 screws at appropriate positions.
4.4.5.1.12 Arc suppression diodes shall be provided across solenoid valve terminals.
4.4.5.1.13 Cable entry size for solenoid valves provided for gas detection system shall be 3/4"
NPT (F).
4.4.5.1.14 Separate junction boxes shall be provided outside on the panel for telemetry and
telecontrol parameters. Multicore cable entries to each junction box shall be 1 ½” NPT
(F) minimum. Junction Box to be located outside /inside(preferably) on the Shut Down
Panel.
4.4.5.1.15 The tubing within the panel shall be:

i) 3/8” OD x 0.049" for ESD/FSD Loop
ii) 3/8" OD x 0.049" for Hydraulic tubing
iii) 1/4" OD x 0.035" for other pneumatic tubing
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SHUTDOWN PANEL
4.4.5.1.16 The tubing shall be SS 316, seamless & fully annealed. Double ferrule 316SS tube-
fittings with ASTM-F-1387 compliance of reputable make from ONGC approved
vendor list shall be used and shall be as per FS-3507 (FS for Instrumentation Bulk
Material).
Fittings/ tubing / Instrument valves and accessories shall meet all the functional
requirements of FS-3507.
4.4.5.1.17 External connection for SSSV, SSV, ESD Loop and FSD Loop shall be suitable
for 3/8” OD 316 SS tubing and for other shall be suitable for 1/4" OD 316 SS tubing.
4.4.5.1.18 All components and logic devices inside the panel shall be made of SS 316. Block and
bleed logics / relays shall be used.
4.4.5.1.19 The panel shall provide the following, in case of abnormal process conditions:
a) Visual indication
b) Audible alarm (the alarm shall sound for a maximum of 3 minutes, unless
reset earlier)
4.4.5.1.20 The pneumatic supply header shall be 3/4" SS 316 pipe. A 1/2" drain valve shall be
provided at the end of supply header opposite to the supply connections. The pneumatic
supply to the panel shall be through dual filter regulators with isolation valves, pressure
gauges, shuttle valve and relief valve.
4.4.5.1.21 Low instrument air/gas supply pressure in the panel shall be sensed by pneumatic
pressure pilot (set @ 5 kg/cm2g) and it shall cause shutdown in same way as defined for
PSL on Instrument air/gas header.
4.4.5.1.22 The panel shall provide a manual by pass for individual relays except ESD, FSD, low
hydraulic pressure, and low pneumatic pressure in panel, 60% LEL in gas detection
system and 50-ppm H2S signal in case of platform handling Sour Well Fluid. These
manual bypass valves shall be provided at panel back with wire seal.
4.4.5.1.23 Manual override facility (for start up alone) shall be provided, for all trip conditions,
except, ESD, FSD, 60% LEL gas, and 50-ppm H2S detection (in case of platform
handling sour well fluid). This shall release as soon as the trip condition returns to
normal.
4.4.5.1.24 All incoming and outgoing signals shall be as per approved P&IDs & SAFE Chart, and
other sections of this Bid document. The Vendor shall check and provide all logic and
all other components as required.
4.4.5.1.25 All Remote operated solenoid valves except remote ESD XSV shall be provided with
Block and By-pass Valves.
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SHUTDOWN PANEL
4.4.5.1.26 Manual shut-in / Reset valve shall be provided for each SSV, SSSV, XSDV and any
other output for shutdown purpose.
4.4.5.1.27 All manually controlled valves shall be panel front mounted.
4.4.5.1.28 Local closing facility for Main line XSDV shall be provided.
4.4.5.1.29 Panel front mounted liquid filled pressure gauges shall be provided, for pneumatic
supply pressure, hydraulic supply pressure, each input signal pressure and each output
signal pressure. All pressure gauges are to be provided with isolation valves.
4.4.5.1.30 Laminated photocopy of the Logic diagram shall be pasted on the inside of the SDP
door.
4.4.5.1.31 The indicative dimensions of the Shut Down Panel shall be as follows: (contractor shall
submit panel internal layout for approvals)
Width: As per no. of modules as described in scope of work.
Height: 2000 mm
Depth: 1200 mm
Door Width: 600 mm (max.)
4.4.5.2 Junction Box Details:
4.4.5.2.1 All electrical components in the shut down panel shall be housed in an explosion proof
junction box outside / inside (preferably) on the panel.
4.4.5.2.2 The junction box shall house all electrical components that are a part of the shut down
panel. This junction box shall be constructed as per FS-3507 and shall be explosion
proof to NEMA 7.
4.4.5.3 Well Control Module Requirements:
4.4.5.3.1 The number of Well Control Modules (WCM) required shall be as per the Basic Bid
Work.
4.4.5.3.2 Each well control module shall have following facilities as a minimum:
• Manual shut in/Reset for each SSV
• Manual shut in/Reset for each SSSV
• Control Supply Pressure Gauge for each SSSV
• Control Supply Pressure Gauge for each SSV
• Remote opening / closing of each SSV
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SHUTDOWN PANEL
• Three-minute time delay for SSSV shut in, in case of simultaneous shut
in of SSV and respective SSSV.
• Start up and primary manifold
• All incoming lines to module shall be provided with isolation / check
valves before entry to module to facilitate removal for maintenance
purpose.
• Lift Gas and / or Water Injection control logic as per requirement
4.4.5.3.3 In-built Gas Lift Logics shall be incorporated in all well control modules, including all
spare well control modules irrespective of type of well.
4.4.5.3.4 At least one spare well control module shall be provided if not indicated in the basic bid
work.
4.4.5.4 Indicating System:
4.4.5.4.1 The Shut Down Panel shall provide first-out visual indication and audible alarm in case
of any abnormal process condition.
4.4.5.4.2 Pneumatic horn shall be provided for audible horn. The horn shall be mounted at the top
of the panel. The horn shall sound for a maximum time of three (3) minutes unless reset
earlier.
4.4.5.5 Instruments for future facilities:
4.4.5.5.1 The Contractor shall provide all panel mounted instruments and accessories required for
future facilities. The Contractor shall also carry out necessary hook-up inside the panel,
related to spare module.
4.4.5.5.2 The Contractor shall also provide all other materials / equipment (e.g. Interconnecting
cables, junction boxes, cable glands, etc.) required to make the Shut Down Panel
complete and functional.
4.4.5.5.3 Inside the Shut Down panel, lay out of the instruments and accessories shall be in a
manner that all the items and terminals and fittings shall be directly accessible for
maintenance.
4.4.6 PLC based Shutdown panel :
4.4.6.1 PLC based shutdown panel if specified in the scope of work, PLC unit shall be
provided as per FS-C101 and the unit shall be placed in safe location. Pneumatic
shutdown panel unit shall be located in the field and to be integrated with PLC with
suitable interfaces.
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SHUTDOWN PANEL
4.4.6.2 All the field instruments ( PSHL, PT, DPT, TT, FT, etc ) shall be electronic type as per
P&IDs and scope of work. Signals from PSHLs shall be directly hooked up with PLC.
All the functional Logics shall be executed in PLC only . However, the related output
signal ( pneumatic/ hydraulic) to field instruments shall be processed in Pneumatic
shutdown panel unit at site.
4.4.6.3 Overall architecture diagram shall be developed by the contractor/vendor based on

functional requirement as indicated in P&IDs, scope of work and this FS-3501 and
shall submit to company for approval prior to submission of purchase specification
(PS) for Shutdown Panel.
4.5 Material:
4.5.1 The material requirements for Shut Down Panel shall in general be according to clause
4.5.2 The material of construction of the various components of the Shut Down Panel shall be
as follows:
Item Material
Skid : Carbon Steel
Panel : 4.0 mm thick SS 316 ( with compatible
panel door)
Components inside the panel : SS 316 (shall meet the requirement of
NACE MR-01-75).
Junction Box : As per FS-3507.
5.1 Shut Down Panel protection requirements shall be as per clause no. 3.6.4.4 of
5.2 Panel shall be weather proof to NEMA 4X.
5.3 Electronic / electrical components like solenoid valves, electric pressure switches,
junction boxes etc., mounted on the panel shall be weatherproof and explosion proof as
per cl 3.6.4.4 of Instrumentation Design Criteria.
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6.0 INSTALLATION REQUIREMENTS:
6.1 The installation of Shut Down Panel shall in general be according to clause 3.6.4.6 of
6.2 All components, which require regular maintenance and / or monitoring, shall be easily
accessible by operations & maintenance personnel, with minimum wiring removal.
6.3 Maintenance space requirement shall be kept to a minimum.
7.0 CALIBRATION, INSPECTION & TESTING:
7.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria. In addition, the following shall also be taken care of:
7.2 Panel shall be completely finished, piped and tested by the Vendor before submitting for
inspection. The panel testing prior to inspection shall be as follows:
• All pneumatic lines and hydraulic lines shall be tested, for leaks by applying 1.5
times the maximum working pressures.
• Wiring Checks (Loop Checks), Continuity Checks
• Utility Consumption
• Internal resistance check and insulation checks for electrical circuits
• Insulation test shall be done for wiring inside the panel.
• Simulation and full functional test (Panels shall be tested by simulating actual
operating conditions.)
• Any additional tests as laid down by the Company
7.3 The Vendor shall perform all other test as required, to place the panel in operating
condition.
7.4 In addition to the tests listed above any other test(s) required for approval shall be
performed to the satisfaction of Purchaser or his representative before shipment.
7.5 Sufficient time, ample space and necessary assistance shall be provided by the Vendor to
assure inspection and testing to the satisfaction of the Purchaser or his Representative.
8.0 DOCUMENTATION:
8.1 The documentation requirements shall in general be according to clause 3.6.6.2 of

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SHUTDOWN PANEL
8.2 The Contractor shall obtain Company’s approval for overall architecture diagram for all
well fluid data monitoring & controls as per scope of work, panel logic diagrams, sizing
calculations for reservoir and accumulator, before proceeding with the panel fabrication.
8.3 The Contractor shall submit complete QA / QC plans for the proposed Shut down panel
for Company’s review / approval.
8.4 The Supplier, and his sub-supplier, shall operate a quality system satisfying the
applicable provisions of BS5750/ISO 9000 (series). A detailed quality plan shall be
8.5 The purchaser reserves the right to carry out quality and technical review at both
supplier’s and sub-supplier’s works.
9.0 TAGGING & NAMEPLATES:

9.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1 of
9.2 All major equipment shall have identifying nameplates firmly fixed on them.
10.0 REVIEW & APPROVAL:

10.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
11.0 VENDOR PRE-QUALIFICATION REQUIREMENTS:

11.1 The Vendor pre-qualification requirements shall in general be according to clause
12.0 PREPARATION FOR SHIPMENT:

12.1 The Shut Down Panel shall be prepared for shipment in accordance to clause 3.6.6.5 of
13.0 RECEIPT & STORAGE:
Receipt and storage of the Shut Down Panel shall be in accordance to clause 3.6.6.6 of
Instrumentation Design Criteria
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SHUTDOWN PANEL
ANNEXURE – I
TYPICAL WELL CONTROL MODULE (WCM) LAYOUT
M 13 M7 M1 M3
M6 M8 M2 M4
M 11 M9 M 12 M 10
M5
M 14
SIZE
ITEM DESCRIPTION QUANTITY (INDICATI COLOUR
VE)
M1 PSHL-XXX Flow line Pressure Gauge 1 (Per Module) 70 x 20 White
M2 PSHL-XXX Flow line Status 1 (Per Module) 70 x 20 White
M3 PSHL-XXX L/G Injection Pressure Gauge 1 (Per Module) 70 x 20 White
M4 PSHL-XXX L/G Status 1 (Per Module) 70 x 20 White
M5 XSDV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M6 SSSV-XXX Output Status 1 (Per Module) 70 x 20 White
M7 SSV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M8 SSV-XXX Output Status 1 (Per Module) 70 x 20 White
M9 Push to Shut In / Pull to reset SSV/XSDV-XXX 1 (Per Module) 70 x 20 White
M10 SSV-XXX Remote S/D Status 1 (Per Module) 70 x 20 White
M11 Push to Shut In / Pull to reset SSSV/SSV-XXX 1 (Per Module) 70 x 20 White
M12 Start-up Primary Selector 1 (Per Module) 70 x 20 White
M13 SSSV-XXX Output Pressure Gauge 1 (Per Module) 70 x 20 White
M14 Well-XXX 1 (Per Module) 70 x 20 White
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SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
CABINET (TIC) Page: 10 OF 10
ANNEXURE - I
FORMAT FOR LISTING OF RTU PARAMETERS
Status
Sr. Signal
Tag No. Service Range Units Remarks
No. Shut Type
Alarm
Down
Note:
The parameters that are to be Tele-metered shall be as per approved P&IDs based on
engineering documents.
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SPECIFICATION FOR
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TELEMETRY INTERFACE
CONTENTS

4.0 Telemetry Interface Cabinet 4
4.1 Purpose 4
4.2 General 4
4.3 Cabinet Construction 4
4.4 Power Distribution Box 4
Terminal Blocks And Safety
4.5 5
Barriers
4.6 Cabinet Illumination 5
4.7 Wiring 6
4.8 Cabling 6
4.9 Material 7
4.10 Power Supply 7
4.11 Signal Types 7
7.0 Inspection And Testing 8
8.0 Documentation 8
Annexure – I List of RTU Parameters 10
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SPECIFICATION FOR
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TELEMETRY INTERFACE
1.1 This specification describes the essential considerations in the design, fabrication,
installation, testing and commissioning of the Telemetry Interface Cabinet (TIC).
1.2 The Contractor shall be responsible for the design, procurement, fabrication, packing,
testing at yard and offshore, shipment to yard and offshore site, installation and
commissioning at site of the Telemetry Interface Cabinet. The Contractor shall be
responsible for hook-up of relevant field signals to the TIC and making necessary
provisions in the TIC for hook-up of the required signals to the Remote Telemetry
Unit (RTU). The hook-up of the parameters from the TIC to the RTU is, however, not
in the scope of the Contractor
1.3 The Contractor shall be responsible for internal wiring up to the terminal Blocks/strip
for all future facilities as well. For all facilities shown as future facilities, the
Contractor shall supply and lay electrical cables from the TIC to the junction boxes to
be located near these future facilities.
1.4 The Contractor shall ensure sufficient design flexibility at the time of detail
engineering to accommodate Company’s operational requirements including ease of
maintenance.

b) Project SAFE Charts & P & IDs
c) Specification No. 3.5: Electrical Design Criteria
d) Basic Bid Work - Instrumentation

3.1 Every new wellhead platform shall in general be provided with one (1) no. of
Telemetry Interface Cabinet (TIC).
3.2 The Telemetry Interface Cabinet shall include Zener Barrier, Signal Isolator, door
switch-actuated fluorescent lamps for illumination, terminal blocks, Din rails power
distribution box, toggle switches, fuses etc. and all other accessories necessary to
make the system complete.
3.3 The scope of supply shall also include commissioning spares and one years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer.
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SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
4.0 TELEMETRY INTERFACE CABINET:
4.1 Purpose:
4.1.1 The purpose of the Telemetry Interface Cabinet is to accommodate cable terminations
(input and output) for electrical and electronic instruments required for the purpose of
telemetry, tele-control and remote data gathering applications and providing
conditioned rated power supply for these instruments.
4.2 General:
4.2.1 The location for housing the Telemetry Interface Cabinet shall be as per Basic Bid
Work. In general, the TIC shall be located in the telemetry room/SAFE Area on the
platform, which may not be air-conditioned.
The environmental parameter for equipment installed in non air-conditioned
atmosphere shall be:
The temp range - 10 to 60o C
Relative Humidity – RH up to 95 % non-condensing.
4.3 Cabinet Construction:
4.3.1 The Telemetry Interface Cabinet shall be free-standing type mounted on a Pedestal of
appropriate height or wall mounted type.
4.3.2 The cabinet shall have lifting eyes to facilitate handling during transportation and
installation.
4.3.3 The cabinet shall be of welded construction. All butt welds shall be ground smooth.
Fillet welds may not require grinding, provided they are neat in appearance.
4.3.4 The cabinet shall have a swing out front door hinged with a continuous stainless steel
hinge, fully gasketed and held closed with heavy T-bar latches.
4.3.5 The top and bottom of the cabinet shall be provided with removable gland plates
suitable for direct screwing in of double compression type cable glands.
4.3.6 The cabinet shall be sand blasted, phosphatised and painted with two coats of sealing
primer and a surface coat. The cabinet finish shall be of high quality, semi glossy
melamine resin painting in a colour consistent with other panels on the platform. The
painting procedure shall be as per specifications for Protective Coating (Spec 2005
with Addendum).
4.3.7 A laminated photocopy of the wiring diagram shall be pasted inside the panel door.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
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TELEMETRY INTERFACE
4.4 Power Distribution Box:
4.4.1 The power distribution box provided inside the cabinet shall consist of circuit
breaker, toggle switch with fuse for individual instruments / circuit / loop, etc.
4.4.2 All switches, circuit breakers, etc. shall be of double pole type.
4.4.3 The power distribution box shall be provided with the components required to cater to
all future facilities as well.
4.5 Terminal Blocks and Safety Barriers:
4.5.1 All wiring to/from the field (other than that of intrinsically safe loops) shall be
terminated at a terminal strip. The wires of intrinsically safe loops shall be directly
terminated on the safety barrier terminals. The type of barriers to be used (i.e., active
or passive) shall be as per the Basic Bid Work.
4.5.2 The terminal blocks shall be flame retardant type. The size of TB shall be not less
than 4 mm. The minimum elevation for the terminals shall be 300 mm from the panel
bottom.
4.5.3 The terminal blocks shall be clip on type having inbuilt fuse with LED indication for
loop status.
4.5.4 Terminal strips shall be spaced at least 125 mm centre-to-centre and 125 mm cabinet
edge-to-centre of terminal strip. Din Rail and terminal strip spacing shall be such that
maintenance shall be easy. The terminal strips shall be 600 V channel mount type.
4.5.5 The terminals shall be of Elmex type made of high-grade melamine suitable for 4.0
mm2 stranded copper conductors. The terminals blocks shall be non-hygroscopic,
vibration proof, stack-on type and shall use captive screws for terminals.
4.5.6 Atleast 20% spare terminals and 20% spare safety barriers shall be provided inside
the cabinet for hook-up of future facilities.
4.5.7 Intrinsic safety barriers shall be arranged in close groups and shall be located as close
to the field wiring entry point as possible.
4.5.8 The barriers shall be electrically insulated from the cabinet frame. The barrier field
terminals shall be covered by an insulator to protect the field wiring from coming in
contact with high-energy source.
4.5.9 The terminal strips and safety barriers shall be mounted in a vertical plane and
elevated to allow for ease of hook-up.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
4.6 Cabinet Illumination:

4.6.1 A door-switch actuated fluorescent lamp shall be installed inside the cabinet for
providing illumination.
4.7 Wiring:
4.7.1 All wiring shall be in accordance with the latest edition of the National Electric Code
and as per clause 3.6.4.7.7 of Instrumentation Design Criteria.
4.7.2 Electronic instrument signal wiring shall be 1.5 mm2-stranded copper. Power wiring
for instruments shall be 1.5 mm2 stranded copper. Other power wiring and earth
wiring shall not be less than 2.5 mm2 stranded copper. All wiring shall be 600 V
grade polyvinyl chloride insulated type.
4.7.3 All wiring shall be adequately supported and protected and shall be accessible from
the TIC front. Power circuits, instrument signal circuits (intrinsically safe) and alarm
circuits shall be segregated in separate wireways.
4.7.4 PVC wire way shall be used to support the wiring inside the cabinet. Wireways shall
be sized to provide at least 20% additional space for future wiring. The PVC
wireways shall be flame retardant type.
4.7.5 All wiring shall be marked with slip-on/sleeves type wire markers at each end.
4.7.6 A minimum 1” x 1.4” copper ground bus bar insulated from the cabinet structure
shall run the entire length of cabinet near the floor level. Compression type terminals
suitable for 4.0 AWG copper ground cable shall be provided at each end of the bar for
connection to platform ground.
4.7.7 All analog circuits shall be grounded at one point only, normally at 24 V DC loop
power supply common along with the analog signal shields and safety barriers.
4.7.8 Ground wiring shall be directly connected to ground bus bar by means of suitable
wire lugs. There shall be no intermediate terminals.
4.8 Cabling:
4.8.1 The cabling requirements shall in general be as per below:
4.8.2 Multi-core and single core armoured cables shall be used to transmit signals from the
field instruments to the TIC.
4.8.3 The cables from the field instruments shall enter the TIC from the bottom of the
cabinet.
4.8.4 The cables to the Remote Telemetry Unit (RTU) shall leave the TIC from the top of
the cabinet.
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SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
4.9 Material:
4.9.1 The material requirements for Telemetry Interface Cabinet shall in general be
4.9.2 The cabinet shall be constructed of 3.5 mm ± 10% thick cold rolled steel plates.
4.9.3 All internal braces and supports shall be fabricated of corrosion resistant material
such as galvanized steel.
4.9.4 The frame shall be of 6mm x 50mm x 50 mm angle steel.
4.10 Power Supply:
4.10.1 The power supply for field transmitters shall be 24 V DC + 5 % Negative earthed.
4.10.2 The power supply for solenoid valves shall be pulses of 24 V DC + 5 % V DC

Negative earthed.
4.11 Signal Types:
4.11.1 Outgoing signals to RTU shall be as follows:

a) For analog signal from the field: 1-5 V DC
b) For status signal switches: Potential free contacts
c) For turbine meter pick-up coil signals: Pulse signals.
4.11.2 Incoming signals from the RTU shall be potential free contacts enabling power
supply circuit to field transmitters, solenoid valves and flow totalizers.
5.1 Telemetry Interface Cabinet protection requirements shall in general be as per clause
no. 3.6.4.4 of Instrumentation Design Criteria.
6.0 INSTALLATION REQUIREMENTS:
6.1 The installation of Telemetry Interface Cabinet shall in general be according to clause
6.2 The Telemetry Interface Cabinet shall be as complete as possible at the Vendor’s
facilities and no further work other than electrical termination shall be required at
platform during erection.
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SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
6.3 The components mounted in the cabinet shall be easily removable for routine
maintenance with minimum wiring removal.
6.4 All components, which require regular maintenance and / or monitoring, shall be
easily accessible by operations & maintenance personnel, with minimum wiring
removal.
6.5 The package shall be designed such that all maintenance shall be carried out with the
minimum of special facilities.
6.6 Maintenance space requirements shall be kept to a minimum without compromising

ease of maintenance.
7.0 INSPECTION & TESTING:
7.1 Inspection and testing requirements shall in general be as per clause 3.6.4.7 of
7.2 The cabinet shall be completely finished, wired and tested by the Vendor before it is
submitted for inspection.
7.3 The following tests shall be carried out as minimum:

a) Panel shall be tested by simulating actual operating conditions.
b) Nameplates shall be checked for correct spelling and size of letters.
c) Continuity test, internal resistance test and insulation test shall be carried out for
electrical wiring.
7.4 Full details of the operating design life of all major components that will be subjected
to planned maintenance / replacement during the life of the package, shall be
provided by the Contractor.
8.0 DOCUMENTATION:

8.2 The RTU parameters that are telemetered shall be listed in the format shown in
Annexure – I of this document.
8.3 The following detailed drawings shall be furnished for the Company’s review:
a) Vendor’s shop fabrication and construction drawings
b) Vendor’s wiring diagrams with identifying bill of material
c) Vendor’s proposed design layout for the cabinet
d) Vendor’s nameplate details and lettering
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
ISO – 9001:2008
TELEMETRY INTERFACE
8.4 The Contractor shall submit complete QA / QC plans for the proposed Telemetry
Interface Cabinet for Company’s review / approval.
8.5 The Supplier, and his sub-supplier, shall operate a quality system satisfying the
applicable provisions of BS5750/ISO 9000 (series). A detailed quality plan shall be
8.6 The purchaser reserves the right to carry out quality and technical review at both
supplier’s and sub-supplier’s works.

12.1 The Telemetry Interface Cabinet shall be prepared for shipment in accordance to
12.2 Instrumentation and other equipment, which might be damaged in shipment, shall be
removed and packed separately. The vendor shall ensure that minimum amount of
dismantling is required for shipment.
Receipt and storage of the Telemetry Interface Cabinet shall be in accordance to

clause 3.6.6.6 of Instrumentation Design Criteria
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000
PACKAGED EQPT Page : 1 of 22
FOR
INSTRUMENTATION FOR
EQUIPMENT PACKAGE
Rev 1 - Revised for updating ISO Format
TOTAL
PREPARED / REVIEWED
REVISED BY BY
PAGES
ET RS GRP 22 28.03.2007 1
MC MC AC 22 13.05.2003 0
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Design Division
For Rev. No : 1
Engg. Services
ISO – 9001:2000
CONTENTS

2.0 Codes And Standards 3
2.2 Other Specifications To Be Followed 3
4.0 Instrumentation For Equipment package 4
4.1 Purpose / Application 4
4.2 General 4
4.3 Electrical Requirements 5
4.4 Unit Control Panels 6
4.5 Control Requirements 6
4.6 Selection Basis for Package Instrumentation 7
4.7 Material Requirements 16
7.0 Calibration, Inspection And Testing 20
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ISO – 9001:2000
1.1 This specification describes the essential considerations in the selection, design,
procurement, testing, installation, calibration and commissioning requirements for
instrumentation forming part of equipment packages.
1.2 The Contractor shall be responsible for the selection of various type of instruments for
equipment packager suitable for their intended application, their procurement, packing,
calibration, testing at yard and offshore, shipment to yard and at offshore site,
installation and commissioning at site.

b) Basic Bid Work
c) Project P & IDs
d) Specifications of various equipment package (e.g. Functional Specification for
M.I.P., Fine Filter, Fuel Gas Compressor, etc.)
e) Functional Specification for Programmable Logic Controller specification no.
MR / OD / INST / FS / C101.
NIL
3.1 The type of instruments to be used with the equipment package and their quantity shall
be as per the process requirements indicated in the Basic Bid Work, the P & IDs and the
functional specification of the respective equipment package.
3.2 The scope of supply shall also include commissioning spares and two years’ spares as
Manufacturer.
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ISO – 9001:2000
4.0 INSTRUMENTATION FOR EQUIPMENT PACKAGE:
4.1 Purpose / Application:
4.1.1 Instrumentation system for equipment package shall provide complete monitoring, local
and remote display, start-up, automatic control, interlock, alarm, normal shutdown and
emergency shutdown for the equipment package.
4.2 General:
4.2.1 The Instrumentation system for the equipment package shall include all items necessary
for the efficient, correct and safe operation of the complete equipment package.
4.2.2 Supply of all necessary items for the equipment package shall be regardless of whether
specifically referred to in the Company’s specifications or not, including the supply of
instrumentation required for control of the equipment installed in pipe work or other
equipment not in Contractors supply, unless specifically excluded in the particular
equipment specification.
4.2.3 The functional requirements of these instruments shall be as per the relevant functional
specification enclosed in the bid document. General requirements as covered in the
Instrumentation Design Criteria shall be applicable to all the instruments forming a part
of the equipment package.
4.2.4 The Contractor shall completely mount, pipe and cable all instrumentation items on the
packaged unit.
4.2.5 All wiring and tubing which requires interconnections with any other equipment
external to the package shall be terminated in appropriate junction boxes and bulkhead
plates, mounted adjacent to the package boundary be the Contractor. The locations and
details of all such junction boxes and plates shall be agreed by Company prior to
installation and clearly marked on the Contractor’s drawings.
4.2.6 Process fluids shall not be piped off the unit for measurement purposes. Measured
variables shall only be transmitted off the package by electronic signals.
4.2.7 Cable entries for outgoing cables shall be clearly marked on the layout drawings,
including the location, size and quantities, and shall be plugged until cable installation.
4.2.8 Equipment package, which requires pneumatic supply for instruments, shall incorporate
a 316SS Supply header of the proper size of the package. The on-package supply
piping shall terminate at the package boundary and the location and size of the supply
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connection shall be noted on the Contractor’s drawings. Each pneumatic instrument

shall be individually connected to a sub-header and provided with filter regulator and
isolation valve.
4.2.9 Control and shutdown functions shall be segregated by the provision of separate
dedicated instruments, process connections and logic solvers.
4.2.10 Electronic instrumentation transmission signals shall be provided by 2 wire transmitters

giving an isolated 4 – 20 mA DC linear output signal from a nominal 24 VDC supply,
and shall be compatible with having either pole grounded. All field transmitters shall be
microprocessor based; intrinsically safe (IS) “smart” type with HART protocol.
4.3 Electrical Requirements:
4.3.1 The electrical power supply for the instrumentation for equipment packages shall in
general be as per clause no. 3.6.4.2 of Instrumentation Design Criteria.
4.3.2 Power supplies and signal voltages shall be as listed below:

Digital I/O : 24 V DC
Analog Signals : 4 – 20 mA Smart signal with HART protocol
Power to control systems : 24 V DC or 110 V AC, 50 Hz single phase earthed neutral
supplies from UPS/Battery Bank
4.3.3 Signal interfaces to other systems shall be as follows:

• Process control system – via redundant serial links and /discrete digital and analog
I/O.
• ESD system – via volt – free contacts, 24 VDC circuit.
• Fire and Gas system – via volt- free contacts, 24 VDC circuit
• Critical Alarms – via. volt-free contacts, 24 VDC circuit.
4.3.4 All terminations shall be made on screw clamp type terminals, correctly certified (Exe)
where necessary. No flying leads shall be used.
4.3.5 Each cable core shall be labeled with a full circular cable ferrule, ‘C’ type are not
acceptable.
4.4 Unit Control Panels:
4.4.1 Where complex equipment packages such as turbo-generators, compressors and gas
chromatographs are supplied with integrated Unit Control Panels (UCP) as a part of the
package such system shall comply with the project specifications.
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4.4.2 Larger UCPs will communicate with the DCS via redundant serial data communication
links and with the ESD and Fire and Gas systems via hardwired signals. Such UCPs
shall be provided with suitable redundant communications ports to allow transmission
of monitoring, control and alarm information via serial interface (RS 232 C, RS 422 or
RS 485 etc.).
4.4.3 This function shall enable the unit to be monitored and controlled from the Central
Control Room (CCR), in addition to the local control and indication.
4.4.4 The Contractor shall ensure robust and secure integration of UCP communications into
the DCS using only standard software modules.
4.4.5 Shutdown and Safety Instrumented Systems (SIS), which are part of UCPs, shall
comply with the integrity requirements arising from the project risk assessment and
PISHAZOP, and IEC –61508.
4.5 Control Requirements:

4.5.1 Operational Requirements:
4.5.1.1 Local panels or field equipment will not normally be manned and therefore, automatic
control systems shall be provided to achieve optimum process operation under the
specified plant conditions. Local indication and manual controls shall be provided to
allow for local monitoring, control, start-up and shutdown of the equipment.
4.5.1.2 A local UCP shall be provided where the grouping of indicators, controls, alarms, etc. is
required for ease of operation or for safety reasons when carrying out manual start-up
and shut down procedures.
4.5.2 Shutdown and Auto Start Requirements:
4.5.2.1 The Control systems shall be designed to automatically ensure a safe shutdown
condition in the event of any malfunction, or when commanded by the platform ESD
system.
4.5.2.2 All shutdown signals, to and from a package, shall be cabled to a dedicated junction box
at the package limit for interfacing with the Platform ESD system.
4.5.3 Alarm Requirements:
4.5.3.1 In general, the alarm signal outputs from equipment package shall be transmitted from
the equipment package through potential free contacts. For larger system, non-critical
alarms may be transmitted to the DCS by serial link.
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4.5.3.2 Where an alarm annunciator is supplied as a part of the equipment package, the
annunciator shall have a “first –out” feature to indicate which of a group of alarm points
operated first.
4.5.3.3 Annunciation of shutdown and auto-start functions shall be provided by a contact

independent of that initiating the control function.
4.5.3.4 Every signal, which initiates a shutdown, shall also have a pre-alarm signal to warn of
an impending shutdown situation.
4.6 Selection Basis For Package Instrumentation:
4.6.1 General:
4.6.1.1 Proven commercial high quality instrumentation shall be utilized with particular
attention to reliability and materials of construction.
4.6.1.2 Instrument parts shall be resistant to the corrosive properties of the process fluid to
which they are exposed and to the external environment.
4.6.1.3 Seals and purges shall be used as necessary, to ensure reliable instrument performance.
4.6.1.4 Housing and exposed parts of field –mounted instruments shall be resistant to the
corrosive environment.
4.6.1.5 All instruments of one type shall be procured from the sane manufacturer.
4.6.2 Control Panels:
4.6.2.1 All enclosures shall be suitable for the environmental conditions specified in the data
sheet for the particular equipment package.
4.6.2.2 Control panels containing PLCs shall be located in non-hazardous areas.
4.6.2.3 Panels for outdoor use shall be fabricated from 316SS, with minimum sheet thickness of
1.5 mm, Panels shall be suitably reinforced to prevent warping or buckling.
4.6.2.4 Free standing Panels of width 1500 mm shall have a 100 mm channel base. Folding
around door opening shall be provided to prevent dust or water lodged on top of the
door from entering the panel when the door is opened. Panels shall have sloped roofs
and guttering to direct water away from doors.
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4.6.2.5 All hinged parts or doors shall be earthed to a fixed part of the frame connected by a
braided strap or fine stranded flexible wire connection.
4.6.2.6 Devices in separate compartments shall be capable of being replaced without shutting
down units in adjacent compartments and without exposing maintenance personnel to
live equipment. Door openings shall be large enough to permit removal of equipment.
4.6.2.7 All control and indicating devices mounted on penetrations shall maintain the IP rating
of the panel.
4.6.2.8 A minimum of 15% of clear mounting space shall be provided for large panels, and
25% for small panels to permit adding future control devices and panel instrumentation.
4.6.3 Flow Measurement:
4.6.3.1 General:
4.6.3.1.1 The Contractor shall select the flow meter best suited to the service whilst considering
maintenance periods and cost. The Company’s preference is to use vortex, Coriolis, or
magnetic flow meters over turbine and PD meters. Vortex meters may also be utilized,
provided they are not installed in areas where vibration will affect accuracy.
4.6.3.1.2 Meter transmitters shall be “Smart” with 24 V DC power supply and 4-20 mA output
and be equipped with a local LCD indicator.
4.6.3.2 Magnetic Flow Meter:
4.6.3.2.1 Magnetic flow meters may be considered where the turn down ratio is less than 1:10
where velocities are <10 m/s and fluid conductivity is >5microsiemens/cm.
4.6.3.3 Coriolis Flow Meter:
4.6.3.3.1 Coriolis meters may be considered where the turn down ratio is less than 1:30. These
may be used for the measurement of hydrocarbon liquid flow and / or density with
process pressure < 40 Kg. /Cm2. Maximum line size shall be DN 80. Consideration
shall be given to the meter pressure drop.
4.6.3.3.2 Where the meter is installed in a bypass line for density measurement, the contractor’s
design shall ensure that the flow rate through the meter provides the accuracy and
response times required by the process.
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4.6.3.4 Ultrasonic Flow Meter:
4.6.3.4.1 Multi path ultrasonic flow meters may be used for measurement of gases and liquids in
accordance with AGA 9. The piping design shall ensure that the meter measures a full
pipe. The Contractor shall ensure that all wetted parts are compatible with the process
conditions. Sensors shall be constructed from 316SS as a minimum.
4.6.3.5 Orifice Plates:
4.6.3.5.1 Flow measurement to AGA 3 and AGA 8 shall generally be carried out by different
pressure measurement across square edge orifice plates with flange tap orifice flanges
or special fittings. Orifice plates shall be concentric for gas flow and eccentric bore for
multiphase flow.
4.6.3.5.2 Other types of orifice plates and methods may be considered for approval where
necessary to satisfy special applications.
4.6.3.5.3 Meter Rangeability shall not exceed 3 to 1, and the design flow shall preferably be
within 0.65 to 0.80 of full range.
4.6.3.6 Flow Nozzles and Venturi Tubes:
4.6.3.6.1 These shall be considered where minimum head loss, and / or high capacity is required
and for use in non-homogeneous fluid with a low percentage of solids and shall be in
accordance with AGA3.
4.6.3.7 Differential Pressure Flow Transmitters:
4.6.3.7.1 Transmitters shall be fitted with 5 way isolation and equalizing manifolds (AISI 316
minimum grade). Mercury type elements shall not be used.
4.6.3.8 Variable Area Flow Meter:
4.6.3.8.1 Variable area flow meters shall be used only for local indication of non-hazardous
fluids. Glass tube meters shall not be used.
4.6.3.8.2 Meters shall be mounted in a vibration free location with pipe work anchored to prevent
stressing of the meter body. The meter shall be suitably protected against mechanical
damage.
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4.6.3.9 Turbine Meter:
4.6.3.9.1 Turbine meters shall be installed directly in the lines with minimum straight run
distances calculated according to API – 2534. Appendix C, but not less than 20 pipe
diameters upstream and 5 pipe diameters downstream. A strainer shall be installed
upstream of each turbine meter.
4.6.4 Level measurement:
4.6.4.1 General:
4.6.4.1.1 All components associated with level measurement shall conform to the vessel design
pressure and temperature, and the project specifications for piping design, materials and
fabrication.
4.6.4.1.2 Level transmitters and float switches shall generally be mounted in external chambers
piped to the vessel. To facilitate maintenance testing and calibration, drain points with
piped drain valves shall be provided. Chambers shall be provided with vent and drain
points.
4.6.4.2 Level Gauges:
4.6.4.2.1 Gauge glasses shall be either steel armoured transparent or reflex type. They shall be
provided with isolating valves, plugged drains and vent valves of size DN 15 minimum
except in certain specified applications.
4.6.4.2.2 Gauge glasses shall be selected on a basis of total visible length giving equal visible
coverage above and below the maximum and minimum anticipated operating levels.
4.6.4.2.3 The level gauge shall not exceed 1100 mm visible length.
4.6.4.2.4 Ranges in excess of 1100 mm visible length shall be covered by multiple gauge
assemblies. Visible length of multiple gauges shall overlap by a minimum of 50 mm.
4.6.4.3 Level Transmitters:
4.6.4.3.1 The primary type of level instrument for remote transmission shall be the displacer type.
Other types of instrument may be proposed for the Company’s consideration where
displacers are not suitable.
4.6.4.3.2 Differential pressure transmitters are only to be employed when specific gravity
changes are considered to be negligible.
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4.6.4.3.3 Meter transmitters shall generally be “SMART” with 24 V DC power supply and 4-20
mA output, and be equipped with a local indicator.
4.6.4.4 Level Switches:
4.6.4.4.1 Level switches shall generally be avoided, however where they are required, fixed
displacement or float type switches mounted in an external chamber shall be used.
4.6.4.4.2 Variable displacement type switches mounted in an external chamber shall be employed
where process requirements or operating conditions prevent the use of float type
switches.
4.6.4.4.3 Float switches shall generally have single pole double throw contacts, with contact
rating of 5A, 240 volt. Ac. The position of the float shall determine the set point. The
switch shall have a fixed differential.
4.6.5 Pressure measurement:
4.6.5.1 General:
4.6.5.1.1 All pressure instruments shall be specified with a range approximately twice the
operating pressure except where process conditions dictate otherwise. They shall be
capable of withstanding an over pressure of 25% above the relevant relief valve setting
without permanent set or loss of calibration.
4.6.5.1.2 All pressure instruments shall be provided with individual block and bleed valves as
well as the primary process isolation valve.
4.6.5.1.3 All instrument used for handling viscous or corrosive materials shall be sealed. Seals
may be the chemical type of suitable material and a silicone oil fill between the
diaphragm and the pressure element of the instrument. Capillary tubing shall be 316SS
3 mm OD with 316SS spiral wound armour. Diaphragm seals shall be flush out type.
4.6.5.1.4 Pressure transmitters shall be ‘SMART’ with 24 VDC power supply and 4-20 mA
output, and be equipped with a local indicator.
4.6.5.1.5 Pneumatic transmitters shall have an accuracy of better than 1% of span and wherever
applicable shall be of the indication type. Process connections shall be ½” NPT.
Transmitter output tubing shall be provided with a plugged tee for installation of a
calibrated pressure gauge.
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4.6.5.1.6 Pressure switches shall have single pole double throw contacts, with gold contacts rated
for low energy use 1A at 28 VDC. These switches shall have adjustable differential as
required.
4.6.5.2 Pressure Gauge:

4.6.5.2.1 Instrument range shall generally be selected so that the normal operating pressure
occurs at approximately two-thirds scale.
4.6.5.2.2 Standard ranges shall be used wherever possible. Gauges shall have an accuracy of ±1.0
% FSD and have 25% over range protection.
4.6.6 Temperature measurement:
4.6.6.1 General:
4.6.6.1.1 RTD transducer type Electronic transmitters shall be used for measurement less than
350oC.
4.6.6.1.2 The use of temperature switches shall be generally avoided. Where they must be used
they shall be single pole double throw contacts, rated for 1A at 28VDC.
4.6.6.1.3 Liquid or gas filled thermal systems are not preferred. However, if supplied they shall
be complete with stainless steel bulb, armoured capillary thermowell and union
connection. Alternatively the switch may be of bi-metallic type.
4.6.6.1.4 A thermowell shall be employed at all temperature measuring points except in

exceptional approved applications.
4.6.6.2 Thermowells:
4.6.6.2.1 Thermowells shall be a minimum of 316 SS, shall be flanged and be DN 40 for piping,
DN 50 for vessels. Screwed wells are not acceptable.
4.6.6.2.2 Thermowell extension shall be of sufficient length to ensure sensor head is clear of any
pipe or vessel insulation.
4.6.6.2.3 Sufficient clearance shall be provided to ensure the element can be withdrawn from the
sensor head without removal of any fittings, etc.
4.6.6.2.4 Test wells shall be equipped with a SS 316 plug. Plugs shall be attached to the well by
a SS 316 chain.
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4.6.6.3 Temperature Gauges:
4.6.6.3.1 Dial thermometers shall be adjustable, every angle bi-metallic type. Construction shall
be of SS 316 with external adjustment and accuracy / better than 1% of full scale.
4.6.6.3.2 The range shall be selected so that the normal operating temperature lies at
approximately two-thirds full scale.
4.6.6.4 Temperature Transmitters:
4.6.6.4.1 Electronic transmitters shall be used for all temperature measurements that are to be
displayed in the Control Room. Platinum RTDs shall be the preferred element. Other
sensor types may only be considered when it is demonstrated that an RTD is not
suitable. Transmitters shall generally be “Smart” with 24 V DC power supply and 4.20
mA output and LCD indicators.
4.6.7 Control valves:
4.6.7.1 General:
4.6.7.1.1 Control valves shall normally be located in horizontal lines and with the top work
mounted upright. Locations shall permit easy access for maintenance operations to the
valve body, actuator and any accessories.
4.6.7.1.2 Body and flange ratings shall be in accordance with the piping design and materials
specification. However, the minimum flange rating shall be ASME 300.
4.6.7.1.3 Valve trim shall be SS 316 minimum.

4.6.7.1.4 Control valve shall have tight shut off in accordance with ASME B 16.04 Class IV
unless otherwise specified.
4.6.7.1.5 All components shall be designed so that they fail-safe, i.e. in all failures the valve shall
move to the safe position.
4.6.7.2 Valve Type:

4.6.7.2.1 Globe valves shall be employed for process control purposes in higher DP, low capacity
service.
4.6.7.2.2 Alternative valves as allowed by the piping design and materials specification may be
used subject to Company approval.
4.6.7.2.3 Rotary globe valves (eccentric plug) with stellite facings with plug downstream may be
considered for flashing service.
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4.6.7.3 Valve Body:
4.6.7.3.1 Minimum Control Valve body size shall be DN 25 when the control valve manifold
piping is DN25 or larger.
4.6.7.3.2 Valves in flashing service shall have a body size at least one size larger than that
necessary to contain the calculated trim size.
4.6.7.4 Valve Packing:
4.6.7.4.1 The packing material shall depend upon the service condition. The recommended
packing material is PTFE for services from –200 to 200 deg. C. Flexible graphite
packing with external lubricator and isolation valve shall be used for service
temperatures above 200 deg. C.
4.6.7.5 Control Valve Sizing:
4.6.7.5.1 Valve flow coefficients shall be calculated for each operating condition in accordance
with the equations and methods in ISA 75.01.
4.6.7.5.2 Valve trim size for equal percentage characteristic valves shall normally be selected so
that:
Minimum flow valve travel is 20%.
Normal flow valve travel 60% to 80%.
Maximum flow valve travel 90%.
4.6.7.5.3 Valve trim size for linear characteristic valves shall normally be selected to be between
50 to 70% travel for normal flow. Maximum flow shall not exceed 90% of capacity.
4.6.7.5.4 Butterfly valves shall be sized so that the normal design flow rate does not exceed 60%
opening for throttling service.
4.6.7.5.5 In addition to the selection of valve and trim combination sized to suit the process
conditions, full consideration shall also be given to the inlet and outlet velocities and
possible occurrence of cavitation causing excessive noise, erosion and vibration. All
control valve sizing shall be verified by the valve vendor to ensure suitability to meet the
4.6.7.6 Valve Actuators:

4.6.7.6.1 Actuators shall be sized for operation under maximum shutoff pressure drop across the
valve, with minimum instrument air pressure or voltage to the actuator as specified in
this specification.
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4.6.7.6.2 A safety margin of 1.5 for regularly cycling valves shall be applied. For long standstill
service safety margin shall be a minimum of 2.
4.6.7.6.3 Each valve set shall be fitted with a 316 SS filter regulator air set combination.
4.6.7.7 Valve Positioners:

4.6.7.7.1 Intelligent valve positioners shall be provided for all modulating control valves.
4.6.7.7.2 Valve positioners shall be “smart type” with integral I/P, direct acting and have a spring
range for 4-20 mA signal.
4.6.7.7.3 Positioner by pass shall be fitted except where agreed with the Company.
4.6.8 Emergency and shut down valves:
4.6.8.1 General:
4.6.8.1.1 All shut down /sequence valves shall be of the ball valve type. They shall provide
bubble tight shut off (class VI) with the higher pressure from either direction.
4.6.8.1.2 All shut down valves shall be fail-safe and shall include a pressure accumulator where
necessary to achieve the required action or number of operations on loss of external
operating pressure.
4.6.8.1.3 All shut down valves shall be provided with a beacon type position indicator. Where
specified in the Datasheet, this shall house open and closed position proximity limit
switches. These shall be certified as Intrinsically Safe.
4.6.8.2 Valve Actuator:

4.6.8.2.1 Valve actuators shall be sized to operate the valve in both directions with zero pressure
downstream, and maximum pressure upstream and also with the maximum differential
pressure in the reverse direction. Sizing shall include a 30% safety margin above the
minimum operating torque requirements of the valve at the maximum DP. Actuator
torque shall not exceed the maximum stem shear torque of the valve at the maximum
supply pressure.
4.7 Material Requirements:

4.7.1 The material requirements for the equipment package instrumentation shall in general
be as per clause no. 3.6.4.5 of Instrumentation Design Criteria and as per the Material
Specifications listed in the Equipment/Instrument Specifications and Data Sheets.
4.7.2 Materials used for parts of the assembly not specifically detailed by the Company shall
be selected by the Contractor on the following basis:
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• Suitability for the specified process conditions.

