3.4.1 It is Vendor responsibility to design its package as required to permit safe and orderly start-up, shutdown and operation.
3.4.2 Vendor’s recommended start-up, shutdown and operating procedure, will be reviewed by PIDEC.
3.4.3 The above procedure shall be included in the package “operating and maintenance manual”.
3.5 INSTRUMENTATION
‘General’
3.5.1 The control and monitoring of ASU unit will be considered in a dedicated control room/building. Additionally, provisions shall be taken into account to perform data communication with offsite ITR. It should be noted that offsite DCS operator stations and cabinets (if any) will be installed in ASU control room.
3.5.2 Control room design (including CCR, auxiliary room, Eng. room, ...) and relevant documents such as Control room layout, Cabinets & Operator/Engineering stations arrangement, cable ladder arrangements and etc. shall be provided by Vendor.
3.5.3 Vendor shall calculate and supply required power supply (110 V AC, 50 Hz, UPS) for control systems and field instruments (redundant feeders shall be considered for control systems of all packages).
3.5.4 Vendor shall design and supply “Safety & Instrument Grounding” requirements.
3.5.5 Vendor shall design and supply all the instrumentation necessary for the safe and efficient operation of the Air Separation Unit (ASU) to fulfill the process requirements specified in this requisition. This includes, but not limited to all the instruments and control required for safe and satisfactory start up, control and shut down of the package units.
3.5.6 All instruments in hazardous area shall be of intrinsically safe (IS) type. Using of explosion proof devices are only acceptable if IS type is not commercially available.
Signals from/to MCC’s shall be considered as non-IS.
All panels, enclosures and junction boxes shall be explosion protected according to their area classification.
All field mounted instruments, enclosures and junction boxes shall be protected to IP-65.
3.5.7 SIL STUDY shall be performed for packages based on IEC- 61508 and ESD loops shall be classified accordingly. Necessary provisions to meet the results of SIL
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study shall be considered for PLC and instruments.
3.5.8 The process override or maintenance override switches shall be shown on relating diagram (if required) and the required facilities shall be foreseen as per Vendor’s common practice.
3.5.9 Air supply to pneumatic instruments and instrument air distribution inside ASU is in Vendor scope of supply and work.
3.5.10 All instruments and control systems shall be calibrated/ configured, programmed and debugged completely before delivery to minimize field works. PLC system and related equipments, barriers, power distributions etc. as well as cabinets, local panels shall be shop fabricated and wired up to the terminals, ready for installation and interconnection at site.
3.5.11 Vendor shall recommend spare parts for commissioning and 2-year operation.
3.5.12 All instruments and devices shall be supplied with nameplates indicating tag no., type, model no., serial no., range, type of protection, certifying authority, etc.
3.5.13 For FCS and respective cabinets, please refer to document No. 1210-00-IN-MSS-601, “Material Standard Specification for Fieldbus Control System” (attached to requisition).
3.5.14 For instruments selection and control / safety systems design, please refer to document No. 1210-00-IN-ESS-603, “Engineering Standard Specification for Package Instrumentation” (attached to requisition).
3.5.15 For PLC-based control / shutdown system and respective cabinets, please refer to documents No.1210-00-IN-MSS-673, "material standard specification for programmable logic controllers" (attached to requisition) and 1210-00-IN-MSS-672,
"material standard specification for cabinets" (attached to requisition).
3.5.16 For MMS, please refer to document No. 1210-00-IN-MSS-676, “Material Standard Specification for Machine Monitoring System” (attached to requisition).
3.5.17 For electrical interface with MCC’s, please refer to document No. 1210-00-IN-SKT-005, “Instrument/Electrical Connection Details” (attached to requisition).
3.5.18 For Vendor documentation, please refer to document No. 1210-61-PR-RFD-104,
“Requirement for Documents” (attachment No. 3).
‘Control System’
3.5.19 The PLC’s used for shutdown of ASU shall be fully redundant (CPU, bus, communication modules, power supply, I/O cards, etc).
3.5.20 Galvanic isolator barriers (with HART feature for analog signals) shall be used.
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3.5.21 The PLC’s shall have the capabilities to integrate and work with the main instrumentation and control and shall have the communication capabilities to exchange data from and to other external PLC based control equipments and FCS.
3.5.22 Each PLC system shall communicate with Plant FCS (if any) by redundant bi-directional Modbus RTU through RS 485 physical layer. FCS will act as the master.
Coordination with FCS Vendor has to be carried out by Vendor.
3.5.23 The PLC’s shall be provided with all required system software including application/utility programs, engineering/configuration tools, checking and self-diagnostic fault detection capabilities.
3.5.24 The required shut-down, start-up and inter-lock diagrams, based on IEC 61131, shall be provided and implemented in ASU’s control system by Vendor.
