General Instruments Specifications

PAC PROJ ECT
INSTRUMENTATION SPECIFICATIONS
SECTION-II
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SECTION-II

GENERAL INSTRUMENTS
SPECIFICAITONS

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INDEX

Sr. no. INDEX Page No.
1 SCOPE 4
2 CODES AND STANDARDS 4
MEASUREMENT UNITS 6
4 BASIC DESIGN CRITERIA 7
4.1 MEASUREMENT & CONTROL 7
4.2 SIGNAL TYPE AND TRANSMISSION 8
4.3 FIELD INSTRUMENATION 10
4.4 FIELD TRANSMITTERS 11
5 ACCURACY & REPEATABILITY 13
6 PROTECTION 14
7 INSTRUMENT AIR SUPPLY 15
8 INSTRUMENT POWER SUPPLY 15
9 INSTRUMENT EARTHING 16
10 PACKAGE UNIT INSTRUMENTATION 17
11 BROAD SPECS FOR VARIOUS INST CABLES 18
12 BROAD SPECS FOR INST JUNCTION BOXES 19
13 FLOW MEASUREMENT 20
13.1 ORIFICE FLOW MEASUREMENT 20
13.2 VENTURI FLOW NOZZLE MEASUREMENT 22
13.3 AVERAGING PITOT TUBE FLOW MEASUREMENT 22
13.4 VARIABLE AREA FLOW MEASUREMENT 23
13.5 ULTRASONIC FLOW MEASUREMENT 23
13.6 CORIOLIS MASS FLOW METER 23
13.7 MAGNETIC FLOW METERS 24
13.8 VORTEX FLOW METERS 24
14 LEVEL MEASUREMENT 25
14.1 LEVEL GAUGE 25
14.2 LEVEL TRANSMITTERS 27
14.3 LEVEL SWTICH 27
14.4 TANK LEVEL MEASUREMENT 28
15 PRESSURE / DIFF. PRESSURE MEASUREMENT 29
15.1 PRESS/DIFF. PRESS TRANSMITTERS 29
15.2 PRESSURE GAUGE AND DIFF. PRESSURE INDICATORS 31
15.3 PRESSURE AND DIFF. PRESSURE SWITCHES 33
16 TEMPERATURE MEASUREMENT 34
16.1 GENERAL TEMPERATURE MEASUREMENT 34
16.2 THERMOWELL 35
16.3 TEMPERATURE GAGUES 35
16.4 TEMPERATURE ELEMENT 36
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16.5 TEMPERATURE TRANSMITTERS 38
17 LIMIT SWITCH/POSITION SWITCH 38
18 CONTROL VALVES 39
19 pH/CONDUCTIVITY ANALYSERS 43
20 MATERIAL HANDLING SYSTEMS 43
21 OTHER INSTRUMENT ITEMS 44

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1. SCOPE

This specification gives directives for the basic design criteria for instrumentation in
general. The specific design requirements for each type of instrument or instrument
system are covered by the individual specification of that particular item/category. Any
conflict between the requirements of this specification and related codes, standards,
data sheets, drawings, requisition, etc., shall be referred to the OWNER for clarification.
Owners approved vendor list shall be followed strictly for procurement of various
instruments.

2.0 CODES AND STANDARDS

The various applicable codes and standards are as mentioned below. In case of any
conflicts / discrepancies in general instrument specifications and individual items
specifications, the most stringent conditions shall apply based on the following
standards. However, in all such cases, before taking any decision, BIDDER shall get
formal approved of data/specification sheets from OWNER.