• Consideration shall be given to the effects of stress corrosion cracking in 316 SS
when in contact with chloride at temperatures above 34deg.C
• Company approval is required prior to the use of aluminium for any instrument
component Aluminium may only be used if no other suitable material is
available from the manufacturer. Aluminum shall not be used for any
component in contact with the process fluid. If aluminium is used for any
housing or component it shall be certified as copper free i.e. less than 0.4%
copper by mass.
• Cast iron shall not be used for any item to which this specification applies.
Ductile iron shall not be used without the Company’s prior written approval of
each item.
• All proposed plastic component shall be non-toxic and fire resistant, UV
stabilized, and compatible with the environmental conditions.
• All spindles, bushing, bolting, screws etc, shall be manufactured from a suitable
grade of stainless steel.
• All molded polyester parts shall be in an anti-static version for hazardous area
locations, and in general be constructed from glass reinforced polyester ultra
violet stabilized. Surface resistance shall be less than 109 OHMS. Impact
resistance shall be –25% (EN 50.14).
• In-line instruments, including valves, shall be specified with suitable materials
in accordance with NACE MR 0175 where H2S is present in significant
concentration.
5.1 The protection requirements for the equipment package instrumentation shall in general
be as per clause no. 3.6.4.4 of Instrumentation Design Criteria.
5.2 Control Room Environment: The control rooms shall be normally pressurized and air-
conditioned environments and shall provide an environment in accordance with ISA
S71.01 and ISA S 71.04. These areas shall be subject to the following condition:
Ambient Air Temperature: 21-24oC
Relative Humidity : 45% to 55%
The equipment in control rooms shall continue to operate properly under conditions of
air conditioning failure, when the ambient conditions may rise to 50 o C and 95% RH
for periods up to 8 hours.
5.3 The majority of the field mounted instrumentation will be mounted in a Division 2
hazardous area although some will be located in a Division 1 classified area and some
in a safe area.
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5.4 For reasons of standardization, all field mounted electrical equipment shall utilize the
following methods of protection :-
• All electrical instrumentation equipment except junction boxes and solenoid
valves shall be certified intrinsically Safe Ex “ia” for Class 1, Div. 1, Group D,
Temperature Class T5 minimum.
• Junction boxes to be certified ‘increased safety” Ex “e” for IS circuits and
explosion proof/Ex”d” for non-IS circuits for Class 1 Div.1 Group D
Temperature Class T5 minimum, hazardous area.
• If instrumentation cannot be provided with the above methods of protection,
then alternative methods suitable for the classified area and certified by an
acceptable Authority shall be proposed for the Company’s consideration.
5.5 All certificates and documentation required to satisfy the conditions of the certification
shall be provided (including IS system entity and cable parameter calculations) in the
Hazardous Area Dossier.
5.6 Equipment shall be designed so that, under normal operating conditions, it shall be
unaffected by radio transmissions. A 5 watt RMS hand –held transmitter in the 50-200
and 400 – 460 MHz bands, positioned with the mid points of its aerial no more than 300
mm from the electronic module shall not impair or degrade the performance of that
module.
5.7 All equipment including entries and blanking plugs shall be dust tight and water proof
to IP 65/NEMA 4X. Instruments not classified IP 65 to be subject to Company’s
approval.
5.8 Weather shields shall be installed over Ex ‘d’ junction boxes, and instruments that do
not meet this standard.
6.0 INSTALLATION REQUIREMENT:
6.1 The installation requirements shall in general be according to clause 3.6.4.6 of

6.2 The principles and details of instrument mounting and location shall be selected so as to
have no adverse effect upon signal accuracy and repeatability. Any physical condition
such as mechanical stress, vibration, temperature etc. shall be limited to the maximum
figures specified by the instrument manufacturer by the use of appropriate mounting
methods.
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ISO – 9001:2000
6.3 Special measures shall be taken to protect engine – mounted instrument from heat and
vibration, and ensure ready accessibility. Cable connecters for such items shall be
sufficiently robust to withstand the conditions and repeated disconnection/reconnection.
6.4 Instruments shall be positioned to provide sufficient space for ease of installation,
removal and maintenance.
6.5 Instrument Mounting:
6.5.1 Instruments shall not be mounted on handrails.
6.5.2 Instruments shall be mounted on DN50 pipe stands (except pressure gauges, dial
thermometers and other instruments which are screwed directly on the line).
6.5.3 Local instruments shall be mounted so that the centerline of the instrument is
approximately 1400 mm above grade or walkway.
6.6 Process and Instrument Connections:
6.6.1 Individual instrument connections shall be provided on process piping and equipment.
Each process connection shall have an isolating valve.
6.6.2 Process piping up to and including the first block valve shall confirm to the vessel or
line classification.
6.7 Tubing & Fitting Installation:
6.7.1 The installation requirements for tubing and fitting shall in general be as per clause no.
6.7.2 Instrument installation shall be in accordance with API RP 550, the instrument
manufacturer’s instructions and the following:
6.7.3 All Process Impulse Tubing and Fittings shall be rated to suit the design conditions but
the following shall be considered minimum requirements.
• ½” X 0.065” W/T Fully annealed AISI 316 seamless stainless steel tubing to
ASTM A269 or equivalent with hardness less than RB 80.
• Fittings to be AISI 316 stainless steel twin ferrule compression type.
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ISO – 9001:2000
6.7.4 All pneumatic tubing and fittings shall be in accordance with the following minimum
requirements.
• ¼” O.D. X 0.035” W/T.
• 3/8” O.D. X 0.035” WT.
• ½ “ O.D. X 0.035” W/T.
• Fully annealed AISI 316 Seamless Stainless Steel Tubing to ASTM A 269 or
equivalent. Hardness to be less than RB 80.
• Fittings to be Swagelok AISI 316 Stainless Steel Twin Ferrule Compression
type.
6.7.5 The tubing wall thickness of any larger size tubing shall be suitably rated to meet the
process design pressure to which it is subjected.
6.8 Instrument Electrical Installation:
6.8.1 Electrical Installation requirements shall be in accordance with the relevant sections of
Electrical Design Criteria.
6.8.2 Cable Segregation:
6.8.2.1 Intrinsically safe signal cables may be run on the same tray as the equivalent non LS
Signal cables but must be segregated by a metal barrier.
6.8.2.2 Cables carrying miscellaneous signals such as frequency/plus /analysis shall be

individually and overall screened and be run on separate tray unless individual approval
has been given to share a tray with other signal cables.
7.0 CALIBRATION, INSPECTION AND TESTING:
of Instrumentation Design Criteria. In addition, the following shall also be taken care
of:
7.2 All equipment shall be comprehensively tested before delivery. The testing shall
demonstrate the full functionality of the equipment.
7.3 In addition to the inspection and testing specified in the accompanying equipment
specifications, the Contractor shall also comply with the following minimum
requirements.
7.4 The Contractor shall provide to the Company, not less than six weeks prior to the date
of commencement of the control and instrumentation system test, a detailed schedule of
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Design Division
For Rev. No : 1
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ISO – 9001:2000
the tests and sample rest record forms for approval. The tests shall not be undertaken
until the test schedule and test forms are approved by the Company.
7.5 The test procedures shall include but not be limited to the following:
• All wiring shall be tested for insulation and the test voltage shall be compatible
with the wiring being tested.(Equipment likely to be damaged shall be
disconnected for these tests).
• Full stimulated function tests of the complete system with all equipment in
position and connected to suitable temporary supplies. The Contractor shall
provide the test stimulator consisting of dummy loads with indication of the
status of every output. The test simulator shall only be connected to the field
connection terminals and the input/output interface shall be individually labeled
to facilitate testing. The Contractor shall obtain Company’s approval of supply
unit characteristics and simulated input/output interface.
• All equipment failure modes e.g. fail-safe, self-diagnostic, power supply dip,
etc. shall be checked.
• Calibration of all instrument items shall be witnessed to ensure the required
accuracy is achieved.
7.6 All tests and corrective work shall be recorded for the Company’s approval.
7.7 The Contractor shall ensure that all inspections and tests are completed satisfactorily.
The Company reserves the right to back-charge any additional inspection work if
Contractor’s preparations are found to be unsatisfactory by the Company.
7.8 Tests shall be witnessed and results recorded on test sheets, which shall include test
reports and be forwarded to the Company for approval and acceptance prior to
shipment.
8.0 DOCUMENTATION:

Instrumentation Design Criteria. In addition, the following shall also be taken care of:
8.2 Design Documentation:
8.2.1 The design documentation shall include the following:

• General arrangement drawings complete with parts list, materials of construction
and description. The drawings shall also include package dimensions,
instrument locations, interconnecting piping or tubing tie in points and tubing
termination bulkhead location, and junction boxes location at which all
instrument cables terminated. The instrument drawing symbols shall be in
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ISO – 9001:2000
accordance with ISA S 5.1 Instrument tag No. on those drawings shall conform
to tag No.on P&ID drawings.
• A table of all instruments, including pressure gauges, relief valves, control
valves, thermometers, c. used throughout the package. This tabulation shall
show item number, model; number, manufacturer, service, size or range,
specification sheet No., set point and other data which would facilitate
identification and location of the instruments.
• Prices list of recommended commissioning spares.
• Prices list of spare parts for two years operation.
• Prices list of special tools.
• Itemized list of Contractor’s Deviations from Specification.
• Weights.
8.3 Final Documentation:
8.3.1 A manufacturing Record Book shall be compiled concurrently with fabrication such
that a full record of the fabrication, materials, inspection and testing is available.
8.3.2 All items in the manufacturing Record Book shall be numbered. Contents shall include,
but not be limited to the following:
• Front cover sheet detailing.
• Project Title.
• PO No.
9.0 TAGGING AND NAMEPLATES:

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Design Division
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ISO – 9001:2000
12.1 Preparation for shipment shall in general be as per clause 3.6.6.5 of Instrumentation
Design Criteria.
13.1 Receipt and storage requirements shall in general be as per clause 3.6.6.6 of
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11 - High, Mumbai HYDRAULIC POWER Discipline Instt.
UNIT CUM CONTROL Page # 1 of 11
ISO 9001: 2000 PANEL
FOR
HYDRAULIC POWER UNIT CUM
CONTROL PANEL
TOTAL
PREPARED / REVIEWED
REVISED BY BY
PAGES
VS SSK GRP 11 16.06.08 1
AK MC RK 11 10.02.06 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

3.0 Hydraulic Power Unit Cum Control Panel 5
3.1 Design Criteria 5
3.2 Inspection & testing 8
3.3 Warranty 9
3.4 Spares 9
3.5 Tools 9
3.6 Packing & transport 10
3.8 Operation & Maintenance Manual 10
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

1.1 This functional specification describes the essential design considerations for
the selection of Hydraulic power Unit Cum Control Panel for the intended
service.
indicated in the Basic Bid Work, Design Criteria and the P & IDs.
2.2 The vendor shall be responsible for the selection of the Hydraulic Power Unit
Cum Control Panel suitable for its intended application, its procurement,
tagging, packing, testing & calibration, preparation for shipment, along with
accessories, spares, and assistance where required for its installation &
commissioning at site. This FS shall be read in conjunction with:-
1. Instrumentation Design Criteria
2. Basic Bid Work
3. Project P & IDs
4. Process Design Criteria
5. Electrical Design Criteria
6. Mechanical Design Criteria
7. Piping Design Criteria
8. Environmental condition of the project
2.3 The following codes and standards (latest edition) as applicable to be referred
ASME, Boiler and Pressure Vessel Code

Sec.VIII,
Div.1
API RP 2A Recommended Practice for Planning, Designing and
Construction of Fixed Offshore Platforms
API-RP-14C Analysis, Design, Installation and Testing of Surface
Safety System on Offshore Production Platforms.
API 17A Recommended practice for design and operation of sub-
sea production systems
API 17D Specifications for sub-sea wellhead and Christmas tree
equipment.
API 17E Sub-sea Production Control Umbilical
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NAS 1638 Cleanliness Requirements of parts used in Hydraulic

system
SAE J 343 Specifications for tests and procedures for hose and hose
assemblies
NEC National Electrical Code
NEMA National Electrical Manufacturer’s Association
IEC International Electro technical Commission
ASTM American Society for Testing and Material
API-610 Centrifugal Pumps for General Refinery Services
API-674 Positive Displacement Reciprocating Pumps
API-676 Positive Displacement Pumps- Rotary

2.4 Vendor shall supply all necessary equipment including major items as specified
below but not limited to the following
• Hydraulic pump driven by electric motor
• Hand hydraulic pump as back-up facility
• Hydraulic fluid reservoir with filter, breather etc.
• Hydraulic accumulators with instrumentation
• Solenoid operated control valves
• Manual control valves
• Interconnected piping, electrical, instrumentation and controls
• Necessary connectors, tubing for connecting HPU with Hydraulic
umbilical
• Pressure relief valves, pressure switches, pressure indicators, SS 316
tubing, valves and fittings.
All above equipments, units and components shall be skid mounted on a
common structural skid, fully assembled, piped with inlet and outlet piping
terminated at skid edge with appropriately rated flanges, wired, tested and
painted for manned environment.
Umbilical hoses shall connect HPU to the sub surface intervention valve
actuators through quick disconnect couplings for hydraulic supply to and return
from actuators
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3.0 HYDRAULIC POWER UNIT CUM CONTROL PANEL:
3.1 DESIGN CRITERIA:
3.1.1 The control system shall consist of the following major components in a single
skid mounted unit.
• Hydraulic power unit
• Control panel with all control and display instruments.
3.1.2 It shall be possible for the operator to actuate the subsea valves from the panel
(HPU) and to observe the status of the valves. Valve status shall be electrically or
electro-hydraulically transmitted by a separate pair of cable/umbilical chords.
3.1.3 The panel should have provision to accept and respond to ESD & FSD signal
commands from the existing platform ESD/FSD loop. An ESD /FSD signal from
the platform should cause a closure of the subsea shut down valve.
3.1.4 Vendor shall also supply the initial charge of hydraulic control fluid for the entire
system (up to the sub-sea valve) as well as nitrogen cylinders.
3.1.5 An integrated test of the HPU cum control panel, subsea shutdown valve and the
Umbilical shall be carried out by the contractor/vendors
3.1.6 The equipment shall be designed for outdoor location on an offshore platform with
site conditions as detailed in BID package.
3.1.7 The equipment shall be selected as per the area classification requirement.
3.1.8 Hydraulic Power Unit shall be designed for a complete life of 25 years minimum
of the platform as specified elsewhere in the BID. The Hydraulic Power Units shall
operate sub-surface intervention valves located at a distance from platform as per
the enclosed P&IDs and data sheet
3.1.9 The following shall be given due consideration in sizing, selection and design of
various components forming a part of the electric motor driven Hydraulic Power
Unit:-
• Working pressure requirement
• Pressure drops in umbilical
• Ease of operation and maintenance
• Overall compactness
• Reliability of Operation
3.1.10 HYDRAULIC RESERVOIR LINE FITTINGS
3.1.10.1 Hydraulic reservoir shall be of SS 316 construction provided with the

following accessories and fittings as a minimum:-
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• Drain point
• Breather screen with desiccant type air filters cum particulate filters
• Level gauge
• Necessary pipe/tubing connections
Hydraulic accumulators shall be in stainless steel 316 constructions with
ASME code stamp and shall be provided with 100% standby capacity. The
Vendor in bid shall describe the make and design and operating conditions of
hydraulic accumulators along with typical drawing. The Vendor shall also
specify the make and material of accumulator bladder and other accessories
suitable for the service and application in bid and describe the operation of
accumulators
3.1.10.2 Pumps shall be driven by electric motor and the Vendor shall furnish full
details of pumps with bid for the technical evaluation.
3.1.10.3 Pump discharge pressure and flow rates shall be decided by the vendor based
on the design and operating conditions required for the operation of sub-sea
valves as per process design criteria and basic scope of work.
3.1.10.4 Hydraulic pipe work in the system shall be done with soft annealed seamless
SS 316 tubes and SS 316 fittings.
3.1.11 FILTERS
Filters at suction to pump shall be provided to provide 5 microns degree or
better of filtration for the safety of the pump. Filter housing shall be in
stainless steel construction with suitable vent and drain connections.
3.1.12 HYDRAULLIC CONTROL FLUID

Hydraulic control fluid shall be Marston Bentley (HW560, Isaac Bentley make
or equivalent and shall meet the following requirements as a minimum.
• The fluid shall be water based, consisting of de-ionized water, biocide and
water-soluble lubricant.
• Viscosity shall be less than 4 Centistokes at +200 C
• The fluid shall contain a corrosion inhibitor and shall be compatible with
the material and seals used in the system.
• The fluid shall be free from foaming. The fluid shall be thermally stable
(i.e. stratification or precipitation shall not occur over a temperature range
of -50 C to +650 C at pressure of 0-5000 psi.
• The fluid shall not form harmful products when exposed to oil, gas, water,
completion fluid and greases or thread sealants employed in equipment
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
manufacture. The fluid should be miscible with unto a minimum of 10%

sea-water.
• The fluid shall be resistant to deterioration by oxidation.
• The fluid shall include biocide to control any biological growth. Vendor
shall state any limitations on its useful life and recommended action to
maintain the required protection.
• The fluid shall meet NAS 1638 Class 6 standard of cleanliness.
• Vendor shall provide procedures for laboratory tests for fluid quality.
• Vendor shall furnish the Test data for fluid pH, viscosity, specific gravity,
water content, pour point and cleanliness.
• The fluid shall not cause deterioration of the materials and seals in the
system.
3.1.13 SPECIAL REQUIREMENTS:
3.1.13.1 Vendor shall furnish with the bid detailed P&ID, system description and bill of
material for the Hydraulic Power Unit.
3.1.13.2 HPU requirement shall be compatible with overall operation and control
philosophy of platform. However, following facilities shall be necessarily
included.
3.1.13.3 Reservoir capacity shall take into account the distances traversed by umbilical
and the type of actuator. Reservoir should have at least 30% reserve capacity
for leakages etc, capacity calculations shall be as per design criteria and
company approval shall be obtained.
3.1.13.4 Hydraulic system shall be capable of withstanding a proof test pressure that is
1.5 times the operating pressure.
3.1.13.5 Hydraulic reservoir shall be complete with breather valve, level gauge,
level switch, drain connection and access opening for inspection and cleaning
of reservoir..
3.1.13.6 The selection, fabrication and installation of piping work shall meet the
minimum requirements defined in the piping specification.
3.1.13.7 Electrical equipment and materials shall be in accordance with the attached
electrical functional specification and electrical design criteria.
3.1.13.8 All equipment selected for hazardous area shall be certified by BASEEFA, UL
or equivalent international testing, agency for the service and area in which it is
to be used
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3.1.13.9 The selection and installation of instrumentation works shall meet the
minimum requirements defined in the instrument design criteria and functional
specification. The material exposed to the sour service shall meet the NACE-
MR-01-75 standard (latest edition).
3.1.14 SKID
3.1.14.1 The skid shall be designed and built to ensure that all the equipment along with
accessories, panel and piping are mounted suitably for convenient operation.
3.1.14.2 A canopy shall be provided above the skid for protection against rain and direct
sun light.
3.1.14.3 The skid mounted unit will be equipped with lifts slots in the slid base. And the
upper from will be equipped with a lifting eye on each of the top four corners.
3.1.14.4 The lift points and skid structures will be designed to withstand four times the
unit’s static weight, in the event of snatch lifts. The skid structure shall be
sandblasted, primed and painted as per the bid requirements.
3.2 INSPECTION AND TESTING:
3.2.1 Vendor shall carryout various tests as per applicable Codes/Standards. Test
certificates shall be submitted for Company’s approval.
3.2.2 Company/its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacture. Company shall specify
hold points/witness points while approving purchase specification during project
execution. During inspection, material certificates, shop test data, certificates for
bought out components and other relevant information shall be furnished for
company’s perusal so as to ascertain that the specifications and quality are
complied with.
3.2.3 In case Vendor/their sub vendors of equipments/packages have in-house elaborate
Quality/Assurance Systems (operating in their shop) for Inspection & Testing of
equipments/packages shall obtain approval of their Quality Assurance System from
the Company prior to commencement of manufacturing activities.
Where such Quality Assurance System is not in operation with the
manufacturer/their sub-vendors, the Tests specified as “witnessed” in the
Specification shall be carried out in presence of the Company/as authorized
representative or certifying agency. The cost of preparation for shop testing of
equipments/packages including inspection fee etc. shall be borne by the
Contractor. Vendor/Contractor shall give minimum 15 days prior intimation to the
Company regarding testing schedules.
Company/its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacturer. During inspection,
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
material certificates, shop test data, certificates for bought out components and
other relevant information shall be furnished for company’s perusal so as to
ascertain that the specifications and quality are complied with. Company shall
specify hold points/witness points while approving purchase specification during
project execution
3.3 WARRANTY
Vendor shall have final and total responsibility for the design and mechanical
performance of all equipment supplied under this specification. Vendor shall
warrant the equipment furnished by him and the performance of the said
equipment in accordance with this specification. Also refer to Warranty clause as
given in bidding documents (Volume I).
3.4 SPARES
3.4.1 Vendor shall recommend and provide list of spare parts needed for startup and
commissioning in purchase specification. In addition, vendor shall also furnish a
separate itemized priced list of recommended spares for one (1) year normal
operation and maintenance. Recommended spares should take into account related
factors of equipment reliability, effect of downtime upon production or safety, cost
of parts and availability of equipment service facilities.
3.4.2 All spare parts furnished by Vendor should be wrapped and packaged so that they
will be preserved in original as-new condition under the normal conditions of
storage to be anticipated in India and shall be properly tagged and codes so that
later identification as to intended equipment usage will be facilitated. They shall
be packaged separately clearly marked as “Spare Parts” and shipped at the same
time as the equipment. Packing lists shall be furnished so that the parts can be
handled without uncrating, if desired start-up spares shall be packed and identified
separately
3.5 TOOLS
Vendor shall provide two sets of special tools, if not stated elsewhere, for operation
and maintenance of the furnished equipment.
3.6 PACKING AND TRANSPORT
The offered equipment along with their accessories shall be shipped packed in
wooden crates. They shall be wrapped with polythene sheets, before being placed
in the crates to prevent damage to finish. Crates shall have skid bottom for
handling.
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UNIT CUM CONTROL Page # 10 of
ISO 9001: 2000 PANEL 11
3.7 DOCUMENTATION
Installation and commissioning procedures for HPU unit and control system. These
shall be submitted to the company for review at least 60 days before the start of
said activities. These shall include, but not necessarily be limited to the following.
• Procedure for installation and interconnection of surface elements of the
system.
• Final cleaning and flushing procedures for control system components.
• Pressure leak test procedures for the hydraulic circuit
• Final check out of the surface equipment prior to connection to the
umbilical.
• Check out of the subsea and surface electrical system
• Procedure for tie-up procedure of umbilical to surface equipments.
• Sequence and functional testing of entire subsea system
• Procedure for removal and reinstallation of subsea connection before and
after work over and wire line jobs, including safety procedures.
• Procedures should also include (where-ever applicable) The required test
sheets indicating clearly the activities /tests tube carried out and acceptance
criteria for each of the tests conducted during installation. Pre-commission
ing and commissioning.
3.8 OPERATION AND MAINTENANCE MANUAL
3.8.1 The contractor shall prepare on operation and maintenance manual for all the
equipment (provided by contractor) and submit to company representative within
10 days subsequent to fabrication completion. This manual shall systematically
include all information on the system equipment. Its installation, operation and
maintenance. In particular, the following information shall be covered where- ever
applicable:
• Component / equipment system description should explain the design
criteria, functional description and mode of operation and start-up and
shut down procedures including logic flow charts
• Checks and test program and procedure for individual sub assembly
level tests and for final tests upon completion.
• Operating instructions during normal operations
• Operating instructions during failure conditions
• Description of monitoring control and safety system
• Fault finding procedures
• Procedure for periodic performance tests
• Maintenance and repair procedures
• Safety precautions and safe practices
• Drawings and equipment schedules
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ISO 9001: 2000 PANEL 11
3.8.2 The maintenance manual shall include the following attachment where
applicable:-
• Drawings showing supporting structure, pressure drawing(s) showing
piping system, value and instrumentation (P&IDs).
• Drawing showing individual component details. Drawing showing the
de tails of each subassembly and assembly.
• Drawing showing controls and safety systems.
• Flow diagrams and schematics.
• Equipment vendor data.
• Instrument list.
• Blank test sheets for all the tests.
• Drawings for electrical system.
• Drawings and description of test equipment and tools
• Recommended parameters for routine system monitoring
• Equipment and instruments parts list.
• List of tools and test equipments.
• As built drawings, inspection and test reports, operation manual and
other relevant documents shall be submitted to the company in hard
copies and as well as in CD ROM.
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SPECIFICATION FOR
Engineering Services Discipline Instrumentation
ISO – 9001:2008 INSTRUMENTATION BULK
MATERIALS Page: 2 OF 11
TABLE OF CONTENTS
Clause
ITEM Page No.
No.
1.0 SCOPE OF THIS DOCUMENT 3
2.0 REFERENCE SPECIFICATIONS 3
3.0 SCOPE OF SUPPLY 3
4.0 BULK ITEM REQUIREMENTS FOR INTERFACING 3
Instrument air Headers, Branch lines &

4.1 3
Distribution.
4.2 Instrument Air Fittings 4
4.3 Instrument Air Tubing 6
4.4 Piping Support 8
4.5 Junction boxes 9
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR

1.1 This specification describes the essential considerations in the selection, installation, testing and
commissioning of the instrumentation Bulk Materials like tubing, fitting, instrument valves (
Miniature Valves / Instrument isolation valves ) & Junction Box.
1.2 The Contractor shall be responsible for the selection of the Bulk Materials suitable for its
intended application, its procurement, testing, packing, shipment to site, installation and
commissioning.
1.3 This Functional specification covers a wide variety of requirements as mentioned in above
mentioned clauses. However, Contractor is required to submit purchase specifications for
Instrumentation Tubing & Fittings for company’s review & approval.
2.0 REFERENCE SPECIFICATIONS:
b) Basic Bid Work
c) Project P & IDs
3.1 Installation materials for instrumentation items shall be as per actuals. Bidder shall submit
detailed hookup drawings for each instrument installation with MOC and Quantities mentioned
therein.
4.0 BULK ITEM REQUIREMENTS FOR INTERFACING:
4.1 INSTRUMENT AIR HEADERS, BRANCH LINES AND DISTRIBUTION.
i) Instrument air/gas header shall be in accordance with the piping specification of
appropriate service and operation rating as per the piping PMS.
ii) The size of instrument air/gas mains shall be established in accordance with the table
below unless otherwise specified. Connections shall be as per the Annexure IV of the
Design Criteria
Nom. Pipe Size Max. Members of Users
½” 3
¾” 14
1” 23
1½” 50
2” 100
iii) All take-off for branch lines shall be of SS 316 & shall be from the top of the main
header with SS 316 block valves (full bore ball valves) equal in size to the branch line.
All low points shall have a ½” valve SS 316 (full bore ball valves) installed as a drain and
blow down point.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
SPECIFICATION FOR
iv) The branches to individual pneumatic instruments shall be as per the Hook-up drawing
provided in Annexure IV of Design Criteria.
v) Every pneumatic instrument requiring instrument air / instrument gas shall be provided
with appropriate volume 316 SS filter regulator fitted with integral relief valve and output
gauge to ensure that suitable quality and pressure of air is received by the instrument.
vi) Wherever the air / gas sub header ends in a distribution manifold, each manifold take-off
valve shall supply only one user and shall be labeled with the user’s tag number. At least
one spare outlets fitted with valves (full bore ball valves) shall be provided for every 20
meters of the distribution manifold, for future use. The total number of spares for future
shall be minimum 20% of the total number of Outlets.
vii) Manufacturer or fabricator supplying equipment or vessels mounted on skids, which
incorporate instrumentation requiring pneumatic supply, shall install a pneumatic supply
header, of proper size, on the skid with end connection at skid battery limit. All
pneumatic instruments mounted on skid shall be fed with pneumatic supply from this
header. The non-skid supply piping shall terminate at skid boundary and the location and
size of the supply connection shall be noted on vendor approval drawings.
viii) Where the process gas is used instead of instrument air, MOC selected shall be NACE
compliant SS316L for the service and composition of the gas, i.e., sour service, H2S,
CO2 etc.
4.2 INSTRUMENT AIR FITTINGS:
4.2.1 Material, Specifications & Sizes:
a) All fittings shall be imperial sizes, expressed in nominal outside diameter (OD) and all
threads shall be NPT. All threaded fittings shall have NPT threads as per ANSI B1.20.1
b) Fittings shall be of 316 SS material to ASTM A 276 or equivalent (i.e., BS 970-316-S31,
DIN4401 or ASME SA 479-316).
c) Stainless Steel Tube Fittings made from bar stock (straight configurations) should meet
ASTM A276/ ASME SA479 standards and those made from forgings (including elbows,
crosses and tees) should meet ASTM A182 / ASME SA182, BS 970-316-S31, DIN 4401
standards.
4.2.2 Fittings shall be ASTM F1387 MAF classification – IV , “Flare-less Mechanical collating grip
type” producing a firm grip on the tube without substantially reducing the tube wall thickness.
Fittings shall be capable of holding the maximum working pressure of the tubing without any
leak after only one and a quarter turn pull up of the nut.
4.2.3 Fittings shall have the body, front & back ferrules and nuts. All the components of tube fittings
shall be from of the same manufacturer.
4.2.4 Nuts for SS fittings shall have silver plated threads to act as a lubricating agent to avoid galling
and to reduce tightening torque.
4.2.5 All fittings shall have hardness not exceeding RB 90. All the fittings end connections shall be
compatible to tube of hardness in the range between RB 70 to 79 and hardness for fittings
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(ferrules) shall be such that, there is a minimum hardness difference of 5 to 10 between tube and
fittings for better sealing.
4.2.6 Bar stock shall be with carbon content <0.05% to provide increased resistance to corrosion.
4.2.7 Heat code traceability number shall be stamped or etched on both body and nut of fittings.
4.2.8 Threaded connections shall be NPT for all components and piping and tubing systems for
process and utilities connections. PTFE threads sealant shall be used on all threaded connections.
For high temperature application suitable sealant shall be selected.
4.2.9 Above API 10000 and above company’ approval shall be obtained for selection of Fittings.
4.2.10 Testing Requirements for tube fittings:
4.2.10.1 Type Testing Requirements:
a. The tests specified in the table below shall be carried out on the samples drawn and in the
sequence, as specified in ASTM F1387–99 (Re-approved 2005). The testing shall consist
of all the following tests as per ASTM F1387–99 (Re-approved 2005):
Mandatory Tests
1 Examination of specimen Annexure A2
2 Pneumatic Proof Test Annexure A3
3 Hydrostatic Proof Test Annexure A4
4 Impulse Test Annexure A5
5 Flexure Fatigue Test Annexure A6
6 Tensile Test Annexure A7
7 Hydrostatic Burst Test Annexure A8
8 Repeated Assembly Test Annexure A9
9 Rotary Flex Test Annexure A10
Supplementary Tests
1 Thermal Cycling Test Section S2
2 Stress Corrosion Test Section S4
3 Vibration Test Section S8
(MOC of Tubing used in
Sizes to be tested: ¼”, ½” 3/8”, 3/4” 1”
testing shall be SS316 as a minimum).
Valid Type Test Report from Accredited Lab/ National Test House for all the above tests
and sizes (as mentioned above in the table) carried out as per ASTM F-1387 (2005
Reapproved) shall be submitted along with the Purchase specification.
4.2.10.2 Following Tests shall be witnessed by TPIA for the lot of supply and report shall be
submitted, along with supply.
• Visual Inspection, Dimensional Check, Heat Code Traceability certificate Review,
Material Test Certificate Review & check for workmanship.
• Positive Material Identification
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• Reviews of certificate for Oxalic Etch Testing for inter granular corrosion resistance.
(ASTM A 262).
• Hydrostatic Pressure test
• Pneumatic Proof Test
4.3 INSTRUMENT AIR TUBING
4.3.1 Material, Specifications & Sizes:
• All tubing shall be imperial sizes, expressed in nominal outside diameter (OD) and all
threads shall be NPT ANSIB1.20.1.
• ‘Tubing’ shall be of TP 316 / 316L (dual certified) material to ASTM ‘A 269’ or
equivalent (i.e., BS 970-316-S31, DIN4401 or ASME SA 479-316), unless otherwise
specified. Molybdenum content shall be 2.5% minimum and carbon content of ≤
0.03%.The minimum size shall be ¼” OD.
• Manufacturing Process: Extrusion followed by cold Pilgering and / or cold drawing .
• Tolerance on OD : +/- 0.08 mm (As Per EN10305-1/DIN 2391)
• Tolerance on wall thickness : +/- 10% (As Per EN10305-1/DIN 2391)
• Pressure Rating: Shall be minimum 250 bar.
• Roughness value on OD: 1.2 Micron RA (max.)
• Concentricity : As per EN 10305(≤0.1)
• Tube Hardness : Up to 80 HRB As per NACE MR 0175 Certification
• Tubing Length : 4-6 meters
4.3.2 The manufacturer shall provide material compliance certificates confirming that the raw material
for fittings conform to ASME section – II.
4.3.3 Fully Bright Annealed Tubes: Tubes shall be annealed in a controlled reducing atmosphere to
ensure a clean oxide-free film on the free surface for reduced chances of corrosion.
4.3.4 Stainless steel tubing shall be soft annealed seamless TP 316 / 316L (dual certified) as per
ASTM A269. Sizes shall be as follows:
S. No. Application Size
¼”O.D. X 0.035” W.T.
1 High-pressure hydraulic lines
3/8” O.D. X 0.049” W.T.
2 ESD/FSD loop 3/8” O.D. X 0.035” W.T.
Pneumatic supply to shutdown valves 1/2” O.D X 0.065” W.T. 316 SS tube ,
3
, control valves 3/8” O.D. X 0.035” W.T. 316 SS tube
4 Process impulse lines 1/2” O.D X 0.065” W.T. 316 SS tube
4.3.5 Signal transmission shall be through ¼” O.D. X 0.035” W.T. tubing run singly or in bundles.
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4.3.6 Monel tubing shall be used on sea water and produced water service and shall be fully annealed
seamless as per ASTM B-165 with size ½” O.D. X 0.035” W.T.
4.3.7 Tubing shall be supported and protected by stainless steel angle / channel or ladder / tray along
the complete length of each run and shall be fastened with stainless steel saddles at a maximum
of 1 m intervals on straight runs.
4.3.8 Channel or tray support for tubing runs shall be sized for a minimum capacity of 30% greater
than that required.
4.3.9 All pneumatic exhaust ports and breathers shall be fitted with bug screens, installed facing
downwards.
4.3.10 Vendor to confirm that following tests shall be carried out by vendor and certificates for the
same shall be given along with supply. Test reports submitted by Vendor shall be reviewed by
TPIA at the time of Supply.
• Visual Inspection, Dimensional Check, Check for workmanship. Material Test Certificate
• Mechanical test : Tensile test (Yield strength, Tensile strength, % Elongation) , Impact
test
• Hardness test
• Chemical test (Product analysis)
• Microstructure examination : Ferrite content, Sigma phase
• IGC test (Austenitic): As per ASTM A 262 specification ,Practice E
• Corrosion test
• Eddy current test: 100% Eddy Current Test acc to ASTM 1016 A/ ASTM A450
• Burst Test: Tube shall be subjected to 'Tube Burst Test' to evaluate the grip of tube
fittings on tubing at the burst pressure of the tubing. LSTK contractor shall get this test
carried out at the manufacturer’s place and submit the test report along with Purchase
Specification.
• Flattening Test
• Heat Number Traceability certificate shall be ensured for above mentioned tests and shall
be reviewed by the TPIA.
4.3.11 Tubing Installation:
a) The primary instrument block valves for all instruments shall be as per piping
specifications. MOC of all the drain valves shall be 316 SS / MONEL as a minimum.
b) All impulse lines shall be run with a slope not less than 1 in 12 except where otherwise
specified. Direction of slope is to be downward from the process for liquid service and
upward from the process for gas service.
c) Tubing shall be joined by double compression fittings.
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d) Instrument lines shall be run in the vertical plane as far as possible and shall be run with
the minimum number of changes of directions consistent with good practice and neat
appearance. All pipe and tubing shall be run in horizontal and vertical planes only.
e) Tubing shall be bent with correct size tubing bender where required to avoid the use of
fittings. Tubing cutter shall always be used to cut tubing. The use of short lengths of
tubing in long runs shall be avoided, to avoid the use of fittings.
f) All tubing shall be run in such a manner as to give the maximum protection against
mechanical damage. Tubing runs shall be grouped together and clamped where possible.
Tubing shall be arranged so that couplings can be tightened without distorting lines.
Instrument tubing shall not run on trays intended for cables and shall not share the same
transit with cables.
g) Where tubing is run in permanent enclosures, the Contractor shall ensure that entry and
exit of such enclosures is clean and smooth.
h) Pipes or tubes installed but not connected, shall have the ends closed in approved fashion
to prevent the entry of foreign material by suitable caps or plugs.
i) All reasonable precautions shall be taken to prevent foreign material entering tubing /
pipelines before and during erection.
j) No pipe or tube shall be left with mechanical strain on it.
k) Where the length of transmission tubing exceeds 60 Mtrs. (200 Ft.) the Company should
be consulted as to the necessary of installing signal booster relays.
l) Where permanent enclosures are left with space for instrument tubing to be pulled in at
some future date, a galvanized pull wire of adequate size shall be left in the tray.
m) On tubing to pipe connections and in making of screwed pipe joints, Teflon tape shall be
applied to make thread in a manner to insure tape is not over the end of the male fittings.
4.4 Piping Supports:
a) Piping and tubing shall be adequately supported and fixed at distances not exceeding
those in the following table:
Single Tubing Max. Distance Between Supports
3
/8” O.D. and less Continuous
½” to ¾” Nom. Size 2 Mtrs. (6 ft.)
¾” to 1” Nom. Size 3 Mtrs. (9ft.)
Multi tube Bundles 3 Mtrs. (9ft.)
b) All field-mounted instrument air tubing shall be supported with galvanized steel angles or
channels of minimum 1/8” thickness fabricated to present a neat appearance.
c) All instrument tubing supports shall be galvanized prior to installation.
d) Mechanical ferrule seater shall be used on tubing for pressure 140 kg/cm2 (2000 psi) and
above.
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e) Pipe bushing shall not be used. Plugs shall be of bar-stock with hex heads.
f) If extended lengths of multiple tubing are to be run, multiple bundles and junction boxes
with weatherproof entries may be used to the best advantage.
g) Manufacturer or fabricator supplying skid mounted equipments or vessels with
instrumentation, which provides, or utilizes pneumatic, offside alarms, shutdowns, or
control functions shall tube signals to a central bulkhead, near skid boundary, available
for hook up by the Contractor for connection to offside equipment. Location of the
bulkhead shall be noted on vendor drawings.
h) Differential or static pressure sensing lines shall not exceed 6 Mtrs. (20 Feet) for direct
connected or locally mounted instruments.
4.5 JUNCTION BOXES:
a) Instrument junction boxes shall be certified for use in the hazardous area in which they
are installed. For intrinsically safe circuits, boxes certified Increased Safety Ex e shall be
used. For non-intrinsically safe circuits, boxes certified Explosion Proof / Flame proof
Ex d shall be used. Boxes (Ex e, Ex d) shall have minimum IP 66 ingress protection.
b) Separate junction boxes shall be used for intrinsically safe wiring. Junction boxes in any
cable path from field to control room shall be limited to one only unless otherwise
mentioned in Basic scope of work related to instrumentation. Instrument junction boxes
shall not be used for electrical power cables
c) For Ex d junction boxes cable entries shall have NPT threads; Where this is not possible a
certified 316 SS adaptor shall be fitted.
d) All Ex e and Ex d enclosures shall have all spare entries sealed with suitably certified 316
SS plugs.
e) Entries shall be suitably spaced to enable ease of installation of cable glands. Tapped
cable entries shall be of good quality, without stripped or damaged threads. The thread
shall be continuous and shall permit the cable gland to fit squarely against the gland plate
(or enclosure).
f) Where the gland plate is not thick enough for tapping, cable glands shall be fitted with
double locknuts.
g) The threads of all cable glands and adaptors shall be greased on assembly.
h) Cable glands fitted to all Ex e enclosures, and industrial enclosures, may have a nylon or
lead sealing washer between the Cable Gland and Gland Plate (or enclosure) to ensure IP
66 protection. Sealing washers shall not be fitted to glands entering Ex d enclosures.
i) All glands, adaptors, reducers and plugs for the Ex e as well as Ex d junction boxes shall
be certified for use in Class I .
j) All junction boxes shall be effectively sealed, once uncrated or fitted into position. All
lids shall be replaced during any break in work. Where this is impractical, e.g. large
multi-cable junction boxes, a heavy PVC sheet shall be used to cover the junction box to
exclude rain and dust.
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k) All terminals (including unused terminals) shall be tightened down. For communing of
terminals, feed through cross connection bar shall be used. Comb connectors shall not be
used.
The construction of junction boxes shall be as under:
a) Increased Safety
i. Junction box construction shall be 1.5 mm 316 SS. Boxes shall be bottom entry with a
removable 316 SS gland plate. The gland plate shall be drilled and tapped, 6 mm thick
for tapered threads and 3 mm thick for parallel threads. The plate shall be bolted to the
box with 316 SS bolts, sealed with a neoprene gasket and fitted with an 8 mm earthing
stud. All incoming cables shall enter from the sides of the junction box. Outgoing cable
shall be from the bottom of the junction box.
ii. Boxes shall have four external mounting lugs, two top and bottom, drilled with 10 mm
fixing holes. A full size removable stainless steel gear plate shall be fitted inside each
box. Terminals shall be Ex e rail-mounted tunnel-type made of melamine. Wiring ducts
shall be colored blue.
iii. Boxes shall have doors hinged minimum at two points with a neoprene seal fitted all
round. Hinges shall be the lift-off pintle type, constructed of stainless steel; piano hinges
are not acceptable. A restraining mechanism shall prevent opening more that 160o.
Screwdriver-operated door latches shall be fitted at the top and bottom.
iv. In addition to the manufacturer’s certification label, each junction box shall have
identification label attached to the box with 316 SS screws in a manner which will not
invalidate the hazardous area certification. The label shall be constructed of white-black-
white laminated plastic. The label shall include an engraved Tag No. An additional tag
stating “Intrinsically Safe Circuits” shall be installed. This shall be blue-white-blue
laminated plastic.
v. The contents of Ex e enclosure shall not be altered without the prior approval of the
company‘s electrical or instrumentation engineer .
vi. The damaged terminals shall be replaced with approved Ex e terminals
b) Explosion Proof
i. Explosion proof junction boxes shall be constructed from 316 SS / epoxy coated copper
free die-cast Aluminium. Boxes shall have at least four external mounting lugs, drilled
with 10 mm fixing holes, and an 8 mm external earth lug. A full size removable stainless
steel gear plate shall be fitted inside each box. Cables shall enter from the bottom, and
20% spare entries shall be provided. Cable entries shall be drilled and tapped to suit the
required glands, and fitted with certified 316 SS plugs. Junction box lids shall have cast
hinges integral to the box with stainless steel pins.
ii. Each junction box shall have an identification label, in addition the manufacturer’s
certification label, attached with 316 SS screws in a manner, which will not invalidate the
hazardous area certification. The label shall be constructed of white-black-white
laminated plastic. Terminals shall be rail-mounted tunnel-type, made of melamine.
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iii. Ex d enclosures shall not be drilled or machined under any circumstances after approval
from the company.
iv. Damaged enclosures shall be completely replaced. Flange surfaces shall be clean and
undamaged .All fixing bolts shall be present and tightened to the correct torque
v. All metal flanges and box lids shall be sealed after assembly with a grease-impregnated
cloth.
Note: Company approval shall be obtained for the use of Aluminium for any instrument
component. Aluminium may only be used if no other suitable material is available but
shall not be used for any component in contact with the process fluid. If Aluminium is
used for any housing or other component, it shall be suitably coated and certified as
copper free i.e. less than 0.4% copper by mass
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ISO – 9001:2008 INSTRUMENTATION CABLES Page: 2 OF 14
TABLE OF CONTENTS
Clause # DESCRIPTION Page No.
1.0 SCOPE OF THIS DOCUMENT 3
2.0 CODES & STANDARDS 3
3.0 SCOPE OF SUPPLY 3
4.0 GENERAL REQUIREMENTS 4
5.0 TECHNICAL REQUIREMENTS 4
5.1 General 4
5.2 Cable Types 5
5.3 Conductor 7
5.4 Conductor Insulation 7
5.5 Bedding and Inner Sheath 8
5.6 Braiding and Armoring 8
5.7 Outer Sheath 8
5.8 Color Coding 8
5.9 Bending Radius 9
5.10 Cable Drums 9
5.11 Cable lengths and Tolerances 10
5.12 Cable Glands 10
5.13 Cable Shrouds 10
6.0 TESTING AND INSPECTION 10
7.0 CERTIFICATION 12
8.0 INSTALLATION REQUIREMENTS 12
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This Specification defines the minimum requirements for design, manufacture, supply
and testing of Instrumentation Cables with cable glands / accessories for installation on
the offshore process / well platforms.
b) Basic Bid Work
2.2 The Contractor shall ensure that the scope of work is executed with all mandatory and
statutory Indian requirements.
All cables, accessories and other components supplied, shall comply with the latest
revisions of the applicable codes and standards.
a) B I S [Bureau of Indian Standards]
b) IEC [International Electro technical Commission].
c) NEMA [National Electrical Manufacturers Association].
d) NEC [National Electrical Code]
e) IEEE [Institute of Electrical and Electronics Engineers].
f) API [American Petroleum Institute].
g) Any other recognized International code or standard may be used in lieu of above,
subject to approval of company.
3.1 Quantity of the Cables for instrumentation works shall be based on the actual
requirements for cable laying, looping, terminations etc., and shall include ‘spare’ length
for exigencies during installation / commissioning.
The Scope for supply of Cables includes the following items:
a) Flame retardant, low smoke, zero halogen, heat and oil resistant low voltage cables.
(Instrumentation Cables - Signal, Alarm, Digital, Thermocouple extension, etc., and
Power Cables for Instrumentation power requirements)
b) Flame retardant and Fire resistant, low smoke, zero halogen, mica glass tape
insulated, heat and oil resistant low voltage cables. (Cables for: F&G systems, ESD
systems, Safety related & for Critical Control, Power and Shut Down applications).
c) Cable glands and Cable accessories
d) Termination Accessories / Connectors where specified.
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3.2 Vendor shall submit detailed Specifications for Company’s approvals, with type of
Cables and Quantities mentioned therein.
4.1 Safety
a) Non-metallic materials, such as conductor insulations shall be non-hygroscopic,
flame retardant and / or fire resistance, self extinguishing and non toxic chaired.
b) Materials that are toxic to the environment or are a potential Carcinogen such as
asbestos, poly chlorinated bi-phenyls (PCBs), Mercury etc., shall not be used in the
making of the cables.
4.2 Materials, Workmanship and suitability:
a) All materials utilized in the construction of the cables shall be to the latest industrial
standard specifications, new and in current production. Should any material prove
unsatisfactory, it will be rejected not withstanding any previous satisfactory
examination or tests of similar material or of completed cables
b) Where required the Contractor shall provide cable sheath oil resistance performance
characteristics.
c) The use of polymeric materials as alternatives to elastomeric materials shall be
subject to acceptance by the company. The Contractor’s proposal for such
alternatives shall be supported by detailed certified evidence of continuous and
complete performance in offshore locations.
4.3 Design life:
Cables and cable accessory shall be suitable for operations without periodic maintenance
applied throughout the design life of the platform specified elsewhere in the bid package.
The overall availability and reliability of the cables and cable accessories shall be
demonstrated by the Contractor.
4.4 Units and information:
All quantities and dimensions shall be expressed in metric units. All information, manual,
certificates, data and inscriptions shall be in the English language.
5.0 TECHNICAL REQUIREMENTS
5.1 General
5.1.1 The cable shall be new and in good condition and shall be suitable for layering and
bunching in ladders, trays and ducts.
5.1.2 All signal, power and control cables on non critical loops shall be flame retardant, low
smoke type with sunlight and oil resistant outer sheets, ‘zero / low halogen’ suitable for
installation on offshore oil and gas processing platforms.
5.1.3 Cables on critical service for safety and emergency systems shall be fire resistant type in
addition to the specifications at 5.1.2 above.
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5.1.4 Conductors shall be stranded and Cables shall be flexible and suitable for easy
termination using standard crimps and terminals.
5.1.5 All instrument signal cables shall be continuously shielded with the shield grounded at
the same point / bus as the signal circuit, generally at the control instrument (panel) end.
5.1.6 Detailed specifications and testing requirements on “inner and outer conductor insulation
and sheathing” material for low halogen / fire resistant / Flame Retardant cables, refer FS
4011 (Electrical – Functional Specifications for Electrical Cables). Fire resistant
characteristics of the cables shall be as per IEC 60331 (750oC for three hours)
5.2 Cable Types:
5.2.1 The cables used shall in general be of the following types:
a) Fire Resistant Cables:
Cables of this type shall be used for all circuits / instrument loops that have a safety-
related function, or are required to remain operational under emergency conditions.
Specification shall be same as that of instrumentation cables as at 5.2.2 (b) below,
however with the Primary Insulation being “Fire Resistant” inclusive of the necessary
protective fire proofing insulations. In addition these shall be listed by UL/FM or equal in
fire service and shall comply with the requirements of IEC 60331 and IEC 60332-3
(Category A) or better. It shall have a fire resistant layer between tinned copper
conductor and extruded insulation of MICA glass tape material. This includes cables for
all parts of F & G Systems (analog / digital signals), ESD systems, PA Systems, warning
beacons and platform status lamps, fire control systems, and power supplies to those
systems.
b) Flame Retardant Cables:
Cables that are not Fire Resistant shall be Flame Retardant type and shall comply
with the requirements of IEC 60332-3 (Category – A). The flame retardant cables to
be used for different applications shall in general be as follows:
i) Signal Cables:
• Twisted Single Pair / Triad cables shall be 600 V rated and shall have 1.5 sq. mm.
PVC covered, 7 stranded Copper conductor, shield with aluminum backed by
Mylar tape with the metallic side down helically applied with either side 25%
overlap of 100% coverage. Minimum shield thickness shall be .05 mm for single
pair and 0.75 mm for triads and multi pair cables.
• 18 AWG, 7 stranded tinned copper drain wire shall be provided and shall be in
continuous contact with the aluminum side of the shield. The drain wire resistance
including the shield shall not exceed 30 Ohms / Km.
• Cables shall have PVC Inner & Outer jacket and galvanized steel armoring.
Jacket shall be light blue in color for intrinsic safe applications and Black for
others.
• Ripcord shall be provided for all cables.
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• All signal cables (Single or Multi-Pair), shall have individual and overall screen
for the conductor pairs / triads, when used for analog 4-20mA and low level
signals such as thermocouple signals, pulsed signals or similar signals. All other
instrumentation cables (alarm / digital / control) cables shall have overall
(collective) screen. For Cored cables there shall be no screen. Drain wire and the
cable conductor screens shall be grounded at one place i.e., at the panel end where
the electronics (signal circuit) in the panel is grounded.
• Pairs and triple (triad) type cables shall be uniformly twisted (at least 10 twists per
meter) to form pairs/triples and shall not be dissociated by normal handling.
Multi-pair / triple cables shall be laid to prevent cross-talk between pairs/triples.
• Instrument signal cable configurations shall in general be: 1 pair, 2 pair, 6 pair, 12
pair, 1 Triad, 6 Triad, 8 Triad etc.
• Multipair cables shall have following additional features:
o Individual Pair / Triad shall be twisted.
o Pair / Triad identification by color coding / numbering.
o Individual pair shielding apart from overall shielding.
o Single Pair Communication Cable, of 22 AWG 7 strand copper wire with
PVC insulation.
ii) Control / Alarm / Status Cables:
These shall be same as signal cables except there shall be no individual pair
shielding in case of multi-pair cables.
iii) Extension and Compensating Cables for Thermocouples:
The cables for thermocouple extension cables shall be of same material as that of
thermocouple, which shall be marked as X behind the identification letter for
thermocouple as per convention. Compensating cable material shall have same
thermo-electric properties as that of thermocouple material. These cables
generally shall be same as signal cables except conductor shall be solid 16 AWG
in single pair and solid 20 AWG in case of multipair cables. Colour coding,
thermoelectric characteristics and limits of errors shall be as per ANSI MC 96.1,
BS, EIN, DIN etc.
iv) Power Cables:
Power cables shall be 3-core, minimum 2.5 mm2 copper conductors, 600V 1.0
KV grade, with PVC insulation, galvanized steel armoring. Larger sizes shall be
used where required to keep cable voltage drop below 2% of the supply voltage.
c) Special Cables:
Cables for special instruments like analyzer, turbine meter, serial interface,
Magnetic flow meters, Ultra sonic flow meters, etc. shall be as per
manufacturer's recommendation.
d) Digital Communication Cables
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i) In addition to the technical requirements stated in the previous sections,