3.5.25 The system logic shall be ‘fail safe’. All instruments shall be considered for fail to safe action upon loss of instrument air or electrical power. The input contacts to alarm, interlock and emergency shutdown system shall be close (make contact) during normal operation and open on alarm or trip. The solenoids shall be energized during normal operation and de-energized to trip.
The status of all switches in normal operating conditions shall be logic high “1”.
3.5.26 Comprehensive system status information shall be available on standard displays.
The PLC shall be capable of on-line replacement of any faulty module without requiring system shutdown.
3.5.27 Sensors for shutdown shall be separated from sensors provided for measurement, control or pre-alarms.
3.5.28 PLC control system shall receive synchronization signal from Plant FCS, at predefined periods and make synchronized with Plant FCS.
3.5.29 Provision shall be made to facilitate Machine Monitoring interface to Machine Condition Monitoring (where applicable).
3.5.30 All the system hardware (including monitoring, control, protection, communications, communication with FCS, etc.) complete with all software (including application software) installed and loaded on the corresponding hardware, are subject to Factory Acceptance Test (FAT). FAT procedure shall be prepared by Vendor, approved by Owner and used as the guideline for performing FAT. Owner reserves the right to modify Vendor’s standard procedure.
‘Field Instruments’
3.5.31 The instrumentation shall be rated to withstand the tropical, dust, humid environmental conditions.
3.5.32 Design and supply of all instruments, including process / air tubing and cabling are within Vendor’s scope of supply.
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3.5.33 All instruments shall be cabled up to auxiliary room through relevant junction boxes / local panels.
3.5.34 All instruments installation materials including fittings, isolation and drain valves, manifolds, junction boxes, cable ladders/trays, glands, instrument support, etc. are in Vendor’s scope of supply.
3.5.35 Vendor shall provide 4-20 mA, HART transmitters with integral indicator and potential free contacts switches. Solenoid valves shall be IS with 24 VDC voltage rating.
All limit switches for automatic valves shall be proximity (NUMOR) type and intrinsically safe.
3.5.36 All instrument/automatic valves wetted parts and process/air tubing materials shall be S.S. 316 as minimum, other materials as per process conditions.
3.5.37 All cable entries shall be M20X1.5 with explosion-proof cable glands.
3.5.38 Isolating valves shall be provided for all instruments. Multi port gauge valves for pressure switches and gauges and 5-valve manifold for DP transmitters shall be considered.
3.5.39 Guidelines for selection of Spare parts for commissioning/ start up and two years operation are listed below:
Erection, pre-commissioning, commissioning and start-up spare parts For Control Panel Cable – Single Pair Cable – Multi Pair Cable Glands
Junction Boxes – Large Pipe and Tube
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1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type Other Analysers:
1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type 1 Cylinder (100 litres) each type Guidelines for selection of two years operation spare parts Flow Instruments
Level Instruments
Temperature Instruments Pressure Instruments Analyzers
To be determined in conjunction with the equipment Vendor (based on Vendor’s experience on similar type of plant)
None unless service is corrosive or erosive.
For corrosive or erosive service, shall be determined in conjunction with the Vendor.
1 of each size/min. 15% or 1 2 of each size/min. 25% or 2 10% (min. one per type/size) 1 of each diameter-
These vary in length depending on valve size. Purchase the longest of each dia. These can be cut to the correct size.
3 boxes of each size used/min.30%
3 boxes of each type used/min.20%
2 of each size used min. 20%
Pressure Gauges 15% each type (min two)
Solenoid and Trip Valves 15% each type (min two)
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Valve Positioners 15% each type
Thermocouples 15% each type (min two)
Blank Orifice Plates Manual Loading Stations
Instrument Air Filters (Regulation sets) Pressure Switches
Plug-in Assemblies for Elect. Instr.