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

1. ASME B1.20.1 Pipe Threads, General Purpose (inch)
2. ASME B46.1 Surface Texture (Surface Roughness, Waviness and Lay)
3. ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings
4. ANSI/ISA S18.1 Annunciator Sequences and Specifications
5. ANSI/ASME PTC 19.3 Pt 3: Power Test Code. Thermowell strength
Calculations
6. ANSI/FCI-70.2 Control Valve Seat Leakage.
7. ANSI/ISA 75.01 Flow Equations for Sizing Control Valves.
8. API RP 520 Sizing, Selection and Installation of Pressure Relieving Devices
in Refineries: Part 1: Sizing and Selection Part 2: Installation
9. API RP 551 Process Measurement Instrumentation.
10. API RP 550 Manual on Installation of Refinery Instruments and Control
Systems - Part I - Process Control and Instrumentation.
11. API RP 556 Instrumentation and Control Systems for Fired Heaters and
Steam Generators.
12. API 607 Fire Test for Soft-seated Quarter-turn Valves.
13. API 670 Vibration, axial position and bearing temperature monitoring
systems.
14. BS 3643 ISO Metric Screw Threads: Part 1: Principles and Basic Data. Part
2: Specification for Selected Limits of size.
15. CE Conformite Europeenne, Harmonized Codes directed by the European
Community.
16. 97/23/EC Pressure Equipment Directive
17. DIN ISO 228, Pt. 1 Pipe Threads where Pressure-tight J oints are not made
on the Threads. Pt. 1: Designation, Dimensions and Tolerances.
18. DIN 16128 Nominal Ranges, Scale Spacing and Scale Numbering of
Accuracy Classes 1.0, 1.6, 2.5 and 4.0 Pressure Gauges.
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19. DIN 19234 (NAMUR) Electrical Distance Sensors; DC Interface for
Distance Sensor and Signal Converter.
20. DIN V19250 Measurement and Control Fundamental Safety Aspects for
Measuring and Control Protective Equipment.
21. DIN 43729 Electrical Temperature Sensors; Connection Heads for
Thermocouple Thermometers and Resistance Thermometers.
22. EN Standards (CENELEC) Electrical Apparatus for Explosive Gas
Atmospheres.
23. EN 10204: Inspection Documents for the Delivery of Metallic Products.
24. EN 60947 : Electrical Distance Sensors; DC Interface for Distance
Sensor/converters
25. IEC 60079:Electrical Apparatus for Explosive Gas Atmospheres.
26. IEC 60085 : Thermal Evaluation and Classification of Electrical Insulation.
27. IEC 60227 : Polyvinyl chloride insulated cables of rated voltages up to and
including 450/750V.
28. IEC 60228 : Conductors of insulated cables
29. IEC 60331 : Test for electric cables under fire conditions. (Fire resistant)
30. IEC 60332: Test for electric cables under fire conditions. (Flame retardant)
31. IEC 60364: Electrical Installation of Buildings.
32. IEC 60391: Marking of Insulated Conductors.
33. IEC 60423 : Conduits for Electrical Purposes: Outside Diameters of
Conduits for Electrical Installations and Threads for Conduits and Fittings.
34. IEC 60529 : Degrees of Protection Provided by Enclosures (IP Code).
35. EC 60534 Industrial Process Control Valves:
Part 1: Control Valve Terminology and General Considerations.
Part 2: Flow Capacity: Section 1: Sizing Equations for Incompressible Fluid
Flow under Installed Conditions.
Part 2: Flow Capacity: Section 2: Sizing Equations for Compressible Fluid
Flow under Installed Conditions.
Part 8: Noise Considerations:
Section 1: Laboratory Measurement of Noise Generated by Aerodynamic
Flow through Control Valves.
36. IEC 60584 Thermocouples - Part 2: Tolerances. Thermocouples - Part 3:
Extension and Compensating Cables Tolerances and Identification System.
37. IEC 60654 Operating Conditions for Industrial Process Measurement and
Control Equipment.
38. IEC 60751 Industrial Platinum Resistance Thermometer Sensors.
39. IEC 60757 Code for Designation of Colors.
40. IEC 60902 Industrial Process Measurement and Control Terms and
Definitions.
41. IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment.
42. IEC 61508 Functional safety of electrical/electronic/programmable
electronic safety related systems.
43. ISO 5167 Measurement of Fluid Flow by Means of Pressure Differential
Devices.
44. NACE MR0175 (95) Standard Material Requirements - Sulfide Stress
Cracking-resistant Metallic Materials for Oil field Equipment.
45. CCOE = Chief Controller of Explosions, India for
intrinsic safe and Explosion proof apparatus.
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3.0 Measurement Units

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

Mass Flow = kg/h
Volumetric Flow = m/h
Steam Flow = kg/h or T/h
Gas/Vapor Flow = Nm3/h
Level Absolute = Absolute Meter or mm
Level Relative = 0-100% in Direct range
Pressure Gauge = Kg/cm2 g / mmwc
Pressure Absolute = Kg/cm2 -a
Temperature = C
Analysis = % or PPM
Viscosity = cP
Conductivity = s/cm
Density = Kg/m
Velocity = m/s
Impulse tube size = or OD