the following requirements are specific to digital communication cables.
ii) In general, the digital communication cables covered by this specification
shall be in accordance with the recommendation of the manufacturers
supplying the digital equipment.
iii) Fiber Optic Cable shall be based on ITU-T Rec. 652. Fiber Optic Cable
shall be in general fiber multimode 62.5 / 125 micro meter buffered fiber,
aramid yarn central strength member and aramid yarn reinforced. Fibre
optic cables shall have 50 % spare fibres or 4 spare fibres whichever is
greater.
iv) Cables for serial communication shall be foil screened twisted (4 pairs),
100 ohms impedance, 12.5 pF/ft and 24 Ohms/mile, to Beldon 9729 or
equivalent.
v) Cabling of Ethernet or fast Ethernet service shall be Category 5e or
Category 5 dependant on location and digital equipment.
vi) Both armoured and un-armoured cables shall be required as per
requirement.
e) Optical fiber cables for Sub-Sea applications: Refer Composite Cable
specifications [FS-4020 Subsea Cable] in Electrical Discipline.
5.3 Conductor:
Conductor shall consist of plain, annealed, high conductivity, standard, tinned copper,
smoothly drawn, circular in section, free from defect, complying with the requirement of
IS:8130 / IEC-60228.
5.4 Conductor Insulation:
5.4.1 The Insulation shall be in general extruded compound of low smoke material complying
with the requirements of IEC 60502.
5.4.2 Voltage grades for insulation shall be as follows:-
Nominal System Voltage: Up-to 240 V
Maximum System Voltage: 264
Voltage Grade: 600 / 1000 V
5.4.3 Properties of Conductor Sheath / Insulation shall meet the following requirements [refer:
FS 4011 (Electrical Discipline – Functional Specifications for Electrical Cables)].
a) Temperature Index: Min.250 oC as per ASTM. D 2863
b) Oxygen Index: Min.30 as per ASTM D 2863
c) Acid Gas Generation: As per IEC 60092-359
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d) Smoke Generation: Less than limit for types SW4 Compounds as per IEC
61034
e) Dielectric strength: Min.60% of original dielectric strength tested in
accordance with NEMA-WC-5 at 75°± 1°C.
f) Flammability: Flame retardant characteristics of electric cable as per
IEC- 60332 Part 3 Category –A
5.4.4 Cables nominated as Fire resistant shall comply with the following performance
characteristic in addition to the above requirements.
• Fire Performance: Fire resistant characteristic of electric cables as per IEC 60331
(750°C for 3 Hrs)
5.5 Bedding and Inner Sheath
5.5.1 The bedding shall be extruded, non-hygroscopic solid filler substantially filled to prevent
any ingress of water inside the cable. The material used for the bedding and fillers shall
be suitable for the operating temperature of the cable and compatible with the insulating
material. The inner sheath shall be effectively filled and shall comply with thickness
requirements as IEC 60502. Removal of inner sheath shall not cause adhesion or damage
to the conductor insulation. Taped inner sheath shall not be accepted.
5.6 Braiding/Armoring
5.6.1 Multicore cables shall be mechanically protected with hot dipped galvanized steel wire
braiding (GSWB) or galvanized steel wire armoring (GSWA) applied over the inner
sheath.
5.6.2 Single core low voltage and high voltage cables shall be mechanically protected with
tinned phosphor bronze wire braiding (PBWB) or hard drawn aluminum round wire
armoring which shall be applied over the inner sheath to confirm to the requirements of
international standards.
5.7 Outer Sheath
5.7.1 The outer sheath shall be heat and oil resistant, suitable for installation in an offshore oil
and gas processing platform, with uniform thickness and fit tightly over the braiding /
armour to ensure no undue residual strain is left in the material.
5.7.2 Outer sheath marking shall be such that details of size of cable (no of cores and conductor
cross section), type of insulation, manufacturers name and international standard
identification shall be embossed on the outer sheath at regular intervals at maximum of 1
metre.
5.8 Colour Coding
5.8.1 Cable outer sheaths shall be permanently colour coded such that colours do not
deteriorate with age or fade with exposure to direct sunlight. Cable shall be UV resistant
and coded as per the requirements of IEC 60502.
5.8.2 Cable Colour Coding
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1 Low Voltage Power and Control (Equal to or less than 1 KV) Black
2 Earth Green / Yellow
3 Instrument Intrinsically Safe (IS) Light Blue
4 Instrument (Non-IS) Black
5.8.3 Cable cores shall be coloured as follows:

• 24 V DC Digital Circuits: Positive – White, Negative – Black
• Analogue Circuits: Positive – White, Negative – Black
5.8.4 Individual cores of multi-core power, control, instrument and telecommunications cables,
if identified by numbers, shall have both the number and the printed word of the number
permanently marked throughout the entire length of the core, at 100 mm interval.
5.9 Bending Radius
5.9.1 Cables shall be suitable for installation with the minimum bending radius, appropriate for
the type of cable supplied, which shall comply with the requirements of IEC 60092 –
359.
5.9.2 The Contractor shall declare the National standards or the other internationally acceptable
standard specification giving minimum bending radius
5.10 Cable Drums
5.10.1 Cables shall be dispatched on suitable barrel diameter, securely battened, with take off
ends of the cable brought to the outside of the drum and fully protected against
mechanical damage.
5.10.2 The wood used for construction of the cable drum shall be properly seasoned, sound and
free from defects. Wood preservatives shall be applied to the entire drum.
5.10.3 The Contractor shall ensure all cable drum lengths supplied shall be continuous as
conductor jointing shall not be acceptable. Cables shall be wound on non-returnable cable
drums.
5.10.4 Each cable drum shall be fitted with a stainless steel or equivalent label. Equivalent
material used for providing the label should be corrosion resistant to saline conditions.
The label shall be fixed to the outside of each flange, engraved or permanently marked
with the following information:
a) Company’s Drum Number
b) Manufacturer’s name
c) Cable type number
d) No. of cores and cable cross sectional area in mm and core construction/stranding
eg. 3C+E 4mm2, (7/0.85)
e) Voltage grade
f) International Standard(s)
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g) Purchase order number/item number

h) Drum length (in meters)
i) Net and gross weights (kg)
j) Weight per meter
k) Date of manufacturer.
5.11 Cable Lengths and Tolerances
5.11.1 Cable drum lengths shall require approval by the Company prior to dispatch from the
manufacturer.
5.11.2 A tolerance of 5% shall be permissible for each cable drum supplied, although a
maximum tolerance of +3% and zero negative tolerance shall be permissible on the
ordered quantity of each cable type.
5.12 Cable Glands
5.12.1 The Contractor shall ensure full tolerance in the dimensional details of the cable outer
diameter and diameter under braiding / armouring (where applicable) is provided by the
manufacturer.
5.12.2 The Contractor shall ensure the cable glands to suit cable sizes are supplied by the
manufacturer. All cable glands (NPT) shall be double compression type dual certified
Exd and deluge protected unless otherwise approved by the Company.
5.12.3 All cable glands and adaptors will be made of nickel-plated brass/SS and will be fitted
with soft sealing nylon washers or integral nitrile washers. Fiber washers will not be
used. Locknuts will be used for entry into sheet steel boxes and enclosures.
5.12.4 Industrial cable glands (ET type) may be used with non-certified equipment in indoor,
non-hazardous locations.
5.13 Cable Shrouds
Material for heat shrink Cable shrouds shall be cross linked polyolefin.
6.0 TESTING AND INSPECTION

6.1 General
6.1.1 The cable shall be tested and inspected at the manufacturer’s works, or at a recognized
testing facility. The Contractor shall ensure all the test equipment necessary to test the
cables is provided by the manufacturer. Test certificates for all tests shall be provided to
the Company, immediately on completion of tests performed. All tests shall be witnessed
by the Company or its authorized representative.
6.1.2 The Contractor shall ensure detailed records and log sheets regarding the results of the
tests and certification that the items supplied will meet specified performance
requirements, are supplied.
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6.2 Inspection
6.2.1 The Contractor shall ensure all material employed shall be available prior to and after the
manufacture of cables, for inspection by the Company. The Contractor shall furnish all
necessary information concerning the supply to the Company’s inspector or
representative. The inspector shall have free access to the manufacturer’s works for the
purpose of inspecting the process of manufacture in all the stages and will have the
authority to reject any material which appears to be unsuitable or of unsatisfactory
quality.
6.2.2 In addition, the minimum inspection requirements, prior to shipment of cable shall be the
following:
a) Verify cable lengths
b) Verify sheath colour
c) Verify gland fit
d) Verify core configuration
e) Verify core colours
f) Check continuity of each core (and screen/drain wires where applicable) on each
drum (to match manufacturer’s data sheet for DC resistance)
g) Check insulation resistance between cores and armour, where applicable (test at
twice working voltage, not less than 10 M Ohm)
h) Verify drum markings
6.3 Factory Acceptance Testing
6.3.1 Electrical and instrument cables shall be tested in compliance with the standards to which
they are manufactured with all optional tests included.
6.3.2 Company shall be advised at least (4) weeks in advance of the scheduled date of each test
and again 20 days prior to the actual test.
6.3.3 Tests shall include but are not limited to the following:
a) Cables shall be tested in accordance with IEC 60092-359 tests to include electrical
resistance of conductors.
b) Verification of design limitations; cable for use in IS circuits shall have their
parameters measured to ensure that these comply with the relevant standards
namely L/R micro F / Km & mH /Km.
c) Instrument cables shall be tested to verify the following:
i. The maximum inductance to resistance ratio (L/R) between insulated conductors
of any one pair of screened cables shall not be greater than 26 micro-henries per
ohm.
ii. The mutual capacitance of screened cable at a frequency of 1 KHz shall not be
greater than 100 pF per meter.
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iii. The pair to pair capacitive unbalance values at a frequency of 1 KHz for
unscreened pairs shall not be greater than 250 pF per meter.
iv. Spark test: a spark test shall be carried out on all instrument cables. All cores shall
be tested at 6 KV rms.
v. Coaxial cables shall be tested for frequency response, attenuation and insertion
loss.
vi. Type tests shall be carried out in compliance with IEC 60331 and IEC 60332 (Part
3) when specified.
vii. Type test certificates may be acceptable, subject to acceptance by the company, in
lieu of the tests.
6.4 Sealing
6.4.1 Immediately after electrical tests, the ends of the cable shall be sealed with heat shrink
caps to prevent the ingress of moisture.
7.0 CERTIFICATION
7.1 All cables and cable accessories of similar design and construction features manufactured
by the same Vendor:
a) Shall have been type tested by an authority approved by the Company.
b) Shall have been in continuous satisfactory service in offshore for a minimum period
of two years.
c) Shall be having current certification/approval/listing by an agency approved by the
Company or UL or FM.
8.0 INSTALLATION REQUIREMENTS
8.1 Cable Runs and Segregations:
a) The Contractor shall ensure that there is no interference between cables having
different voltage or signal types. Instrument cables shall be segregated from antenna
cables and others carrying RF signals so as to avoid interference.
b) All instrumentation cables shall be supported / laid in trays. Power cables shall not
be run in trays carrying signal cables. The physical separation of power and signal
cables shall be as per API-550 Part –I SECTION VII. Cables in intrinsically safe
circuits shall preferably be not run in the tray for cables in non-intrinsically safe
circuits. If run in the same tray a metallic earthed separator shall be provided.
Conduits carrying intrinsically safe cables shall be painted with the blue color bands
at each end.
c) Where cables are run through conduit, the entry and exit shall be smooth and free
from burrs. The use of conduits shall be kept to a minimum, as far as possible.
d) Cables must be pulled into conduit in a way that ensures there is not damage to the
cable.
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e) Splices shall be made only at terminals, in instruments or approved equipment /

junction boxes in any cable path.
8.2 Cable Marking:
a) All cables shall be identified with stainless steel cable markers securely fixed to the
cable with cable tie wraps at the following locations:
• All cable glands
• Entering and leaving cable ladders, ducts and supports
• Both sides of walls or bulkheads
b) Cable markers shall be fitted during or immediately after cable installation.
8.3 Cable Identification:
a) All wiring, cables, tubes, multi-tube bundles, junction boxes and auxiliary equipment
shall be suitably identified as per applicable codes and practices. Plastic adhesive tapes
shall not be used for identification. Identification and details of all such equipment and
wiring/tubing shall also be clearly marked on appropriate drawings. All wiring shall be
tagged with slip on or clip-on wire marker at both ends with the wire number specified
on the drawings.
b) Terminals for electrical connections including thermocouple extension wires shall be
numbered and identified to indicate polarity, ground Connections, test connections, and
any other pertinent information.
8.4 Cable Installation:
a) All instrument signal cables shall be continuously screened, with screens grounded at
the equipment room end only, and securely insulated at the field end. All cables exiting
equipment rooms shall be protected / armoured, including serial link and data highway
cables. Where armour is not possible for certain cables, same shall be protected by way
of pipes (GI) along the length up-to and into the MCT.
b) For ease of instrument disconnection, an adjustable elbow or union shall be provided
between the terminating gland and the instrument.
c) A neat loop of cable 250 mm diameter shall be left immediately adjacent to all
instrument devices in the field.
d) Cabling to locally mounted instruments shall not be routed across normal or emergency
walkways nor interfere with access to equipment.
e) Multi Cable Transits (MCT) shall be used to provide gas-tight cable penetrations
through control room wall, decks or firewalls.
f) Contractor shall size and provide MCT considering 50% spares for each cable
size/Cable OD. Power, Control and signal cables shall be suitably separated within the
MCT Frame.
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8.5 Cable Termination:

a) All cables shall be terminated using double compression type glands on explosion proof
equipment. These glands shall be explosion proof, certified. All cable glands in
outdoor service and on equipment subjected to salt water spray shall be weather proof
to IP 67. All terminations shall be screw clamp type terminals for 2.5-mm2 conductors
minimum (no flying leads) and correctly certified where necessary. Insulated crimp
lugs shall be used for all cable core connections, with only one conductor per terminal
side.
b) No wire shall be terminated/left with mechanical strain on it in any conduit or trunking.
c) Cables shall be terminated in 316 SS glands, suitably certified where necessary. The
inner sheath shall be left on the cable after the gland, and removed at the point of entry
into wiring duct.
d) Cable cores shall not be ‘pig tail’ finish.
e) Cable screens and drain wires shall be securely fastened and insulated at the final field
termination.
f) The communications conductor of a cable shall be terminated in the bottom terminal(s)
of a row of terminals.
g) Printed sleeve-type ferrules shall be fitted to all cable cores on both sides of every core.
‘C’ type and adhesive type shall not be used.
h) All cables shall be individually loomed at maximum fixing centers of 60 mm and where
cores leave the loom.
i) Only one conductor shall be used per terminal side.
j) All cables ends terminated at each end shall be covered with heat shrink type cable
shrouds for protecting them from ingress of water, and foreign particles.
k) Cable entry to control room/other rooms shall be through listed multi-cable transits.
l) Terminal blocks shall be non-hygroscopic, Vibration proof, stack on type and shall use
captive screws for terminals. Terminals shall be tinned or Silver plated. All
terminations shall be through use of wire lugs. Terminal blocks shall be flame retardant
type.
m) Cable Termination for Skid Items: Manufacturer or fabricator supplying skid mounted
equipment or vessels with instrumentation which provides or utilizes off skid alarms /
shutdowns / control functions, shall terminate signals on a central junction box, near
skid boundary, available for hook-up by Contractor. The location of this junction box
shall be noted on vendor drawings.
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ISO – 9001:2008 SUBSEA UMBILICAL
Page: 2 OF 12
CONTENTS

3.0 Sub Sea Umbilical 4
3.1 Design 4
3.2 Material and construction 7
3.3 Inspection and testing 10
3.4 Storage, Load out & Installation 12
3.5 Warranty 12
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design, manufacture, testing and supply of hydraulic control sub-sea umbilical.
This FS is for the Umbilical for SSIV (sub-sea intervention valve) actuators.
1.2 Umbilical shall be used to house steel tubes, thermoplastic hoses, electric cables,
communication (optic fiber) cables for various uses like subsea in subsea
applications.
Steel tubes in the umbilical shall be used to transmit the hydraulic pressure / signal
from the hydraulic power unit (HPU) on the platform (or from topside / ships /
vessels etc., for the operation of the actuator of the sub surface intervention valve
(SSIV). Thermoplastic hoses in the umbilical shall be used for delivery of the
chemicals / utilities for well head operation /maintenance purposes. Electrical
cables & fiber optic cables (wherever specified / required) in the Umbilical shall be
used for transmitting valve status signals and communication signals respectively.
The umbilical along with all its tubes, hoses, cables & associated equipment like
terminations and fittings shall be a permanent part of the ‘complete umbilical
assembly’.
2.2 The vendor shall be responsible for the selection of the Hydraulic control umbilical
in requisite single continuous length from the HPU located on the platform to the
actuators of sub surface intervention valves ) located sub-sea on the well head or
subsea pipeline at a distance from the platform, suitable for its intended
application, procurement, tagging, packing, testing & calibration, preparation for
shipment, along with accessories, spares, and assistance where required for its
installation & commissioning at site. This FS shall be read in conjunction with:-
b) Basic Bid Work
c) Project P & IDs
d) Process Design Criteria
e) Electrical Design Criteria
f) Piping Design Criteria
g) Mechanical Design Criteria
h) Structural Design Criteria
i) Environmental condition of the project
j) Functional Specifications for HPU (FS 3506)
k) Subsea Valve Actuators (FS 3509)
Reference Codes and Standards:
S.No. Number Description
1 API-RP 2-A Recommended practice for planning, designing and
construction of fixed off shore platforms
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2 API-RP 14-C Analysis design, installation and testing of surface safety

system on offshore production platforms
3 API-RP 17-A Design and operation of sub-sea production system
4 API-RP 17-D Specifications for sub-sea wellhead and Christmas tree
equipment
5 API-RP 17-E Sub-sea production control umbilical
ISO 13628-5 Design and operation of Subsea production systems – Part-
5 Sub-Sea umbilicals
6 API-RP 17-I Installation guidelines for Sub-Sea Umbilicals.
7 SAE J-343 Specifications for tests for and procedures for hose and
hose assemblies
8 NAS 1638 Cleanliness requirements of parts used in hydraulic system
9 ASTM G48 Pitting and Crevice Corrosion Resistance of Stainless
Steels and Related Alloys by the Use of Ferric Chloride
Solution.
10 U-CR-006 NORSOK Standard for Subsea Production Control
Umbilical.
3.0 SUBSEA UMBILICAL
3.1 DESIGN Considerations:
- The umbilical shall be designed for submarine application with the site condition
as detailed in the bid package. Umbilical may consist of steel tubes, electrical
cables, optic cables, hoses (thermoplastic) individually or in any combination
meeting the process requirement s.
- ‘Steel tube’ shall be used in Umbilical for all SSIV actuators. ‘Thermoplastic hose’
in Umbilical may be used for delivery of fluids / chemicals for well head in
shallow water. ‘Electric cables’ shall be used in the Umbilical for status signals
from Actuators of the SSIVs. ‘Optic fiber cable’ shall be used in the umbilical
where communication cable is required / necessary. Umbilical shall be double
armored as a minimum and internal components, especially the thermoplastic hoses
if used, shall be fully strengthened and protected against damages. Number of steel
tubes, cables and hoses shall be frozen based on the requirements of the project
during the detailed engineering.
- Vendor shall collate the inputs from the HPU and Sub-Sea actuator vendors for
basic design, sizing and material selection for the components of the umbilical. All
the line sizing and material selection shall be vetted by the HPU & valve + actuator
vendor for final approvals by the client.
3.1.1 GENERAL:
a) The design and construction considerations for the umbilical with steel tubes shall
include but not be limited to the following:
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Tube material shall be SS 316 L / Duplex / Super Duplex, suitable for the hydraulic
liquid, pressure and temperature conditions / ranges. Vendor shall take special care
in selection of the steel tube manufacturer and the steel tube shall be fully
prequalified by testing in accordance with requirements of ASTM A450 and the
associated components of ASTM A370, Ann A2.
i) Ambient effects: Cooling; Effects on pressure, Fluid expansion effects, Low
ambient temperature.
ii) Dynamic effects: Impact, Vibration, Discharge reactions, Long term effects on
elasticity
iii) Weight effects: Live loads, Dead loads.
iv) Thermal expansion/contraction effects: Thermal loads due to restraints, Loads
due to temperature gradients, Loads due to differences in expansion.
v) Effects of support and terminal head movements.
vi) Cyclic effects: Pressure, thermal and other cyclic loads.
vii) Galvanic reactions.
viii) All metal alloys used in the total umbilical system shall be corrosion resistant in
the specified temperature range, or equipped with a suitable corrosion protection
system. This shall also include the platform topside termination assemblies.
ix) The metal alloy tubes can be seamless or welded. The complete tube string shall
be hydrostatically tested to 1.5 x WP.
x) Repair welding of base material is not accepted. Repair of weld defects shall be
performed in accordance with an approved and qualified procedure.
A minimum of one spare tube shall be made available in the umbilical. (Supply
tube & return tube per actuator plus ‘one spare tube as a minimum’)
b) The design and construction considerations for the umbilical with thermoplastic
hoses shall include but not limited to the following: (Also Refer ISO Standards
527, 1402, 3949, 4406 for the Thermoplastic hoses selection and testing in
Umbilical)
i) The thermoplastic hoses shall be supplied by a prequalified supplier. The raw
material (pellets) shall be new unused material which is kept to a high level of
cleanliness.
ii) The extruded hose shall be compatible with the specified hydraulic, injection
and annulus fluids.
iii) The hose braiding material shall be made from a high strength fibre. The
braiding shall be applied in a way which minimizes the torsional forces
generated during the line pressurization and to minimizes volumetric expansion
and elongation.
iv) There shall be no jointing of the thermoplastic hoses, except when required for a
field joint or a complete umbilical factory joint.
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v) Seabed conditions and relevant Geotechnical parameters shall be considered for

the umbilical stability and designed accordingly. Permeability of the hose and
collapse due to specific gravity of the fluid shall be duly considered in the
design stage. Umbilical shall as a minimum be double wire armoured.
Number of hoses shall be determined by the process requirements. However a
minimum of one spare thermoplastic hose shall be left as spare in the umbilical.
c) Where scope of work / Basic Bid work requires valve actuator status from the
subsea SSIV, electrical cables shall be used in the umbilical. The design and
construction considerations for the umbilical with electrical cables shall include but
not limited to the following:
The umbilical shall include insulated electrical conductors as cable units. The cable
should consist of unshielded pairs twisted together in form of pair or quads, or a
coaxial design. Conductors shall be in accordance with recognized international
standards. A minimum of three spare conductors / cable cores shall be available in
the umbilical.
i) Sufficient cushioning shall be provided to prevent damaging of the copper
conductors, insulation and sheeting during umbilical manufacturing processes,
installation and the operational life of the umbilical.
ii) The conductors shall be plain annealed, copper wire and stranded with a
minimum of 7 strands and a minimum cross sectional area of 2.5 mm2. The
electrical cable shall be filled with material such as petroleum jelly etc. that
minimizes void spaces and allows for element movement.
iii) All conductors shall be insulated with an appropriate thermoplastic material
suitable for subsea operation.
iv) At least the following shall be performed during manufacturing, in addition to
measurement of all electrical parameters and characteristics:
• Continuous spark test on all insulation and sheathing production runs, when
extruded over a conductive layer.
• High Voltage test when immersed in water, for all production lengths of
insulated conductors. The insulated conductors should be immersed in water
for 48 hours prior to testing.
• Dimensional: Insulation and sheathing thickness and diameter.
d) The results from evaluation of the above (a, b & c) shall also be reflected in the
umbilical design with regard to the tube lay angle, armouring and outer sheathing.
e) All umbilical lines shall be designed for the required Sea depth, Sea conditions and
working pressures. The umbilical shall contain the required number of hydraulic
lines plus one spare line as minimum.
f) Marking shall be performed with not more than 0.5 meter spacing along the tube
length. Identification marking may be performed at any stage up to but preceding
the hydraulic testing. The marking shall not contain any harmful elements which
may cause corrosive attack in the temperature range.
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g) All metal alloy hydraulic tubes shall be numbered and be legibly marked with
manufacturer's name or brand, standard dimension, grade identification and
working pressure. The marking shall also indicate whether the tubing is seamless
or welded.
h) In the electrical cables, all conductors shall be identifiable with different coloured
insulation. The colouring shall be such as not to degrade the quality and
permeation characteristics of the insulation material.
3.1.2 Design and manufacturing of hydraulic umbilical and its accessories shall meet the
functional requirements of minimum design life of 25 years for steel tube
umbilical, and 20 years for thermoplastic tube umbilical. The design offered by the
vendor shall be in the regular manufacturing range of the manufacturer and shall
have been (a) tested (b) in continuous and satisfactory service under similar
conditions for a minimum period of two years.
3.1.3 The ‘umbilical’ design shall meet the following installation requirements:
• It shall be installable using typical installation vessel and equipment such as
reels, baskets, carousels, turntables, tensioners, etc.
• It shall endure all installation loads, including load-out, handling on installation
vessel, lay tension, initiation, laying, abandonment, pull-in and connection,
trenching, rock-dumping, possible disconnection and recovery. It shall also
endure a backstroke, if required, during connection / disconnection.
• It shall be possible to repair the umbilical during installation. A sealing system
to preserve the umbilical shall be included for use in case of cutting and
abandonment during lay. There shall be a possibility for cutting the umbilical on
the seabed in case of failure. This aspect shall be reflected in the design with
regard to water ingress.
• The umbilical shall have sufficient specific gravity to lie stable on the seabed
and to enable installation in predefined route including laying curves. The
submerged specific weight shall also be sufficient to enable trenching.
• Umbilical termination units shall be capable to handle the extreme temperature /
pressure combinations, to which the umbilical is exposed to, and shall be
demonstrated before dispatch from factory. All electrical terminations shall have
2 independent barriers against water ingress, which shall be separately tested
during qualification and final product assembly.
3.2 MATERIAL AND CONSTRUCTION:
3.2.1 ARMORING
a. The Vendor / Contractor shall propose an armoring design, if relevant, with due
consideration to the mechanical properties of the components.
b. Number of layers of suitably sized hot dip galvanized steel wire, contra wound,
torque balanced, and armor shall be designed to suit the design criteria finalized by
the manufacturer. The wires shall confirm to the requirement of BS 1441 shall give
the umbilical elements mechanical protection. The design to be suitable to resist
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impact and abrasion, and shall be torque balanced over the range of loads (during
installation and operation).
c. The armor wires shall be of such a design and size as to carry all tensile loads,
protect the umbilical during all installation phases and shall provide adequate
corrosion resistance for duration of design life and as per environmental parameters
specified in the bid specification (Structural design criteria).
d. Outer covering ‘plastics’ shall be resistant to ultra violet light.
e. All the analysis for the umbilical shall be effectively performed, with its
components, as performed for the pipes / composite cables for subsea application.
(i.e., flexibility and fatigue analysis)
3.2.2 INNER JACKET
An inner jacket of polyethylene, minimum thickness of 4mm shall be extruded
over the bundle of components, i.e, hoses / stainless steel tube / electrical cable or a
combination of them as a ‘bundle’. The interstices shall be filled with suitable
material to ensure good jacket concentricity and uniform distribution of radial
compression from the armor layers under tension. The jacket material shall be
impermeable to water and shall be resistant to cold flow.
3.2.3 OUTER SHEATHING
A jacket of polyethylene or equivalent shall be extruded over the armor wires to
provide protection to armor wires against mechanical damage and to provide
additional corrosion protection. The thermoplastic material shall have a minimum
thickness of 5 mm and shall be resistant to sea water, degradation due to ultraviolet
exposure and pipe temperature of 50ocentigrade.
The outer sheath shall be yellow in color. a longitudinal black stripe, minimum
6mm wide shall be concurrently applied to the full length of umbilical as a means
of indicating twisting .
Length markings shall be applied every 10 meters for the first and last 250 meters.
Distance indication without numbers shall be applied every 100 meters for the
remaining length with length markings applied every 250 meters , marking shall be
clearly visible to divers and ROV’s.
3.2.4 JOINTING
The number of factory joints in each umbilical shall be kept to the absolute
minimum. The manufacturer shall submit full details factory joint including joining
method employed
3.2.5 ASSOCIATED UMBILICAL EQUIPMENTS
Each umbilical shall be supplied on a field deployment reel complete with the
following components:-
- J-Tube hang-off points
- Pull-in heads
- J-Tube seals
- TUTA (The Topside Umbilical Termination Assembly )
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- SUTA (Subsea Umbilical Termination Assembly).

- Weak Link Assembly.
At each end of the umbilical shall be terminated in to umbilical termination to
provide an interface to transfer forces and moments from the umbilical into the
connection. Various elements of the umbilical shall be terminated into individual
handoff arrangements
3.2.6 UMBILICAL HANGOFFS /ANCHORAGE AT ENDS
The Manufacturer shall design and supply the umbilical termination arrangement
that shall consist of a J-Tube hang-off collar and split flange arrangement at each
end. The hang-off assembly shall be designed to support the full breaking load of
the umbilical.
The diameter of the umbilical hang-off shall not exceed the diameter of the
umbilical pull-in head. Armor wires shall be mechanically attached to both sides
of the hang-off point and continue from the upper side, into the pulling head. The
structural design of the support shall be in accordance with API RP 2A and
environmental parameters given in Structural design criteria.
One of the half flanges at each hang-off shall include a port to allow for dosing of
the fluid contained in the J-Tube.
The Manufacturer shall provide all items associated with the hang-off system
including split flanges, collars, and nuts and bolts.
The umbilical hang-off design shall permit rapid anchorage of the umbilical after J-
Tube pull-in.
3.2.7 PULL IN HEADS
The umbilical shall be supplied with a factory temporary pull-in heads at each end,
complete with pulling shackles. Access to the hydraulic hose end fittings shall be
facilitated by removal of the pull-in head after the J-tube pull-in and hang-off
operations are completed. The armor wires shall be terminated at or in the pull-in
head and the fitted assembly shall be capable of withstanding all installation loads
without loss of structural integrity. The umbilical pull-in head shall be capable of
sustaining the full breaking load of the umbilical.
The pull-in head shall be designed for rapid dismantling to allow monitoring
during the installation of the umbilical. The pull-in head shall be suitably
streamlined design to ensure that snagging does not occur during the J-tube pull.
The outside diameter shall be minimized to as near the umbilical diameter as is
commensurate with the load carrying capability
3.2.8 J - TUBE SEAL
The Manufacturer shall design and supply seals to be fitted by divers at the bottom
end of the J-Tubes after pulling-in the umbilical. The seal design shall be such that
after the pull-in through J-Tube, the seal shall block the annulus between the J-tube
and umbilical close to the J-tube bell mouth. Full details of the design and
materials of the sealing unit shall be submitted to Company for review and/or
approval.
ODS/SOF/004 ODS/SOP/023 01 00 21/07/2010
Spec. No. 3510
Rev. No. 01
Page: 10 OF 12
The J-tube seal shall form a permanent seal between the inside and outside of the
steel J-tube just inside the bell mouth. The seal will permanently be in contact with
seawater at local seabed temperature. The seawater inside the J-tube will be
treated with a chemical corrosion inhibitor and / or oxygen scavenger. The J-tube
seal shall prevent the dilution of inhibited seawater inside the J-tube by seawater
from outside.
The unit shall seal against the J-tube by means of two or more sets of flexible
circular seals.
3.2.9 Subsea terminations
The umbilical manufacturer shall be closely involved with the chosen control
system manufacturer in the design of the subsea termination.
The umbilical manufacturer's scope of work in this area of interface include the
following:
• Tensile strength termination (Armour Anchorage Block)
• Termination bend restrictor and/or armour rods
• Fittings
• Electrical Penetrator.
There shall be penetrators including water blocking of each individual conductor
for fitting into the interface boundary, that is, the boundary of the electrical
connector subject to open face pressure.
The umbilical electrical termination at the subsea end shall be blocked by an
approved method to prevent water ingress in the cable or harness. A pressure
compensated oil filled inerface chamber shall be incorporated between the cable
water blocking/penetrator and the electrical connector/harness.
It shall be demonstrated that the termination system is capable to handle the
extreme temperature/pressure combinations, to which the umbilical is exposed to.
All electrical terminations shall have 2 independent barriers against water ingress,
which shall be separately tested during qualification and final product assembly.
The axial load requirements shall not allow structural damage to the termination or
template landing structure. Weak link(s) shall be used to prevent axial or tensile
damage to the termination and landing structure.
3.3 INSPECTION & TESTING
3.3.1 Vendor shall carryout various tests as per applicable Codes/Standards. Test
procedures and mutually acceptable tests for FAT shall be frozen at the time of
detailed engineering. Tests certificates shall be submitted for Company’s approval.
3.3.2 Manufacturer shall submit detailed test procedures for all applicable mandatory
tests required as per API Specification 17E as a minimum, for review and approval
by Company prior to commencement of any testing operations.
a. In addition, procedures for following test for the tubes in line with ASTM A 450,
shall be submitted. – ((Tensile test, Flattening test, Reverse flattening test (welded
tubes), Hardness test, Hydrostatic test, Radiographic testing of welds, Visual and
ODS/SOF/004 ODS/SOP/023 01 00 21/07/2010
Spec. No. 3510
Rev. No. 01
Page: 11 OF 12
dimensional checks & Corrosion tests)). The complete tube string shall be
hydrostatically tested to 1.5 x WP.
b. For the thermoplastics, the following tests shall be carried out on un-aged sample
hose lengths to the requirements of ISO 3949:
Change in length test, Burst test, Cold flexibility test, Oil resistance test, Impulse
test, Leakage test, volumetric expansion, Coupling retention & Compatibility test.
c. For Electrical Cables, Testing shall be as per NORSOK standards.
Following tests shall be carried out as a minimum:
- CR, IR and HV dc tests
- Attenuation
- Mutual Capacitance
- Signal Propagation Delay Time
- Crosstalk attenuation (signal/signal)
- TDR. (Time Domain Reflecto-metry)
FAT shall be carried out on all umbilical lengths complete with terminations at the
respective storage location. Test fluid shall be as specified in data sheet. Visual
test, Proof Pressure tests, Flushing and cleanliness verification tests, Flow rate test
shall be performed.
All lines shall be circulated with an acceptable hydraulic fluid at a Reynolds
number greater than 4000. If this is impossible to achieve, an alternative cleaning
method must be proposed. The cleaning process shall continue, minimum 3 total
volume change-outs, until three consecutive cleanliness readings indicate
cleanliness level equal to or better than ISO 4406 (for Hydraulic fluids
contamination levels by solid particles, SAE AS4059 Class B through F for
Hydraulic LP & HP tubes, & NAS 1638 class 8 for other umbilical tubes.
3.3.3 Company / its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacture. Company shall specify
hold points / witness points while approving purchase specification during project
execution. During inspection, material certificates, shop test data, certificates for
bought out components and other relevant information shall be furnished for
company’s perusal so as to ascertain that the specifications and quality are
complied with.
3.3.4 In case Manufacturer / their sub vendors of equipments / packages have in-house
elaborate Quality Assurance Systems (operating in their shop) for Inspection &
Testing of equipments / packages, the witnessing of inspection and testing by
Company is not necessary. However, witnessing of inspection and testing by Third
Party Inspector of Contractor is required as per approved Quality Assurance
System. Manufacturer / sub vendors of equipment / packages shall obtain approval
of their Quality Assurance System from the Company prior to commencement of
manufacturing activities.
Where such Quality Assurance System is not in operation with the manufacturer /
their sub-vendors, the Tests specified as “witnessed” in the Specification shall be
ODS/SOF/004 ODS/SOP/023 01 00 21/07/2010
Spec. No. 3510
Rev. No. 01
Page: 12 OF 12
carried out in presence of the Company / its authorized representative or certifying

agency. The cost of preparation for shop testing of equipment / packages including
inspection fee etc. shall be borne by the Contractor, Vendor / Contractor shall give
minimum 15 days prior intimation to the Company regarding testing schedules.
Company / its authorized representative or certifying agency shall have access to
inspect the equipment at any stage during manufacture. During inspection,
material certificates, shop test data, certificates for bought out components and
other relevant information shall be furnished for company’s perusal so as to
ascertain that the specifications and quality are complied with Company shall
specify hold points / witness points while approving purchase specification during
project execution.
3.4 STORAGE LOADOUT AND INSTALLATION
3.4.1 The umbilical shall be stored on a suitable carousel/as per manufacture’s
recommendations for transfer to the installation vessel reel system.
3.4.2 In the event of delay between the completion of the umbilical factory acceptance
test and load-out onto the transportation vessel, the Manufacturer shall ensure that
the umbilical is suitably protected from the environment in which it is to be stored.
3.4.3 The Manufacturer shall be responsible for the safe and efficient transfer of the
umbilical to the installation Contractor’s vessel and shall submit a load out
procedure also specifying the anticipated duration of this operation.
3.4.4 Manufacturer shall control and be responsible for, all necessary facilities and
assistance for load-out of the umbilical from Manufacturer’s storage to the
installation vessel.
3.4.5 Details of manufacturer’s load facilities and arrangements shall be submitted.
3.4.6 The Manufacturer shall provide personnel on installation Contractor’s vessel to
oversee the umbilical installation. The Manufacturer shall also provide personnel
at the well-head jackets to remove the pull-in heads and strip back the armor wiring
on completion of the J-tube pull.
3.4.7 The Manufacturer shall co-ordinate with installation Contractor in order to
complete this work. The installation contractor shall cut J-tubes to required length
and re-terminated the same with new female plugged SAE J516 fittings supplied
by Manufacturer
3.5 WARRANTY
Vendor shall have final and total responsibility for the design and mechanical
performance of all equipment supplied by him. Vendor shall provide the warranty
for the equipment furnished by him and Performance Guarantee for the said
equipment in accordance with Warranty / Guarantee clauses of the bid document.
ODS/SOF/004 ODS/SOP/023 01 00 21/07/2010
11 - High, Mumbai HI-LO PILOT SWITCH Discipline Instt.
ISO 9001: 2000 Page # 1 of 7
FOR
HI – LO PILOT SWITCH
TOTAL
PREPARED / REVIEWED
REVISED BY BY
PAGES
VS SRS GRP 7 18.02.2008 4
ET RS GRP 10 28.03.2007 3
ET MC RK 10 23.06.2005 2
ET MC RK 10 03.01.2005 1
AK MC AC 10 17.04.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 2 of 7
CONTENTS