Plug-in Assemblies for Pneum. Instr. 10%
Seal, Condensate and Vent Pots (for all) Solenoid and Trip Valves
Thermowells Signal Lights
I/P Converters
FCS/DCS/ESD/PLC (for each system) the Following Items:
I/O Cards Main Cards
Power Supply (AC, if any) Power Supply (DC, if any) Barrier Cards
20%, min. one for each type 1 set
1 set 1 set
20% for each type (min. 1 for each type)
On-Line Gas Chromatographs:
Main Mother Cards One set
Column One per type
Barrier Cards 20% for each type
(min. 1 for each type)
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3 CALCULATION FOR SHORT CIRCUIT STUDIES V N/A
4 CALCULATION FOR LOAD FLOW STUDIES V N/A
5 CALCULATION FOR LARGE DRIVE STARTING STUDIES V N/A 6 CALCULATION FOR RELAY SETTING SCHEDULE &
COORDINATION STUDIES V N/A
7 CALCULATION FOR ELECTRICAL LOAD BALANCE SUMMARY V N/A
8 SWITCHGEARS V V
14 EQUIPMENT ARRANGEMENT LAYOUT IN BUILDINGS V V 15 SUBSTATION CABLE ROUTING LAYOUT IN BUILDINGS V V
16 LIGHTNING PROTECTION LAYOUT P V
30 HAZARDOUS AREA CLASSIFICATION DRAWING V N/A
31 UNDERGROUND CABLE ROUTING P N/A
32 CABLE TRAY/LADDER/GLAND/ACCESSORIES V V
33 LIGHTING & DISTRIBUTION PANEL IN BUILDINGS P V 34 LIGHTING & DISTRIBUTION PANEL IN AREA V V
35 VARIABLE SPEED DRIVES V V
This document with all its rights is the property of BUPC and must be held in confidence. No disclosure, reproductionorotheruseofthedocumentinwholeorpartsistobemadewithoutthepriorconsentofBUPC
3.6.1 Selection, sizing and supply of electrical equipments should be as per the below project specifications:
a. 1210-00-EL-MSS-502: Material standard specification for MV switchgears.
b. 1210-00-EL-MSS-503: Material standard specification for LV switchgears.
c. 1210-00-EL-MSS-504: Material standard specification for power and distribution transformers.
d. 1210-00-EL-MSS-505: Material standard specification for PDCS.
e. 1210-00-EL-MSS-506: Material standard specification for AC UPS.
f. 1210-00-EL-MSS-507: Material standard specification for DC battery charger.
g. 1210-00-EL-MSS-508: Material standard specification for electrical panel boards.
h. 1210-00-EL-MSS-509: Material standard specification for electrical cables and wires.
i. 1210-00-EL-MSS-510: Material standard specification for cathodic protection.
j. 1210-00-EL-MSS-515: Material standard specification for electrical heat tracing.
k. 1210-00-EL-MSS-517: Material standard specification for LV variable speed drives.
l. 1210-00-EL-MSS-519A: Material standard specification for MV capacitor banks.
m. 1210-00-EL-MSS-519B: Material standard specification for LV capacitor banks.
n. 1210-00-EL-MSS-520: Material standard specification for aircraft warning lights.
o. 1210-00-EL-MSS-521: Material standard specification for LV induction motors.
p. 1210-00-EL-MSS-522: Material standard specification for MV and HV Motors.
q. 1210-00-EL-MSS-528: Material standard specification for local control stations.
r. 1210-00-EL-MSS-534: Material standard specification for MV variable speed drives.
3.6.2 Electrical installation/electrical design should be as per the below project specifications:
a. 1210-00-EL-ESS-501: Engineering standard specification for electrical system design.
b. 1210-00-EL-ESS-502: Engineering standard specification for
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lighting system design.
c. 1210-00-EL-ESS-503: Engineering standard specification for earthing and lightning system design.
d. 1210-00-EL-CSS-501: Construction standard specification for electrical installation in area.
e. 1210-00-EL-CSS-502: Construction standard specification for electrical installation in building.
f. 1210-00-EL-MSS-524: Material standard specification for Electrical Equipment as Part of Package.
3.6.3 Purchaser will provide only two 20KVAC, 50 HZ, 3Ph feeders from different sections of the source switchboards of main substation. Design and supply of a local substation based on above mentioned standard specifications included but not limited to transformers, bus ducts, switchgears, cables, wires,
lighting/distribution panels, PDCS, trays, ladders, DC battery charger, UPS, lighting equipments, installation and fixing materials required for proper installation of the electrical equipment, etc. is in Vendor scope of work/supply.
Electrical system distribution and philosophy should be as per “Engineering standard specification for electrical system design” no. 1210-00-EL-ESS-502.
3.6.4 Preparation of the following drawings / document in addition to the drawings and documents specified in attachment no. 3 of this requisition is in Vendor scope of work/supply (But not limited to follow):
1. CALCULATIONS:
a. Power system calculations & studies.
b. Short circuit study.
c. Load flow studies.
d. Large drive starting studies.
e. Relay setting schedule & coordination studies.
f. Electrical load balance summary.
g. Cable sizing calculations (Sample calculation), reference lists.
h. Lighting calculations & illumination levels (Sample calculation).
i. Electrical heat tracing calculation list. (If any) 2. SINGLE LINE DIAGRAMS:
a. Overall electrical one line diagram.
b. Single line diagram for MV Switchgears.
c. Single line diagram for LV Switchgears.
d. Single line diagram for AC UPS.
e. Single line diagram for DC Charger.
f. Auxiliary supply distribution, lighting & receptacle panels single line diagram.
g. Substation lighting & receptacle panel single line diagram.