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4.0 Basic Design Criteria

4.1 Measurement and Control

4.1.1 All field transmitter shall of 2 wire, 24 V DC, SMART with HART protocol
and with local LCD type display
4.1.2 All Switch function shall be snap acting, Single-pole Double Throw (SPDT),
hermetically sealed and potential-free gold plated contacts with 230 V AC/5
amp or 24 V DC/2 amp contact ratings.
4.1.3 The use of Foundation Field Bus/ PROFIBUS or any other
cluster/Multiplexer type I/O philosophy shall not be allowed in project and
any part thereof as an alternate to conventional 4-20 ma dc signal
transmission by individual pair of wires.
4.1.4 Minimum contact rating for disconnecting inductive loads shall be:

- 1.0A for 24-48 V DC
- 0.4A for 110-125 V DC
- 5.0A for 60-260 V AC

4.1.5 Transmitters shall be utilized for indication, control/trip/calculation functions.
In principle no switches to be used in process related areas, except ON-
OFF valves limit/position switches.
4.1.6 Instrument ranges for trip functions and control functions in the same
service shall be equal.
4.1.7 Ranges used for measurement and control instrumentation shall overlap
alarm and trip settings by minimum 5% of the span.
4.1.8 Mercury, Asbestos and asbestos compounds are not allowed.
4.1.9 All field instruments, junction boxes, cabinets, panels etc. shall be provided
screwed SS tag plate with tag no. engraved or embossed on it.
4.1.10 All remote seal diaphragm type Pressure and Diff. pressure transmitters for
pressure, diff. pressure, and flow and level application shall have 2 size
Flange with diaphragm as process connection with calibration ring.
However in case of measurement of vary low range pressure ( in the range
of vacuum to mmwc pressure measurement), the diaphragm flange size
shall be 3
4.1.11 All displacer type level transmitters, externally mounted float/displacer type
level switches, the process connection size shall be 2 on vessel.
4.1.12 All temperature measurement points on vessel, pipe line, towers, columns,
etc. shall with 1 flanged thermowells with min. flange rating of ANSI
300#.
4.1.13 Instrument air headers, pipes and distributors shall be of SS316.
Instrument air manifold shall be used for supplying instrument air to control
valves and other instruments. These shall be with 10 nos. of tapings and
be with NPT (F), SS 316 valves. From the nearby air manifold,
instrument air shall be supplied to the control valves. For the purpose, all
tubing shall be used shall be of SS316, or OD, seamless tubes, laid
in perforated FRP trays. All intermediate fittings shall be double
compression, SS316 MOC, Swagelok make, double compression type
only.
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4.1.14 Standardization features shall be taken care of during design and
packages for junction boxes, instrument air headers, instrument fittings,
and other erection hardware like cable duct, cable trays, etc.
4.1.15 Air conditioning capacity shall meet the total requirement of the control
room and cabinet room all instrument system hardware in addition to man
power movement/losses, etc.
4.1.16 All equipment/materials supply should include spares required for
commissioning and 2 years operation.

4.2 Signal Types & Transmission

4.2.1 Electric Signals

Electric signal transmission shall be applied in conjunction with
electronic/digital control systems.

In general the loop power will be supplied by the systems.

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

4.2.2 The standard signals for transmitting measuring and control shall be a
current of 4 to 20 mA. DC, superimposed with digital communication
protocol (HART). All interlock shall also be realized from 4-20 ma analog
input transmitters in the DCS. No field switches shall be used for interlock
purpose, except NAMUR type proximity sensors for valve positions
switches for ON-OFF valves.
4.2.3 All signal exchange between field and central cabinet room shall be via
individual hardwire pair of cable as specified in detailed cable
specifications. From the field, all field transmitters shall be routed to field
mounted junction boxes, from where these shall be taken to central cabinet
room via multi pair cables. Use of 6 pair or 12 core cable is not allowed.
All analog multi pair cable shall be 12 pair only. All Digital input/output multi
pair cables shall be either 24 core or 12 pair only. Multi pair power cable
shall also be 12 pair only.
4.2.4 To the extent possible, direct run cable from field instrument to central
cabinet room shall not be employed. All the signals to the central cabinet
room shall be routed through multi pair cables via field mounted junction
boxes only.
4.2.5 Usage of Foundation Field bus / Profibus type clustered I/O wiring
philosophy is not allowed at any location in the whole plant as an alternate
to conventional 4-20 ma dc signal transmission.
4.2.6 Few dedicated, special type of cables from special control system may be
directly routed to cabinet room in place of multi pair cables.
4.2.7 All the power/control and signal cables in a single or multi pair cables
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between field instruments to field junction boxes and between field junction
boxes/local panels to the central cabinet room shall be thru overhead
perforated cable trays / MS cable duct with min. 3 mm thickness on the pipe
racks. No underground cabling for any type of instrument cables is allowed.
4.2.8 On the main cable route, FRP ladder tray of min. 3 mm thickness shall be
used with separate ladder trays of various low voltage signal cables
(AI/AO/DI/DO with 24 V DC and lower voltage) and high voltage power
cables (e.g. 110 V AC for Solenoid valves, 110 V A.C. power supply cables
to field instruments, etc.). On the trunk and branch route from main cable
duct to field junction boxes and local panels, 300 mm(w) x 60mm (H)x3mm
thick FRP perforated cable trays will be used. For other branch cables
various sizes of perforated FRP cable trays shall be used with the following
general specifications.