4.0 Hi – Lo Pilot Switch 3
4.1 Type 3
4.2 Material 4
4.3 Accuracy 4
4.5 Miscellaneous 4
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 3 of 7

selection of Hi – Lo Pilot Switch for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Hi – Lo Pilot Switch
4.0 HI-LOW PILOT SWITCHES:
4.1 SWITCH TYPE:
4.1.1 The pneumatic switch shall be block and bleed type.
4.1.2 GENERAL:
4.1.2.1 Hi-Lo pilots (PSHL) used in well head instrumentation shall be spring and piston
type. For use elsewhere on the platform coil and tube type may be considered.
4.1.2.2 All shutdown and alarm switches shall be fail safe and abnormal condition shall
cause a loss in output signals for pneumatic instruments.
4.1.2.3 Pressure gauge for supply, input and output shall be filled with liquid for damping.
4.1.2.4 Out put shall remain at 3.5 Kg/Cm2 between High and Low settings and 0
otherwise.
4.1.2.7 Connection for air or gas supply, transmission and control signals shall normally
be internally threaded ¼” NPT.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 4 of 7
4.1.2.8 Dead band shall be less than the difference between the normal operating pressure
and set point. Dead- band shall be fixed type unless otherwise specified.
4.1.2.9 The high and low-pressure ports shall be clearly marked on the instrument.
4.1.2.10 The switching mechanism shall have long life and minimum wear and tear.
4.1.2.11 In general compressed instrument air/gas will be used, as pneumatic supply to
instruments and vendor shall indicate pneumatic supply pressure requirement.
4.1.2.12 Pressure switches shall be field adjustable. Adjustments shall be tamper proof.
4.1.2.13 Switch mounted in the field shall be Ex d.
4.2 MATERIAL:
4.2.1 The material requirements for Pressure switch shall in general be according to
provided in Annexure I of this specification.
4.3 ACCURACY:
4.3.1 The maximum error shall not exceed 1% of the span. Repeatability shall be ±1%
for fixed dead band.
4.4 READING SCALES:
4.4.1 Units for pressure switch shall be in kg/cm2.
4.5 MISCELLANEOUS REQUIREMENTS
4.5.1 Mountings accessories required for Pressure Instrument shall be 316SS or better.
4.5.2 Pneumatic Pressure switches shall be tested for set points. These switches shall be
calibrated using a hydraulic or dead weight tester or precision pneumatic calibrator
prior to installation. A precision output meter, gauge or manometer shall be used
to monitor the output. The manufacturer before shipment shall perform calibration
and alignment of all instruments
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 5 of 7
ANNEXURE – I
Material Selection Chart for Pressure switch
S. No. Piping Class ELEMENT/SOCKET
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 SS316
2 INJECTION WATER SERVICE MONEL
3 A4, A6, A9, B9, D9, E9 SS316
4 A5 MONEL
5 A7

SS316
7 A10, B10, D10, E10, F10 SS316L
A11, B11, D11, E11, F11, PA11, PB11,

8 PD11, PE11, PF11
MONEL 400
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 6 of 7
ANNEXURE -II
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 7 of 7
ANNEXURE – III:-TYPICAL DATA SHEET – HI-LOW PILOT
PRESSURE SWITCHES (PNEUMATIC)

1 Type Pneumatic MEASURING UNIT
2 Function Indicate Pressure 26 Service
3 Mounting 27 Element Type
4 Case, Window 28 Element Material
5 Electrical Area Class - 29 Socket Material
6 Enclosure Class 30 Body Material
7 Intrinsically Safe 31 Connection location
8 Air Supply 32 DIAPHRAGM SEAL (Wherever Required)
9 Power Supply Type
10 Cable entry Wetted Parts
11 Accuracy Other Material
12 Repeatability Process Connection
SWITCH Facing & Finish
13 Electric Capillary Material
14 Quantity Armour Material
15 Form Capillary Length
16 Type Flushing Filling conne.
17 Rating MISCELLANIOUS
18 Load Type 33 Over range protection
19 Cable Entry 34 Blow out protection -
20 No. of Entries 35 Options
21 Pneumatic a) Mounting accessories
22 Type b) Air filter regulator
with
Gauge
23 Signal c) Intrinsically safe
weather proof out put
meter
d) Pressure
gauges for supply,
input and output
24 Set point adjustment 36 Pneumatic Connect.
25 Differential Load driving capability
TAG RANGE SET SET PRESSURE TEMP. FLUID SERVICE OPTIONS
No. POINT POINT OVER MAX OPER MAX
1 2
NOTE ;-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
SPECIFICATION FOR
ISO – 9001:2008
“PRESSURE INDICATING
CONTROLLER” Page: 2 OF 7
CONTENTS

4.0 Pressure Indicating Controller 3
4.1 Type 3
4.2 Material 3
4.3 Accuracy 3
5.0 Installation Requirements. 4
6.0 Calibration, Inspection & Testing. 4
Tagging & Nameplates:
7.0 4

Annexure II Data Sheet Format 6-7
SPECIFICATION FOR
ISO – 9001:2008

selection of Pressure Indicating Controller for the intended service.
b) Basic Bid Work
c) Project P & IDs
d) Instrument Process Data Sheets.
in the Basic Bid Work, and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Pressure Indicating
Controller suitable for its intended application, its procurement, tagging, packing,
testing & calibration, preparation for shipment, along with accessories, spares, and
assistance where required for its installation & commissioning at site. This FS shall
be read in conjunction with the Instrument Design Criteria.
4.0 PRESSURE INDICATING CONTROLLER:
4.1 Type: Pneumatic.
4.1.1 General:
4.1.1.1 Process Impulse connection shall be ½” NPTF and pneumatic connection
shall be ¼” NPTF.
4.1.1.2 The input pneumatic supply to the controller shall be 1.5 kg/cm2g. The
controller out put shall be 0.2 to 1.0 kg/cm2. The controller shall have local
set point adjustment.
4.1.1.3 The pneumatic controller shall have proportional and integral control mode.
4.1.1.4 The pneumatic controller shall have two-position auto manual switch. The
pneumatic controller shall have internal manual regulator.
4.1.1.5 The pneumatic controller shall be provided with air filter regulator with gauge
as per functional specification numberMR/OD/INST/FS/3606.
4.1.1.6 Over range protection shall be 130% of FSD.
4.1.1.7 Pointer- process variable pointer shall be in red colour and set point pointer
shall be green in colour.
4.2 Material:
4.2.1 Instrument parts shall be resistant to the corrosive properties of the process
fluid and ambient conditions to which they are exposed.
4.3 Accuracy: Accuracy shall be ±1% of span. Repeatability shall be ±0.2% of
span.
4.4 Reading Scales: Pressure: Kg/cm2.
SPECIFICATION FOR
ISO – 9001:2008
4.5 Enclosure Class: The Pressure indicating controller enclosure shall be

weatherproof to IP-55. Pressure indicating controller shall be furnished with all
necessary weather and anti-corrosion protection to prevent damage from saline
and corrosive process atmosphere.
5 INSTALLATION REQUIREMENTS:
5.1 The installation of Pressure indicating controller shall in general be according to
5.2 All Pressure indicating controller shall be mounted as close as possible to

sensing point. Mountings accessories required for Pressure indicating controller
shall be 316SS or better. All instrument supports shall be galvanized prior to
installation.
6 CALIBRATION, INSPECTION & TESTING:
6.1 Calibration, inspection and testing requirements shall in general be as per clause
3.6.4.7.8 of Instrumentation Design Criteria.
6.2 All the instruments shall be factory calibrated for the specified ranges.
7 TAGGING & NAMEPLATES:
7.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1
of Instrumentation Design Criteria.
7.2 The Pressure indicating controller shall be provided with SS name plate indicating
the following:
• Tag Number
• Manufacturer’s Name and Model Number.
• Element material
• Enclosure classification.
• Body material.
SPECIFICATION FOR
ISO – 9001:2008
ANNEXURE – I
(Hook Up Drawing)
PRESSURE INDICATING CONTROLLER (PNEUMATIC)
SPECIFICATION FOR
ISO – 9001:2008
ANNEXURE – II:- TYPICAL DATA SHEET
PIC (PNEUMATIC)
1 Type
MEASURING UNIT
2 Function 19 Service
3 Mounting 20 Pressure Element
4 Case Material 21 Element Material
5 Enclosure Class 22 Socket Material
6 Supply Air Pressure 23 Body Material
7 Accuracy 24 Connection location
8 Repeatability 25 DIAPHRAGM SEAL (Wherever Required)
9 Air Consumption Type
10 Ambient temperature Wetted Parts
11 Relative Humidity Other Material
Process Connection
Facing & Finish
Capillary Material
Armour Material
Capillary Length
CONTROLLER
12 Output Flushing Filling
connection.
13 A/M Switch Position
MISCELLANIOUS
14 Set Point Adjustment 26 Over range protection
Setting range 0-100 %FS
15 Manual Regulator 27 Blow out protection -
16 Mode 28 Options
17 Chart a) Mounting
accessories
18 Moving Parts Material b) Air filter regulator
with
Gauge
29 Pneumatic Connect.
SPECIFICATION FOR
ISO – 9001:2008
TAG RANGE OPERATIN MAX. OPERATING MAX. FLUID SERVICE

No. PRESSURE SERVICE TEMPERURE SERVICE
PRESSURE TEMP.
OPTIONS
NOTE :-
11 - High, Mumbai P to I CONVERTER Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FOR
P TO I CONVERTER
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 4 18.02.2008 2
AK RS GRP 6 23.03.2007 1
AK MC AC 6 03.03.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 2 of 4
CONTENTS

4.0 P to I converter 3
4.1 Converter Type 3
4.2 Material 3
4.3 Accuracy 3
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 3 of 4

selection of P to I converter for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the P to I converter suitable for
4.0 P/I CONVERTOR:
4.1 Converter Type: Pneumatic to current.
4.1.1 General:
4.1.1.1 The input signal range of P/I shall be 0.2-1.0 Kg/cm2 (g).
4.1.1.2 The P/I converter shall be provided with one Nos. ½”NPT (F) cable entries.
4.1.1.3 The converter signal range shall be 4-20mA, DC, 2 wire type and capable of
delivering the rated current signal into external load of 600 ohms when powered
with 24V DC.
4.1.1.4 The change in out put due to change in ambient temperature (10 degree Celsius)
should be very minimum.
4.1.1.5 P/I shall have externally adjustable zero and span. Setting adjustment shall have
locking adjusting
4.1.1.7 Process seal is used to isolate pressure instruments from process fluid
4.2 Material:
4.3 Accuracy: ± 0.5% of span.
4.4 Reading Scales: Units for P/I converter shall be in mA.
4.5 Enclosure Class: In addition to weatherproof, the converter enclosure shall be
explosion-proof to NEMA-4X and certified by third party agencies like
UL/FM/BASEEFA or equal for use in hazardous area (CL 1,DIV.1, GR.D).
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 4 of 4
ANNEXURE-I -TYPICAL DATA SHEET
PNEUMATIC ELECTRO TRANSDUCERS
1 Type 11 Conduit
Connection
2 Mounting Electrical
3 Ambient Temperature Pneumatic
4 Air Supply 12 Accuracy
5 Electric Supply 13 Actuation
6 Output 14 Housing Type
Input 15 Accessories
7 Pneumatic connection 16 Intrinsically safe
8 Measuring Circuit 17 Body material
9 Cold Junction 18 Internal material
Compensation
10 Burn-out Feature 19 Area
Classification
REV. ITEM TAG NO RANGE CALIBRATION ON BURN- SERVICE NOTES

NO OUT OUTPUT
As per P &
ID
NOTE :-
VENODR EAL AND SIGNATURE
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
11 - High, Mumbai RECORDER Discipline Instt.
ISO 9001: 2000 (ELECTRONIC) Page # 1 of 3
FOR
RECORDER (ELECTRONIC)
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 3 18.02.2008 2
AK RS GRP 5 28.03.2003 1
AK MC AC 5 25.08.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS

4.0 Recorder (electronic) 3
4.1 Type 3
4.2 Accuracy 3
4.3 Repeatability 3
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Recorder (electronic)for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Recorder (electronic)
4.0 ELECTRONIC RECORDER:
4.1 Type: Electronic
4.1.1 General:
4.1.1.1 Power supply to electronic recorder shall be 24V dc. Power supply to Chart drive
shall be 24V dc. The input signal to the recorder shall be 4-20 mA.
4.1.1.2 Three different colour pens shall be used in 3-pen recorder for representing the
each process variable. The colour coding, engineering units etc shall be clearly
marked on the recorder.
4.1.1.3 Type of the chart recorder shall be strip.
4.1.1.4 The Electronic recorder shall have provision for alarms. Electronic recorder shall
be microprocessor based.
4.1.1.5 Contractor shall provide 0-100% linear scale chart for P & T and Sq-Rt 0-10 with
multiplying factor to suit rate of flow requirements Chart for flow.
4.1.1.6 The Electronic Recorder shall have externally adjustable zero and span. Setting
adjustment shall have locking arrangement.
4.1.1.7 Contractor shall provide dual scale chart (0-100 linear for pressure and square root
for flow).
4.1.1.8 The related transmitter signal range shall be 4-20mA, DC, 2 wire type and capable
of delivering the rated current signal into external load of 600 ohms when powered
with 24V DC.
4.2 Accuracy: accuracy shall be ±0.5% of span.
4.3 Repeatability: Repeatability shall be ±0.5% of span.
4.4 Enclosure Class: Electronic Recorder shall be installed in safe and closed area.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
11 - High, Mumbai PORTABLE Discipline Instt.
ISO 9001: 2000 CALIBRATOR Page # 1 of 5
FOR
PORTABLE CALIBRATOR
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 5 18.02.2008 3
ET BK GRP 6 28.03.2007 2
ET MC RK 6 03.01.2005 1
ET MC AC 6 25.08.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
CONTENTS
Page
Clause No. ITEM
No.
4.0 Portable calibrator 3
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

selection of Portable calibrator for the intended service.
b) Basic Bid Work
c) Project P & IDs
indicated in the Basic Bid Work & Design Criteria.
3.2 The vendor shall be responsible for the selection of the Portable calibrator
4.0 PORTABLE CALIBRATORS:
4.1 The Portable Calibrators shall be used for simulating, testing and calibrating
electronic pressure instruments, electronic temperature instruments, and P/I
converters.
4.2 The Portable Calibrators shall be portable and lightweight.
4.3 The Portable Calibrators offered shall be of proven design and shall have been in
satisfactory service on offshore installation and should be under manufacture for
the last three years. It shall be Intrinsically safe and have the Certification of the
statutory bodies for use in hazardous area Class I Division I Gp C & D.
4.4 Calibrator shall be certified for the accuracies and shall have been tested at
recognized “testing Laboratories”.
4.5 The Portable Calibrators shall be microprocessor based and shall have a non-
volatile type memory with battery back up.
4.6 The Portable Calibrators shall be internally powered by chargeable, user-
replaceable batteries. Battery charger shall be provided and it shall be suitable
for 230 V AC, 50 Hz.
4.7 The Portable Calibrators shall be user-friendly, with keyboard and digital
display.
4.8 Calibrator shall generate the impulse signals (electrical / pneumatic / Hydraulic /
mV) for calibration. Pressure, DP & Flow Transmitters shall be calibrated with
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
actual inputs from the calibrator for checking the transmitter output / calibration.
It shall also have the facility to generate mV for checking the temperature loops.
4.9 Necessary connectors, length of cable / impulse tubes and all accessories shall be
provided.
4.10 The Portable Calibrators shall be weather proof to IP 53 minimum and shall be
intrinsically safe.
4.11 Intrinsic safety certificate for the Portable Calibrator shall be provided with the
Purchase specification.
4.12 It shall have data retention capability of at least 100 Tags with all calibration data
and time stamping.
4.13 It shall have facility of communication with the PC (EWS in Control room / PC /
Lap Top as the case may be) on serial bus RS-232 as a minimum. Necessary
software for downloading of all calibration data and creation of a data base on
the PC shall be supplied along with the calibrator.
4.14 The Contractor shall submit a reference list for Portable Calibrators, which are
operating in similar offshore platform with the purchase specification. This list
shall clearly indicate the name of the platform, name of client, application, model
number, quantity supplied and the month and year of commissioning of platform.
The Contractor shall also submit with the purchase specification, a list of makes
of Smart Transmitters with which the offered Portable Calibrator is compatible.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ANNEXURE – I :- Typical Data Sheet – Portable Calibrator
Sl.
Details
No.
1. Quantity
2. Service
Simulation, Testing & Calibration of pressure / DP transmitters (Yes
3.
/ No)
Simulation, Testing & Calibration of temperature transmitters /
4.
Thermocouples (Yes/No)
5. Simulation, Testing & Calibration of P/I Converters (Yes / No)
6. Memory
7. Power Supply
8. Battery Back up provided (Yes / No)
9. Rechargeable Batteries (Yes / No)
10. User replaceable batteries (Yes / No)
11. No. of Batteries
12. Type of Battery
13. Battery Charger Included (Yes / No)
14. Cable with connectors (Yes / No)
15. Length of cable
16. Area classification
17. Intrinsically safe (Yes / No)
18. Ingress Protection
19. Manufacturer
20. Model No.
NOTE :-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
11 - High, Mumbai FILTER REGULATOR Discipline Instt.
ISO 9001: 2000 Page # 1 of 4
FOR
FILTER REGULATOR
PREPARED / REVIEWED APPROVED TOTAL No.

DATE REV. No.
REVISED BY BY BY OF PAGES
VS SRS GRP 4 18.02.2008 3
AK BK GRP 6 31.09.2006 2
ET MC RK 6 23.06.2005 1
ET MC AC 6 28.08.2003 0
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 2 of 4
CONTENTS

1.0 Scope of This Document
2.0 Codes and Standards
2.1 Reference specifications
3.0 Scope of Supply
4.0 Filter Regulator
Annexure I Data Sheet Format
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 3 of 4

selection of Filter Regulator for the intended service.
b) Basic Bid Work
c) Project P & IDs
3.2 The vendor shall be responsible for the selection of the Filter Regulator suitable for
3.3 The Filter Regulator shall be provided for all instruments requiring regulated gas
or air supply .The Filter Regulator shall include integral relief valve and output
gauge and all other accessories necessary to make the system complete.
4.0 FILTER REGULATOR:
4.1 The Filter Regulator shall be provided with Gauge, Spring & Diaphragm, Drain
Cock and Intermittent Bleed.
4.2 The inlet pressure to the filter regulator shall be as follows:
Maximum: 10.6 Kg/cm2g
Minimum: 5.0 Kg/cm2g
4.3 The Filter Regulator shall have an adjustable range of 1 to 7 Kg/cm2g. Range
adjustment shall be possible with a hand wheel with lock nut.
4.4 The output gauge dial size shall be minimum 40mm.
4.5 The pneumatic connection size to the filter regulator shall be ¼” NPTF.
4.6 Mounting accessories required for 2” pipe mounting of the filter regulator shall be
provided.
4.7 The enclosure for Filter Regulator shall be Weather Proof to NEMA 4X / IP55.
4.8 Material:
4.8.1 The Body of the filter regulator shall be made of SS 316 as minimum and the filter
shall be 20-40 micron sintered Bronze or better.
4.8.2 The Diaphragm shall be made of reinforced Neoprene.
4.8.3 The internals of the filter regulator shall be SS 316 as minimum.
4.8.4 Wherever sour gas is used, the material of construction for the body and the
internals shall meet the requirements of NACE MR-01-75 (Latest Edition)
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
ISO 9001: 2000 Page # 4 of 4
ANNEXURE – I:-TYPICAL DATA SHEET FOR FILTER REGULATOR
FILTER REGULATOR
1. Regulator type
2. Fluid
3. Inlet pressure
4. Outlet pressure
5. Range
6. Output gauge size
7. Regulator range adjustment mechanism
8. Drain cock
9. Connection size
10. Construction
Body
Bowl
Material
Filter
11.
Diaphragm
Internals
Spring
12. Mounting accessories
13. Manufacturer
14. Model
15. Notes
NIOTE :-
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Spec. No. 3700
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 1 OF 13
FOR
CONTROL VALVE
TKK ARD AKR 13 23. 02. 2010 4
VS SRS GRP 12 18.02.2008 3
AK BKK GRP 13 28.03.2007 2
AK BKK GRP 13 30.08.2006 1
MC MC AC 13 25.08.2003 0
Spec. No. 3700
Discipline Instt
Page: 2 OF 13
CONTENTS
Page
Clause No. ITEM
No.
4.0 Control Valve 3
4.1 Valve selection & construction 3
4.2 Control valve sizing 4
4.3 Actuator 4
4.4 Positioner 5
4.5 Material 5
4.6 Miscellaneous Requirements 6
Spec. No. 3700
Discipline Instt
Page: 3 OF 13

selection of Control Valve for the intended service.
b) Basic Bid Work
c) Project P & IDs
3.2 The vendor shall be responsible for the selection of the Control Valve suitable for
its intended application, its procurement, tagging, packing, stroke testing &
4.0 CONTROL VALVE:
4.1 Valve Selection & Construction:
4.1.1 The Contractor shall select control valve based upon process flow capacity.
The Contractor shall select reduced trim as required to satisfy the expected
range of flow rate.
4.1.2 Valve selection shall consider all possible effect of erosion, cavitations and
noise.
4.1.3 Maximum permissible noise level shall be 85 dBA at 1 m from valve in all
direction. Noise mitigation by external noise reduction attachments shall be
considered where noise levels increase beyond the limits.
4.1.4 Equal percentage and linear trim characteristic shall be used as applicable to
process requirement. Quick opening type valve may be used for ON/OFF
service only.
4.1.5 Globe valves are preferred for general service and shall be cage guided for
low db application. In dirty or abrasive services (Produced liquids) post
guiding is preferred. Pressure balanced plug type valve shall be used wherever
diff. pressure across valve is high.
4.1.6 Butterfly control valves shall be used for water services, low differential
pressure high flow and non-critical applications only.
4.1.7 In general, except flare gas service, process fluid entry to Cage type single
seated globe valves shall be such as tending to open the valve (flow to open).
4.1.8 Shut-off leakage of valves shall be in accordance with ANSI B16.104. Tight
shut-off (TSO) valves shall be class VI or better with soft seating (reinforced
PTFE or similar).
Spec. No. 3700
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4.1.9 Body rating, flange rating & facing and material of construction shall be in
accordance with PMS / FS 401 the piping class specification for the associated
piping.
4.1.10 Valve Packing boxes shall be flange bolted to the bonnet. Valve packing shall
be spring loaded and adjustable. Teflon V rings shall be used up to 2120C.
Above this temperature graphite shall be used with an external lubricator and
isolation valve.
4.1.11 Valve bonnets shall be flange bolted to the body. Screwed bonnets shall not be
provided. For operating temperature of 2000C or greater, a radiating finned
bonnet may be required. For temperature below 00C an extension bonnet is
required. If bellows seals are required they shall be constructed from 316SS.
4.1.12 Minimum body size shall be DN25.
4.1.13 Where a valve is for flare gas service, TSO valve with soft seats are required.
For high-pressure drop application in gas service, multiple orifice trim design
shall be used. Labyrinth design shall not be used.
4.1.14 Pneumatic connections shall be ¼” NPTF as minimum. Larger Port sizes shall
be used wherever required for larger sizes of actuators.
4.1.15 Flow direction shall be stamped or cast on the body of all valves.
4.1.16 The Contractor shall provide detailed pressure temperature envelope curves
for each combination of valve body, trim and elastomer material.
4.2 Control Valve Sizing:
4.2.1 The Control valve shall be selected to pass high extreme of flow at 80%
maximum opening of the valve travel and low extreme of flow at 20%
minimum opening of the valve travel. The control valve shall be sized for
required maximum diff. pressure and shut-off pressure. Butterfly valves shall
be sized to pass high extreme of flow at 60% maximum opening of the valve
travel.
4.2.2 The Contractor shall submit Control Valve sizing calculation performed in
accordance with ISA S 75.01 and based on approved Process data, Process
flow diagram and material balance.
4.3 Actuator:
4.3.1 Control valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal.
Piston type actuator shall be used where diaphragm actuator cannot be used
due to capacity limitation. Electric actuator shall be used wherever specified.
4.3.2 Actuators shall be sized for operation under maximum shutoff pressure drop
across the valve minimum instrument air pressure or voltage to the actuator as
specified in this specification.
4.3.3 Actuators shall be selected to achieve specified valve failure positions. All
accessories, including pilot valves, relays, volume bottles etc. for double
Spec. No. 3700
Discipline Instt
Page: 5 OF 13
acting actuator or air block relays for fail in position valves, shall be supplied
with the valve.
4.3.4 A valve stem position indicator shall be provided. All control valve scales
shall be calibrated from 0-100 % of valve travel. Smart positionar transmitters
shall be considered for valve status indications in Process control room.
4.3.5 Side mounted heavy-duty hand wheels shall be provided for control valves
wherever specified. Hand wheels material shall be corrosion resistant and with
C-allowances over and above the thickness required as per design
requirements. Hand wheels shall be normally in disengaged position and
locked during normal Platform operation. These are to be used only during
maintenance / manual operation.
4.3.6 Actuator action shall be designed and sized for Failure position indicated.
4.3.7 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon
reinforced Neoprene or Buna N Rubber Diaphragm and shall be corrosion
resistant / with sufficient corrosion allowances to last the life of the platform.
4.4 Positioner : (Unless otherwise specified it shall be SMART Positioner)
4.4.1 Control valve shall be supplied fitted with positioner for all services except
on/off control.
4.4.2 Wherever specified for non-smart positioner the control valve shall be
provided with integral positioner with intrinsically safe “smart” type integral
i/p converter, and shall be direct acting, with field reversible provision.
4.4.3 Gauges shall be fitted to indicate pressure of the pneumatic supply, signal and
output to the actuator.
4.5 Material:
4.5.1 The material requirements for Control Valves shall in general be according to
the Material Selection Chart provided in Annexure – I of Pressure Control
Valve.
4.5.2 Control valve bodies shall generally be cast or forged carbon steel to ASTM
A216 Gr WCB/WCC or A105 respectively with 316 SS trim as a minimum.
However, more demanding services may require other materials as specified
in the applicable valve specification/Material selection chart. Consideration
shall be given in selection of all other valve part materials for
erosion/corrosion due to process fluid and ambient conditions and valve trim/
plug shall be stellited.
4.5.3 For painting, in general, Manufacturer standard procedures shall be followed.
However, specification enclosed in the bid shall govern and shall form the
minimum requirements.
4.5.4 All mounting accessories such as mounting bolts shall be of SS 316.
4.5.5 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double
ferrule compression fittings.
Spec. No. 3700
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4.6 MISCELLANEOUS REQUIREMENT:

4.6.1 Control valves shall be installed in horizontal lines with Actuator vertically
above the valve.
4.6.2 Clearance shall be provided to allow inline maintenance of valves. Adequate
clearance shall be provided above and below the valve to allow removal of the
valve actuator and internal cage (trim) and valve bottom plate as applicable
while not impeding access ways.
4.6.3 Control valve assembly shall be installed with two line isolation valves. One
shall be provided at the upstream side of the control valve and the other at the
downstream side. A bypass line shall be provided across the control valve
with a line isolation (bypass) valve (globe type). Capacity of the bypass valve
shall be in line with the control valve.
4.6.4 Control valves shall be installed in the direction recommended by the
manufacturer and the valve shall not be subjected to stress due to pipeline
movement or misalignment.
4.6.5 All valves shall be tested in accordance with API 598, hydro-tested to ASME
B 16.34 clause 7.1, leak tested to ASME / FCI 70.
4.6.6 Testing and Calibration :
In accordance with nameplate data and instrument specification following
Testing and Calibration shall be carried out:
i. All diaphragm and piston operated control valve shall be stroke tested
pneumatically using a pressure regulator and pressure gauge against
spring range.
ii. Mechanical sealing and travel shall be checked.
iii. Valve position shall be calibrated on control valve.
iv. Split range or reverse acting positioner shall not have bypass and shall
be checked carefully.
v. Zero position shall be live zero (just off the seat at minimum setting with
air).
vi. Signal line shall be bled to zero and failure action shall be confirmed.
vii. Control valve accessories such as hand wheel, booster, relay, Volume
bottle etc. shall be checked operationally. Declutchable hand wheel shall
be operable both with and without air signal to diaphragm.
viii. Check shall be made in shop prior to installation.
ix. Butterfly valves shall be checked carefully to see that vane moves freely
into upstream and downstream piping. Proper vane movement to stroke
shall be confirmed when specified.
Spec. No. 3700
Discipline Instt
Page: 7 OF 13
4.6.7 Each Control valve shall have a 316 SS Name plate attached firmly to the
body furnishing the following information:
• Tag Number
• Body and Port size
• Stem Travel
• Action on air failure
• Spring Range
• Air supply Pressure
• Manufacturer Model Number for valve body, actuator and positioner.
• P.O. Number
• Serial Number
• Leakage Class
• Body rating and material grade
• Signal range
• Trim Characteristics
• Body Test Pressure
• Bench set Pressure
Spec. No. 3700
Discipline Instt
Page: 8 OF 13
ANNEXURE – I
Material Selection Chart for Control Valves
Control Valves
S. No. Piping Class
Body Trim
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 CS SS 316
XG1, A1H, A3, B3, A8
2 INJECTION WATER SERVICE CS SS 316
3 A4, A6, A9, B9, D9, E9 SS 316 SS 316
ALUMINIUM
4 A5 MONEL
BRONZE
5 A7 HASTALLOY C. HASTALLOY C.
SS 316 confirming
CS NACE
A1N, B1N, D1N, E1N, F1N, XF1N, PA1N, to NACE
6
PB1N, PD1N, PF1N, XG1N
PACKING - GRAPHOIL
SS 316 SS 316
7 A10, B10, D10, E10, F10
PACKING - GRAPHOIL
DUPLEX SS SOLID ALLOY

A11, B11, D11, E11, F11, PA11, PB11,
8
PD11, PE11, PF11
PACKING – GRAPHOIL/Teflon
Spec. No. 3700
Discipline Instt
Page: 9 OF 13
ANNEXURE – II
(Hook Up Drawing)
Spec. No. 3700
Discipline Instt
Page: 10 OF 13
ANNEXURE II (Contd.)
AIR FAIL TO OPEN CONTROL VALVE WITH I/P AND POSITIONER
AIR FAIL TO CLOSE CONTROL VALVE WITH I/P AND POSITIONER
Spec. No. 3700
Discipline Instt
Page: 11 OF 13
CONTROL VALVE WITH PILOT VALVE
Spec. No. 3700
Discipline Instt
Page: 12 OF 13
SMART POSITIONER
AIR FAIL TO OPEN CONTROL VALVE WITH SMART POSITIONER
SMART POSITIONER
AIR FAIL TO CLOSE CONTROL VALVE WITH SMART POSITIONER
Spec. No. 3700
Discipline Instt
Page: 13 OF 13
ANNEXURE – III: - TYPICAL DATA SHEET FOR CONTROL VALVE

UNITS: Flow → Liquid : M3/Hr, Gas : SM3/Hr or Kg/Hr, Steam : Kg/Hr, Pressure : Kg/Cm2 G, Temp: 0C Level / Length : MM
General 1. Tag No.
2. Inlet No.
3. Outlet No.
4. Service
5. Line Size Schedule
6. Inlet Line I.D. Outlet Line I.D
Body 7. Type of Body
8. Body Size Part Size
9. Guiding No. of Parts
10. End Conn. Type. Size & Rating
11. Facing & Finish
12. Body Material
13. Bonnet Type
14. Packing Material
15. Lubricator Isolation . Valve
16. Trim Form
17. Trim / Plug (Stellite Mat.) /Disc/Ball & Seat Mat.
18. Other Wetted Parts
19. Soft Seating Material
20. ANSI Leakage Class
Actuator 21. Type
22. Close At Open At
23. Failure Position
24. Hand wheel & Location
Positioner 25. Air Supply Pressure
26. Input Output
27. Bypass Gauges
Options 28. Solenoid Valve
29. I/P Converter
30. Filter with Gauge
31. Limit Switch
32. Smart Positioner
33.
Service 34. Fluid State
Conditions 35. Flow Liquid- Min Normal Max
36. Flow Vapour- Min Normal Max
37. Flow Water Min Normal Max
38. Inlet Pr. – Nor Min.
39. Process Flow Rate Min Normal Max
40. Pressure Shut Off
41. Temp. Oper. Max
42. Oper. S. G. Mol. Wt.
43. Cp/Cv Compress Factor
44. Flash % Visc. mPass (Oper)
45. Deg. Of Superheat
46. Vapour Pr. Critical Pr.
Valve 47. Cv Min. Cv. Max.
Data 48. Cv. Nor. Selected Cv
49. Predicted Sound Level dBA
50. Inlet Velocity m/s
Model 51. Valve Actuator
Nos. 52. Positioner Solenoid Valve
NOTE :-
Spec. No. 3701
Rev. No. 3
ISO – 9001:2008 SAFETY RELIEF VALVE Page: 2 OF 8
CONTENTS
Page
Clause No. ITEM
No.
2.0 Reference Documents and specifications 3
4.0 Safety relief valve 3
4.1 Basis of selection 3
4.2 Sizing 4
4.3 Set pressure 4
4.4 Material 4
4.5 Valve springs 5
4.6 Miscellaneous requirements 5
Safety relief valve for the intended service.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
b) Basic Bid Work
c) Project P & IDs
Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Safety relief valve suitable for its
commissioning at site. This FS shall be read in conjunction with the Instrument Design
Criteria.
4.0 SAFETY RELIEF VALVES:
4.1 Basis of selection:
4.1.1 All relief valves of size 1" and above shall be full nozzle full lift type. Relief valves with size
less than 1" shall be base or modified nozzle type.
4.1.2 Flanged relief valves for process piping, excluding steam and air pressure piping, shall be
either the enclosed spring type or pilot-operated type.
4.1.3 Balanced relief valves shall be used if the variable backpressure is more than 10% of valve set
pressure or where the service is corrosive. Balanced relief valves suitable for variable
backpressure may also be used where appreciable savings in the discharge disposal system
piping can be affected by virtue of the increased allowable backpressure. Balanced bellow
materials shall be the same as the valve trim.
4.1.4 Rupture disc type pressure relief devices shall not be used as primary relief devices.
4.1.5 Relief valves 1" and larger shall be of the type having a nozzle bushing which extends through
and beyond the base of the inlet-bolting flange, and which forms the gasket-bearing surface for
the inlet flange.
4.1.6 ¾ " and 1" relief valves may have screwed ends. All process Relief valve 1” size and larger
shall have flanged inlet and outlet connections.
4.1.7 Thermal relief valves shall have a minimum orifice area of 38.7mm2.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
4.1.8 Venting and breathing equipment for low pressure above ground storage tanks shall be in
accordance with the API Std 2000 “Guide for Tank and venting atmospheric and low pressure
storage tanks”.
4.1.9 Lifting levers may be provided for periodic testing of the Safety Valve. Closed bonnet
construction shall be used.
4.1.10 All castings and welding shall be 100% radiographed.
4.2 Sizing:
4.2.1 The contractor shall size safety relief valve according to capacity, set point, reset differential
and the blow down requirements of the Process for the Project.
4.2.2 The selected orifice shall be the next standard orifice size available above the calculated area.
Valve capacity shall then be calculated based on the selected orifice code.
4.2.3 For two-phase liquid / vapour relief application, the total orifice area shall be the sum of the
orifice areas calculated individually for liquid and vapour at the actual conditions.
4.2.4 In Safety Relief valve sizing calculations, the fail open state of a control valve (if any) shall be
taken into consideration.
4.3 Set Pressure:
4.3.1 Set point of the Safety Relief valves shall not be higher than the design pressure of the system
being protected by the valve, except as permitted by the relevant ASME Codes & API 521/526.
4.3.2 The allowing tolerance in set pressure are as below:
a) ±0.14 Kg/cm2g for set pressure up to and including 5 Kg/cm2g.
b) ±3% for set pressure above 5 Kg/cm2g.
4.4 Material:
4.4.1 The material requirements for safety relief valve shall in general be according to clause 3.6.4.5
of Instrumentation Design Criteria and the material selection chart provided in Annexure –1 of
this specification.
4.5 Valve Springs:
4.5.1 Relief valves for set pressures of 17.5 kg/cm2g (250 psig) or less shall have springs suitable for
a range of adjustment of plus or minus 10% of the set pressure.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
4.5.2 Relief valves set at pressures higher than 17.5 kg/cm2g (250 psig) shall have springs suitable
for a range of adjustment of plus or minus 5% of the set pressure. Range identification shall be
provided on the spring.
4.6 MISCELLANEOUS REQUIREMNTS :
4.6.1 Relief valve shall have tamperproof sealing, by wiring of screw cap and body, and lead sealing.
4.6.2 The installation of Safety Relief Valve shall in general be according to clause 3.6.4.6 of
4.6.3 Where no possibility of hydrocarbon pollution (such as in water and air service), safety relief
valves may be vented to atmosphere, with due consideration of position and angle of venting.
4.6.4 Safety relief valve shall be installed after testing/setting for set pressure, blow down and seat
tightness.
4.6.5 Discharges from all safety valves shall be individually routed to a safe location, unless
specified otherwise.
4.6.6 All safety valves discharge lines shall join the relief header from top and shall be at an angle of
30 to 40 degrees with the axis of the header.
4.6.7 All safety valves discharge and equipment depressurizing lines shall be free draining to vent
header and shall have no pockets up to and including header.
4.6.8 Discharge piping shall be designed to avoid liquid collection, backpressure build up, and stress
on the valve body under all conditions. A low point discharge drain may only be fitted on relief
valves venting to atmosphere.
4.6.9 Inlet piping shall be arranged to ensure that pressure drop at full flow does not exceed 3% of
set pressure.
4.6.10 Isolation valves provided at up-steam of double PSVs should have both lockable open and
lockable closed provisions with mechanically interlocked arrangement so that both the valve
cannot be isolated simultaneously (one LO and other shall be LC).
4.6.11 Contractor shall provide all facilities free of cost to company engineer or their authorized
representative for inspection and witness to the following tests at vendor’s works:
• Material –Body, trim etc.

• Physical- Visual and dimensional as per API/ASME/ASTM standards.
• Pop-up test.
• Seat tightness test
4.6.12 Safety relief valves shall be tested for opening at specified set pressure and also for seat
tightness.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
4.6.13 Testing for seat tightness shall be in accordance with the latest edition of API Std. 527.soft
seating (coring) shall be provided wherever tight shutoff is called for.
4.6.14 Compressed air or nitrogen shall be used for testing safety-relief valves (gas service) and shall
be furnished by the CONTRACTOR prior to handover.
4.6.15 For liquid service safety valve, water may be used as testing medium.
4.6.16 The following information shall be shown on the nameplates as a minimum:
• Manufacturer’s Name and trade mark.

• Valve Model and serial number
• Tag number.
• Valve catalogue number.
• Set pressure.
• Purchase order number.
• Valve manufacturer.
• Valve body, spring and nozzle material.
• Orifice designation
• Valve inlet and outlet connection sizes and ratings.
• Back pressure.
• ASME Code stamp shall be marked
ANNEXURE – I
Material Selection Chart for Safety relief valve
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
Pressure relief valve

S.
Piping Class Bellows/Spring material
No. Body/ Nozzle/disc
Bellows
Bonnet (forge) Bellows /
Conventional
spring
A1, B1, D1, E1, F1,
XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, CS/ASTM Chrome steel /
SS316/SS
1 A2, B2, D2, E2, XG1, A216 Gr
PH17/4
SS316 chrome Alloy
A1H, A3, B3, A8 .WCB /SS316
(EXCEPT WAT. INJ.
SERVICE)
Chrome steel /
INJECTION WATER CS/MONE
2
SERVICE L-400
MONEL-400 MONEL chrome Alloy SS316
/SS316
Chrome steel /
3 A4, A6, A9, B9, D9, E9 SS316 SS316 SS316 chrome Alloy SS316
/SS316
AL. Chrome steel /
4 A5 BRONZE / MONEL MONEL chrome Alloy INCONEL
MONEL /SS316
Chrome steel /
HASTALL HASTALL
5 A7
Y-C
HASTALLY-C
Y-C chrome Alloy HASTALLY-C
/SS316
A1N, B1N, D1N, E1N, Chrome steel /
F1N, XF1N, PA1N, INCONEL
6
PB1N, PD1N, PF1N,
CS SS316
625 chrome Alloy INCONEL 625
XG1N /SS316
Chrome steel /
A10, B10, D10, E10, INCONEL
7
F10
CS SS316L
625 chrome Alloy INCONEL 625
/SS316
A11, B11, D11, E11, Chrome steel /
DUPLEX SS / INCONEL
8 F11, PA11, PB11, CS
MONEL 400 625 chrome Alloy INCONEL 625
PD11, PE11, PF11 /SS316
ANNEXURE-II:-TYPICAL DATA SHEET

Pressure Relief Valves
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> ˚ C Level/Length-> mm
1. Tag Number
General
2. Line Number
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
Spec. No. 3701
Rev. No. 3
3. Vessel Protected
4. Safety / Relief
5. Type
6. Full Nozzle, Full Lift / Modified Nozzle
7. Bonnet Type
8. Conventional/Bellows/
9. Inlet Connection : Size & Rating
10. Facing & Finish
Valve 11. Outlet Connection : Size & Rating
12. Facing & Finish
13. Cap over Adjustment Bolt
14. Screwed Bolted
15. Lifting Gear Type
16. Test Jig
17.
18. Body & Bonnet
19. Nozzle & Disc.
20. Spring
21. Bellows
Material
22. Resilient Seat Seal
23.
25.
26.
27. Code
Basis 28. Basis of Selection
29.
30. Fluid & State
31. Corrosive Constituents
32. Required Flow Capacity
33. Mol. Wt. / Sp. Gr. At Relieving Temp.
34. Operating Pressure
35. Operating Temp./Relieving Temp.
Service 36. Valve Discharges to : Flare/Vent/Close Drain
Conditions 37. Back Pressure : Constant / Variable
38. Set Pressure
39. Cold Bench Test Pressure
40. % Over Pressure / %Blow Down
41. P/Cv/Compressibility Factor
42. Viscosity At Relieving Temperature cP
43. Vessel Wall Temp. Surface Area M3
45. Calculated Area
46. Selected Area Orifice Designation
47. No. of valves required for capacity
Orifice
48. Total Area
49. Actual Flow Capacity
50.
51 Model Number
Model 52. ASME UV Stamp
NOTE:-
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
FUNCTIONAL SPECIFICATION Spec. No. 3702
Offshore Design Section FOR Rev. No. 4
Engineering Services “Self Actuated Pressure Discipline Instt
ISO – 9001:2008
Control Valve” Page: 2 OF 7
CONTENTS

4.0 Self Actuated Pressure Control Valve 3
4.1 Type 3
4.2 Material 4
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ISO – 9001:2008

selection of Self Actuated Pressure Control Valve for the intended service.
b) Basic Bid Work
c) Project P & IDs

the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Self Actuated Pressure Control
Valve suitable for its intended application, its procurement, tagging, packing, testing &
4.0 SELF ACTUATED PRESSURE CONTROL VALVE:
4.1 Type: Self actuated pressure control valve.
4.1.1 General:
4.1.1.1 All flanges shall have serrated finish unless otherwise specified. (MOC shall be
governed by the PMS)
4.1.1.2 Internal passages shall offer minimum restriction to flow. Pockets and shoulders
tending to create turbulence or solids accumulation shall be minimized.
4.1.1.3 The flow direction shall be clearly marked on the valve body.
4.1.1.4 Single port valves shall be used unless otherwise specified.
4.1.1.5 Self actuated pressure control valve for downstream pressure regulation shall have
integral pressure relief valve. This clause shall be applicable if there is no external PSV
downstream of SAPCV.
4.1.1.6 Unless otherwise specified, diaphragm/piston spring actuators shall be used.
4.1.1.7 The set pressure adjustment shall be internal and field adjustable. Pilot type pressure
adjustment may also be used.
4.1.1.8 Noise level in the valves under operating conditions shall not exceed 85 dBA at 1 meter
from the valve in all direction. Noise mitigation by external noise reduction attachments
shall be considered where noise levels increase beyond the limits. (Attachments for
attenuation of the sound shall be the responsibility of the valve manufacturer)
4.1.1.9 For high pressure drop applications contractor shall provide balance trim.
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
ISO – 9001:2008
4.1.1.10 For 3″ and larger valve, lifting lugs or eyelets shall be provided to enable the valve to
be lifted and supported vertically during installation.
4.1.1.11 All castings and welding shall be 100% radio graphed.
4.2 Material:
4.2.1 The material requirements for Self actuated pressure control valve shall in general be
according to Annexure-1(Material selection chart).
4.2.2 The body castings shall be free from injurious blowholes, parasite, shrinkage faults,
cracks or other faults.
4.2.4 Orifice material shall be of Stainless Steel.
4.3 MISCELLANEOUS REQUIREMENTS:
4.3.1 Self-actuated pressure control valve shall be furnished with all necessary weather and
anti-corrosion protection / painting to prevent damage from saline and corrosive
process atmosphere.
4.3.2 All the instruments shall be factory calibrated for the specified ranges.
4.3.3 The Contractor shall submit SAPCV Sizing calculation performed in accordance with
ISA S 75.01 and based on process data, Approved Process flow diagram and material
balance.
4.3.4 The Self actuated pressure control valve shall be provided with SS name plate
indicating the following:
• Manufacturer’s Name and trade mark.
• Valve Model Number and Serial No.
• Tag number
• Valve catalogue number
• Valve size and body pressure rating.
• Trim material, size and characteristic.
• Output Set pressure range
• Input Pressure range
• Orifice designation
• Valve body, spring and nozzle material
• Valve inlet and outlet connection sizes and ratings
• Purchase order number
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
ISO – 9001:2008
• A metal tag shall be firmly fixed to the valve consisting Tag Number, valve
packing and type of lubricator (if used).
ANNEXURE-I
MATERIAL SELECTION CHART FOR SAPCV
Self Actuated Pressure Control Valve

S.
Piping Class Regulator
No. Body Diaphragm
Spring
A1, B1, D1, E1, F1, XF1, F1,
PA1, PB1, PD1, PE1, PXF1,
PF1, A2, B2, D2, E2, XG1,
1 A1H, A3, B3, A8 CS Plated Steel SS316
(EXCEPT WAT. INJ.
SERVICE)
INJECTION WATER
2 SERVICE
CS MONEL SS316
3 A4, A6, A9, B9, D9, E9 SS316 Plated Steel SS316
ALLUMINIUM
4 A5
BRONZE
MONEL MONEL
HASTALLY-
5 A7 HASTALLY-C
C
HASTALLY-C
A1N, B1N, D1N, E1N, F1N,

INCONEL SS316/Neoprene/
6 XF1N, PA1N, PB1N, PD1N, C.S PACKING
625 VITON
PF1N, XG1N
INCONEL
7 A10, B10, D10, E10, F10 SS316L
625
SS316L
A11, B11, D11, E11, F11, DUPLEX SS

INCONEL
8 PA11, PB11, PD11, PE11, (PACKING-
625
SOLID ALLOY 6
PF11 GRAPHOIL)
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
ISO – 9001:2008
ANNEXURE-II
HOOK UP DRAWING
SAPCV (EXTERNAL) SEA WATER SERVICE
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
ISO – 9001:2008
ANNEXURE-III
SELF ACTUATED PRESSURE CONTROL VALVES

o
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr ,Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> C Level/Length-> mm
1. Tag No.
2. Line No.
General 3. Line Size & Schedule
4. Service
5.
6. Type. Of Regulator :Std Pilot op
7. Size : Body Port
8. End Conn. : Size & Rating
9. Facing & Finish
10. Body Material
11. Trim Material
12. Set Point
13. Impulse Conn. : Int. Ext.
14. Conn. Size & Type if External
15. Material of Diaphragm
Valve
16. Bonnet Type
17. Cv : Min. Max.
18. Cv : Normal
19. Selected Valve Cv
20. Predicted Sound Level dBA
21. Inlet Velocity
22. Packing or Seals
23. Lubricator ISO Valve
24. Guiding No. of Ports
25.
26. Pressure Indicator
Access-aries 27. Relief Valve
28. Line Strainer
29. Fluid & State
30. Flow Min. Max
31. Flow Normal
32. Inlet Pr. Min. Max
33. Inlet Pr. Normal
34. Del. Pr. Max. Nor. Min.
Service 35. Del. Pr. Shut Off
Conditions 36. Temperature C. Oper. Min.
37. Oper. S.G. Mol. Wt.
38. Cp/Cv Compress. Factor
39. Flash % Oper. Visc. mPas(cP)
40. Deg. Of Superheat % Solids
41. Vapour Pr. Critical Pr.
42. Model No. valve Actuator
43. Max Sound Level dBA
44. IBR Certificate
45 Specification Remarks
NOTE :-
ODS/SOF/004 ODS/SOP/023 01 00 21.07.2010
11 - High, Mumbai DELUGE VALVE Discipline Instt.
ISO 9001: 2000 Page # 1 of 7
FOR
DELUGE VALVE
TOTAL
REVISED BY BY No.
PAGES
VS SRS GRP 7 18.02.2008 3
ET RS GRP 7 28.03.2007 2
SRS MC GRP 7 08.05.2006 1
MC MC AC 11 13.05.2003 0
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ISO 9001: 2000 Page # 2 of 7
CONTENTS

4.0 Deluge Valve 3
4.1 Valve Selection & Construction 3
4.2 Actuator 4
4.3 Positioner 4
4.4 Material 4
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ISO 9001: 2000 Page # 3 of 7

selection of Deluge Valve for the intended service.
b) Basic Bid Work
c) Project P & IDs
Process Parameters
3.2 The vendor shall be responsible for the selection of the Deluge Valve suitable for
4.0 DELUGE VALVE:
4.1 Valve Selection & Construction:
4.1.1 The Contractor shall select Deluge valve based upon plant capacity.
4.1.2 Valve selection shall consider all possible effect of erosion, cavitations and noise.
4.1.3 Maximum permissible noise level shall be 85 dBA at 1 m from valve in all
direction.
4.1.4 Shut-off leakage of valves shall be in accordance with ANSIB16.104. Generally
shut-off shall be class IV or better. In General, valves shall be Drip-Free.
4.1.5 Body rating and flange rating and facing shall be in accordance with the piping
class specification for the associated piping.
4.1.6 Valve packing boxes (where applicable) shall be flange bolted to the bonnet. Valve
packing shall be spring loaded and adjustable. Teflon V rings shall be used up to
2120C. Above this temperature graphite shall be used with an external lubricator
and isolation valve.
4.1.7 Valve bonnets shall be flange bolted to the body. Screwed bonnets shall not be
provided. For operating temperature of 2000C or greater, a radiating finned bonnet
may be required. For temperature below 00C an extension bonnet is required. If
bellows seals are required they shall be constructed from 316SS.
4.1.8 Minimum body size shall be DN25.
4.1.9 Pneumatic connections shall be ¼” NPTF as minimum. Larger Port sizes shall be
used wherever required for larger sizes of actuators.
4.1.10 Termination in wiring enclosures shall be via fixed terminals. Flying leads shall
not be permitted
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ISO 9001: 2000 Page # 4 of 7
4.1.11 Flow direction shall be stamped or cast on the body of all valves.
4.1.12 The offered make and model of the Deluge valve shall be certified / listed by
Underwriters Laboratory (UL) or BV or DNV for Fire Water Deluge service.
4.1.13 Valve shall be sized as per the requirements of the platform for fire fighting
4.2 Actuator:
4.2.1 Deluge valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal. Piston
type actuator shall be used where diaphragm actuator cannot be used due to
capacity limitation. Electric actuator shall be used wherever specified.
4.2.2 Actuators shall be sized for operation under maximum shutoff pressure drop
across the valve minimum instrument air pressure or voltage to the actuator as
specified in this specification.
4.2.3 Actuators shall be selected to achieve specified valve failure positions. All
accessories, including pilot valves, relays, volume bottles etc. for double acting
actuator or air block relays for fail in position valves, shall be supplied with the
valve.
4.2.4 Detachable side mounted heavy-duty hand wheels shall be provided for Deluge
valves wherever specified.
4.2.5 Actuator action shall be field reversible.
4.2.6 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon
reinforced Neoprene or Buna N Rubber Diaphragm.
4.3 Positioner: (if applicable)
4.3.1 Deluge valve shall be supplied fitted with positioner for all services except on/off
Deluge.
4.3.2 The Valve positioner shall be intrinsically safe “smart” type with integral I/P
converter and shall be direct acting, with field reversible action.
4.3.3 Gauges shall be fitted to indicate both input & output pressure.
4.4 Material:
4.4.1 The material requirements for Deluge Valves shall in general be according to
clause 3.6.4.5 of Instrumentation Design Criteria and according to the Material
Selection Chart provided in Annexure – I of this document.
4.4.2 Deluge valve bodies shall generally be Cast 5% Al Bronze to BS 1400.A.B.2C.,
however more demanding services may require other materials as specified in the
applicable piping specification/Material selection chart. Consideration shall be
given in selection of all other valve part materials for corrosion due to process fluid
and ambient conditions.
4.4.3 Accessories such as mounting bolts shall be of SS 316.
4.4.4 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double
ferrule compression fittings.
4.5 MISCELLANEOUS REQUIREMENTS:
4.5.1 Clearance shall be provided to allow inline maintenance of valves. Adequate
clearance shall be provided above and below the valve and shall be installed on
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ISO 9001: 2000 Page # 5 of 7
horizontal lines with actuator as per manufacturer’s installation standards, and shall
not impede access ways.
4.5.2 Deluge valve assembly shall be provided with double block, double bleed and
bypass piping and valves. The bypass valve shall be a globe valve no smaller than
one pipe size than the Deluge valve but with a CV no greater than that of the
Deluge valve.
4.5.3 Deluge valves shall be installed in the direction recommended by the manufacturer
and the valve shall not be subjected to stress due to pipeline movement or
misalignment.
4.5.4 All valves shall be tested in accordance with API 589, hydro-tested t ASME B
16.34 clause 7.1 and leak tested to ASME / FCI 70.2.
4.5.5 Contractor shall remove in line instruments and Deluge valve and provide
necessary spool pieces/ Flanges prior to flushing/hydro testing.
4.5.6 All diaphragm and piston operated Deluge valve shall be stroked pneumatically
using a pressure regulator and pressure gauge against spring range shown on name
plate Mechanical sealing and travel shall be checked against name plate. Check
shall be made in shop prior to installation.
4.5.7 All Deluge valves shall be checked carefully against nameplate data and
specifications.
4.5.8 Each Deluge valve shall have a 316 SS Name plate attached firmly to the body
furnishing the following information:
• Tag Number
• Body and Port size
• Stem Travel
• Action on air failure
• Spring Range
• Air supply Pressure
• Manufacturer Model Number for valve body, actuator and positioner.
• P.O. Number
• Serial Number
• Leakage Class
• Body rating and material grade
• Signal range
• Trim Characteristics
• Body Test Pressure
• Bench set pressure
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ISO 9001: 2000 Page # 6 of 7
ANNEXURE – I
Material Selection Chart for Level Gauge
COCK COCK
S. No. Piping Class CHAMBER
BODY TRIM
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 CS CS SS316
2 INJECTION WATER SERVICE CS CS SS316
3 A4, A6, A9, B9, D9, E9 SS316 SS316 SS316
5 A7 Ti Ti Ti

6 SS316 SS316 SS316
PA1N, PB1N, PD1N, PF1N, XG1N
7 A10, B10, D10, E10, F10 SS316L SS316L SS316L
A11, B11, D11, E11, F11, PA11, PB11, MONEL-

8 MONEL- 400 MONEL-400
PD11, PE11, PF11 400
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ISO 9001: 2000 Page # 7 of 7
ANNEXURE –II TYPICAL DATA SHEET FOR DELUGE VALVE

o
UNITS: Flow-> Liquid- m*3/hr Gas- Nm*3/hr ,Steam- kg/hr Pressure- > kg/cm*2 G Temperature-> C Level/Length-> mm
1 TAG NO.
2 LINE NO.
SERVICE
3 LINE SIZE & SCH.
4 SERVICE
5 TYPE SIZE
6 NO. OF PORTS PORT SIZE
7 GUIDING
8 END CONNECTIONS : SIZE & RATING
9 FACING & FINISH
10 BODY MATERIAL
11 BONNET TYPE | MATERIAL
BODY
12 PACKING MATERIAL
13 LUBRICATOR ISOL. VALVE
14 TRIM FORM
15 TRIM MATERIAL
16 OTHER WETTED PARTS
17 FLOW ACTION
18 LEAKAGE CLASS
19 TYPE
20 OPEN | CLOSE
ACTUATOR
21 FAILURE POSITION
22 HAND WHEEL & LOACATION
23 AIR SUPPLY PRESSURE
POSITIONE
R 24 INPUT KG/CM2 OUTPUT
25 BYPASS GAUGES
26 FLUID & STATE
27 FLOW : MIN. MAX.
28 FLOW : NORMAL
29 INPUT PRESSURE : NORMAL | MIN
30 D.P. SIZING @ FLOW
SERVICE 31 DIFF. PRESS. SHUTOFF KG/CM2G
CONDITION 32 TEMPERATURE : OPER. | MAX.
33 SG @ 15°C
34
35 VISCOSITY @ OP. TEMP.Cp
36 Deg OF SUPER HEAT % SOLIDS
37 VAPOUR PRESS. CRITICAL PRESS
38 Cv. MIN. / NORM. / MAX.
VALVE 39 SELECTED VALVE Cv
DATA 40 PREDICTED SOUND LEVEL dBA
41 INLET VELOCITY m/s
42 SOLENOID VLAVE
43 I/P CONVERTOR
OPTIONS
44 FILTER REGULATOR WITH GAUGE
45 LIMIT SWITCHES
46 IBR CERTIFICATION
47 MIDEL NUMBER : VALVE
MISC. 48 ACTUATOR
49 POSITIONER
50 MANUFACTURER
NOTE :-
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Design Division FUNCTIONAL F.S # C-100
SPECIFICATION Revision # 3
Engineering
FOR
Services Discipline Instrumentation
DISTRIBUTED
ISO – 9001:2000 CONTROL SYSTEM Page 1 of 84
DISTRIBUTED CONTROL
SYSTEM (DCS)
OIL AND NATURAL GAS CORPORATION LTD.

MUMBAI
Rev 3: revised to reorganize the document and correct minor errors

Rev 2: revised Clause 4.4.6.4 & Issued for MHN Project
3 11.07.07 AK RS GRP 84
2 09.12.06 AK RS GRP 98
1 13.05.03 ET MC AC 98
0 08.05.03 ET MC AC 94
APPROVED & NO. OF
REV NO. DATE PREPARED BY CHECKED BY
ISSUED BY PAGES
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TABLE OF CONTENTS
4.0 Distributed Control System 4
4.1 Definitions and Abbreviations 4
4.2 General 7
7.0 Inspection And Testing 65
9.0 Training 79
Annexure 1 Data Sheet – Proven Track Record 81
Annexure 2 Data Sheet – Responsibility Chart 82
Annexure 3 Typical format for certificate of logistic support 83
Annexure 4 Data Sheet – Distributed Control System 84
Annexure 5 Data Sheet – Communication Sub-System 85
Annexure 6 Data Sheet – Controller Sub-System 86
Annexure 7 Data Sheet – Data Acquisition Sub-System 87
Annexure 8 Data Sheet – Operator Interface Sub-System 88
Annexure 9 Data Sheet – Engineering Interface Sub-System 89
Annexure 10 Data Sheet – Printers 90
Annexure 11 Data Sheet – Hard Copy Unit 91
Annexure 12 Data Sheet – Hard wired Console 92
Annexure 13 Data Sheet – Foreign Device Interface 93
Annexure 14 Data Sheet – Hard wired Instruments 94
Annexure 15 Data Sheet – Intrinsic Safety Barriers 96
Annexure 16 Data Sheet – Console, Panels, Cabinet & Accessories 97
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1.1 This specification describes the essential considerations in the selection,
installation, calibration, testing and commissioning of Distributed Control System
(DCS) to ensure reliable, effective and optimum control and monitoring of the
process on the platforms as mentioned in the Basic Bid Work.
1.2 The Contractor shall be responsible for the design, system engineering,
procurement, packing, calibration, testing at factory / yard and offshore, shipment
to yard and offshore site, installation and commissioning at site of the Distributed
Control System (DCS) as per this document.
b) Basic Bid Work
NIL
3.1 The DCS shall include all the sub-systems described in this specification,
Engineering software, and all necessary interfaces for maintenance modifications,
monitoring, testing and troubleshooting.
3.2 The scope of supply shall also include commissioning spares and two years’ spares
as required by clause 3.6.4.8 of Instrumentation Design Criteria, and as per clause
____ of this document.
4.0 DISTRIBUTED CONTROL SYSTEM (DCS):
4.1 DEFINITIONS & ABBREVIATIONS:
The various terms used in this specification are defined as follows:
4.1.1 Distributed Control System:
The class of instrumentation which in addition to executing the stated control
functions also permits transmission of control, measurement and operating
information to and from a single or a plurality of user specified locations connected
via a communication sub-system.
4.1.2 Accessible:
A system feature that is viewable by and interactive with the operator and allows
the operator to perform user permissible control action e.g. set point change, auto-
manual transfers or on-off actions.
4.1.3 Assignable:
“Assignable” shall imply system feature that permits an operator to direct a signal
from one device to another without the need for change in wiring, either by means
of switches or via keyboard command to the system.
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4.1.4 Configurable:
A system feature that permits selection through entry of keyboard commands of
basic structure and characteristics of a device or system, such as control algorithm,
display format or I/O termination.
4.1.5 I/O:
I/O shall represent Input/Output with respect to process/operator.
4.1.6 System Size:
System size shall be defined as maximum number of process inputs or tags those
can be connected to the system and viewable from any one of the CRT / LCD TFT
MONITOR of an operating console in all hierarchical displays without changing
the configuration or without operator interaction considering.
a) All inputs as close loops
b) All inputs as open loops
4.1.7 Operator Console:
Operator console is the main operator's interface device via which operator can
view the plant and can give instructions to peripherals to execute commands, and
can configure and maintain the system to the extent it is permitted.
4.1.8 Engineering Console:
Engineering console shall be the engineer's main interface device via which
engineer can view the plant, give instructions to peripherals to execute commands,
and can configure and maintain the system.
4.1.9 Switch Over Time:
Time required for a back up instrument to come on-line automatically in case of
the failure of the main instrument.
4.1.10 Loop Integrity:
A system shall be said to have loop integrity if the failure of one component in the
system/sub-system does not affect more than one loop.
4.1.11 Interchangeability:
System/sub-systems shall be said to have full interchangeability if the functions
and information available on one system/sub-system shall also be available on the
other totality.
4.1.12 User’s Memory:
Free memory space available in addition to the memory required for system
configurations and other system related functions which a user can utilize to
execute his own programs for plant calculations, process optimization or MIS (line
free formatting of certain logs). The programs shall normally be written in high-
level language like FORTRAN, BASIC etc.
4.1.13 Redundancy:
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A system component shall be termed as redundant if it takes over the operation

automatically on the failure of the main component without causing any
interruption in the system functioning and upsetting the process. The repaired or
replaced device shall be brought in-line only through operator action.
4.1.14 Scan Time:
Scan time for different sub-system shall be defined as follows:
a) Close-Loops:
Scan time for a close-loops shall be defined as the cycle time taken by
controller to read a process input, perform control calculations, and update
control output for all the loops configured within the controllers.
b) Open-Loops:
Scan time for an open loop shall be defined as the cycle time required by the
data acquisition sub-system to read a process input and perform computation of
all the open loops configured within the data acquisition sub-system.
4.1.15 Data Base:
Database shall be defined as the information stored temporarily or permanently in
the system to meet all its functional requirements.
4.1.16 Bus-Degradation:
Bus-degradation shall be defined as a change in the system performance from the
specified one while loading the communication sub-system from 10 through 100
percent.
4.1.17 Event:
An event shall be defined as any action like change of set point, change of control
mode, start/stop of motor, open/close of shut down valves, alarm acknowledge etc.
performed by the operator or taking place in auto mode.
4.1.18 Real Time Trend:
Real time trend shall be defined as a continuously progressing graphical record
showing continuously updated parameter with most recent value and a past record
of minimum of 10 minutes without depressing any additional key for moving
backward in time.
4.1.19 Call Up Time:
Call up time shall be defined as the time taken by the system to display a particular
display/data on the CRT / LCD TFT MONITOR after getting the corresponding
command from the operator.
4.1.20 Display Update Rate:
Display update rate shall be defined as the rate at which the information present at
the system input terminal is getting updated on the current display on the CRT /
LCD TFT MONITOR.
4.1.21 Central Level:
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Operator consoles and Engineering console shall be referred as Central Level.

4.1.22 Local Level:
All those sub-systems, which directly interface with field devices, shall be referred
to as local level.
4.2 GENERAL:
4.2.1 System shall be microprocessor based having functional distribution and data base
distribution, Sub-system wise. This system shall also have networking capability
with other systems distributed geographically in the various units as applicable.
4.2.2 The system shall be designed fault avoidant as a minimum by selecting high-grade
components of proven quality and proper design of system electronics. Required
redundancy shall be provided to ensure system availability and reliability. The
system proposed shall have a high MTBF and low MTTR.
4.2.3 The system shall be of modular construction with provision for future
expandability by addition of modules. The type of modules shall be kept to the
minimum possible in order to have interchangeability and low inventory.
4.2.4 Galvanic isolation shall be provided for all field signals. Isolation shall also be
provided between Engineering/Operator Console/PLC programming terminal and
related sub-systems connected to it, if there is any possibility of high voltage from
CRT / LCD TFT MONITOR being transmitted to the sub-systems.
4.2.5 Use Of Standard Products:
4.2.5.1 The system shall be composed of standard hardware, system software and
firmware (those published in standard product literature, which can be configured
to meet the stated requirements). No prototype system or systems of experimental
nature will be accepted.
4.2.5.2 The standard operating system software shall not require modification to meet any
of the project requirements.
4.2.6 Distributed / Open Architecture:
4.2.6.1 The system shall be distributed computer process control system. It shall permit
data acquisition and control functions to be performed at remote locations (for
example, the other platforms) while providing the capability to monitor and control
distributed functions from any of several operator consoles.
4.2.6.2 The DCS shall be based on “open” system architecture, maximizing the use of
general purpose computing hardware and software products and having inherent
capabilities to integrate and exchange information with other brand software
packages, system devices and platforms via industry standard communications,
platforms and protocols. The Open Systems Foundation X-Windows/Motif/
OpenLook graphical interface is one example of a typical standard.
4.2.7 System software:
4.2.7.1 The system software shall be governed by the operating system running in a real
time mode and shall be able to meet all functional requirements. Any other
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standard /special software package, if available with the package, shall be offered,
with a description of its capabilities.
4.2.8 Software Protection:
4.2.8.1 Software locking mechanisms that restrict users from copying (for backup
purposes) software source or compiled executable code from storage media shall
not be used. In addition, these mechanisms shall not be used to restrict users from
booting up. This means that no “key disks” or password protection shall be
required to use software that is supplied as part of the system.
4.2.9 Software Revision Levels:
4.2.9.1 Standard system operating software delivered to the installation site shall be the
most recent field proven revision available at the beginning of the pre-factory
acceptance test (pre-FAT) applicable to the system hardware. Unless otherwise
directed by the Company, standard system operating software provided at time of
placement of contract or purchase order shall be upgraded to pre-FAT revision
prior to the start of pre-FAT.
4.2.9.2 Third party software shall be the most recent field-proven revision available that is
applicable to system hardware at the time of the placement of contract or order.
4.2.9.3 The system shall allow for upgrading of operating software on all redundant
modules of the system without shutting down the process, losing the operator
interface to the process or losing any basic control functions. If online control is
interrupted, control outputs shall be frozen for no longer than eight seconds.
Testing of this function shall be part of the acceptance testing.
4.2.9.4 There shall be a detailed, step-by-step procedure manual to accomplish all software
upgrades during and after procurement of the system.
4.2.9.5 The upgrade procedure shall allow different releases of software to coexist on
communications network and on different units of redundant modules during the
upgrade implementation. Otherwise the Contractor shall provide assistance to
ensure a safe and secure migration. The Contractor shall ensure compatibility with
all the Contractor’s existing software before the upgrade is performed.
4.2.9.6 The system shall have all necessary software to translate any system data to make
it compatible with the new software release.
4.2.9.7 Application code shall not require modifications to run under new releases of
standard software. If modifications are required, supporting documentation shall
be provided.
4.2.9.8 The system shall provide an indication of differences in system operating software
between redundant units.
4.2.9.9 The Contractor shall make no software revisions or upgrades after completion of
the FAT.
4.2.10 On-Line Card Changeover:
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4.2.10.1 All printed circuit boards shall be able to be removed or installed while the system
is operating without causing hardware damage or system errors
4.2.11 Third-Party Equipment:
4.2.11.1 All third party equipment provided as part of the system shall be currently
available for sale from the original supplier at time of placement of the contract or
order and shall be also available for next five years. All such equipment shall meet
the same standards applied to the original equipment and meet all applicable
project specifications and standards referenced in this specification.
4.2.12 ELECTRICAL REQUIREMENTS:
4.2.12 The electrical requirements for the DCS shall in general be as per clause no.
3.6.4.2.2 and 3.6.4.3 of Instrumentation Design Criteria. In addition to the
referenced clause, the following shall also be taken care of.
4.2.13 External Power Supply:
4.2.13.1 The DCS shall preferably use supplies from 24VDC battery systems, to reduce the
UPS requirements. AC voltage for illumination / lighting shall be 240 V, 50 Hz.
4.2.13.2 Power supply shall be made available at one point. Power supplies shall be
arranged so that a single power fault in any instrumentation branch of the system
shall not cause a trip of the entire system. Each consumer shall be provided with a
separate switch and fuse for isolation and protection of the system.
4.2.13.3 Each transmitter shall preferably be powered with individual power supply.
However when several transmitters are powered by a common DC source, each
power supply branch shall have a separate switch and fuse. The distribution
network shall be designed in such a way that overload in any branch shall not trip
the main power supply. Enough redundant power supplies/battery banks shall be
provided which shall take over automatically in case of main common power
source failure. Redundant floating power supply shall be provided for all sub-
systems, cabinet-wise.
4.2.13.4 The Contractor shall provide all necessary electrical equipment to condition and
distribute AC and DC power to the DCS including: AC UPS, DC batteries and
chargers, distribution switchboards, circuit breakers fuses, terminals and the like.
4.2.13.5 If power is sourced from the onsite generating plant, then the DCS equipment shall
be able to operate with power quality and fluctuations typical of such sources.
4.2.14 AC Power Conditioning and Distribution:
4.2.14.1 The Contractor shall provide a UPS system, where required, for each DCS
location, including UPS batteries and chargers that will support DCS operation
following loss of external main power to the system. Equipment shall be sized for
a nominal 2 hours, which will be confirmed by the Contractor following project
risk assessments and HAZOP. The Contractor shall provide detailed calculations
to support equipment sizing, including deratings for battery age and other effects.
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4.2.14.2 Each device with a direct AC power input shall be protected by a circuit breaker or
fuse.
4.2.14.3 The DCS power supply shall be 110 AC ± 10%, 50 Hz ± 3% or 60 Hz or 24VDC
with maximum static transfer time of 5 msec or better. In line AC transient
protectors shall be provided to protect all DCS power supplies.
4.2.14.4 DCS systems shall be grounded in accordance with the supplier’s
recommendations. Transient suppressors shall be grounded by the shortest
possible straight path to facility ground.
4.2.14.5 Circuit protection shall be properly sized and coordinated to protect equipment and
prevent shutdown of the whole DCS system by confining tripping to the affected
circuit.
4.2.14.6 DCS power supplies shall be designed to operate at less than 80 percent capacity.
4.2.15 DC Electrical Power:

4.2.15.1 The Contractor shall provide all necessary DC power distribution power
conditioning, power supplies bus bars and power wiring etc.
4.2.15.2 Battery chargers shall be able to safely allow operation of the DCS system when
batteries are removed for maintenance.
4.2.15.3 24VDC DCS systems shall operate properly with voltages within the range 19-30
VDC, and may be supplied directly from batteries.
4.2.15.4 Power to each termination board shall be fused or otherwise protected to prevent a
fault in one board from affecting other boards. Circuit protection shall be properly
sized and coordinated to protect equipment and prevent shutdown of the whole
DCS system by confining tripping to the affected circuit.
4.2.15.5 Redundant power supplies shall be sized and connected so that failure of one
power supply shall not effect operation of the system.
4.2.15.6 Failure of any power supply shall cause an alarm.
4.2.15.7 Each power supply shall be connected to an independent circuit in the AC power
distribution panel.
4.2.16 Earthing:
4.2.16.1 Each panel cabinet, console and other equipment on control room shall be provided
with an earthing lug. All these lugs shall be properly secured to the AC mains
earthing bus.
4.2.16.2 All circuit grounds of electronic instruments, shields and drain wires of signal
cables shall be connected to instrument ground bus, which is electrically isolated
from the AC mains earthing bus. This bus shall be typically 25 mm wide and 6
mm thick of copper. The instrument ground bus is connected to independent
instrument system ground buses through insulated wires.
4.2.16.3 All Zener barriers, if used, shall be securely grounded. The Zener barrier ground
wire shall be capable of carrying a maximum fault level current of 0.5 ampere at
250V rms per barrier.
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4.2.16.4 Cable shields of thermocouple extension cables for grounded junction

thermocouples shall not be grounded in the control room.
4.2.16.5 The UPS for the DCS and other systems may be grounded / ungrounded / isolated.
4.2.16.6 The system earth and electrical earth shall be separated and shall have resistance
less than 10 ohms.
4.3 SYSTEM REQUIREMENT:
4.3.1 GENERAL:
4.3.1.1 The system, as a minimum shall meet the following requirements without the
supervisory computer:
a) Control
b) Data Acquisition & monitoring
c) Alarming
d) Logging & report generation
e) Historical data storage
f) Trending
g) System shall have some free memory space available for the user and CPU
shall have the additional capability to perform advance control functions,
process optimization programs or generate management reports as required.
h) Plant process and safety shutdown shall be independently performed by
programmable logic controller, if specified in the Basic Bid Work. (The
specification of this PLC shall be as per MR/OD/INST/FS/C101).
4.3.1.2 The system when specified along with a supervisory computer, shall meet the
following requirements in addition to those specified in para 4.4.1.1 above.
a) Advanced Control
b) Unit and plant optimization
c) Management information service reports.
4.3.2 SYSTEM OVERVIEW:
The DCS shall comprise of the following as a minimum:
• Cabinets containing field cable marshalling, terminations, cross-patching and
IS isolations
• Cabinets containing I/O modules, processors and network communications
interfaces
• Operator / Engineering Station which will mainly be used for maintenance
• Power conditioning and distribution equipment, including UPS
• Required software to enable effective control and monitoring
• Hard wired instruments as per clause 4.4.11 of this document and as per the
Scope of Work.
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The system configuration shall in general consist of the following major sub-
systems. The exact types of sub-systems for a particular facility shall be as per the
Basic Bid Work – Instrumentation.
4.3.2.1 Controller Sub System:
Controller sub-system shall interface with field instrumentation like transmitters
and final control elements to control process parameters like flow, temperature,
level etc. The sub-system shall include a comprehensive set of control algorithms
and auxiliaries to provide close loop control and data monitoring capability of the
system.
4.3.2.2 Data Acquisition Sub System:
Data acquisition sub-system shall interface with various types of open loop process
inputs, analog as well as discrete for process monitoring.
Note: The Controller and Data Acquisition Sub Systems may be combined or
may be offered separate.
4.3.2.3 Input / Output System for Data Acquisition and Controller Sub Systems:
The input / output system shall be capable of accepting analog and digital inputs
and generating analog and digital outputs. This system shall be similar for both the
Data Acquisition Sub System as well as the Controller Sub System.
4.3.2.4 Operator Interface Sub System:
Operator interface sub-system shall consist of one or more operator consoles for
monitoring and controlling process parameters and performing other process
related functions.
4.3.2.5 Engineer Interface Sub System:
Engineer interface sub-system shall consist of an engineering console primarily for
tuning, configuring and maintaining the system.
4.3.2.6 Communication Sub System:
Communication sub-system interconnects various sub-systems over which they
can communicate with each other to meet all functional requirements.
4.3.2.7 Supervisory Computer Sub System:
Supervisory computer, when specified, shall be employed for providing
supervisory level control, plant and unit optimization and other computer baed
plant management capabilities.
4.3.2.8 Foreign Device Interface:
Foreign Device like Gas Chromatographs, Analyzer systems, Gas turbine systems
etc. when specified shall communicate with other subsystems over the
communication sub system for plant monitoring and control using foreign device
interface.
4.3.2.9 Hardwired Instrumentation:
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Hardwired instrumentation shall be provided as a back up to the distributed control

system for critical process parameters.
4.3.2.10 Barriers:
Barriers shall be provided to ensure an intrinsically safe system. The IS barriers
shall preferably be of isolating type and shall be located in panels adjacent to the
I/O modules. The barriers shall ensure that the system as a whole is intrinsically
safe and shall be based on entity concept. The Barriers shall be located in a safe
area and shall have grounding through bus bar. The maximum fault voltage shall
be 250 V rms. Approval certificate from recognized statutory body shall be
provided for the IS barriers. The barriers shall be suitable for the cable parameters.
4.3.3 CONTROLLER SUB SYSTEM:
4.3.3.1 The control function of the system shall be executed by microprocessor based
single loop or multi-loop controller consisting of I/O ports and a set of algorithms,
which are easily field configurable using user-friendly software.
4.3.3.2 Controller shall be capable of accepting process signals from various process
sensors and switches preferably without requiring external or auxiliary signal
conditioning devices. The system inputs shall include 4-20mA, DC
thermocouples, resistance temperature detector (RTD) and discrete inputs as a
minimum, apart from others as specified in the job specifications.
4.3.3.3 The controller shall be able to generate 4-20mA DC current signals for analog
outputs and potential free contacts for the discrete outputs as a minimum, apart
from others as specified in the job specifications.
4.3.3.4 All controller racks shall be provided with redundant floating power supply.
4.3.3.5 It shall be possible to change set point, tuning constant, operating mode, controller
configuration from the central level i.e. operator's interface keyboard and
engineer's interface keyboard.
4.3.3.6 The controller sub-system shall be capable of maintaining loop integrity by
providing one-to-one back-up controller, with automatic transfer switching.
Further redundancy requirements shall be as per clause no. 4.4.13 of this
document.
4.3.3.7 The Input / Output requirements for the Controller sub system shall be as per
clause 4.4.5 of this document.
4.3.3.8 The Controller sub-system shall in general be used for Regulatory Control
functions as given in para 4.4.3.9 below. The controller sub-system be capable of
executing Sequential Control functions as given in para 4.4.3.9 below. The
Controller sub-system shall also be capable of performing Logic Control Functions
and Advanced Control Functions as given in para 4.4.3.10 and 4.4.3.11 below.
4.3.3.9 REGULATORY CONTROL:
The system shall include as standard the functions listed in the following sections
4.3.3.9.1 Algorithms:
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4.3.3.9.1.1 Standard software algorithms in engineering units, able to perform regulatory

control functions.
4.3.3.9.1.2 Control and data acquisition algorithms for linearizing, square root, ISA
thermocouple and 100 ohm platinum RTD signals, time based filtering, conversion
of pulse input to rate, tantalization, flow computation with temperature and
pressure compensation.
4.3.3.9.1.3 Input filtering signal conditioning shall be performed before alarming check and
any control calculations.
4.3.3.9.1.4 Computational algorithms for math functions such as addition, subtraction,
multiplication, division, comparison, exponential polynomial, square root,
logarithms, differentiation, integration, accumulation and fifth order polynomial.
4.3.3.9.1.5 Computational algorithms for gas flow, including AGA 3,8 and 9.
4.3.3.9.1.6 Logical functions (and or, not, nor, exclusive or, exclusive nor)
4.3.3.9.1.7 Ramp generation, lead lag, dead time compensation, high/low select median select
time average, signal selector switch, limiter functions, auto ranging for dual
transmitter, override, etc.
4.3.3.9.1.8 Control algorithms shall include PID, PI, PD, P only, external feedback, PID based
on error, PID with anti-reset windup, auto/manual with bias control, ratio control,
integral only, PID with nonlinear gain and gap action
4.3.3.9.1.9 Output algorithms for providing linear inputs and linear outputs with clamping
(high and low restricted)
4.3.3.9.1.10 Output support for both positional and incremental control output modes.
4.3.3.9.2 Input Scanning:
4.3.3.9.2.1 Regulatory controllers shall scan inputs at a sufficient frequency to provide freshly
sampled data for each control loop execution cycle, as described below.
4.3.3.9.2.2 Control Loop Execution Cycle:
The system shall have automatic phase load leveling and warning messages for
pending CPU overloads.
4.3.3.9.2.3 Control Loop Scan Time:
It shall be possible to configure execution frequency of each control loop. The

control loop scan time shall be 500 msec or better.
4.3.3.9.3 Fault Handling:
4.3.3.9.3.1 The following invalid data capabilities shall be provided:
• Invalid or out-of-range value status shall be generated for inputs and

calculated variables.
• Propagation of invalid value status through control schemes.
• Inhibition of propagation of invalid value status
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• Use of invalid value status as a logical input to effect control algorithm

changes
• All control algorithms shall have a configurable option to continue
operating with the last valid information in the event of communications
subsystem failure. If this option is selected, the return to normal shall also
be bumpless.
• It shall be possible to configure the final output of a process controller to
maintain its current position or be driven to zero upon input or processor
failure. For redundant systems, this action shall only take place upon
failure of both input or processor modules
4.3.3.9.4 Control Modes:
4.3.3.9.4.1 It shall be possible to configure any control loop for automatic bumpless and
automatic transfer between any control modes.
4.3.3.9.4.2 It shall be possible to put any individual control loop into manual mode. It shall
be possible for an operator to manipulate output of a control loop in manual mode.
4.3.3.9.4.3 An output signal from a field output module shall change within one second from
the last operator action commanding the change.
4.3.3.9.4.4 For cascade control, it shall be possible to configure remote set points from other
regulatory controllers or other DCS modules. All control blocks, which can accept
a setpoint, shall be capable of being switched between local set point (operator
entered) and remote set point.
4.3.3.9.4.5 In cascade loops, the primary controller shall be able to track the set point of the
secondary controller when the secondary controller is not operating in cascade
mode. For cascade loops with two loops in separate modules, signals to inner
controller shall be available within one second of the value calculated in the outer
controller. For cascade loops executed in the same module, this time shall be one
half second.
4.3.3.9.4.6 For cascade control loop, it shall be possible to configure the outer controller to
have its output clamped to the inner algorithm’s setpoint limits. The system shall
have interlocks to prevent a controller from being put into the cascade mode if
inner is in manual.
4.3.3.9.4.7 Control blocks shall be capable of performing automatic mode switching based
on external or internal logic inputs. Mode switching shall include:
• Auto/manual switching
• Local/remote setpoint switching (open/close cascade)
• Anti-reset windup capability shall be provided
• Status shall be propagated from secondary controllers to higher level
controllers.
• It shall prevent windup at the secondary controller.
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• It shall allow immediate control action in the opposite direction

4.3.3.9.5 Initialization:
4.3.3.9.5.1 Variables that are being initialized (control block turned on, returning to normal
from invalid state) shall be subject to the following:
• The system shall suppress nuisance alarms created by first calculation of
the algorithm
• Calculations involving time based data, such as filters and rates of changes,
shall be reset
4.3.3.9.5.2 Control blocks shall offer the option of either initializing a setpoint to the input
value or maintaining last setpoint upon algorithm initialization. Configured
initialization shall occur when a block mode changed from manual to automatic or
from off to on.
4.3.3.9.6 Alarms:
4.3.3.9.6.1 Inputs shall be provided with high warning (HIGH) low warning (LOW), high
absolute (HIGH_HIGH) low absolute (LOW-LOW) rate of change, input-out-of-
range high/failure and input-out-of-range low/failure.
4.3.3.9.6.2 Control and computational points shall be provided with high/low deviation of
process variable from set point warning, high output and low output.
4.3.3.9.6.3 To minimize analogue input “chattering” (a point going in and out of an alarm
condition rapidly), there shall be configurable dead band parameters, on a per
alarm basis.
4.3.3.9.6.4 Contact input change of state shall provide an alarm condition.
4.3.3.9.7 Precision:
4.3.3.9.7.1 Algorithm calculations shall be performed in floating-point engineering units or

other such equivalent methods that do not require scaling.
4.3.3.9.7.2 Analogue database values shall be stored and processed to at least five significant
decimal digit precision.
4.3.3.9.7.3 The database shall be capable of maintaining analogue data values of a magnitude
10±8
4.3.3.10 SEQUENTIAL CONTROL:
4.3.3.10.1 Sequence Language:
4.3.3.10.1.1 A structured high-level programming language and / or sequence function table

shall be available to implement sequential control. This language shall provide the
necessary facilities for real-time control of sequential process. It shall have access
to process control and other database information.
4.3.3.10.1.2 It shall be possible to modify logic while other sequences are active.
4.3.3.10.1.3 Sequential control and batch control shall conform to ISA S88.01
4.3.3.10.2 Sequential Functions:
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The following types of sequential functions shall be provided:

• Relational expressions such as equal to, not equal to, less than, less than or
equal, greater than and greater than or equal
• Mathematical functions such as addition, subtraction, multiplication,
division, exponential (whole and fractional) and square root
• Timer functions such as output true after preset delay and output false after
preset delay
• Counter functions such as count up and count down
• Logical expressions such as and or, not, exclusive or and single bit memory
elements (flip / flop)
4.3.3.11 LOGIC CONTROL FUNCTIONS:
4.3.3.11.1 Logic control capabilities like those available in PLCs shall be provided. Logic
functions shall be implemented by interconnecting logic blocks or algorithms.
4.3.3.11.2 Other functions shall be included for comparison of signals, flip-flop, on and off
delays, timer, counter and pulse generator.
4.3.3.11.3 Input to logic algorithms shall include analogue inputs, discrete inputs, any alarm
state, display points or outputs of other logic algorithms. Outputs from logic
algorithms shall be used to drive discrete outputs, inputs of other logic algorithms,
modes of controller algorithms, discrete display points, alarms or switch positions.
4.3.3.12 ADVANCED CONTROL DEVELOPMENT:
4.3.3.12.1 The DCS shall provide an environment that facilitates development of advanced
control applications both within and external to the DCS. A menu-driven interface
to upper level computers for data exchange, which allows an engineer to install and
test advanced control programs and control functions such as scheduling and audit
tools, is highly desirable.
4.3.4 DATA ACQUISITION SUB SYSTEM:
4.3.4.1 Data acquisition sub-system shall be capable of accepting analog and discrete
inputs. The inputs shall include 4-20mA DC, thermocouples, resistance
temperature detector (RTD), pulse inputs from flow meters and discrete contacts,
as a minimum.
4.3.4.2 The system shall be capable of processing linear and non-linear analog inputs,
linearization and compensation for thermocouples, linearization of RTD inputs,
square root extension for flow inputs.
4.3.4.3 The system shall be capable of providing analog and digital outputs. The analog
outputs shall be 4 to 20 mA DC unless otherwise specified.
4.3.4.4 All data acquisition cabinets shall be provided with redundant floating power
supply.
4.3.4.5 The Input / Output requirements for the Data Acquisition sub system shall be as
per clause 4.4.5 of this document.
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4.3.5 INPUT / OUTPUT SYSTEM FOR DATA ACQUISITION & CONTROLLER