300 mm (W) x 60 mm(H) x 3 mm thick perforated FRP cable trays
200 mm (W) x 50 mm (H) x 3 mm thick perforated FRP cable trays

4.2.9 All the fiber optic cables / system cables, special cables shall be laid in GI
conduit preferable in overhead trays/duct only.
4.2.10 All type of single and multi pair power, control and signal cables in the field
shall be with GI armored only for mechanical protection, including fiber optic
cables.
4.2.11 In the whole plant area, where there are chances of fluid leakages/spillage
in normal operating conditions, all cable trays/cable ducts shall be provided
with closed covers made of 2 mm thick SS304 sheets.
4.2.12 All fiber optic cables shall also be with armored only
4.2.13 All the cable exchange between the central cabinet room and field
instrumentations shall be from any one side of the cabinet room through
MCT blocks.
4.2.14 All the above mentioned philosophy shall be followed for various type of
cable exchange between electrical and instruments signals. Signal and
power/high voltage cables shall be laid in separate cable duct between
cabinet room and MCC. The central cabinet room and MCC room design
shall be such that there shall be a minimum distance between these two
buildings.

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4.3 FIELD INSTRUMENTATION

4.3.1 Field instrument connections shall be as follows.

Instrument Type

Piping/Vessel
Connection

Instrumentation
Connections

DP Flow Instruments

NPT

NPT
External Displacer
(as per pipe class)
2" Flanged

2" Flanged

Internal Displacer
(as per pipe class)
4" Flanged

4" Flanged

External Ball Float
(as per pipe class)
2" Flanged

2" Flanged

Internal Ball Float
(as per pipe class)
4 Flanged

4 flanged

Level Gauge
(as per pipe class)
2 Flanged

2" Flanged

D/P Level

NPT

NPT

D/P Level with Remote Diaphragm
Seal
(as per pipe class)
2 Flanged

2 Flanged

D/P Level Direct Vessel Mounted
(as per pipe class)
2 Flanged

2 Flanged

RADAR
(as per pipe class)
4" flanged

4" flanged

Pressure Instruments

NPT NPT
Press. Gauge

NPT NPT
Pressure with diaphragm seal
(as per pipe class)
2" Flanged

2" Flanged

Thermowell
(as per pipe class)
1 Flanged on
pipe and 2 flanged
on equipment

1 Flanged on pipe and 2
flanged on equipment

4.3.2 Flanged instrument connections shall be in accordance with ASME B16.5.
4.3.3 Flange surface finish shall be as per relevant piping specification and in
accordance with ASME B46.1.
4.3.4 Screwed connections shall be in accordance with ASME B1.20.1 (NPT)
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4.3.5 Cable gland connections to be M20 x 1.5mm as a minimum in accordance
with EN 60423.
4.3.6 Standard instrument connection shall be NPT female, except that
pressure gauges and pressure switches shall have NPT male
connections. A parallel thread should be used in cases of a hazardous
process fluid.
4.3.7 Except for steam service instrument impulse lines, all other location shall be
OD SS tubes. The thickness of impulse tube shall be 1.6 mm for OD
SS304 tubes and 1.0 mm for OD SS tubes, unless otherwise specified.
These thickness shall be followed as standard minimum, except special
case requirements for vary high pressure and temperature services. For
steam services, it shall be CS/IBR pipes (Min. SCH160).
4.3.8 For very low pressure measurement, the remote seal size PT/DPT size
shall be 3 ANSI in place of 2 ANSI.
4.4 Field Transmitters:
4.4.1 All field transmitters shall be 2 wire type, 24 Volt DC, loop powered, SMART
with HART protocol, and shall be equipped with Local LCD type digital
indicator.
4.4.2 The transmitters shall be suitable for 2pipe mounting and shall be supplied
with SS304 MOC mounting brackets, hardware, nut/bolts, etc.
4.4.3 The basic accuracy of all transmitters shall be 0.075% of span or better with
1:30 rangeability to reduce the inventory. The accuracy shall remain constant
throughout the above range. However the overall rangeability shall be 1:100.
4.4.4 All transmitters shall be supplied with local digital display configured in
engineering unit.
4.4.5 All transmitters shall be supplied with NPT (F) cable entry and either
NPT (F) process connection.
4.4.6 All transmitters shall be supplied with SS304 MOC, double compression cable
glands, certified for weatherproof to IP67 as per IEC529 with PVC hood.