SUB SYSTEMS:
4.3.5.1 All inputs shall be filtered and isolated to eliminate noise and provide electrical
input isolation.
4.3.5.2 Common mode rejection ratios of 60 dB or better from 0 to 50Hz and normal mode
rejection ratio of 30dB or better at 50Hz are required.
4.3.5.3 Photo-optic isolators or inductive surge protectors shall be provided on all signal
leads into and out of each equipment rack and panel in the system to prevent
damage from transient and inductive surge isolation shall be at least equivalent to a
maximum of either power supply to the I/O modules in the rack or power supply to
the field inputs/outputs. Inductive surge protectors shall be used on all power leads
into each equipment rack and panel in the system.
4.3.5.4 Interposing relays will be provided in equipment supplied by others, to ensure that
no 240 or 110 volts I/O circuits enter the DCS cabinets, excepting power supply
circuits.
4.3.5.5 Isolated relay outputs shall be provided for all other discrete output requirements.
Outputs that drive inductive loads shall be equipped with external “fly-back diode
circuits” designed into the output module. Interposing relays are also acceptable.
4.3.5.6 I/O points shall be logically grouped and appropriately, segregated between I/O
modules to build in system flexibility.
4.3.5.7 I/O designs shall be modular with keyed quick-connect wiring terminations that
allow replacement modules without disturbing field wiring.
4.3.5.8 I/O modules shall be provided with status LED’s for each discrete I/O and module
“health” status LED(s) for analog and specialized I/O.
4.3.5.9 All discrete I/O shall be optically isolated and provide minimum of 1500W
channel-to-channel isolation. Ratings for isolated analog I/O and galvanically
separate circuits shall be 300V minimum channel-to-chassis and channel-to-
channel.
4.3.5.10 I/O circuit designs shall be based on 24VDC.
4.3.5.11 All I/O shall be protected from inadvertent reverse polarity connection.
4.3.5.12 All I/O shall be electrically isolated from the system’s internal power supply.
4.3.5.13 All I/O modules shall be designed to prevent inadvertent insertion into the wrong
side.
4.3.5.14 Minimum design requirement for analog A/D converters is 12 bits. The load
driving capability of I/O card shall be 750 ohms. The I/O cards shall have
retentive memory.
4.3.5.15 All output circuits shall be individually fused with fuse-status indication.
4.3.5.16 All input circuits shall be fuse-protected to minimize impact on the control system
when there is an input short circuit. Individual fusing of each input is required if
analysis of logical grouping of inputs is unclear.
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4.3.5.17 Interposing relays shall be grouped into AC and DC in different racks. AC

switching 110V and above shall be identified indicating the AC voltage hazard.
4.3.5.18 For intrinsically safe systems, IS barriers will be located in panels adjacent to I/O
modules. Plug-in modular back plane type IS isolating barrier assemblies are
preferred.
4.3.5.19 One-to-one redundancy shall be provided for all I/O modules catering to closed
loops. All I/O modules shall have redundant power supply. Further redundancy
requirements shall be as per clause no. 4.4.13 of this document.
4.3.5.20 All the open loop inputs shall be scanned at maximum of 1-second interval.
4.3.6 OPERATOR INTERFACE SUB SYSTEM:
4.3.6.1 The operator interface sub-system shall provide the centralized information to the
plant Operator.
4.3.6.2 The operator interface sub-system shall consist of the following as a minimum:
• Operator Console with all accessories such as CRT / LCD TFT Monitor,
HDD, FDD, CD ROM drive and communication devices
• Printers
4.3.6.3 Failure or disconnection of any operator console shall not affect the operation of
any other device on the communication system.
Unless otherwise specified in the scope of work or in ICS functional specifications,
Console monitors shall be supplied as specified here in this specification.
4.3.6.4 Operator Console:
4.3.6.4.1 Each Operator Console shall consist of three identical colour CRT / LCD TFT
Monitor and three identical keyboards as a minimum, unless otherwise specified in
the Basic Bid Work. The CRT / LCD TFT Monitor and the keyboards shall be
driven by independent electronics or common redundant electronics.
4.3.6.4.2 Each operator console as a minimum shall also have one logging printer, one alarm
& event printer and a hardcopy unit.
4.3.6.4.3 In case the CRT / LCD TFT Monitor are driven by common electronics, the
operation of peripherals shall remain unaffected by the failure of one of the
electronics.
4.3.6.4.4 Each console shall be connected to the dual redundant data highway and shall auto-
switch to the standby data highway when the duty highway fails.
4.3.6.4.5 The Operator Consoles shall use ergonomically acceptable and consistent
principles, guidelines and standards. Each CRT / LCD TFT Monitor shall be
suitable for use by a seated operator, and shall allow easy viewing of all monitor
displays from a wide angle, and shall provide easy access for operation of all
keyboards and other controls. PC based, open system hardware is preferred.
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4.3.6.4.6 The CRT / LCD TFT Monitor shall have touch screen facility if it is a standard
feature available in the manufacturer range of DCS. However start/stop from
‘touch screen’ shall be disabled under normal operator functions.
4.3.6.4.7 The display requirements of the operator console shall be as per clause no.
4.4.6.4.11 given below.
4.3.6.4.8 All the functions of CRT / LCD TFT Monitor and keyboards of an operator
console shall be fully interchangeable. Further any change made in the database of
one CRT / LCD TFT Monitor shall automatically update the database of other
CRT / LCD TFT Monitor of the same console.
4.3.6.4.9 The real time clock of each operator console shall be crystal controlled one, which
shall be independent of line frequency. All the real time clocks in the system be
synchronized shall with each other.
4.3.6.4.10 The operator console / workstation shall use 24 V DC power supplies.
4.3.6.4.11 Each CRT / LCD TFT Monitor shall have an industrial high-resolution, minimum
21" (Twenty One inch) color screen capable of displaying alphanumeric & graphic
displays. The displays shall provide as a minimum 256-colours, including black
and white. Distinct & Multiple colors shall be used to distinguish parameters such
as control, information, process and alarms etc.
4.3.6.4.12 Key board:
4.3.6.4.12.1 Alphanumeric keys shall be arranged as “QWERTY” keyboards. A trackball

pointing device shall be provided with the keyboard.
4.3.6.4.12.2 Keyboard shall be self explanatory, easy to operate and shall meet all the
functions to configure, operate and maintain the system. User-friendly software
shall be used for operation, configuration and maintenance of system.
4.3.6.4.12.3 Keyboard shall preferably be touch sensitive membrane type. Each keyboard
entry shall be registered with an audio beep. The keyboard shall be dustproof and
waterproof.
4.3.6.4.12.4 It shall not be possible to override any process variable or digital status from
operator keyboard.
4.3.6.4.12.5 Each keyboard shall have a set of dual function user configurable keys. These
keys shall be configured to access important pages in single keystroke. Also keys
shall have LEDs, which flash on pre- configured alarm conditions.
4.3.6.4.12.6 The operator, as a minimum shall have access to the following through the
operator key board at all times:
a) Selection of all the displays including the direct selection of loop in alarm,
page turning facility, overview, group view and loop view selection etc.
b) Selection of loop for operation.
c) To acknowledge alarms as and when they are annunciated on the operator
console.
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d) Facility to enter any changed parameter like set point, manipulated variable,
digital commands and to cancel any wrong entry while making such change.
e) Facility for easy positioning of cursor for the selection of any parameter.
f) Selection of hardcopy printout, logging printout, alarm history printout and
assignable trend recorder points.
g) Auto / Manual / Cascade / Computer mode changeover of each controller
4.3.6.4.12.7 The keyboard shall be provided with function keys, each of which shall be
assigned to a plant area. Any alarm within that area shall cause an LED in the key
to flash. Pressing the key at any time shall immediately select the relevant graphic
display.
4.3.6.4.13 The operator console shall be capable of performing the following functions as a
minimum:
a) Indication of all analog and digital process variables of control loops, open
loops and all loop related parameters.
b) Manipulation of control loops including changing set point, mode, output,
configuration, tuning and computational constants.
c) Alarm displays and annunciation
d) Graphic displays and status indication
e) Logging, trending and archiving including historical trend recording.
f) Trend recording on assignable trend recorders.
g) Self-diagnostic screens.
h) Data storage and report generation software
i) Access to Emergency Shutdown (ESD) and Fire and Gas (F&G) system
j) Activation and alarming of start-up process bypasses in the ESD system
k) Access for maintenance, including provision for maintenance bypass and
corresponding “alert alarm” logging
l) Access for engineering, if the same workstation is used as both Operator as
well as Engineering Console: This shall be achieved via an appropriate level of
security access as stated in clause no. 4.4.7.2.
m) Simple data exchange with Microsoft applications including Excel and Access
n) Auto boot up by each operator station and auto boot up on power-up
4.3.6.5 Printers:
4.3.6.5.1 Two laser printers shall be provided with each of the Operator Console system –
one colour printer and one black-and-white printer.
4.3.6.5.2 Each operator and engineering console shall have access to all the printers for
printing of alarm logs, event logs, standard and special reports, screen dumps and
other information.
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4.3.6.5.3 The printer shall be capable of handling atleast 128 ASCII character types and
shall have a minimum printing speed of 300 lines / minute. The minimum number
of print columns shall be 132. The paper width shall be 381 mm and shall be
continuous fanfold type. The number of copies shall be three (3), inclusive of the
original. An acoustic cover shall be provided for each printer.
4.3.6.6 Displays:
4.3.6.6.1 The minimum number of display characters shall be 80 x 40 per line. The
minimum number of characters shall be 96 ASCII. The minimum number of
character construction shall be 5 x 7 dots and the construction pattern shall be 7 x 8
dots.
4.3.6.6.2 Each CRT / LCD TFT MONITOR screen shall be able to display the full
alphanumeric tag number of a process variable. A minimum of nine (9) digits shall
be required for the tag number and 15 digits for the process description as per
example given below:
Tag No. Description
12PIC 1401 12C201 PRESSURE
4.3.6.6.3 Display Refresh Times: Displays and graphics that show real-time data shall be
automatically updated when the display or graphic is on a screen. Updates shall
not require operator initiation. CRT / LCD TFT MONITOR data display update
rate shall not be more than two (2) seconds. During this period, changes in state of
discrete points shall be updated immediately they occur. This requirement applies
to both data displayed alphanumerically and symbolically (shape changes, colour
changes, etc.). Update frequency shall be configurable. For systems that update
data upon change of data, data shall be updated when the change exceeds a
configurable value between 0.1 and 0.2 percent of span. It shall be possible to set
the minimum change to zero. Call-up time for all types of displays shall not
exceed 1 second.
4.3.6.6.4 Display Response: Initial display response shall occur within one second of an
operator’s request. Display call-up shall require no more than two operator
keystrokes. All displays, including all updated fields, shall be completed, within
four seconds of an operator’s request. User interaction with the display shall be
possible within three seconds of request. If the update interval is configured at a
faster rate, interaction intervals shall match. Multipage displays shall respond to
page change requests with a fully operational new page within one second.
4.3.6.6.5 Operators shall be able to easily access specific displays and graphics by pressing
dedicated function keys, selecting from a list of displays in directories or menus or
by typing a display name.
4.3.6.6.6 It shall be possible to move between related displays and graphics of different
detail levels or of the same detail level with a maximum of two operator actions.
4.3.6.6.7 Multiple windowing of graphics shall be possible.
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4.3.6.6.8 Faceplates shall be provided as graphic elements or as separate displays. It shall be

possible to configure faceplates to appear in any graphic in which the associated
point is displayed. It shall be possible to access the faceplate display for any point
on a graphic display with a maximum of two keystrokes.
4.3.6.6.9 It shall also be possible to display other process information about analogue inputs,
manual output stations and discrete inputs/outputs in a faceplate format.
4.3.6.6.10 The system shall have the following standard displays:
a) Overview Display:
Overview display shall incorporate a minimum of 128 analog or discrete
inputs, which can be monitored simultaneously on the CRT / LCD TFT
MONITOR screen (Referred as page.) Each page shall be organized into a
suitable number of groups. Each group shall be identified separately. Each
group shall further incorporate suitable number of inputs (Referred as tags).
Suitable identification and description shall be shown for each group on the
overview display to relate it to a group or loop display.
All analog points in the overview shall be represented as variable lengths
indicating deviation above or below the normal operating value or set point.
Alarms shall be displayed in change of colour against each variable if the
variable crosses a set value. Control loops operating in manual mode shall be
indicated. Any input in alarm condition shall be identified by flashing.
In case, any hard-wired instrumentation backup is provided, overview pages
shall be assigned indicating the tag number and type of hardwired instrument.
b) Group Display:
Group display shall be limited to the group of inputs as displayed in the
overview display. Each group shall preferably include eight (8) numbers of
inputs.
Each input in the group shall be identified by the tag number, unit of
measurement and process description, which shall be displayed on the CRT /
LCD TFT MONITOR screen.
Display, as a minimum shall show following degree of details:
a) Process variable in analog form shall show, as a percentage of the
transmitter span on a linear scale bar graph of 0-100% or engineering units
and in digital form as alphanumeric display in engineering units.
b) Set point value in analog form as a percentage of the transmitter span on
linear scale bar graph of 0-100% and in digital form as alphanumeric
display in engineering units.
c) Output value in analog form as a percentage on linear scale bar graph of 0-
100% and digital form as percentage.
d) Controller mode i.e. auto, manual, cascade, computer.
e) Process alarm on process variable, deviation or velocity.
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f) Selected loop within the group shall be identified by cursor marking or

similar identification.
g) Control valve failure position.
h) The contact input/output shall be represented by simulated graphic lamps
and configurable alphanumeric status description.
It shall be possible to control the process from group views. Following control
actions shall be possible.
a) Increase/decrease of set point value either slow or fast.
b) Change of controller mode i.e. 8 Auto/manual
c) Changing output to the final control element.
d) For digital points, start/stop or open/close command.
It shall be possible to repeat any tag number in more than one group/console.
However it shall be possible to control or change configuration from only pre-
assigned group.
c) Loop Display:
Loop display shall provide a separate display for each of the process inputs.
The graphic representation of analog and digital points shall be similar to group
display. However, in addition, the following information shall also be
presented in alphanumeric form as a minimum:
a) Controller tuning constants
b) Process variable zero and span values
c) Alarm set point on various parameters
d) Limits on set point, output, velocity, etc.
e) Controller action (direct / reverse)
f) Failure position of final control element
g) Computational constants like ratio or bias
h) Integrated value
i) Output to the final control element
j) Engineering units
It shall be possible to change the following through the keyboard of operator
console:
a) Changing tuning constants
b) Changing scale, zero and span
c) Changing limits on set point, output, velocity, etc.
d) Changing configuration of any loop
e) Changing alarm set points
f) Changing control mode
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g) Changing output to the final control element

h) For digital points, it shall be possible to issue start / stop or open / close
command
All changes to loop control parameters shall be restricted by a key lock control.
The loop display shall also contain a trend playing process variable, set point
and output with a sample interval time of maximum 1 second and full scale
time base of minimum 60 seconds for tuning the process control loops.
d) Dynamic / Graphic Display:
It shall be possible to display dynamic / graphic of different sections of plant
on the operator console CRT / LCD TFT MONITOR. Graphic displays shall
be field configurable only through engineering keyboard with standard/user
defined graphic symbols. Different plant sections dynamics shall be displayed
on different pages.
The system shall have the capability of having and developing graphic symbol
library as per ISA - 5.1 and 5.3. In addition standard industrial symbols like
distillation columns, heat exchangers, pumps, compressors, tanks etc. shall also
be provided as a standard.
Graphic displays shall be interactive type through which it shall be possible to
control the process. It shall also be possible to send motor start/stop and
shutdown valve open/close command from this display.
It shall be possible to view the process variable and alarm points and view and
change set point value, manipulated variable, controller mode etc. form the
graphic display. Also compressor/pump status and valve status shall be
displayed on the graphic display with different colours.
Various colours used in the generation of graphics like colour of the process
lines, utility lines, Instrument signal lines and event modifier conditions shall
be finalized during detailed engineering. The colours used to identify event-
modified conditions shall generally be as follows unless otherwise indicated
during detailed engineering. Red: All alarm annunciator; Blue: Valve open,
pump running Green: Valve closed, pump stopped Flashing Shutdown valve
green: transition state.
It shall be possible to go from any graphic page to related graphic pages or any
group view or alarm summary in single key stoke using soft key function.
e) Trend Display:
All operator workstations shall be capable of displaying trends. Both real time
trends and historical trends shall be provided. It shall be possible to display
historical data up to 25 hours.
Each trend display shall consist of plotted trend graph(s) and a table showing
trend parameters.
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It shall be possible to call up real time trend displays for any process point.
The trending facility shall not allow any display exception reporting i.e. all raw
data shall be displayed as it is collected or stored.
Trend displays shall be available as one trend on a full screen up to a minimum
of eight displays on a single screen. Each display shall handle a minimum of
eight pens.
It shall be possible to incorporate trends in graphic displays.
Consecutive trend data points shall be connected by straight lines.
In full screen format, resolution of the graph shall be equal to or better than 210
value points on the process value axis for at least 60 tag data points.
It shall be possible to trend at least three different analogue points
simultaneously on one trend display. It shall be possible to display the set
point, measured variable and output of any loop simultaneously.
If only one point is on the trend display, the vertical axis shall be used for
engineering units and engineering units for that point shall be shown. If
multiple points are on trend display, then the vertical axis shall be in percent of
engineering units for each point shall be listed in a table if they are not shown
on the vertical axis.
Time period of display and time interval of the trend shall be adjustable. As a
minimum, time period between 15 minutes and 31 days shall be available.
Real time trending shall have time intervals of 10 seconds and below.
Historical trends shall have time intervals of 1 minute, 10 minutes and 1 hour.
Auto scaling and time base changes of the trend shall be available to the
operator through a simple action (e.g. one or two key strokes).
Trend display shall be either single line or bar graph type and the parameter
table shall show the tag ID, minimum scale value, maximum scale value,
present value of the trended point, alarm status and engineering units for each
point, in the same colour as the tag graph. Zooming facility shall be provided
for this view.
f) Alarm Summary Display:
It shall be possible to provide separate alarm summary displays for each plant
section in the following format:
• Multi-page displays may be used for alarm summaries. It shall be possible
access these pages sequentially (forward or backward) by a single operator
action.
• The alarm summary display shall list alarms in tabular format in order of
occurrence with most recent alarm at the top. An option shall be available
to list alarms by priority with the highest priority alarms starting at the top
of the page.
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• It shall be possible to display at least 600 alarms in each alarm summary

via multiple pages.
• Accessing alarm summary displays from any other display shall require no
more than two operator actions.
• Alarm display format shall be one line of 80 characters minimum. The
alarm message shall contain the following information as a minimum:
1. Time of alarm in “hours minutes seconds” in a 24 hour format
2. Tag ID
3. Tag description
4. Type of alarm
5. Engineering units
6. Alarm priority and alarm type
7. Alarm limit and actual value or desired state and actual state
8. Colours for different alarm states shall be configurable for graphics.
9. Serial number of alarm in the sequence of its occurrence
In addition to the above, each workstation shall display at the screen bottom the
three most recent alarms for the related plant area irrespective of which graphic
page is being displayed.
g) Configuration Display:
Configuration display shall provide a separate detailed display for each loop
indicating the configuration of that loop. When control of more than one loop
is required, all interrelated loops shall also be displayed. Following
information shall be made available for configuration display:
a) Loop configuration, giving designation of each block
b) Control block interconnection showing soft wiring or hardwiring.
c) Value of each block parameter like P & ID, ratio, bias, dead time, lead-
time etc.
It shall be possible to configure & reconfigure the loops from this view using
user-friendly software.
h) Communication System Status Display:
Communication system status displays shall show operational status of the
communication system. Communication parameters of each module connected
to the system (online, offline, failed, primary failed backup failed) shall also be
shown.
i) Module Status Display:
The Module Status display shall provide an overview of the different sub-
systems connected over the communication sub-system, showing the status of
each sub-system.
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When a failure is detected by the system self-diagnostic routine, the Sub

System Status Display shall indicate the location and nature of malfunction.
Any failure / abnormal condition in a sub system, or any other functional
device shall also generate an alarm. This display shall have the following data
as a minimum:
• Identification of the failed sub-system (Sub-system number and type)
• Details of the failed module
• Error code and description
j) Diagnostic Display:
The self-diagnostic display for a subsystem failure shall appear on the operator
console irrespective of display selected. The choice of the detailed self-
diagnostic displays shall be made by the operator via a key-lock switch.
Diagnostics shall be provided to check system operation and aid in system
maintenance. Online and offline diagnostics shall be provided to assist in
system maintenance and troubleshooting. Diagnostics shall be provided for
system modules, redundant components and peripheral.
At the local level, failure of a module in a sub-system shall be identified by and
individual LED display.
Online displays shall be supported by scheduled self-tests. Failure diagnoses
shall be sufficiently specific to indicate which printed wiring boards, modules
or devices are at fault. Displays shall be designed to help maintenance and
engineering personnel diagnose faults in system and communications paths.
Each category of diagnostic display shall be organized hierarchically.
Communications diagnostic displays shall show communications errors for
each redundant communication path.
k) Miscellaneous Display:
Alarm summary displays, trend displays and event summary displays shall be
provided. Overviews, help screens and menu screens shall also be provided.
l) User Defined Graphics:
User defined graphics capability shall include the following minimum features:
• Control and monitoring attributes of any tag shall be displayable on
graphics
• Format of numeric data shall be configurable on an individual basis
• It shall be possible for each state of a multistate device to be indicated by a
unique foreground/background colour combination.
• It shall be possible for inactive alarm or status messages to be invisible to
the operator. This may be used for displaying information only when an
alarm or state is active.
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• Numeric data and other text shall be displayable in the minimum of two
different character sizes.
• It shall be possible to display numeric data in dynamic vertical and
horizontal bar graph formats. Height and width of each bar group shall be
configurable on an individual basis.
• Symbolic representation of data on graphics shall be performed by shape
changes, colour changes (foreground and background independently) and
flashing in any combination.
• It shall be possible to position any symbol anywhere on a graphic.
• Each graphic shall be capable of handling a minimum of any mix of 1000
calculated, analogue and discrete dynamic display elements including
graphical symbol representation of process status, for real time data
display.
• Within the console, it shall be possible to move displays from one screen to
any other using data entry devices. The operator shall have the ability to
manipulate operation of process directly from graphics using data entry
devices.
• Access to the faceplate for any analogue or digital controller by selecting
the associated graphic point.
• Pop-up facility for tag information.
4.3.6.7 ALARM MANAGEMENT:
4.3.6.7.1 The DCS shall have comprehensive alarm display and management facilities. The
alarms shall be configured so as to minimize unnecessary operator distractions,
utilizing intelligent alarm management including the following:
• Process and system alarms shall be annunciated audibly and displayed at
appropriate workstations. They shall be logged in alarm history files, and
printed on appropriate alarm printers if required.
• The operator console shall display alarms from the ESD and F&G systems
and from the other systems as required, communicated via the data
highway or other interfaces.
• An audible signal shall sound each time an alarm occurs. Audible sounds
shall have different configurable, priority tone levels such as increasing
tone pulse rate for higher priority alarms.
• A visual signal shall indicate at the operator workstation the plant section in
which the alarm has occurred, i.e., the relevant page shall be flashed and
the group number of the alarm input shall be displayed irrespective of the
type of display at the time of occurrence of alarm.
• It shall be possible to alarm any point in the system
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• It shall be possible for an operator to acknowledge any alarm configured at

his workstation with no more than two keystrokes. The operator shall be
able to acknowledge a single alarm, a group of alarms or all alarms on
current page.
• As a minimum, the system shall be able to indicate basic process alarms as
follows:
Alarm Condition Graphic Alarm Summary
Representation Representation
Unacknowledged alarm Flashing red Flashing red
Acknowledged Solid red Solid red
Unacknowledged alarms Flashing normal colour Flashing normal or
that have returned to reversed foreground
normal background colour
Acknowledged alarms Normal colour Removed
that have returned to
normal
4.3.6.7.2 Unacknowledged alarms shall not be removed from summary displays except
when buffer capacity has been exceeded.
4.3.6.7.3 Unacknowledged alarms shall not be removed from any other displays.
4.3.6.7.4 Alarms status of plant sections assigned to each workstation shall be indicated by a
panel with flashing backlit graphic access keys associated with each plant section.
4.3.6.7.5 It shall be possible for an operator to access detail display or other display from
which they may take corrective action by no more than two operator actions.
4.3.6.7.6 It shall be possible to set priorities to all alarms into at least two levels. There shall
be queues for each priority level.
4.3.6.7.7 When an alarm is silenced at one workstation, the audible alarm signal at all
workstations configured for that alarm shall be silenced. If any workstation
contains any other acknowledged alarms, the audible signal at that workstation
shall not be silenced. Conversely, it shall not be possible to silence and
acknowledge alarms from workstations where the point is not configured.
4.3.6.7.8 The system shall not put off the audio alarm and visual flashing even after the
condition returns to normal unless the alarm is acknowledged by the operator.
4.3.6.7.9 It shall be possible to assign alarm groups by plant areas, alarm types and
individual pieces of process equipment.
4.3.6.7.10 Audible annunciation of an alarm condition of any process variable field input
shall occur within one second. Alarm condition shall be indicated on the next
refresh of the console monitor.
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4.3.6.7.11 It shall be possible to disable audible alarm annunciation for a configurable period
of time.
4.3.6.7.12 The following types of process alarms shall be provided as a minimum:
• Process input high/low warning value
• Process input high/low absolute value
• Process input excessive rate of change
• Process input out of range high/low failure
• Process input set point deviation from control and computational point
high/low warning value
• Process input set point deviation from control and computational point
high/low absolute value
• Process input high/low dead band deviation
• Contact input change of state
4.3.6.7.13 Each process alarm shall be saved in an alarm history file and also, if so
configured, on black and white alarm printer.
4.3.6.7.14 The following information shall be logged in the alarm history file as a minimum:
• Alarm tag ID
• Alarm description
• Type of alarm
• Time of alarm, time acknowledged and time returned to no alarm expressed
in “hours:minutes:seconds” in a 24 hour format (day and month shall also
be logged)
• Process value at alarm
• Alarm priority
4.3.6.7.15 Log entries shall be generated for tags going into alarm state and for tags returning
to normal. Tags going into alarm shall be indicated by red colour or by some other
easily recognized characteristic. Tags returning to normal shall be indicated by
black colour or some other easily recognized characteristic.
4.3.6.7.16 It shall be possible to log up to 100 alarms per minute on each alarm logger. It
shall be possible to display and print out the alarm history of minimum 300 alarms
at a time.
4.3.6.7.17 It shall be possible to print alarm history on a shift basis.
4.3.6.7.18 It shall be possible to manually inhibit alarms on a point-by-point group or system-
wide basis. This capability shall be protected by system access control. These
actions shall be logged. A list of suppressed alarms shall be available at the
operator station.
4.3.6.7.19 An alarm output function shall be provided to automatically suppress alarms upon
occurrence of another alarm.
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4.3.6.7.20 A logic based alarm output function shall be provided to suppress selected
subsidiary alarms when a related higher priority alarm is raised.
4.3.6.7.21 A logic based alarm output function shall be provided to deactivate groups of
alarms for equipment that is out of service.
4.3.6.7.22 All devices connected to the communications network shall be monitored for
failure. An alarm indication shall be generated for each failure detected.
4.3.6.7.23 It shall be possible for system alarms to be logged on a printer separate from the
process alarm printer.
4.3.6.7.24 Alarm Summary Display requirements shall be as per clause no. 4.4.5.6.9.f of this
document.
4.3.6.8 HISTORICAL DATA LOGGING AND TRENDS:
4.3.6.8.1 The system shall have configurable real time and historical data collection package
to support trending.
4.3.6.8.2 It shall be possible:
• For operators to trend tags as needed
• To store the value of any analogue point or calculated value, operator
actions, alarms from operator consoles, etc. in history files
• To record the change of state of any discrete point in one of the event
histories
4.3.6.8.3 At last two DVD/CD read/write drives shall be provided in the Central Control
Room and one in each instrument equipment room.
4.3.6.8.4 It shall be possible to transfer data to removable media for historical data storage
and/or archiving. The historical device shall not support any type of data
compression algorithm that is not 100 percent recoverable. The system shall
provide historical storage for low, average and high data values as listed below and
shall be readily capable of further expansion:
• Eight hours of five second snapshots
• Ninety six hours of one minute snapshots
• Hourly averages for last 168 hours
• Eight hour averages for last 168 hours
• Daily averages for last 30 days
• Monthly averages for last 12 months
4.3.6.8.5 A configurable trend package shall be provided to fulfill the following real time
and historical trending requirements:
• It shall be possible to configure any analogue point for trending
• Historical data collection rates shall be configurable between five seconds
and one hour, inclusively
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• When an analogue point is not available (point off scale, out of range, etc.)
an unavailable code shall be entered in history.
• Standard reports shall be provided to print history values.
4.3.6.8.6 It shall be possible for the system to be configured to support online real time and
historical trends for at least the following data collection rates and retention times.
• One minute snapshot and/or average values for four days
• Five or six minute average values for a month.
4.3.6.8.7 A real-time trend feature shall be provided to make it possible for an operator to
initiate a real time trend for any analogue point.
4.3.6.8.8 The logging format shall be user definable. However, each event history file / log
file entry shall contain time and date of occurrence, tag ID, tag description and
value/state and type of event.
4.3.6.8.9 The following events as a minimum shall automatically be stored in history files
for later reporting and analysis:
Process Events
All discrete process events shall be stored in history files. These shall include:
• Inputs changing state
• All alarms occurring and returning to normal
• Equipment changing state (running/stopped, open/closed)
Operator Events
All operator actions that affect the process shall be stored in history files. This
shall include any operator command such as:
• Opening/closing isolation valves
• Starting/stopping of pumps and motors
• Changes to set points
• Changing control blocks between automatic and manual
If the system is provided with password or card key access for operators, these
events shall be printed with user’s identification.
Engineer Events
All engineer actions that change the control and monitoring of the process shall be
stored in history files:
• Placing stations and devices online and offline
• Changes to alarm set points
• Inhibiting/enabling alarms
• Changes to tag parameters
• Point placed on or off scan
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If the system is provided with password or card key access for engineers, these
events shall be printed with user identification.
System Events
The following system events shall be stored in history files:
• Failed process I/O modules
• Communication errors
• Program error messages
• Switchover between primary and backup
• Failed controller modules
• Other function module failures
4.3.6.8.10 Number of pages in each log report shall be sufficient to accommodate all the
parameters for logging.
4.3.6.8.11 Hourly report shall be printed only as and when initiated on demand by the
operator and shall not be printed automatically after the end of the hour. All other
reports shall be printed automatically at the end of the pre-defined time or when
required by the operator. The maximum storage time for log information shall be
15 minutes after the predefined print out time for a format.
4.3.6.8.12 Sequence of Events: Sequence of events (SOE) functions shall be integrated with
the system. Resolution of event detection shall be one millisecond or better. This
function may be accomplished by integration of third party equipment into the
system, provided function and indication of results is transparent to the operator.
• Reports shall be printed or displayed at the user’s option
• Report displays shall allow paging forward and backward through time
• Reports shall allow reporting of data by plant section, tag and time
• Events shall be time tagged and stored in history files
4.3.6.8.13 Event History Capacity: Historical files shall be capable of storing a minimum of
10,000 events.
4.3.6.8.14 It shall be possible to print logs on hourly, shift-wise (8-hours) and daily basis.
Provision shall also be made to print logs on weekly and / or monthly basis,
shutdown reports, initiator sequence, on-demand reports, trip initiator logs, etc.
4.3.6.8.15 Trend Display requirements shall be as per clause no. 4.4.5.6.9.g of this document.
4.3.6.9 ASSIGNABLE TREND RECORDERS:
4.3.6.9.1 The number of assignable trend recorders shall be as given in the Basic Bid Work
– Instrumentation.
4.3.6.9.2 It shall be possible to provide real time trend on the assignable recorders for any
process or calculated variable. The variable shall be assigned through the
keyboard of operator console on any point and any recorder connected to that
console.
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4.3.6.9.3 Assignable trend recorders shall be located on the hard-wired console of the
Distributed Control System. Each recorder shall have four pens. The recording
speed shall be 1” / hour in general.
4.3.6.10 HARD COPY UNIT:
4.3.6.10.1 Hard copy unit shall be used to make permanent copy of any CRT / LCD TFT
MONITOR page and when demanded through the operator console/Engineer
console.
4.3.6.10.2 CRT / LCD TFT MONITOR page shall not be locked for more than 5 seconds
while taking the video-copy.
4.3.6.10.3 Copies of display shall be in full colour.
4.3.7 ENGINEERING INTERFACE SUB SYSTEM:
4.3.7.1 Engineer interface sub-system shall be provided in the Central Control Room and
shall serve as an interface for the engineer to configure and tune loops, execute
system maintenance, display data, build reports, and, generate and edit database of
the Distributed Control System.
4.3.7.2 The Engineering interface sub-system shall consist of one Engineering console.
The Operator’s console may be used as engineering console, provided, adequate
access security by way of key-lock and password protection is given.
4.3.7.3 Each Engineering console shall consist of one colour CRT / LCD TFT MONITOR
and one engineering keyboard. The requirements of these shall be same as that of
the operator console. The engineering console shall also have one configuration
and maintenance (C&M) printer and a hard copy unit.
4.3.7.4 Engineering console shall have, as a minimum the same capability as operator
console. All the plant views as specified under operator console shall also be
available on Engineering console.
4.3.7.5 The Engineering console shall be capable of communicating with all other sub-
systems over the communication sub-system.
4.3.7.6 The engineering console be capable of executing the following functions as a
minimum, both online and offline:
a) All functions of the operator console
b) Data base configuration including overview, group, loop, multiloop and
multi variable configuration
c) Display, report building, database generation and editing
d) Generation and modification of user-defined displays
e) Generation and modification of control algorithm
f) Generation and modification of reports
g) Group or multi group alarm inhibit from the plant under maintenance.
h) Configuration or re-configuration of alarm settings, their values addition or
deletion of any control block or component in a loop.
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i) Tuning of control loops like changing, PID dead time values

j) Viewing of ESD and F&G systems
k) Compilation of graphic displays
l) Setting of real time clock
m) Compilation of logs/reports/historical trend points.
n) Execution of detailed self-diagnostic displays for maintenance aid.
o) Console / Monitors and keyboard plant section assignments
4.3.7.7 Tuning of a control loop shall be possible from Engineering as well as from
operator console, the location shall be selected by the operator using a 'Tuning
mode' key-lock switch provided on the operator console. In Tuning mode it shall
be possible to operate only the loop under tuning from Engineering console. In
case of simultaneous commands from operator and Engineering consoles, operator
console shall over-ride.
4.3.7.8 During the normal operation, the Engineering console, in no case, shall interfere
with the process operation or system software. However any change in the
configuration shall be down loaded into the system with proper knowledge of the
operator.
4.3.7.9 All detailed diagnostics of the system shall appear on the Engineering console with
a print out on the configuration and Maintenance (CM) printer. A common
diagnostic message on the operator console shall indicate the need of the
maintenance. To aid the system maintenance and effective fault location following
displays shall appear on the engineering console:
a) Communication system status display
b) Device diagnostic display System diagnostics upto module level
should be possible from the diagnostic software.
4.3.7.10 Any special diagnostic package available with the system shall also be offered.
Detailed description and capability of this package shall be supplied.
4.3.7.11 Configuration & Maintenance (C&M) Printer shall be used for printing the
configuration made by configuration changes, printing system alarms as and when
they appear and put print out any engineers command from Engineering console.
4.3.7.12 Hard copy unit, if specified, shall be used to take hard copy of the engineers
console.
4.3.7.13 The Engineering keyboard shall have the following capabilities for restricted
user/engineer through a key-lock:
a) Setting the process alarm limits, i.e., alarm limits on absolute value of
measured variable, rate of change of measured variable high and low
deviation set points, and high, extra-high and low, extra-low points on
process variable and output.
b) Date base configuration including overview group, loop, multiloop and
multivariable control configuration.
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c) Group or multigroup alarm inhibit from a plant under maintenance.

d) Reconfiguration of alarm settings and their values, addition and deletion of
components in a loop.
e) Turning of control loops including change of PID dead-time etc.
f) On-line compilation of graphic displays using standard user defined
symbols.
g) Changing of parameters to be logged.
h) Setting of real time clock
i) Assigning of parameters for historical trending.
j) To call detailed self-diagnostic for maintenance. Any change made for any
parameter for an input from any display shall be automatically updated on
all displays configured for that input.
4.3.8 COMMUNICATION SUB SYSTEM:
4.3.8.1 The communication sub-system shall be via digital communication bus, that
provides a high speed data transfer rapidly and reliably between the operator
consoles, process 1/0 devices, process computer and other devices connected to it.
4.3.8.2 The communication system shall be dual redundant, consisting of two separate
communication buses and two separate communication system interfaces for each
device. In case of systems having traffic directors, redundant traffic directors shall
also be provided. All nodes on the communication system shall be capable of
automatic switchover to the redundant component in case of system failure.
4.3.8.3 The transfer to the back up device or bus shall be automatic without interrupting
the system operation and without any operator's intervention. Information about
the failed device/bus shall be displayed on the operator console. The system shall
also have provision for manual switch over.
4.3.8.4 Communication speed of the bus shall be sufficient to update the operator console
database once every second. The overall system performance shall not be
degraded whether communication sub-system is 10% loaded or 100% loaded.
4.3.8.5 Connection or removal of any component of the communication sub-system shall
not disturb the operation of the DCS on the whole.
4.3.8.6 Error checking on all data transfer shall be done by cyclic redundancy check and
other advanced codes.
4.3.8.7 Types of communication cable shall be fibre optic, steel wire armoured / co-axial.
Electrical noise sources shall not affect operation of communication systems.
4.3.8.8 Differences in length between primary and secondary communication cables shall
not affect operation of the communication system or the requirements shall be
explicitly stated.
4.3.8.9 System performance shall not be degraded by failure of one of the redundant
networks.
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4.3.8.10 Communication error checking techniques shall be incorporated so that the

probability of an undetected single bit error occurring is one in 100 million.
4.3.8.11 Communication systems configured as redundant shall either use the backup path
continuously or check the backup path at least once per minute to determine if it is
operating normally.
4.3.8.12 Failure or planned shutdown of any one device connected to the communications
network shall not affect the ability of the system to communicate with any other
device on the network.
4.3.8.13 All serial communications lines shall be protected from lightning and switching
transients using protective devices. Exceptions can be made for circuits that do not
exit a control panel enclosure and for temporary local connection of programming
equipment.
4.3.8.14 High-speed proprietary communications networks shall be applied where serial
bandwidth is insufficient to transfer data in large networked applications.
4.3.8.15 Communications with Other Systems:
4.3.8.15.1 The DCS shall be able t interface and communicate, including import and export of
data, with the external equipment and systems listed below:
• ESD system
• F&G system
• Other platforms and onshore via the existing telemetry system on the
existing platforms
• New and existing subsystems on all parts of the complex, such as PLC’s,
rotating machinery, vibration and temperature monitoring and/or speed
governors. Fine Filter system, Fire and Gas system or other Contractor’s
DCSs.
• Intelligent electrical switchgear networks.
• Commercially available PC’s and process computers and LAN’s.
• Remote dial-in access.
4.3.8.15.2 These external interfaces and software shall be established, standard features of the
DCS. All devices providing external interfaces shall use standard protocols and
provide electrical isolation between the communicating systems. Interfaces shall
be sized for a utilization of no more than 75 percent capacity and shall be capable
of dual redundant implementation. OPC (OLE for Process Control) support for
external links shall be included.
4.3.8.15.3 The type of communication may be: Floating Master / Fixed Master / Periodic
Reporting / Exception Reporting.
4.3.8.15.4 The following capabilities shall be provided for communicating with systems
provided by others:
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• RS-232, RS-422 and RS-485 synchronous or asynchronous mode

communication at selectable industry standard baud rates up to 144kb aud.
• Ethemet ports, using twisted pair, AUI, fibre optic or coaxial cable with
TCP/IP and DECNET/OSI transport protocols. The bandwidth of the
network shall be 10Mbps (minimum) with optional consideration of
100Mbps.
• Common serial communication drivers including X.25 and
implementations of Modbus, RTU and ASCII protocols.
• Alen-Bradley Data Highway and Data Highway Plus, Modbus Plus and
HART network protocols.
• It shall be possible to modify master/slave mode of the system based on
the mode of the system based on the mode of the system provided by
others.
• Access to DCS database for advanced control applications and data
acquisition.
• Export of data to common PC applications such as spreadsheets and
databases.
4.3.8.16 Communication Faults:
4.3.8.16.1 The system shall provide automatic communication retries for any malfunction
occurring during message transfers.
4.3.8.16.2 Recoverable and unrecoverable communications errors shall be counted by the
system for each communications channel. All unrecoverable communications
malfunction, including no reply or invalid message shall be alarmed, logged on a
printer and/or stored in a history file.
4.3.8.16.3 The system shall support DECNET and TCP/IP standard failure/recovery
procedures.
4.3.8.17 Report by Exception: (This is applicable if the communication type offered is of
‘exception reporting’ type)
4.3.8.17.1 The system uses a report by exception method to obtain field inputs from remote
units such as an RTU or PLC then the following requirements shall be met:
• It shall be possible to configure the system so that changes of field inputs
are reported to the system within one second of field input unit detecting
the change.
• There shall be a time-out function for the report by exception algorithm
such that, when a configurable time period has elapsed, the field input is
reported to the system regardless of whether the input has changed.
• There shall be a configurable dead-band parameter for each analogue input
that designates how much input shall vary before the input shall be reported
to the system.
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• The system shall support DECNET and TCP/IP standard link utilization.
4.3.9 SUPERVISORY COMPUTER SUB SYSTEM:
4.3.9.1 The necessity of a supervisory computer sub system shall be governed by the
requirements in the Basic Bid Work.
4.3.9.2 The supervisory computer shall be capable of the following functions as a
minimum:
a) Advanced Control
b) Unit and plant optimization
c) Management information service reports.
4.3.10 FOREIGN DEVICE INTERFACE:
4.3.10.1 Foreign device interface shall be capable to transfer data from all the foreign
devices like analyzer systems, gas chromatographs, gas turbine system, package
instruments etc. to other sub-systems connected to communication sub-system and
vice-versa wherever specified.
4.3.10.2 Each device interface shall be redundant.
4.3.10.3 Interface hardware and software shall be suitable to match the foreign device
communication requirements like hardware interface, communication protocols
etc.
4.3.10.4 While writing software or mapping the input/output in the interface device it must
be ensured that integrity of the data to be transferred like resolution, correctness
etc. shall be maintained.
4.3.10.5 Redundant interface switchover shall be designed based on the type of redundancy
available in the foreign devices.
4.3.10.6 The total responsibility of selection of hardware, writing of software, switchover of
redundant interface etc. shall be distributed control system Vendor only.
4.3.11 HARD WIRED INSTRUMENTATION:
4.3.11.1 Hardwired instruments shall be stand alone type and shall meet their functional
requirements fully without depending on DCS. The type of instruments required shall be
as per the Basic Bid Work – Instrumentation. Even power supply and input/output circuits
of hardwired instruments shall be totally independent of DCS system. 20% additional
spares shall be provided for each item on the hardwired console.
4.3.11.2 Hard wired instruments shall be microprocessor based. Each instrument shall have as a
minimum the necessary firmware to meet its functional and operational requirements.
4.3.11.3 Each device shall have its own analog to digital/digital to analog converter.
4.3.11.4 The display of each device shall preferably be paragraph type.
4.3.11.5 Controller shall be digital type capable on performing automatic control based on the set
points given locally or from a remote device like another controller or Distributed digital
Control System or Supervisory computer. The controller as an instrument shall also have
provision for manually controlling the process by means of a manual loader and cascade-
computer auto-manual transfer switch. The operation of the transfer switch shall be
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procedures-less and bumpless while changing mode from computer to cascade to manual
and from manual to auto to cascade to computer. During such a change the output shall
not change more than 1% of span. Controller shall have a facia giving continuous
indication of process variable, set value, controller output and controller mode. It shall be
possible to remove an instrument for maintenance without upsetting the process by use of
device like service station. Operation of the controller like set point change, manual
control, controller mode change shall be possible from the front of the controller.
Controller shall be flush panel mounting type on the panel/hard wired console.
Configuration and tuning of controller shall be possible through a portable and pluggable
configurator. The enclosure shall be general-purpose type. The Controller shall be
Intrinsically safe with external barriers. The Controller shall be capable of handling 4-20
mA signal and shall have self-diagnostic feature. The controller shall have local Bar graph
/ Digital display. The Controller shall have set point adjustment, manual loader and auto
tracking facilities. Other requirements shall be as per Controller & Data Acquisition
System specifications.
4.3.11.6 Recorder shall have independent circuit and pen drive assembly for each channel.
Recorder shall have capability of continuous line marking or digitized marking of input
value with high resolution. Recorder chart drives shall be of multi-speed type and shall be
operator selectable. Recorders shall be flush panel mounting type on the panel/hard wired
console.
4.3.11.7 Manual loader unit shall have continuous display of process variable and manual loader
output. It shall be possible to manually change the output to control valve. Manual
loaders shall be flush panel mounting type on the panel/hardwired console.
4.3.11.8 Temperature transducers and trip amplifiers shall accept inputs from standard industrial
thermocouples and resistance temperature detector. Linearisation of the thermocouples
and RTDs shall be done inside each instrument. Transducers and amplifiers shall be
suitable for rack mounting.
4.3.11.9 Alarm cards shall accept standard outputs and shall produce changeover contact output.
The alarm cards shall have SPDT contact. Each alarm card shall have one continuously
adjustable blind setting device. Alarm cards shall be suitable for rack mounting.
4.3.11.10 Hardwired pushbuttons with sealed contact housing shall be provided. These pushbuttons
shall have a silver alloy plated, make-before-break contact.
4.3.11.11 Trip amplifiers shall accept inputs from Grounded Thermocouples (types – T/E/K) & RTD
Pt 100. The maximum source resistance shall be 2000 ohms. Thermocouple burnout
protection shall be provided for both upscale as well as downscale readings. A field-
configurable, RTD open protection shall be provided. The contact type shall be SPDT
with a rating of 2 A @ 24 V DC. The trip amplifiers may be rack-mounted or surface-
mounted.
4.3.11.12 Signal isolators shall cater to 4-20 mA DC (2 wire) input signal and shall be capable of
generating an isolated 4-20 mA DC signal. Each signal isolator shall have two outputs.
The signal isolators may be rack-mounted or surface-mounted.
4.3.11.13 Alarm & Annunciator System
4.3.11.13.1 The alarm logics shall be plug-in modules. Where integral logic has been indicated, the
logic module shall be accessible from the front of the annunciator after opening the swing
door, the design of each module shall be such that by simply jumpering suitable point. It
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may be changed from normally open mode of operation to a normally closed mode of
operation and vice versa.
4.3.11.13.2 Lamps shall be replaceable from the front. The power consumption of each lamp shall
be approximately 10 watts.
4.3.11.13.3 The initiation of alarm condition in the annunciator shall take place approximately 330
milli second after the condition sensing contacts have assumed the off normal state. An
integral or separate alarm acknowledgement facility shall be provided.
4.3.11.13.4 Hooter, in general shall be solid-state type with audibility of the order of 100 db at a
distance of 3 meters. An interruption of power supply for a duration of 20 milli-seconds
or less shall not effect the functioning of the annunciator.
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4.3.12 OLE FOR PROCESS CONTROL (OPC):

4.4.12.1 The DCS should have on its network, a server having OPC (OLE for
process control) interface (i.e OPC Server) allowing atleast 500 number of
tags data transfer from the DCS network to any third party OPC client on
TCP/IP- Ethernet based system for:
A) Flexible and efficient reading and writing of data between an application of
the third party OPC client and the DCS.
B) Notifying the application of the third party OPC client about the specified
event and alarm conditions in the DCS.
C) Allowing the application of the third party OPC client to read, Process and
edit data of the historian engine of the DCS
4.4.12.2 The OPC server should be able to communicate with the OPC client at a rate
decided by the client.
4.4.12.3 The OPC server must implement both the custom interfaces as well as
automation interfaces .
4.4.12.4 The shutdown capability of the OPC server should have the feature of
requesting all its clients to disconnect them from the server prior to its
shutdown, so that the clients can make use of this feature to support a graceful
shutdown.
4.4.12.5 The data items of the DCS which are to be made accessible to the OPC clients
through the OPC server shall be considered as security objects as defined in
OPC foundation specifications and the manner in which they are to be
secured, must confirm to the above specifications. The OPC server shall
function as reference monitor and shall make access authorization for the
security objects exposed by the OPC server preferably using NT Access
Token Approach.
4.4.12.6 Regarding all issues of the OPC server, including those of its installation and
registration, the respective requirements of the relevant specifications of OPC
foundation should be complied with.
4.3.13 EQUIPMENT ASSEMBLY, CABINET & CONTROL PANEL CONSTRUCTION:
4.3.13.1 All hard wired instruments like indicators, recorders annunciators and system back
up instruments like manual loading station etc., if required, shall be mounted on
the control panels or hard wired consoles. Control panels shall be non-graphic
type unless otherwise specified.
4.3.13.2 Following cabinets shall be required, in general:
a) Power distribution cabinet (For AC distribution and DC distribution)
b) Barrier mounting cabinets (If field is hazardous)
c) Controller system cabinet.
d) Data acquisition system cabinets
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e) Trip amplifier and other auxiliary card mounting cabinets

f) PLC processor cabinets
g) PLC I/O system cabinet
4.3.13.3 System cabinets shall be located behind the panels and shall be freely accessible
from front and/or back as required. A minimum space of 1500mm shall be
provided between the back of the panels and the cabinets. Access to all equipment
within the cabinets and workstations shall be provided without the need to
disconnect wires or shut down system power. Equipment shall be installed so that
connectors are easily accessible.
4.3.13.4 All the cabinets shall be of freestanding, enclosed type and shall be designed for
bottom entry for cable connection. Cabinet structure shall be sound and rigid and
shall be provided with removable lifting lugs to permit lifting of the cabinets.
4.3.13.5 Cabinets shall be fabricated from cold rolled steel sheet of minimum 2 mm thick
suitably reinforced to prevent warping and buckling. Doors shall be fabricated
from cold rolled sheet of minimum 1.6 mm thick. Cabinets shall be thoroughly
deburred and all sharp edges shall be grounded smooth after fabrication.
4.3.13.6 Each cabinet shall be of maximum of 2100 mm height and 1200 mm width.
Construction shall be modular preferably to accommodate 19" standard electrical
racks. All racks shall be of same height. Maximum swing out for pivoted card
racks, doors and drawers shall be limited to 600 mm maximum.
4.3.13.7 Cabinets shall be equipped with front and for rear access doors. Doors shall be
equipped with locakable handles and concealed hinges with pull pins for each door
removal.
4.3.13.8 In order to effectively remove dissipated heat from the cabinets, vent louvers
backed by wire fly screen shall be provided to cabinet doors. In case louvers are
insufficient, ventilation fans shall be provided.
4.3.13.9 Illumination shall be provided for all cabinets by fluorescent lamps and door-
operated micro switch.
4.3.13.10 Equipment within the cabinet shall be laid out in an accessible and logically
segregated manner. Clamping rails shall be provided for incoming cables to
prevent excessive stress on the individual terminal all metal parts of the cabinets
including doors shall be electrically continuous and shall be provided with a
common grounding lug.
4.3.13.11 Control Panel / Hard Wired Console Construction:
4.3.13.11.1 Control panels, if required shall be non-graphic self supporting free standing
cubicle with back doors made up of sectional steel panels. Each section shall be
2100 mm high, 1200 mm wide and 1000 mm deep and shall be mounted on 100
mm high channel base. Care shall be taken to ensure that the face of the panel is
truly flat and smooth.
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4.3.13.11.2 Panels/hard wired console shall be fabricated preferably from 4 mm thick cold
rolled steel sheet. Angle iron frame shall use a minimum section of 50 x 50 x 4
mm angle.
4.3.13.11.3 Panel/hard wired console finish shall include sand blasting, grinding chemical
cleaning, surface finishing by suitable filler and two coats of high-grade lacquer
with wet sanding between coats. Two coats of paint in the panel color and final
coat shall be given after assembly at site for non-glossy high satin finish, colour of
the panels shall be as per job specifications.
4.3.13.11.4 Normal mounting heights on panel of instruments (centre lines of instruments to
floor) shall conform to the following, with minor adjustments depending upon
instruments selected.
• Miniature & sub-miniature Bottom Row 1100 mm
instruments
(3 rows) Middle Row 1350 mm
Top Row 1600 mm
• Annunciators 1950 mm
• Electrical Push Buttons 700 mm
4.3.13.11.5 Front of panel/console instrument nameplates shall be black laminated plastic
with white core. Nameplate shall be provided on the rear of the panel also for each
instrument.
4.3.14 REDUNDANCY:
4.3.14.1 Redundant Equipment:
4.3.14.1.1 All communications, processor and memory equipment shall be supplied in

redundant configuration. This includes power supplies and all equipment required
for process controllers and process interface units to communicate with remote I/O
nests.
4.3.14.1.2 Critical process functions of a system may dictate that redundant equipment
configuration be provided to achieve required system reliability levels. The system
requires redundant transmitters, input modules, output modules, regulatory
controllers and other parts of the system.
4.3.14.1.3 All processors and I/O equipment for continuous control loops and critical batch
control operations shall be redundant. Systems that offer single loop integrity can
be considered in lieu of redundancy.
4.3.14.2 Redundancy Requirements:
4.3.14.2.1 The following requirements apply to those parts of a system identified in the
functional specification as redundant, except for historical data collection
hardware.
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• Failure of any one redundant part shall not interrupt other system
functions. A failure can be a hardware failure, software failure, power
supply failure or the loss of one AC feeder in a dual feeder system.
• Redundant equipment hardware and software shall be continuously
monitored for errors. Switchover to backup device shall occur
automatically upon failure of primary device. It shall be possible to
manually switchover (change from back up to active status) any redundant
module.
• Automatic switchovers shall not interrupt other system operations.
• Detection of failed equipment and automatic switchover to full operation
shall occur within the following times:
Maximum Allowable Fail over Time:
Function Seconds
Communication Device 3
Regulatory Control 3
Sequential Control 3
Supervisory Control 5
Input / Output Module 1
• Current operating parameters shall be continuously updated on backup
equipment so that only current process data is lost during switchover
• Switchback to repaired equipment shall be by manual command.
• Where multiple communications systems are used, failure on one system
shall not cause failure or adversely affect any other system. That is,
protection shall be provided to prevent failure of a device or a
communication system fro preventing communication to other devices or
other communication systems.
• It shall not be possible for an external or third party system connected
through a communications interface to interrupt operation of any device
within the system. There shall be security in these interfaces to limit
access of external systems.
• Redundant devices shall have two independent paths to the redundant data
communication system.
4.3.14.3 Monitoring of System Status:
4.3.14.3.1 All dual equipment and subsystems shall be continuously monitored for their
integrity. Automatic and manual switchovers shall be displayed, logged and
alarmed.
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4.3.14.3.2 The system shall continuously monitor and test all backup equipment to determine
whether backup equipment is capable of system control. If a failure is detected in
any backup equipment, the operator shall be notified and failure shall be logged.
4.3.15 SPARE REQUIREMENT:
4.3.15.1 Redundant capacity shall not be considered as spare capacity. The Distributed
Control System shall be delivered to the installation site with installed spare
capacities and future expansion capabilities as described in this specification.
4.3.15.2 Installed Spares:
4.3.15.2.1 Installed engineering spares of 20% shall be provided in each sub-system for each
type of module to enhance the system functional requirements including
programmable logic controller (if specified) and hardwired instrumentation.
4.3.15.2.2 Process I/O racks shall contain 20% installed spare I/O modules. Where
terminations are pre-wired to the process I/O, spares shall also be pre-wired to the
spare I/O.
4.3.15.3 Future Spare Capacity:
4.3.15.3.1 In addition to the installed spare capacity as given in clause 4.4.14.2 above, all
parts of the system shall have capability of further expansion by an additional 30%
to cater for future expansion. This shall include hardware, software, firmware and
communication.
4.3.15.3.2 The system shall have capability to extend its historical trending, logging and
user's memory by 30% to meet future expansion with/without adding additional
memory modules. Estimating tools to calculate the expected processing and
memory capacity usage shall be included with the system.
4.3.15.3.3 I/O racks of programmable logic controller shall have 20% usable spare space for
installing additional I/O cards of each type in future. However internal wiring for
the same shall be connected up to the I/O terminals.
4.3.15.3.4 Sufficient additional software capacity shall be available in the system to take care
of spares requirement as specified in this specification.
4.3.15.4 Processor, Memory and Communications Loading:
4.3.15.4.1 Contractors shall provide calculations demonstrating the design and future loading
of the processor, memory and communication systems to substantiate the following
requirements.
4.3.15.4.2 The expansions described above shall be possible without modifying or replacing
existing equipment communications cables or system operating software.
4.3.15.4.3 The installed communication system, including all the nodes required to interface
to the required systems shall have 25 percent node expansion capability for future
development, and still be capable of meeting the requirements of this specification.
4.3.15.4.4 System processing and memory capacity shall have 50 percent expansion
capability for future application programming and configuration including, but not
limited to:
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1. Alarm and equipment monitoring

2. Trend and history collection
3. Reports and displays (including user-defined graphic displays)
All fibre optic cable shall have 200 percent minimum spare fibres.
4.3.15.4.5
4.3.16 CONSUMABLES:
4.3.16.1 Any paper and ink required for printers, assignable recorders, video copier or any
other consumable item shall be supplied along with system required for minimum
of six months duration after system acceptance.
4.3.17 SPECIAL TOOLS:
4.3.17.1 Special tools if any shall be provided by the Contractor as a part of the system.

5.1 Environmental Conditions:
5.1.1 All parts of the DCS system (except for data highway cables linking the platforms,
if applicable) will be housed in pressurized air-conditioned rooms, with
temperature and humidity maintained within the ranges 21-24 deg.C, and 45-55%
RH. The Contractor shall allow for air-conditioning failure, when the ambient
conditions could rise to 50 deg C and 95% RH for periods upto 8 hours.
5.1.2 The Contractor shall ensure that DCS environment complies with ISA S71.01 and
ISA S71.04.
5.2 Equipment Noise:
5.2.1 The maximum acceptable noise level for each piece of equipment installed in the
control and equipment rooms shall not exceed 55 db measured at a distance of 1 m
lateral from the source and 1.5m vertical from the floor with a sound level meter
using the “A-weighted” sound level scale.
5.3 Hazardous Areas:
5.3.1 Certain parts of the platforms will be designated hazardous areas, classified
according to API 500 and equipment in these areas will be specified accordingly.
All DCS equipment, except for the data highway cable between platforms (if
applicable), will be located in non-hazardous area within pressurized rooms and
will be automatically disconnected from all power sources under certain
conditions. These conditions include platform shutdown, loss of room
pressurization and combustible gas within the room.
5.4 Enclosure Internal Environment:
5.4.1 The enclosure’s internal environment shall meet the required operating
specifications for all DCS equipment housed in the enclosure. Exposure to heat,
dust, humidity, vibration and corrosive gases shall be evaluated and properly
addressed in the package design, based on the specified conditions.
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5.5 The system as a whole shall be intrinsically safe based on entity concept. Intrinsic
safety shall be achieved via external Zener barriers. The selection of Zener barriers
shall be done based on the type of transmitter or I/P converter located in the field.
Any limitation or special requirements for cables to meet the intrinsic safety
requirement shall be brought out in the offer.
6.0 INSTALLATION REQUIREMENT:
6.1 Vendor shall offer the services of the installation team, which would install the
equipment in the control room, lay the interconnecting cabling inside the control
room, check out, test and commissioning the system.
6.2 All technical personnel assigned to the site by the Vendor shall be fully conversant
with the supplied system and software package, and shall have both hardware and
software capability to bring the system on line quickly and efficiently with a
minimum of interference with other concurrent construction and commissioning
activities.
6.3 Vendor's responsibility at site shall include all activities necessary to be performed
to complete the job as per material Requisition including:
a) Receipt of hardware/software and checking for completeness of supplies.
b) Installation of the system including free supply equipment and field cable
termination in the system.
c) Check out of the equipment installation.
d) Checking of interconnection, hardware & software configuration, overall
system functioning etc.
e) Loop checking.
f) Liaison with Vendor's home office.
g) Field tests
h) Commissioning and on-line debugging of the system.
i) Performance of final acceptance test.
6.4 The only exclusion from Vendor's responsibility shall include the following:
a) All civil works in the control room including false flooring, control room
lighting & air conditioning ducting.
b) Laying of Cables and identification of field cables
c) Field instrument installation and calibration.
7.0 INSPECTION AND TESTING:
7.1 General:
7.1.1 This Section defines the minimum requirements for inspection and testing of the
Distribute Control System, including all sub-systems, hardware and software.
7.1.2 On the basis of this specification, Vendor shall submit his own testing, installation,
commissioning and acceptance procedures for review and approval by the
Company.
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7.1.3 A complete plan for Factory and Site Acceptance Testing shall be submitted for
approval 8 weeks before the scheduled commencement of testing. This plan shall
be complete and in sufficient detail to indicate the exact nature and purpose of each
test, time required, type / definition of inputs expected results and step-by-step
procedure, and acceptance criteria. The plan shall include hardware and software
reliability testing requirements as well. For hardwares, the procedures shall include
purpose of test definition of input, procedure, results expected and acceptance
criteria. For software, it shall include details of the methods, list of tests, sequence
of execution, results expected and acceptance criteria.
7.1.4 The results of all tests including the Contractor’s internal tests, successful or not,
shall be available for inspection by the Company.
7.1.5 The Company / Company designated representative may choose to witness any or
all tests, including the Contractor’s own pre-acceptance tests. The Contractor shall
give at least two week’s prior notice of all testing.
7.1.6 Acceptance tests shall be conducted in thee stages:
• Pre-Factory Acceptance Test (PRE-FAT)
• Factory Acceptance Test (FAT) or staging test
• Site Acceptance Test (SAT)
7.2 PRE-FACTORY ACCEPTANCE TEST (PRE-FAT):
7.2.1 PRE-FAT for DCS shall be carried out by the vendor prior to FAT. All reports and
documentation on PRE-FAT shall be submitted to the Company 30 days in prior to
the commencement of FAT, for review by Company.
7.3 FACTORY ACCEPTANCE TEST (FAT):
7.3.1 The objectives of the FAT are to verify the DCS system (as configured for
delivery) meets or exceeds specified design and functional requirements. Tests
shall be conducted at the DCS staging site and shall be done according to Factory
Acceptance Test procedures for the project. These procedures shall include
hardware I/O simulation using the plant database, subsystem interface checkout
and performance checkout of any special gateways.
7.3.2 Before the system is delivered to the site, satisfactory performance of the entire
system shall be demonstrated. The system shall simulate the final onsite
configuration as closely as possible.
7.3.3 The Contractor shall have a technician and test equipment available full time
during testing.
7.3.4 The tests undertaken shall demonstrate each of the following responsibilities has
been fulfilled.
• The system has been tested as an integrated system
• The hardware and software responsibilities have been fulfilled
• All tests have been documented in a checklist fashion
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• The system is fully proven and ready for service

• The system satisfies the requirements of this specification and the particular
project application.
7.1 The test procedures shall be developed by the Contractor as system engineering
proceeds and shall be submitted to the Company for approval at least one month
before commencement of the first factory test.
7.2 No material or equipment shall be transported until all required tests are
successfully completed and certified "Ready for Shipment" by the
owner/consultant.
7.3 The owner/consultant reserves the right to be involved and satisfy himself at each
and every stage of inspection. The owner/consultant shall be free to request and
specific test on any equipment considered necessary by him although not listed in
this specification. The cost of performing all tests shall be borne by the Vendor.
7.4 During acceptance tests of integrated systems, formal testing of all operating and
application software shall be conducted. Tests shall be based on established
software reliability test procedures. As a minimum, test procedures shall be based
on recognized industry standards for devlopment and testing of the system and
application software. Examples of acceptance industry standards are IEEE730,
IEEE828 and IEEE1042. Software reliability procedures including industry
standard references shall be provided as part of pre-FAT and/or FAT test
procedure.
7.5 Vendor to note that acceptance of any equipment or the exemption of inspection or
testing shall in no way absolve the Vendor of the responsibility for delivering the
equipment meeting all the requirements specified in Material Requisition.
7.6 It shall be Vendor's responsibility to modify and/or replace any hardware and
modify the software if the specified functions are not completely achieved
satisfactorily during testing and factory acceptance.
7.7 Failure of components/modules/sub-systems
7.7.1 Vendor shall not replace any system component/modules/sub-system unless it is
failed. A log of all failed components/modules in a sub-system shall be maintained
which shall give description of the failed component/module, effect of failure on
the sub-system cause of failure and number of hours of operation before if failed.
7.7.2 Any component of hardware or software failed during a test shall be retested as
necessary to prove rectification has been completed satisfactorily.
7.7.3 If malfunction of a component/module in a sub-system repeat, the test shall
terminate and Vendor shall replace the faulty component/module. There after the
test shall commence all over again. If even after this replacement, the sub-system
fails to meet the requirements, Vendor shall replace the full sub-system to the one
meeting the requirements and the system shall be tested all over again.
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7.7.4 If a sub-system fails during the test and is not repaired and made successfully
operational within four hours of active repair time after the failure, the test shall be
suspended and restarted all over again only after the Vendor has replaced the
device into the acceptable operation.
7.8 FAT Procedures:
7.8.1 The inspection and factory acceptance shall be carried out in two phases i.e. Phase
I and Phase II. The minimum requirements for testing during these two phases are
as follows:
7.8.2 Phase –I:
7.8.2.1 Vendor shall perform tests at his works to ensure that all components function in
accordance with their respective specifications for each type of test. A test report
shall be submitted to the owner/consultant for review within two weeks of
completion of each type of test giving details. All sub-systems shall undergo a
minimum of 30 days burn-in period.
7.8.2.2 The test log book shall contain the following information about the tests:
a) Date/Time
b) Assembly designation/loop tag number
c) Test input
d) Test results and sign off with personnel name
e) Action required (if deficiency is detected)
f) Action taken, date of completion and sign off
g) Special test methods (including special equipment requirement,
bypasses used etc.)
7.8.2.3 Test details:
The Vendor shall perform the following tests and report shall be forwarded to the
owner/consultant.
7.8.2.3.1 Quality Control Test:
a) Quality control tests shall be carried out to assure quality of all components and
modules in accordance with Vendor's quality control and assurance procedures.
Vendor shall for ward the details of these procedures for owner/consultant's
review.
b) The sampling procedures for all purchased components or components
manufactured by the Vendor, for quality assurance tests shall be in accordance
with relevant international standards.
c) All assemblies shall be aligned and adjusted and all test observations shall be
recorded as manufactures published set ups and testing methods.
7.8.2.3.2 System power-up test:
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Vendor as a minimum shall check the functions of all the systems hardware and
software including diagnostic software at sub-system level by simulating the
inputs.
7.8.3 Phase-II:
7.8.3.1 This test shall systematically, fully & functionally test all the hardware and
software in the presence of purchase representative. All the sub-systems shall be
inter connected to simulate, as close as possible, the total integrated system.
Vendor purchased item e.g. programmable logic controller etc. shall also be
connected in the system. Barrier cabinets shall be used as the connecting points for
test inputs and outputs.
7.8.3.2 The duration of the testing shall be mentioned by the Vendor with reasons. System
shall be shipped to site only after this testing and certified ready for shipment by
owner/consultant.
7.8.3.3 Data review:
a) Owner/consultant shall perform a comparison of all current data. Any revision
or changes required shall be informed to the Vendor.
b) The test report/log book forwarded by Vendor after Phase-I testing shall be
reviewed. Owner/consultant has right to witness any test performed in Phase I,
if found necessary.
7.8.3.4 Testing record:
a) During testing of Phase II, each test carried out shall be recorded. Any
deficiency or problem shall be clearly brought-out and shall be corrected.
b) Any change in the data or configuration etc. informed to the Vendor shall be
recorded and carried out by the Vendor.
7.8.3.5 Visual and mechanical testing Visual and mechanical testing shall be carried out in
principle to assure correct, proper, good and neat workmanship by the Vendor.
7.8.3.6 Functional testing shall include the simulation of each input and output to verify
proper system response for both analog and discrete signals.
7.8.3.7 Complete system configuration loading:
7.8.3.7.1 Demonstration of all controller functions from local as well as from central
level e.g. changing of tuning constants, loop tuning, checking of algorithm
functions changing algorithms, changing controller mode, changing controller
action etc.
7.8.3.7.2 Checking of scan time values for controllers and data acquisition sub-system.
7.8.3.7.3 Checking of loop configuration for correctness with respect to ranges, limits,
alarm points, engineering, units etc.
7.8.3.7.4 Checking of all types of CRT / LCD TFT MONITOR displays including
process and system displays on operator and Engineering and PLC console.
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7.8.3.7.5 Checking of correct functioning of keyboard operation for operator,

Engineering and PLC console.
7.8.3.7.6 Checking of correct changeover of the back-up units in case of main units
failure. This shall include:
a) Uninterrupted controller operation shall be checked. The failed
controller database, point record, input and output etc. shall be
transferred to the back up controller without any interruption. The same
shall be repeated for transfer back from back up controller to the main
controller card. Maximum transfer time shall not exceed the specified
value. The test shall be repeated for controller cards.
b) Uninterrupted auto and manual transfer of main communication bus and
interfaces to the redundant ones shall be checked. Further it shall be
checked that the transfer back to main bus or interface should not be
automatic. This test shall be repeated for all interface units in the
system.
c) Uninterrupted operation of system should be checked on failure and
resumption of any of the power supplies where redundant floating
power supplies are provided.
7.8.3.7.7 System diagnostics shall be thoroughly checked for all sub-systems on local
level as well as on operator/Engineering console. These shall include failure of
a sub-system, module, power supply, interface unit, failure of transfer to
redundant module on main module failure etc. and other detailed diagnostic
displays. Diagnostic alarms for any ventilation fan failure shall also be
checked.
7.8.3.7.8 Testing of proper functioning of all printers and hard copy units.
7.8.3.7.9 Testing of system features like interchangeability between CRT / LCD TFT
MONITORs of a console, synchronization of system clocks, selective tuning
from Engineering console, key-lock functions etc.
7.8.3.7.10 Checking of various log formats, shutdown reports I/O mapping and other MIS
formats printing.
7.8.3.7.11 Checking and shutdown and interlock configuration and proper operation
thoroughly.
7.8.3.7.12 Proper system operations at power supply specifications specified in the
Material Requisition.
7.8.3.7.13 Checking of proper operation of all interfaces with the system like interface
with PLC, computer, analyzer system etc. as specified in Material Requisition.
7.8.3.7.14 Checking of bus-degradation while loading the bus from 10% to 100%.
7.8.3.7.15 Simulation of power failure and restarts.
7.8.3.7.16 Checking of all hardwired instrumentation including all alarm cards, alarm
Annunciator system, switches and other indicating instruments.
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7.8.3.8 The Vendor shall notify the owner/consultant at least three weeks prior to final
system testing. In the event that representatives arrive and the system is not ready
for testing, the Vendor will be liable for back charges for any extra time and
expenses incurred.
7.8.4 Loop Checking:
7.8.4.1 Loop check shall be carried out by the Vendor and checking the interconnection,
configuration and over all system functioning.
7.8.4.2 Calibration and installation of field instruments, installation of junction boxes,
interconnection between instruments and junction boxes, laying of single multi pair
cables upto control room, tagging all field cables, performing continuity/insulation
test of cable, core identification of field cables etc. shall not be in the Vendor
scope. The field Contractor shall carry out this work.
7.8.4.3 Vendor scope of work in loop checking shall include termination of field cables in
control room, checking of interconnection between instrument/equipment
ferruling, tagging of interconnecting cables in control room, ferruling of field
cables in control room and performing overall loop performance check.
7.8.4.4 Loop checking shall be carried out to check the functional performance of all
elements comprising the loop and thereby ensuring proper configuration,
functioning and interconnection.
7.8.4.5 Vendor shall co-ordinate with the field Contractor for smooth and proper loop
checking. Any discrepancy found during checking shall be brought to the notice of
Engineer-in-Charge. All loop checking shall be performed in his or his authorised
representative presence. All readings shall be recorded on a suitable format and
shall be submitted for approval.
7.8.4.6 All the components of the loop shall be checked for proper functioning. All field
instruments connected to control room shall be loop checking at 0%, 25%, 50%,
75% & 100% of FS (for both increasing and decreasing signals) and the mode of
generating signal from the field shall be as follows for different instruments types
Types of Instrument Mode of Signal Generation
a) Differential pressure/flow By applying impulse to the primary
instruments/DP type level by squeeze bulb or regulator at field
insts.
b) Pressure instruments By applying impulse to the
instrument using instrument air
regulator & standard gage or using
portable hydro pump and standard
gage.
c) External Displacer Gauge shall be filled type level
instrument with water for different
levels and specific gravity correction
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shall be applied.
d) Other type of tank level By lifting the float level instruments
instruments for 0%, 100% of range.
e) Temperature loops with Appropriate mV signals shall be fed
thermocouple from thermocouple head
f) Temperature loops with Appropriate resistance shall be fed
RTD from RTD head
g) Field switches for Abnormality shall be alarm and
shutdown simulated by
disconnecting and connecting the
wires at field instrument end
h) Owner supplied items As per Engineer-in-Charge's
Instructions
i) Special instruments & any As per Engineer-in-Charge's
other type of instruments Instructions
7.8.4.7 Receiver alarms cards shall be checked for different settings on both increasing
and decreasing signals. Shutdown schemes shall be checked for proper
functioning, configuration and actuation. Performance of individual loops may be
accepted for an overall accuracy of ± 1% unless otherwise specified. Where
deviation exists, re-calibration of instruments, based on the scope of work, shall be
carried out either by field Contractor or Vendor.
7.8.4.8 Signal from controllers/shutdown schemes control valves/shutdown valves shall be
checked at the respective valves. The stroke checking including checking of time
of operation of control valves/shutdown valves also forms a part of loop checking.
7.8.4.9 After loop checking is completed, Vendor shall connect back any terminals and
connections removed for loop checking.
7.8.5 Field Testing:
All the equipment shall be checked thoroughly after its receipt at site. The tests, as
a minimum, shall include:
a) Visual and mechanical testing.
b) Complete system configuration loading.
c) Demonstration of all system functions.
d) Checking of loop configuration.
e) Checking of all CRT / LCD TFT MONITOR displays.
f) Checking of correct functioning of all keyboards.
g) Demonstration of all system diagnostics.
h) Checking of correct change over of redundant devices.
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i) Checking of bus-degradation.
j) Checking of proper functioning of all printers and hard copy units, sample
printing of all types of log reports, shutdown reports and MIS reports.
k) Checking of all disc drives, historical trending points, alarm summary and
alarm history.
l) Complete checking of shutdown system
m) Complete checking of hard-wired instruments.
n) Demonstration of proper operation of system at specified power supply
specifications.
o) Loading of user's program and check out of results.
7.8.6 FINAL ACCEPTANCE TEST:
The owner will take over the system from the Vendor after the final acceptance
test, which is defined as successful uninterrupted operation of the integrated
system for three weeks for all units of the plant. Vendor's personnel shall be
present during the test any malfunctioning of the system components shall be
replace/repaired as required. Para 2.1.6 shall be applied for failure of components
& readjustments. Once the system failure is detected, the acceptance test shall start
all over again from the beginning. The warranty period commences from the day
owner takes over the system.
7.9 SITE ACCEPTANCE TEST:
7.9.1 The objective of the SAT is to verify the “as installed” DCS meets or exceeds
specified structural and functional requirements. The SAT shall be conducted in
two phases. The first phase shall consist of post installation inspection and
software module testing. The second phase shall be an abbreviated version of the
FAT. Tests shall verify that all equipment, interconnecting cables, external power
connections and grounding connections have been installed correctly. Data
communication cables installed by others shall be tested.
7.9.2 The SAT shall essentially be a repeat of the FAT with the following additions:
• The connecting wiring between distributed components shall be the actual field
installed wiring and cable
• The field inputs and shutdown devices shall be connected and exercised to
confirm the correct connection and compatibility of the field components
• The system will be interfaced with other systems (Package Contractor PLC’s
etc.)
• Electrical Installation Test as described below:
Electrical systems shall be tested for insulation resistance, correct
polarity and continuity. To prevent damage to electronic and extra-low-
voltage equipment all such equipment shall be disconnected at both
ends of the cable prior to the cable test and reconnected prior to the
functional test of the system
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Grounding shall be tested for faults, continuity and conformity with the
Contractor’s requirements
Terminations, glands, junction boxes and equipment enclosures shall be
inspected for correct application, installation assembly and closure.
Power supply tests over the required range
Series and common mode noise rejection on input signals to required
specifications
7.10 Shop Inspections:
7.10.1 The Company’s designated representative shall be entitled to inspect equipment,
materials and any part at the Contractor or any subsupplier’s premises during any
phase of manufacturing. Inspecting visits shall be coordinated through the
Contractor’s project manager. The Company shall have access to all quality
control and other records that document design, testing and integration of the
system. Photographs shall be permitted during system assembly to record progress
of manufacture with reasonable advance notice.
7.11 Quality Control Procedures:
7.11.1 The Contractor shall apply to the project a total quality assurance (QA) program
covering design conception, software implementation, assembly, testing and
delivery.
7.11.2 This QA program shall be based on ISO 9000 Standards such as ISO 9001 (1994),
ISO 9004-1 (1994) and ISO 9000-03 (1991) and shall have current third party
certification from a recognized body.
8.0 DOCUMENTATION:
8.1 General:
8.1.1 The documentation requirements shall in general be according to clause 3.6.6.2 of
8.1.2 Duly filled in data sheets shall be furnished along with the purchase specification.
Typical data sheets are provided as Annexure – 1 to 16 of this document.
8.1.3 Documentation shall include a functional design document that is developed in
conjunction with the Contractor. This document represents the agreed system
definition prior the beginning of fabrication. There shall also be a detailed design
document that provides details of the functional design and includes, but is not
limited to, the following:
• List of equipment and accessories on system drawings
• System overview drawings, cabinet and console layout and arrangement
drawings
• Module arrangement, insert drawings and internal arrangement drawings
for all system cabinets
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• Outline dimensions, mounting details, interconnection drawings, cable lists,

weights, heat load and power requirements for all equipment
• Itemized cable list with cable lengths, TO/FROM destinations and cable
identification
• Detailed power distribution diagrams for all power levels within the system
including circuit breaker power entries, plug and mold strips for power
distribution within workstations and system cabinets.
• Electrical connection drawings
• Detailed grounding diagram for the system
• Test plan
• An index of all documentation provided for the system
8.2 Additional Requirements:
8.2.1 Documentation shall include installation and maintenance manuals providing
detailed procedures for installation, maintenance and troubleshooting of all DCS
equipment, as well as operating and programming manuals describing operating
modes, programming procedures, parameters and guidelines.
8.2.2 Documentation shall include a complete bill of material on all purchased items and
a complete spare parts list.
8.2.3 All documentation shall be provided with the project number, a documentation
identification number and project number. The documentation shall be marked
with issue date, revision identifiers and provided in the English language. The
project requires unlimited internal copying rights to all documentation supplied.
8.2.4 CD-ROM containing word processor files of manuals listed in this Section shall be
provided. Auto-Cad files shall be provided for final issue of all project drawing.
8.2.5 Documentation shall include updates for any and all system upgrades,
modifications, documentation errors or bugs discovered by the project. Contractor
or other users of the system projects. These updates shall extend through to
expiration of the warranty and any extended service or maintenance agreements
purchased.
8.3 Documentation for Contractor Services:
8.3.1 The Contractor shall provide a comprehensive suite of documentation for the DCS,
including standard documents, as well as a Functional Specification and other
documents, which are specific to the system described by this specification and its
references and attachments.
8.3.2 These documents shall include the requirements described below and shall be
submitted for review at the times specified in the requisition. The Contractor shall
also provide accurate “as-built” issues of all documents at the completion of
commissioning.
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8.3.3 All documentation for configuration, programming and other related project
engineering services shall be provided. As a minimum these shall include:
• System configuration diagrams and workstation assignments
• Source code for all application code written for this system
• Cross reference listings of tags, tag descriptors and addresses for all
elements of the system
• I/O assignment list
• Copies of graphics and printouts of reports and logs
• Documentation of completed FAT, SAT and SPT test results
8.3.4 All application software shall be well documented. Word processor files of all
application software documentation shall be provided on CD ROMs in addition to
printed descriptions.
8.3.5 Software coding and documentation shall be in English, including code syntax and
comments in the source code, and error messages.
8.3.6 The following shall be provided for all control strategies to supplement the
representations of applications on software listings, instrument loop diagrams and
P&ID’s:
• Functional diagrams
• Narrative descriptions of strategy and functionally and engineering
information including derivations of constants
• Implementation description for all elements, control processor blocks or
high level language programming elements
9.0 TRAINING:
9.1 Training System:
9.1.1 The Contractor’s scope shall include the provision of a training system, including
the following:
• One fully configured system processor and I/O cabinet
• Simulator to allow realistic simulation of actual operations
• A fully configured operator station, including data storage/archiving
facility.
• A second workstation providing access for system maintenance and
engineering
• A dual data highway network
9.1.2 The system shall be a stand-alone entire operating system, complete with all type
of I/O, processors and communications hardware and software used on the actual
system.
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9.1.3 The training system will be connected to an SIS training PLC of the same type
used for the ESD and F&G systems and will provide training access to that system.
10 TAGGING & NAMEPLATES:
10.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1
of Instrumentation Design Criteria.
11 REVIEW & APPROVAL:
11.1 Review and approval of purchase specifications and other related documents shall
in general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
12 VENDOR PRE-QUALIFICATION REQUIREMENTS:
13 PREPARATION FOR SHIPMENT:
13.1 The DCS shall be prepared for shipment in accordance to clause 3.6.6.5 of
14 RECEIPT & STORAGE:
14.1 Receipt and storage of the DCS shall be in accordance to clause 3.6.6.6 of
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ANNEXURE 1 – DATA SHEET - PROVEN TRACK RECORD

NAME OF THE VENDOR:
As offered System as installed in
S.
Description for this
No. 1 2 3 4
project
1. Name of Plant
Name, address, telex no., telephone number of
2.
contact person in the plant
Name, address, telex no., telephone number of
3.
Consultant
4. Month & Year of supply
5. Month & Year of commissioning
6. Major break downs if any
7. System details with model numbers
a) Console Electronics / Database
b) Controller and Data Acquisition system
c) System used for:
i) Overall regulatory process control Yes/No Yes/No Yes/No Yes/No
ii) Data Acquisition only Yes/No Yes/No Yes/No Yes/No
iii) Package units only Yes/No Yes/No Yes/No Yes/No
iv) R & D pilot plant only Yes/No Yes/No Yes/No Yes/No
d) Major sub-systems:
i) No. of controllers / DAS cabinets
ii) Model no. of controllers offered
iii) No. of operator console
iv) No. of engineering console
v) Independent PLC for shutdown
vi) PLC interface with system through
serial link
vii) PLC interface with system through
hardwired connection
viii) Computer interface with system
ix) Any other interface
e) System details
i) No. of open loops
ii) No. of closed loops
iii) No. of graphic pages
iv) No. of historical trend points
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v) MIS reports
vi) User memory
vii) No. of digital I/Os for PLC
f) Scope of Vendor’s responsibility
i) Design & Supply
ii) System Engineering
iii) Installation
iv) Commissioning
v) Training
Salient features of the offered system over earlier
8.
systems, if any
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ANNEXURE 2 – DATA SHEET – RESPONSIBILITY CHART

S. Responsibility
Description Location
No. Bidder Collaborator
A. Source of Supply
1. Controllers and Data Acquisition Sub-System
a) Processor Module
b) I/O Modules
c) Communication Modules
d) Power supply modules
e) Any other
2. Operator Console & Engineering Console Sub-System
a) Processor Modules
b) Memory Modules
c) Communication Modules
d) Keyboard
e) CRT / LCD TFT MONITOR
f) Any other
3. Hard Wired Instruments
a) Hardwired Consoles
b) Trip amplifiers
c) Receiver switches
d) Barriers / Isolators
e) Annunciators
f) Any other
4. Shutdown System (PLC)
5. Hardwired consoles & racks other than system racks
6. Printers
7. Hard Copier
8. Any other
B. System Engineering
1. Basic System Design
2. Detailed system engineering including finalizing work sheet
3. Standard Configuration and Generation
4. Logging and report Generation software
5. Special software including foreign device interface
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6. System software loading testing and debugging

7. Hard copier
8. Any other
C. System integration and Factory testing
D. Installation field testing and commissioning
ANNEXURE 3
TYPICAL FORMAT FOR
CERTIFICATE OF LOGISTIC SUPPORT
(To be signed by Bidder’s Corporate level signatory on Company’s letter head)
I, on behalf of M/s.___________________ confirm that the Distributed Control System

quoted by M/s. __________________ for ________________ Project, ONGC shall be
continued to be supported by us and our principal. The quoted system shall not be
withdrawn from Indian market as a matter of corporate policy as supported by attached
certificate from our principal M/s.____________ .
I further confirm that in case of placement of order on M/s ________________, we shall

continue to support M/s. _____________ in providing backup engineering maintenance
support and spare part support to ONGC for a period of 15 years from the date of
placement of order.
(VENDOR’S SIGNATURE WITH SEAL)
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ANNEXURE 4 – DATA SHEET – DISTRIBUTED CONTROL SYSTEM
S.No. Item Details

1. Type of system distribution (Geographical / Functional)
2. Location
3. System size considering all inputs as closed loops
4. System size considering all inputs as open loops
5. System availability
6. Maximum length of Communication Bus
7. Maximum number of systems on Communication Bus
8. Standard number of nodes on Bus
9. Number of nodes with bus expander
10. Standard number of consoles on Bus
11. Number of consoles with bus expander
12. Standard number of computer interface on Bus
13. Number of computer interface with bus expander
14. Standard number of subsystems on Bus
15. Number of subsystems with bus expander
16. Model No. of Data Acquisition Subsystem
17. Model No. of Controller Subsystem
18. Model No. of Communication Subsystem
19. Model No. of Operator Interface Subsystem
20. Model No. of Engineer Interface Subsystem
21. Model No. of Programmable Logic Controller (PLC)
22. Model No. of Foreign Device Interface for GT driven PGC control system
23. Model No. of Foreign Device Interface for MOL Pump control system
24. Model No. of Foreign Device Interface for PLC based F&G system
25. Model No. of Foreign Device Interface for PDP main computer
26. Model No. of Remote monitoring terminal
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27. Model No. of personal computer

28. Model No. of Hardwired Instruments
29. Model No. of PLC
30. Module level self-diagnostics provision Yes / No
31. UPS System sizing factor
32. Type of UPS for the System
33. Type of UPS for equipment other than the system
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ANNEXURE 5 – DATA SHEET – COMMUNICATION SUB SYSTEM
S.No. Item Details
1. Communication Topology
2. Type of bus redundancy
3. Switch over of communication buses (auto / manual / both)
4. Type of communication bus
5. Type of communication
6. Type of protocol
7. Communication speed
8. Message error checking method
9. Redundant bus controller
10. Redundant communication interface for Controller Subsystem Yes / No
11. Redundant communication interface for Data Acquisition Subsystem Yes / No
12. Redundant communication interface for Operator Interface Subsystem Yes / No
13. Redundant communication interface for Engineer Interface Subsystem Yes / No
14. Redundant communication interface for PLC Yes / No
15. Redundant floating power supply for communication interface Yes / No
16. Communication Loading
17. Model No. of Communication Bus
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ANNEXURE 6 – DATA SHEET – CONTROLLER SUB SYSTEM
S.No. Item Details

1. Type of Controller (Single Loop / Multi Loop)
2. Model No. of Controller
3. Number of Controllers per rack (nest)
4. Number of rack (nest) per cabinet
5. Number of Controller cabinets
6. Cabinet-wise MTBF
7. Cabinet-wise MTTR
8. Enclosure type
9. In case of Indicating Controller
a) Face size
b) Display type
c) Mounting
d) Number of loops per controller – available
e) Number of loops per controller – with 60% loading
10. Time for Switch-over to back-up controller
11. Controller scan time
12. Control cycle time
13. Controller configurable from – Central / Local level
14. Controller tuning from – Central / Local level
15. Control modes offered
16. Tuning constant for Proportional band
17. Tuning constant for Integral rate
18. Tuning constant for Derivative time
19. Tuning constant for Dead time
20. Tuning constant for Lead Lag time
21. Anti-reset wind up feature Yes / No
22. Algorithms offered (List all the algorithms offered)
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ANNEXURE 7 – DATA SHEET – DATA ACQUISITION SYSTEM (DAS)
S.No. Item Details

1. Data acquisition sub system mounting
2. Number of inputs per processor
3. Processor redundancy
4. Time for switch over to redundant module
5. Scan time of the sub system
6. DAS configurable from – Central / Local level
7. DAS – MTBF
8. DAS – MTTR
9. DAS – Model No.
10. Type of input isolation
11. Type of output isolation
12. Type of input modules and number of inputs per module
13. Type of analog output modules & number of outputs per module
14. Type of digital output modules & number of outputs per module
15. Type of barriers for intrinsic safety (Integral / External)
16. Power Supply for transmitters
17. Maximum number of alarm settings
18. A/D converter resolution
19. D/A converter resolution
20. Load driving capability
21. Load driving capability of transmitter at 24 V DC
22. Availability of on-line self-diagnostic message (local / central level / both)
23. Type of memory for configuration (retentive / volatile)
24. Battery back-up in case of volatile memory Yes / No
25. CPU / Memory loading – maximum
26. Memory utilization – maximum
27. I/O processor loading – maximum
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28. Communication processor loading – maximum
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ANNEXURE 8 – DATA SHEET – OPERATOR INTERFACE SUB SYSTEM
S.No. Item Details

1. Number of Operator consoles
2. Interchangeability between operator consoles Yes / No
3. On-line configuration change Yes / No
4. Type of voltage isolation
5. Operator Interface Sub System – MTBF
6. Operator Interface Sub System – MTTR
7. Console electronics (Common / Separate for individual console)
8. Model no. of Operator Console
9. Memory size of Operator Console
10. Type of database (Global / Functionally separate)
11. Number of CRT / LCD TFT MONITORs
12. Number of Keyboards
13. Number of Alarm & Event Printers
14. Number of Log Printers
15. Number of Hard Copy Unit
16. Number of Assignable Trend Recorders
17. Number of Floppy Disks & Winchester Drives
Provision for interchangeability between CRT / LCD TFT
18. Yes / No
MONITORs
19. Switch-over of peripherals upon failure of console electronics Auto / Manual
20. User memory capacity

21. Database update rate
22. Type of keyboard
23. Maximum number of key strokes for accessing Group view
24. Maximum number of key strokes for accessing Loop view
25. Maximum number of key strokes for accessing Loop in alarm
26. Maximum number of key strokes for accessing Graphics view
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27. Size of CRT / LCD TFT MONITOR (diagonal)

28. Type of CRT / LCD TFT MONITOR (Colour / Black-and-white)
29. Number of display characters per line & Number of lines
30. Display update rate
31. CPU Loading
32. Memory Utilization
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ANNEXURE 9 – DATA SHEET – ENGINEER INTERFACE SUB SYSTEM
S.No. Item Details
1. Is operator console usable as engineering console Yes / No
If engineering console is different from operating console – Specify

2.
number of engineering consoles
3. Number of CRT / LCD TFT MONITORs per engineering console
4. Type of electronics (Common / Separate)
5. Memory size
6. Model number
7. Number of engineering keyboards
8. Number of maintenance keyboard
9. Type of voltage isolation
10. Peripherals provided (Printer, Hard Copy Units, etc.)
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ANNEXURE 10 – DATA SHEET – PRINTERS
S.No. Item Details
1. Type of printer (Colour / Black-and-white)
Printer application (Logging / Alarm / Event / Configuration &

2.
Maintenance / with Hard Copy Unit)
3. Printing speed
4. Number of print columns
5. Acoustic cover Yes / No
6. Paper feed
7. Mounting
8. Cord length
9. Noise level while printing
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ANNEXURE 11 – DATA SHEET – HARD COPY UNIT
S.No. Item Details
1. Type of hard copy unit
2. Screen lock-out time
3. Number of channels
4. Type of high voltage protection
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ANNEXURE 12 – HARD WIRED CONSOLE
S.No. Item Details
1. Number of Hard wired consoles
2. Number of assignable recorders on the hard wired console
3. Number of indicating controllers on the hard wired console
4. Number of indicators on the hard wired console
5. Number of recorders on the hard wired console
6. Number of totalizers on the hard wired console
7. Number of hardwired annunciators on the hard wired console
8. Number of indicating lamps on the hard wired console
9. Number of switches on the hard wired console
10. Number of push-buttons on the hard wired console
11. Number of telephone sets on the hard wired console
12. Other components, if any and their number
13. Power supply for instruments
14. Power supply for switches, lamps, push-button, etc.
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ANNEXURE 13 – FOREIGN DEVICE INTERFACE (FDI)
S.No. Item Details
1. Model No. of FDI with GT driven process gas compressor
2. Model No. of FDI with GT driven MOL pump control system
3. Model No. of FDI with PLC based F & G System
4. Model No. of FDI with PDP main computer (RTU)
5. Type of interface
6. Type of redundancy
7. Time for switch over to redundant component
8. Number of analog inputs
9. Number of digital inputs
10. Standard interface software and protocol
11. Type of communication
12. Time taken to transfer data from foreign device to operator console
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ANNEXURE 14 – HARDWIRE INSTRUMENTS
S.No. Item Details

A) Indicator / Indicating Controller / Recorder
1. Type
2. Mounting
3. Enclosure type
4. Intrinsically safe Yes / No
5. Power supply
6. Input signal type
7. No. of inputs per indicator
8. Indicator display type
9. Model no. of Indicator
10. Indicating Controller:
a) Model no.
b) Output
c) Number of I/O per instrument
d) Scan time
e) Display type
f) Set point adjustment Yes / No
g) Manual loader Yes / No
h) Auto tracking of controller Yes / No
11. Recorder:
a) Chart type
b) Type of recording
c) Chart speed
B) Hardwired Annunciator:
1. Annunciator type
2. Mounting
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3. Power supply
4. Logic unit (integral / separate)
5. Display type
6. Window size
7. Hooter (External to DCS / Solid state)
8. Alarm acknowledgement (integral / separate)
C) Hardware Switches / Pushbuttons:
1. Make
2. Model Number
3. Contact type
4. Contact housing
5. Contact rating
D) Receiver Switches (Alarm Card):
1. Make
2. Model number
3. Type of input
4. Type of contact
5. Contact rating
6. Number of settings per module
7. Power supply
8. Mounting
E) Trip Amplifier:
1. Make
2. Model number
3. Type of input
4. Source resistance
5. Thermocouple burn out protection
6. RTD open protection
7. Type of contact
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8. Number of settings per module

9. Power supply
10 Mounting
F) mV/I Converter:
1. Make
2. Model number
3. Type of input
4. Source resistance
5. Thermocouple burn out protection
6. Compensation
7. Output
8. Power supply
9. Maximum load resistance
10 Mounting
G) Signal Isolator:
1. Make
2. Model number
3. Type of input
4. Type of output
5. Type of isolation
6. Number of outputs
7. Power supply
8. Mounting
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ANNEXURE 15 – DATA SHEET – INTRINSIC SAFETY BARRIERS
S.No. Item Details
1. Safety barrier area classification
2. Location
3. Barrier type (isolating / non-isolating / single / dual)
4. Power supply
5. Fault voltage (max.)
6. Grounding
7. Intrinsic safety certificate (attached / not attached)
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ANNEXURE 16 – DATA SHEET – CONSOLE, PANEL, CABINET AND

ACCESSORIES
S.No. Item Details

1. General:
a) Type
b) Graphic displays Yes / No
c) Power supply for lighting inside the panel
d) Type of ventilation
e) Fan failure alarm Yes / No
f) Number of front doors
g) Rear door Yes / No
h) Door dimensions
i) Vibration proof Yes / No
j) Explosion proof Yes / No
k) Cable entry
2. Number of DCS system cabinets with weight and dimensions
3. Number of DC power distribution cabinets with weight and dimensions
4. Number of Trip amplifiers with weight and dimensions
5. Number of Auxiliary cabinets with weight and dimensions
6. Number of PLC Processor Cabinet with weight and dimensions
7. Number of Operator Consoles with weight and dimensions
8. Number of Engineering Consoles with weight and dimensions
9. Number of PLC Consoles with weight and dimensions
10. Number of Hardwired Consoles with weight and dimensions
11. Number of HART Maintenance system with weight and dimensions
12. Painting Colour:
a) External
b) Internal
c) Channel base
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d) Panel finish
13. Constructional Details:
a) Material of front plate
b) Material of top plates
c) Material of system cabinet front, sides & top
d) Material of door panel
e) Anchor bolt size
f) Frame angle size
g) Lifting eye bolt Yes / No
h) Card rack size
i) Card rack type
14. Wiring:
a) Size of power supply wiring used external to cabinet / panel
b) Type of insulation for power supply wiring used external to cabinet/panel
c) Size of signal wiring used inside cabinet / panel
d) Type of insulation for signal wiring used inside the cabinet / panel
e) Size of signal wiring external to cabinet / panel
f) Type of insulation for signal wiring external to the cabinet / panel
g) Terminal type
h) Terminal size for signal wiring
i) Terminal size for power distribution
j) Terminal block type
15. Power Distribution Box:
a) Location
b) Power supply isolation
c) Fuse type / rating
d) Switch type / rating
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Functional Specifications Spec No : C-101
Design Division
Rev. No : 1
Engg. Services For Programmable Logic
Discipline: Instrumentation
ISO – 9001:2000 Controller
Page : 1 of 26
FOR
PROGRAMMABLE LOGIC
CONTROLLER
(PLC)
Rev-1: Revised for scan time of 250 mSec, LCD Monitor & DO Contact Ratings.
TOTAL
PREPARED / REVIEWED
REVISED BY BY
PAGES
AK BK GRP 25 28.03.2007 1
MC MC AC 25 17.03.2003 0
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Design Division
Rev. No : 1
Page : 2 of 26
CONTENTS

4.0 Programmable Logic Controller 4
4.1 General 4
4.2 System Hardware Requirements 5
4.3 System Software Requirements 14
6.0 Installation, Inspection And Testing Requirement 23
7.0 Training 25
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Page : 3 of 26
1.1 This specification describes the essential considerations in the selection, installation,
calibration, testing and commissioning of Programmable Logic Controllers (PLC). This
specification is applicable to PLC for package equipment, PLC for Safety Systems such
as ESD, FSD and F & G, and PLC for plant safety shutdown logics as a part of DCS.
1.2 The Contractor shall be responsible for the design, manufacture, configuration,
installation, testing, operational functionality, training, shipment to yard and offshore
site, installation and commissioning at site, documentation and support for the PLC.

b) Basic Bid Work

NIL
3.1 The PLC System shall include all the sub-systems described in this specification,
Engineering software, two note book computers and all necessary interfaces for
maintenance modifications, monitoring, testing and troubleshooting.
3.2 The scope of supply shall also include commissioning spares and two years’ spares as
Manufacturer. The scope of supply shall also include spare parts for start-up and
commissioning, spare parts for two years’ operation, consumables for six (6) months
and all special tools as well as complete spare system for training.
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Design Division
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Page : 4 of 26
4.0 PROGRAMMBALE LOGIC CONTROLLER:
4.1 GENERAL:
4.1.1 Use Of Standard Products:
4.1.1.1 The PLC shall be chosen for simplicity, use of established proven components, use of
techniques that minimize the need for maintenance, ease of configuration and overall
integrity of design.
4.1.1.2 The system shall be microprocessor based and shall be composed of standard hardware
and system software, which can be configured to meet the stated requirements.
4.1.1.3 The standard operating system software shall not require modification to meet any of
the project requirements.
4.1.2 On-Line Card Changeover:

4.1.2.1 All printed circuit boards shall be able to removed or installed while the system is
operating without causing hardware damage or system errors. On-line replacement of
any module shall be possible in such a way that removal and addition of a module shall
be possible without de-energizing the system. Further there shall not be any
interruption the system or the process while replacing a faulty module wherever
redundant modules are provided
4.1.3 PLC Scan Time: (rev-1)

4.1.3.1 The scan time of the PLC shall be 250 milli-Seconds or better. Scan time of PLC is
defined as the cycle time taken by the system to read input, process input executing
logic, and update control output for all the logics configured within the system. Other
activities like diagnostic routines, output/dump of data to peripherals, or any other
activity that consume processor time shall also be accounted while computing scan
time.
4.1.4 Hazard Analysis And Risk Assessment:

4.1.4.1 The PLC implementation plan for safety-related PLC shall be based on the Hazard
Analysis and Risk Assessment specification developed by the Contractor.
4.1.5 Detail Design:

4.1.5.1 The detail design, installation, commissioning and testing, pre-start-up Safety Review,
PLC start-up operation, Maintenance and periodic functional testing and PLC
decommissioning shall be as per IEC 61508.
4.1.5.2 The system shall be designed such that the testing frequency for any single component
is not less than 3 months. The Contractor shall provide a set of test procedures for each
PLC loop to enable this testing frequency to be met in accordance with the requirements
of IEC 61508.
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Page : 5 of 26
4.2 SYSTEM HARDWARE REQUIREMENTS:
4.2.1 The PLC shall be “Fault avoidant” and shall be based on high-reliability, high-
availability programmable electronic systems.
4.2.2 PLC envisaged for safety-related functions, such as ESD-FSD PLC and F&G PLC shall
be certified to TUV AK 6, and shall be suitable for use on systems requiring SIL 3
integrity in accordance with IEC-61508.
4.2.3 The overall system availability of the PLC shall be 99.99% or better. Single point
component failure shall not result in the loss of availability of entire PLC.
4.2.4 Input / Output System:
4.2.4.1 The I/O modules shall be mounted in the I/O racks located in the Control Room. The
maximum number of Input/Output per I/O module shall be limited as per the following
table.
Sr. No. Type of configuration No. of I/Os
1. Single I/O system 8
2. Dual I/O system 16
3. Triple Redundant system 32
4.2.4.2 Each I/O shall be galvanically isolated from external control circuit by suitable means.
The minimum isolation level between I/O and logic circuit shall be 1000 volts DC.
4.2.4.3 Each I/O shall be protected against the reversal of polarity of the power voltage to I/O.
4.2.4.4 Each I/O module shall have a LED per channel to indicate the status of each
Input/Output.
4.2.4.5 Each input shall be provided with filters to filter out any noise in the input line and
contact bouncing noise.
4.2.4.6 The PLC inputs shall be provided with only dry contacts (Potential free) unless
otherwise specified. All the inputs shall preferably be double ended i.e. two wires per
input and not with common return for all inputs.
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Design Division
Rev. No : 1
Page : 6 of 26
4.2.4.7 The interrogation voltage to the input contacts shall be powered from separate power
supply / supplies and shall not be a part of PLC, unless otherwise specified. This power
supply shall be supplied at one point and shall be distributed by the Vendor.
4.2.4.8 In case of triple redundant system, if standard system architecture does not allow
triplicated signal conditioning circuits per I/O, dual redundant signal conditioning
circuits shall be provided per I/O.
4.2.4.9 Output contacts from the PLC shall be potential free dry contacts with contact rating as
per para 5.6.8.1.10. Wet contacts/powered contacts/TTL outputs etc. shall not be
acceptable. Vendor must provide arc suppression device for each output contact.
4.2.4.10 The output contact rating in general, shall be as follows: (rev-1)
S. No. Applicable for Voltage Current

Rating Rating
1. All output cards driving 110V DC 0.5A

solenoid valve and alarm
annunciator system unless
otherwise specified.
2. All LT motor/pumps/ 240V DC 5.0A

compressor output cards
3. All HT motors/pumps/ 220V DC 2.0A

compressor (6.6KV Inductive
and above) output cards
However, LSTK contractor shall, during design and detailed engineering stage
of the contract, propose the electrical scheme and the Voltage ratings for the
“Output Contact ratings” based on the electrical system / Switchgears selected,
and submit the same for Client’s approvals.
4.2.4.11 Each output shall be short circuit proof and protected by fuse. Visual indication of fuse
blown must be provided for each module.
4.2.4.12 The communication of I/O system with central processor shall be carried out redundant
with complete error checking.
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4.2.4.13 Wherever redundant communication bus and communication interface of I/O subsystem
with central processor are specified, Vendor must ensure that healthiness of each
redundant module is monitored.
4.2.4.14 It shall be possible to exchange I/O modules while the system is in operation:
a) Without influencing other logic function than the one's which are
covered by the I/O modules being exchanged for single I/O
configuration.
b) Without upsetting the process for dual I/O or dual PLC configuration.
c) In case of triple redundant system hot replacement of I/O modules shall

be provided. Additional slots must be provided in the I/O nest for hot
replacement of these modules. Also, hot replacement of the signal
conditioning modules shall be possible. No output shall be affected
while replacing these modules in either case.
4.2.5 Processor System:
4.2.5.1 The processor shall have capability to implement all the control functions required to
implement the logic scheme attached along with as logic/ladder diagram.
4.2.5.2 The size of the memory shall be sufficient for storage of the program instructions
required by the logic schemes and other functional requirements. Offer shall indicate
the amount of memory capacity occupied by the actual program and spare capacity
available for later program modifications or additions.
4.2.5.3 Memory shall be non-volatile. However in case volatile memory is provided, battery
back up shall be provided with a minimum of 3 months lifetime to keep the program
storage intact. A battery drain indication shall be provided at least one week before the
battery gets drained. A potential free contact shall be provided for hardwired
annunciation in the central control room.
4.2.5.4 Watchdog timer shall be a software device. Watchdog timer shall continuously monitor
the healthiness of processors. Any hardware or software problem in the processor
system, which shall include, CPU, memory, power supply, communication interface etc.
shall cause the watch dog timer to report processor failure.
4.2.5.5 Wherever dual redundant processor is specified, redundancy shall be provided in such a
way that in case of failure of the main processor, the standby shall take over
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automatically. The changeover shall bump less and the system shall be fail proof,
unless any other requirement is specified in the job specifications. Redundancy shall be
provided for complete processor system including CPU, memory power supply and
communication sub system.
4.2.5.6 In case of triple redundant system all the three processor shall execute the same
instructions / programs and check their results and majority vote to correct any faulty
result. The faulty processor diagnostic shall be made available.
4.2.5.7 Failure of a single processor shall not affect the system. In case of failure of complete
processor system i.e. both processors in case of dual configuration and two or more in
case of triple redundant system outputs shall take fail-safe state automatically.
4.2.5.8 Incase multiprocessor configuration is offered, the processors must be able to

communicate with each other over the interconnecting data link. Vendor must ensure
that system performance shall not be degraded by any means when such a system is
offered.
4.2.5.9 It shall be possible to generate the first out alarm contact by the PLC in case where a
group of parameters are likely to trip a system
4.2.6 PLC Console:
4.2.6.1 The PLC Console shall be used for programming, program storing, fault diagnostics and
alarm monitoring. It shall also be possible to use this for plant operation, whenever
specified.
4.2.6.2 It shall consist of a single colour 19" size TFT LCD Monitor (also referred as Monitor)
screen unless otherwise specified and one programming keyboard and printer and
operating keyboard whenever specified.
4.2.6.3 PLC console when used for plant operation shall be supplied with dedicated operator
keyboard. Even when touch screen is specified, the console in addition must be
supplied with operator keyboard, which shall have the same capability as the touch
screen as a minimum.
4.2.6.4 The keyboard shall preferably be touch sensitive sealed type, easy to operate with each
key clearly identified. It shall be provided with a lock and key to prevent any un-
intentional program modifications.
4.2.6.5 All illegal entries shall be rejected by the terminal and shall be identified by warning
signal on Monitor.
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4.2.6.6 Manual forcing of any input or output contact connected to PLC shall be possible from
keyboard.
4.2.6.7 It shall be possible to modify, add or delete the application program on line without
affecting the outputs.
4.2.6.8 PLC Console Monitor shall display logic and/or ladder diagram indicating power flow
and shall show description and status of each contact. It shall also be possible to
display process alarms and diagnostic messages as and when they appear. Further it
shall also be able to display I/O map in a user-defined format.
4.2.6.9 Whenever PLC console is used for the operation of the plant, it shall be able to display
process dynamic graphics, overview and group display. It shall also be possible to
operate the plant i.e. start and stop of rotating machinery, opening and closing of valves
etc. from dynamic graphics and group displays. All such displays shall be user
configurable.
4.2.6.10 It shall be possible to print out the ladder/logic diagram on the dedicated PLC printer.
The Printer in addition shall also print out:
a) The diagnostic messages as and when generated and diagnostic reports,

when called for.
b) Process alarms connected to the programmable logic controller as and when
they appear and alarm report whenever initiated. The choice of printing
alarms on this printer shall be operator selectable from a key lock switch on
PLC console.
c) Shutdown report as and when initiated.
d) The I/O maps showing status of all inputs and corresponding out in a user
defined format.
4.2.6.11 The PLC console shall be provided with self-diagnostics feature, which shall display
error messages and initiate an audible alarm if the fault is detected. A potential free
contact for diagnostic group alarm shall be provided which shall be connected to the
hardwired alarm and annunciator system.
4.2.6.12 In addition, a service unit or hand held programming unit for trouble shooting and
initial check-ups from local level shall be quoted separately.
4.2.6.13 The system shall be able to identify the failure at least upto the any module level
including I/O system and redundant processor through detailed TFT LCD Monitor
display and report print out.
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4.2.6.14 Isolation shall be provided between the programming panel and related subsystems if
there is any possibility of high voltage from MONITOR being transmitted to other
subsystems.
4.2.7 PLC Communication Sub-System:
4.2.7.1 The PLC communication subsystem shall be a digital communication bus that provides
a high speed data transfer rapidly and reliably between the processor, I/O Sub-system,
PLC console and other devices connected in the PLC System. The PLC shall
communicate with the DCS via dual serial interfaces to the DCS dual redundant data
highway.
4.2.7.2 Safety-related shutdown signals to and from the PLC shall be via hard-wired I/O, not
via the data highway or other communications link.
4.2.7.3 Failure of equipment associated with communications shall not affect any aspect of the
PLC functionality.
4.2.7.4 Redundancy in PLC communication subsystem shall be provided as follows unless

otherwise specified.
a) The communication subsystem between PLC processor and I/O subsystem

shall be single unless otherwise specified. This shall include single
communication bus and single interfaces/buffers.
b) For dual I/O configuration, each I/O sub set shall have separate
communication interface and bus for connecting to PLC processor.
c) For the triple redundant system, each processor shall have a separate set of
PLC communication subsystem.
d)The communication subsystem between processor subsystem and PLC

console shall be dual redundant, consisting of two separate communication
interfaces and two buses, each one configured in redundant mode, unless
this is only used as programming aid.
4.2.7.5 In case of redundant PLC communication sub system, on the failure of the active
device, the redundant device shall take over automatically without interrupting the
system operation. Information about the failed device shall be displayed at local as well
as on PLC console. It shall be possible to manually switch over the communication
from main bus/device to redundant bus / device without interrupting any system
function.
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4.2.7.6 The mechanism used by the system for error checks and control shall be transparent to
the application information/program. Error checking shall be done on all data transfers
by suitable codes.
4.2.7.7 Interface with Distributed Digital Control System.

4.2.7.8 The PLC shall be required to be interfaced to the offered Distributed Digital Control
System bus. A suitable interface shall be offered in order to achieve the following
functions:
a) Display of all input points under alarm/first out alarm connected to PLC or
generated by PLC on the main operator console.
b) Generate shutdown reports on the logging printer of Distributed Digital

Control System.
c) To receive certain operating commands from the operator console for the
operation of certain output devices connected to PLC.
d) To display diagnostic messages of PLC.
4.2.7.9 The interface shall be dual redundant
4.2.8 System Spare Capacity:
4.2.8.1 Redundant capacity shall not be considered spare capacity. The PLC shall be delivered
to the installation site with the following minimum spare capacity and expansion
capabilities:
• I/O Racks shall contain 20% installed spare I/O modules.
1) Module types shall be provided in the approximate ratio of non-spare
types and distributed throughout I/O racks.
2) Other system components to support installed spare I/O, such as I/O
power supply capacity, terminal blocks, I/O cables, I/O communications,
etc., shall be installed with capacity for all installed I/O plus an
additional 20% spare capacity.
3) If terminal blocks are pre-wired to the process I/O, then these shall also
be pre-wired to the spare I/O.
• I/O Racks shall have an additional 20% spare rack space without installed
modules.
• Processing modules shall be sized so that the average load uses no more than
60% of the processing capacity and memory. Historical storage shall have 75%
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spare capacity. Estimating tools to calculate the expected processing and

memory capacity usage shall be included with the system.
• Cabinets that contain terminal blocks shall be provided with 20% spare terminal
blocks. This is in addition to the requirements above.
• Whenever relays are used to interface process input / outputs with the PLC, 20%
additional relays shall be provided. In addition, 20% spare space shall be
provided in cabinets to install 20% additional relays in future.
4.2.8.2 Vendor shall quote separately for 5% modules as mandatory spares or minimum one
module of each type for all types of cards/modules used in their system including I/O
modules, processor module, memory module, power supply module etc., but shall not
include hardware like hard disc, disc drives, MONITOR's terminals, switches etc.
4.2.8.3 Paper and ink required for printers, copier or any other consumable item shall be
supplied with the system required for minimum of six (6) months durations.
4.2.8.4 Safety barriers shall be provided for intrinsically safe input/output circuits wherever
specified. In such cases, the system shall be designed intrinsically safe based on entity
concept. The barriers shall be certified by a statutory authority like BASEEFA,
CENELEC, FM, PTB, CMRI etc., for use in the area classification as specified
elsewhere in the job specifications. The proper selection of the safety barriers shall be
the Vendor's total responsibility.
4.2.9 Bypass Switches:
4.2.9.1 The following shall apply when dealing with maintenance bypasses:
• Maintenance bypasses shall form part of the overall PLC design, to meet
maintenance and testing requirements. System design shall minimize the
requirement for bypasses, consistent with maintaining the required system
integrity.
• Under no circumstances shall manual emergency shutdown switches be
bypassed.
• Maintenance bypass switches shall be implemented by hard-wired manual
switches directly connected to the PLC as digital input signal, and bypass
functionality shall be carried out by the PLC’s application software.
• Maintenance bypass switches shall not operate multiple bypass functions.
• The system shall be configured so that only one maintenance bypass can be
activated at a time.
• Operation of any bypass switch shall be logged on the PLC and the DCS event
loggers and shall initiate a DCS alarm, a common alarm on the hard-wired
annunciator.
• Bypass switches shall not inhibit associated process alarms.
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4.2.9.2 The following shall apply when dealing with start-up bypasses:
• System design shall minimize the need for start-up bypasses.
• Start-up bypasses shall be initiated from soft-switches of the DCS stations in the
Central Control Room.
• Start-up bypasses shall be automatically reset by a time-out or by the associated
process parameter reaching normal limits.
• Start-up bypass time-out values shall be minimized, and shall be evaluated
during risk evaluation and HAZOP. Adjustment of start-up time-outs shall not
be available to operators.
• Start-up bypasses shall be alarmed and displayed to the operator on the DCS.
• A hard-wired key switch shall be provided to prevent unauthorized operation of
the Start-up bypass system.
4.2.10 PLC System Cabinets:
4.2.10.1 All PLC system cabinets shall be completely wired with all modules in place. Inside
cabinet wiring shall preferably be done using ribbon type pre-fabricated cables.
4.2.10.2 All the cabinets shall be free standing, enclosed type and shall be designed for bottom
entry of cables. Cabinet structure shall be sound and rigid and shall be provided with
removable lifting lugs to permit lifting of the cabinets.
4.2.10.3 Cabinets shall be fabricated from cold rolled steel sheets of minimum 2 mm thickness
suitably reinforced to prevent warping and buckling. Doors shall be fabricated from
cold rolled steel sheet of minimum 1.6 mm thickness. Cabinets shall be thoroughly
devoid of all sharp edges shall be grounded smooth after fabrication.
4.2.10.4 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filter and two coats of high grade lacquer with wet sanding between two
coats. Three coats of paint in the cabinet colour shall be given for non-glossy high satin
finish. Colour of the cabinets shall be as per job specification.
4.2.10.5 Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base), 1200
mm wide and 1000 mm deep, in general. Construction shall be modular preferably to
accommodate 19" standard electrical racks. All cabinets shall be of same height.
Maximum swing out for pivoted card racks, doors and drawers shall be limited to 600
mm. Dimensions given here are indicative/ tentative only, bidder shall take prior
approval from the company for the finalization of dimensions of cabinet at the time of
Detail Engg.
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4.2.10.6 Cabinets shall be equipped with front and rear access doors,. Doors shall be equipped
with lockable handles and concealed hinges with pull pins for easy door removal.
4.2.10.7 In order to remove dissipated heat effectively from cabinets, yent louvres backed by
wire fly screen shall be provided in cabinet doors. Further, ventilation fans shall be
provided, if required.
4.2.10.8 Illumination shall be provided for all cabinets by incandescent lamps, which shall be
operated by door switch.
4.2.10.9 Equipment within the cabinet shall be laid out in an accessible and logically segregated
manner. Cable glands shall be provided for incoming and outgoing cables to prevent
excessive stress on the individual terminals. All metal parts of the cabinet shall be
electrically continuous and shall be provided with a common grounding lug.
4.2.10.10 Each I/O module shall be provided with separate terminals for individual inputs
and outputs. All inter cubicle and internal signal wiring shall be done using minimum 1
mm2 stranded copper conductor, and power wiring shall be done using minimum 1.5
mm2 stranded copper conductor. All terminals shall be suitable for minimum 2 mm2
cables.
4.3 SYSTEM SOFTWARE REQUIREMENTS:
4.3.1 The system software shall include all programs for the PLC and PLC console which are
required to perform all PLC functions including communication and self-diagnostics.
4.3.2 All operating and application software shall be the latest revision of all proprietary
software. The Contractor shall provide any new revisions of software during the
development of the project.
4.3.3 Logic program shall be recorded on the floppy disc or cassette tape, which shall be
delivered in duplicate together with the system.
4.3.4 The PLC programming language for implementation of logic operations shall be based
on the following representations:
a)) Logic diagrams - Binary logic symbols such as AND, OR, NOT Gates,
Timers and Flip Flops.
b) Ladder diagram - Series parallel connection of relay contacts.
c) Combination of (a) & (b) above.
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4.3.5 Details of the diagnostic package and its related equipment and software shall be
supplied by the Vendor with the offer. A list of additional diagnostic packages
available including their description and capabilities shall be provided as a separate
quote.
4.3.6 It shall be possible to print out the ladder/logic diagram on a dedicated printer. The
printer shall also print out all diagnostic reports. Vendor must supply the off line
software package to enable the owner to modify/add/delete any part of program and for
documentation.
4.3.7 Software for the generation of various displays including dynamic graphics, whenever
specified shall be provided.
4.3.8 The software for printing alarms, system as well as process and events on the PLC
printer must be provided. All alarms must be printed as and then they appear.
4.3.9 Software package for displaying I/O map showing status of inputs and corresponding
output as per logic shall be offered. The I/O map format shall be user definable.
4.3.10 System software for the report generation for reports like hourly, on demand, per shift,
daily and weekly report shall be provided in the user-defined format.
4.3.11 Software for printing system as well as process alarms and events shall be provided.
All alarms shall be printed as and when they appear.
4.3.12 All details and description shall be provided for the software package including the on-
line I/O testing software.
4.3.13 The system shall have an extensive set of self diagnostic routines which shall be able to
identify the system failure at least upto module level including redundant components
and power supplies through detailed MONITOR displays and report print out.
Diagnostic software shall have the capability to provide information about the failed
modules/system either in the form of a system configuration display or provide
information in the form of a statement.
4.3.14 Automatic self-testing and system diagnostics shall be incorporated in the PLC
configuration. At the local level, failure of a module in any subsystem shall be
identified by an individual LED. All testing and system diagnostics shall be a proven
integral part of the standard system and shall be completely transparent to the user when
the application is implemented. Self-diagnostic software shall have capability to detect
faults which make the system permanently close/open in the I/O modules or I/O signal
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conditioning modules (in case of triple redundant system). This may be achieved by
automatically running the testing software at cyclic intervals. The automatic cyclic
testing feature shall also be provided for dual I/O configuration and dual I/O signal
conditioning for triple redundant system. The testing software cycle time may be field
adjust able by engineer. However, system performance shall not be degraded whenever
testing feature is specified.
4.3.15 System diagnostics shall identify all possible faults and provide a means to annunciate
diagnosed malfunctions. An alarm shall be initiated in the event of any malfunction or
authorized maintenance procedure, which as a minimum, shall consist of the following:
• Removal of, or any defect in, any logic unit, communication module or
processor
• Removal of, or any defect in, any input or output module, channel on a module
or I/O interface device.
• Power supply failure
4.3.16 On-Line Self Testing:

4.3.16.1 PLC systems shall be designed for high availability, with on-line self-testing.
4.3.16.2 As a minimum the following basic functions shall be verified by on-line testing:
• Individual check of the system’s ability to change the state of an input channel
• Individual check of the system’s ability to change the state of an output channel,
i.e., loop back testing feature
• Check of the logic-solving ability
• Standard PLC diagnostics (watchdog, etc.)
• Power-up initialization checks and checks for communication failures.
• Testing of field wiring and End-of-line devices (ELDs)
4.3.16.3 The frequency of the self-diagnostic tests shall be required to provide 99.99% system
availability.
4.3.17 In case of dual I/O or dual signal conditioning modules for triple redundant system,
whenever output module testing software detects any faulty channel, the power supply
to that particular module in that particular bank is removed automatically and further
testing on the corresponding module in the other mirror image bank is stopped.
However, the testing shall continue uninterruptedly in other output modules. Testing
software shall be capable of detecting faults in case of normally closed system as well
as in normally open system.
4.3.18 Feedback must be provided in case of triple redundant system from the output voter
system to detect any latest faults of the system in addition to other diagnostic software.
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4.3.19 Diagnostic package and its related equipment and software shall be supplied. A list of
additional diagnostic packages available and the packages provided, including the
description and capabilities shall be provided with separate quote.
4.3.20 Security Measures:
4.3.20.1 The protective system implemented by a PLC shall be adequately protected against
unauthorized access by key-lock or password or a combination of both.
4.3.21 Application Software:
4.3.21.1 The configuration language shall feature the choice of ladder, functional logic block,
sequential function chart or structured text programming, and shall comply with IEC-
61131.
4.3.21.2 Functional logic blocks shall be pre-defined as standard for the system. The Contractor
shall submit the proposed format to the Company for approval prior to implementation.
4.3.21.3 Logic blocks may be used when a function block is not available.
4.3.21.4 Combination logic implementation shall use functional logic diagrams or cause and
effect charts.
4.3.21.5 Flow chars shall be used for sequencing.
4.3.21.6 Whichever method is chosen, the representation shall be kept as simple as possible to
allow participation by non-control system specialists such as operations, loss prevention
and process engineers.
4.3.22 Consideration shall be given to using application development tools that allow the PLC
application software to be presented in one of the preferred methods to enable the
project to:
• Eliminate a large portion of work through the design phase
• Eliminate coding errors in not having to translate the application specification
from a functional logic diagram to ladder code
• Provide effective documentation.
4.3.23 All protective system shall be self-documenting in:

• Original programming of the application
• Any changes made after the installation
4.3.24 The following shall be generated as a minimum:

• A program listing that includes a functional description
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• A system configuration
• Logic or ladder diagrams
• A cross-referenced listing of tag numbers and program use locations
• The application software shall be structured and annotated to provide anyone
with a good understanding of the protection implemented.
4.3.25 All networks shall be fully annotated including logic description, alarm and trip set
points and point tag numbers. This shall appear on the maintenance / engineering PC
and hard copy printouts.
4.3.26 It shall be possible to download at least minor changes in software from the
programming terminal to the protective system while it is on-line without disturbing the
operation of the plant. Adequate testing procedure shall be available to verify the new
logic prior to activating it in the on-line program.
4.3.27 The Contractor shall provide a complete list of the limitations to on-line changes.
4.3.28 Software changes throughout all phases of the project shall be controlled in accordance
to IEC-61508.
4.3.29 Key lock and password protection shall be provided to prevent downloading of altered
software to the operating PLC, and unauthorized software code on the programming
terminal.
4.3.30 The application software shall not use more than 60% of the available system memory.
The central processing unit shall, under normal working conditions, be less than 50%
loaded. This loading shall be demonstrated during FAT. Worst-case conditions shall
also be simulated to determine if degradation of loading is within acceptable limits.
These include multiple alarms, automatic shutdowns and so forth.
4.3.31 Sequence of Events (SOE) handling shall be implemented so that time and date
stamping provides a correct sequence for troubleshooting. The PLC shall perform SOE
recording but the display shall be via the Engineering workstation. The DCS shall not
be used as SOE recorder. SOE resolution shall be 1 millisecond. The PLC shall be
provided with access to the local printer for printing SOE logged data, programme
listings, systems alarms and the like.
4.3.32 Access To System:
4.3.32.1 Normal access to the system for operations purposes shall be from the DCS
workstations.
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4.3.32.2 If engineering and maintenance functions cannot be accessed from the DCS
workstation, a separate engineering workstation computer shall be provided at each
PLC location.
4.3.32.3 The System shall allow application software to be developed and tested off-line on the
Engineering Workstation.
4.3.32.4 Failure of any component in the operator interface shall not cause a spurious shutdown,
nor shall the component failure go undetected.
4.4 ELECTRICAL REQUIREMENTS:
4.4.1 The power supply configuration to the PLC shall be kept as simple as practical.
Complex external mechanical change over system using contactors shall not be used.
4.4.2 The PLC shall use supplies from 24VDC battery systems, to reduce the UPS
requirements. The 24 V DC battery power shall be provided with dual 50% battery
banks and dual chargers.
4.4.3 Operation of PLC shall be completely unaffected by a momentary loss of power of the
order of 20m sec.
4.4.4 The primary power source to the PLC shall be capable of supplying power for nominal
periods of not less than 2 hours for the ESD PLC and 24 hours for the F&G PLC.
These periods shall be confirmed by the Contractor following project risk assessments
and HAZOP.
4.4.5 The PLC and its sub-components shall be selected so that two supply sources can be
connected; the power supply paralleling shall be integral to the equipment design. This
eliminates the need for complicated paralleling schemes in the electrical supply
configuration and thus a common point of failure.
4.4.6 The primary power supply system for the PLC shall have at least one common alarm as
an input to the PLC or the facility DCS so that any fault on the power supply systems is
annunciated in a permanently manned location. The common alarm shall annunciate at
least loss of supply to the system, charging system fault and low battery voltage.
4.4.7 The primary power supply shall be sized to the requirement of the installed load with
approximately 50% excess capacity for the manufacturer’s design life of the batteries.
4.4.8 The electrical distribution to the PLC and its sub-components, including the distribution
network for interrogation voltage, shall be arranged so that there is no single point of
failure that will affect the availability of the system.
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4.4.9 The PLC shall be suitable for correct operation in the event of the following supply
variations:
• Voltage depression to 80% of system voltage for up to 10 seconds during motor
starting
• System frequency tolerance of +/- 1% coincident with the AC voltage variation
4.4.10 Each I/O rack shall have a separate independent power supply system. Each power
supply shall be sized to take full load of the I/O rack/signal conditioning panel/rack and
shall be provided with dual redundant power supply. Suitable battery back up shall be
provided to protect volatile memory.
4.4.11 In general all output contacts and solenoids shall be powered with 110V + 10% dc /
24V ± 10% dc power supply. However, the actual interrogation voltages shall be as per
job specifications and logic diagrams.
4.4.12 Sequential starting of various load centers shall be provided whenever required.
4.4.13 Power distribution network shall use bus bars of adequate capacity with DPDT switches
and HRC (high rupture capacity) fuses in each branch network. Vendor may select
circuit breaker if short circuit characteristics do not match the HRC fuse.
4.4.14 All cubicles lighting shall be on 240 V, 50 Hz AC normal power supply.
4.4.15 Earthing Requirements:
4.4.15.1 Each cabinet, console and other equipment supplied, as a part of PLC system shall be
provided with an earthing lug. All these lugs shall be properly secured to the AC mains
earthing bus.
4.4.15.2 All circuit grounds, shields and drain wires of control cables shall be connected to the
system ground bus which shall be electrically isolated from AC mains earthing bus.
This bus shall be typically of 25 mm wide and 6 mm thick of copper.
4.4.15.3 All barriers, if used, shall be securely grounded. Safety barrier ground wire shall be
capable of carrying a maximum fault level current of 0.5 A at 250 r.m.s. per barrier.
4.5 FUNCTIONAL REQUIREMENTS;
4.5.1 The PLC used for safety-related / shutdown functions shall execute the following
distinct shutdown levels:
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Design Division
Rev. No : 1
Page : 21 of 26
• ESD-0 – Abandon Platform – Shutdown of all systems except navigation aids,

emergency radio and lighting
• ESD-1 – Sub-surface shutdown
• ESD-2 – Surface shutdown
• ESD-3 – Process Unit Shutdown
4.5.2
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Design Division
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Page : 22 of 26
Alarms And Sequence Of Events:
4.5.2.1 Control Room Alarms (Process):

4.5.2.1.1 First-out indication shall be provided for alarms.
4.5.2.1.2 Pre-shutdown alarms shall be generated and displayed by the plant DCS. Generally
these will be generated by the field devices connected to the DCS that monitor the same
process variable as the PLC shutdown initiation device.
4.5.2.1.3 Shutdown alarms displayed by the DCS shall be initiated by the same logic that
implements the shutdown. The DCS inputs shall provide an independent and positive
indication that a PLC has executed a shutdown.
4.5.2.1.4 Consideration shall be given to the technology of expert systems to enhance alarming.
Features shall include:
• Qualifying individual alarms by comparing against other input criteria
• Providing criteria for rate of change
• Predicting when a dangerous condition is about to occur and cutting back on
critical variables to bring the process or equipment into a safe operating region
4.5.2.2 Control Room Alarms (System):

4.5.2.2.1 System alarms generated by the PLC to indicate system malfunction shall be
annunciated in the DCS.
4.5.2.2.2 Alarms from the F&G PLC shall be clearly segregated from those from the ESD PLC.
4.5.2.3 Visual Alarms:

4.5.2.3.1 Visual alarms in the field or located on local field panels shall be oriented and shaded to
ensure that alarms are clearly visible in bright sunlight. LED clusters are preferred and
shall be used for visual indicating lamps to provide reliable and fault free operation.
4.5.2.4 Alarm Functionality:

4.5.2.4.1 Consideration shall be given to implement the required alarm functionality from the
application program of the PLC, allowing the use of simple devices in panels. The
same signals can then also be used to map through onto the DCS with the same
functionality.
4.5.2.5 Visibility of Annunciator Lamps:

4.5.2.5.1 Test, acknowledge and reset buttons shall be located so that all affected annunciator
lamps are clearly visible from the button location. If the PLC is implementing the alarm
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
Rev. No : 1
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functionality, the test feature shall be directly built into the PLC, thus testing the entire
system.
5.1 Environmental Conditions:
5.1.1 The PLC shall in general be housed in pressurized, air-conditioned rooms, with
temperature and humidity maintained within the ranges 21-24 deg.C, and 45-55% RH.
The Contractor shall allow for air-conditioning failure, when the ambient conditions
could rise to 50 deg C and 95% RH for periods upto 8 hours.
5.1.2 The Contractor shall ensure that the PLC environment complies with ISA S71.01 and
ISA S71.04.
5.2 Equipment Noise:
5.2.1 The system shall have a very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and Electro-
magnetic disturbances expected in a plant. The maximum acceptable noise level for the
PLC system in the Control Room shall be 55 db measured at a distance of 1 m lateral
from the source and 1.5m vertical from the floor with a sound level meter using the “A-
weighted” sound level scale.
5.3 Hazardous Areas:
5.3.1 The PLC will be located in non-hazardous area within pressurized rooms.
6.0 INSTALLATION, INSPECTION & TESTING:
of Instrumentation Design Criteria. In addition, the following shall also be taken care
of:
6.2 The acceptance tests shall include:

• Hardware and software tests
• Factory Acceptance Test (FAT)
• Site Acceptance Test (SAT)
6.3 The tests undertaken shall demonstrate that each of the following responsibilities has
been fulfilled:
• The system is tested as an integrated system
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
Rev. No : 1
Page : 24 of 26
• The hardware and software responsibilities are fulfilled

• All tests are documented in a checklist fashion
• The system is fully proven and ready for service.
6.4 The test procedures shall be developed in parallel with the system design.
6.5 The test procedures shall be developed by the Contractor as system engineering
proceeds and shall be published at least one month before commencement of the first
factory test.
6.6 Any component of hardware or software failed during a test shall be re-tested as
necessary to prove rectification has been completed satisfactorily.
6.7 Hardware Tests:
6.7.1 Comprehensive hardware tests shall be completed by the Contractor prior to any
acceptance. Contractor shall carry out the following tests as part of their QA procedure
and sign off as part of the QA requirement:
• A heat soak test of 48-hour duration shall be carried out
• All modules will be tested individually after being installed in the purchased
system.
• The Contractor shall provide documented test programs that fully exercise all
functions in the purchased system.
• The Contractor’s quality control test records shall be made available for
examination.
6.8 Factory Acceptance Test (FAT):
6.8.1 Before the system is delivered to the site, satisfactory performance of the entire system
shall be demonstrated. The system shall simulate the final onsite configuration as
closely as possible.
6.8.2 Detailed test schedules, including at least the tests listed below, shall be submitted for
the Company’s approval one month before the testing. The Contractor shall have a
technician and test equipment available full time during testing. The tests shall be
conducted after the 48 hours heat soak test.
• Inspection of equipment
• Shock or vibration test (Contractor shall supply certification to demonstrate such
a test was passed for the generic system)
• Power supply variations
• Radio interference test
• Functional tests, including:
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
Rev. No : 1
Page : 25 of 26
1) Operator control panel functions

2) Module replacement and standby changeover
3) Operation of multiple processors
4) Operation of communication channels, including PLC to DCS
communication link
5) Operation of power supplies
6) Failures and interaction between different parts of the system
7) Systematic diagnostic test, including self-test facilities
8) System and report alarms
• Electrical isolation test

• Application logic test
• Application software functional change test as per the Logic and / or the Cause
and Effect diagrams
• System responsiveness (e.g.: scan time, alarm discrimination, logging and
screen updates)
• SOE test, including accuracy of time-stamping
• Spare capacity verification
6.9 Site Acceptance Test (SAT):
6.9.1 The SAT shall essentially be a repeat of the FAT with the following additions:
6.9.2 The connecting wiring between distributed components shall be the actual field-
installed wiring and cable.
6.9.3 The field inputs and shutdown devices shall be connected and exercised to confirm the
correct connection and compatibility of the field components.
6.9.4 Test of interfaces with actual systems i.e., DCS, etc.
6.9.5 A repeat of the FAT shall be required after field connections of the actual system
connections are made. Input output signal simulation shall be at the transmitter end to
enable the system to be tested end-to-end.
7.0 DOCUMENTATION:

DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
Rev. No : 1
Page : 26 of 26

11.1 The PLC shall be prepared for shipment in accordance to clause 3.6.6.5 of
12.1 Receipt and storage of the PLC shall be in accordance to clause 3.6.6.6 of
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

Full Specifications For Off Shore Platforms

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LIST OF FUNCTIONAL SPECIFICATIONS – INSTRUMENTATION

(As applicable for Sagar Laxmi Modification Project)

S.No. FS # Description Rev Date Revision

1. 3100 Level Gauge 04-05-2011 4

2. 3101 Level Switch (Pneumatic) 18.02.2008 3

3. 3102 Level Switch (Electrical) 18.02.2008 3

4. 3103 Level Transmitter 30.03.2011 4a

5. 3200 Flow Switch 18.02.2008 2

6. 3201 Flow Totalizer 31.03.2011 4a

7. 3202 Electronic Flow Transmitter 30.03.2011 5a

8. 3203 Orifice Plate Assembly 31.08.2009 4

9. 3204 Restriction Orifice Assembly 18.02.2008 3

10. 3205 Senior Orifice Assembly 27.08.2009 3

11. 3206 Rotameter 18.02.2008 3

12. 3207 Turbine Flow Meter 26.08.2009 4

13. 3208 Coriolis Meter 31.03.2011 4a

14. 3209 MPFM 16.12.2010 4

15. 3210 Gas Flow Computer 18.02.2008 3

16. 3211 Liquid Flow Computer 28.09.2009 4

17. 3212 Ultrasonic Flow Meter 03.05.2010 1a

18. 3213 Electro Magnetic Flow Meter 09.02.2009 1

19. 3300 Temperature Gauge 18.02.2008 4

20. 3301 Temperature Switch (Electrical) 18.02.2008 2

21. 3302 Temperature Transmitter (Electronic) 16.07.2010 3

22. 3400 Differential Pressure Gauge 30.09.2011 5

23. 3401 Pressure Gauge 31.03.2011 5b

24. 3402 Pressure Switch (Electrical) 18.02.2008 2

25. 3403 Pressure Transmitter (Electronic) 30.03.2011 4a

26 3404 Current to Pneumatic Convertor 21.12.2010 0

27. 3500 Fire & Gas Detection System 13.12.2011 4

28. 3501 Shut Down Panel (Pneumatic) 23.09.2010 4

S.No. FS # Description Rev Date Revision

29. 3502 Telemetry Interface Cabinet 31.03.2011 3

30. 3503 Instrumentation for Equipment Package 28.03.2007 1

31. 3506 Hydraulic Power Unit Cum Panel 16.06.2008 1

32. 3507 Bulk item requirements for interfacing 15.05.2008 1

33. 3508 Instt Cables 02-05-2011 2

34. 3509 Sub Sea Intervention Valve Actuator 28.07.2008 1

35. 3510 Sub Sea Umbilical 05.09.2011 1

36. 3511 Electro Hydraulic System (Marginal Fields) 08.12.2011 0

37. 3600 Hi-Lo Pilot Switch 18.02.2008 4

38. 3601 Pressure Indicating Controller 31.03.2011 4a

39. 3602 P / I Converter 18.02.2008 2

40. 3603 Recorder (Electronic) 18.02.2008 2

41. 3604 Recorder (Pneumatic) 18.02.2008 2

42. 3605 Portable Calibrator 18.02.2008 3

43 3606 Filter Regulator 18.02.2008 3

44 3700 Control Valve 23.02.2010 4

45 3701 Safety Relief Valve 14.12.2010 3

48 C100 Distributed Control System 11.07.2007 3

49 C101 Programmable Logic Controller 28.03.2007 1

50 C102 Integrated Control System 06.12.2006 0

51 C103 Telecom System 07.12.2006 0

52 C104 HIPPS 15.06.2010 2

Clause No. ITEM Page No.

1.0 SCOPE OF THIS DOCUMENT:

Material Selection Chart for Level Gauge.

2 A4, A6, A9, B9, D9, E9 SS316 SS316 SS316

3 A5 MONEL MONEL MONEL

4 A7 Titanium Titanium Titanium.

6 A10, B10, D10, E10, F10 SS316L SS316L SS316L

A11, B11, D11, E11, F11, PA11, PB11, PD11, MONEL-

LEVEL GAUGE CONNECTION TOP AND BOTTOM