4.4.7 Wherever the above requirement of 2 wire, 24 V DC transmitters can not be
fulfilled, the 4 wire transmitter (SMART with HART protocol) option shall be
used such as RADAR type level transmitters, Magnetic Flow meters, Mass
Flow meters, etc. All theses device shall be powered with 110 V AC UPS
supply only. The power shall be fed from PDB located at central cabinet room.
4.4.8 All the field instruments shall be weatherproof to IP65 as per IEC529 as a
minimum.
4.4.9 The wetted parts MOC of all transmitters/devices/instruments shall be suitable
for process fluid, pressure and temperature, but SS316 as a minimum unless
otherwise specified.
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4.4.10 All DP transmitters used for flow/level and PDI measurement application shall
be supplied with 3 way valve, SS316L Manifold or better MOC to suite process
fluid. All Pressure transmitters used for Pressure measurement application
shall be supplied with 2 way valve manifold with SS316L MOC or better MOC
to suite process fluid. The process connections for manifold shall be
NPT(F).
4.4.11 All the transmitters housing MOC shall be die cast aluminum and it shall be
supplied with EPOXY paint, suitable for protection against harsh environment
4.4.12 While designing, a care shall be taken to choose transmitters ranges/
rangeability, etc. for various applications in such a way that there shall be min.
type of diff. models of the same category of transmitters are required to be
maintained as spares.
4.4.13 For all remote mount transmitters, the sensor and transmitter cable shall be
with min. 15 meter in length and it shall be either armored or shall be laid in
PVC protective conduit only.
4.4.14 Head mounted Temperature transmitters are not acceptable. All temperature
transmitters, wherever applicable shall be remote mount (mounted in the field)
type only.
4.4.15 All remote seal diaphragm type PT/DPT shall be supplied with min. 5 mtr. of
capillary with SS armored in PVC sheath for protection
4.4.16 The following types of reports/certificates should at least be considered:

- EC declaration of conformity;
- Calibration report;
- Functional test report;
- Welding procedure/report;
- NDE report;
- Material certificates;
- Electrical certificates;
- IBR certificates for IBR service control valves, PSV, orifice assemblies,
level gauges, thermowells, annubars.

4.4.17 All instruments/equipments to be supplied shall be manufacture's standard
type. The instruments / equipment shall be purchased only from
manufacturers with long-standing experience. The vendor list approved by
OWNER shall be followed for the purpose. For items not covered in the
vendor list, OWNERs prior approval shall be taken.
4.4.18 The material components, which come into contact with the fluids to be
measured, shall be resistant to corrosion caused by said fluids. It shall be
compatible with the piping material when being clamped, welded or
connected by other methods.
4.4.19 All instruments and equipments shall be suitable for use in specified site
climatic conditions and industrial environment in which corrosive gases and
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/ or chemicals may be present. All external surfaces shall be suitably
treated to provide protection against corrosive plant atmosphere with epoxy
painting / powder coating.
4.4.20 The design of electronic instruments shall be in compliance with the
electromagnetic compatibility requirements as per IEC 801 'Electromagnetic
Compatibility for Industrial Process Measurement and control Equipment.'
4.4.21 Flange ratings for instruments may differ when instrument flanges and the
mating flanges on piping / equipment are of different materials (e.g. SS-316
thermowell on CS pipes). The contractor shall in such cases, ensure that
the rating of flange is chosen for the instrument and the corresponding
flange on piping / equipment.
4.4.22 Instruments like control valves, orifice flanges, level instruments,
thermowells, etc. coming on pipes and vessels under Indian Boiler
Regulation (IBR) shall be certified by IBR. (or authorized representative if
procured outside India).
4.4.23 Piping/Instrument scope change for instrumentation shall always be after
first isolation/drain valve for all types of instruments, including local
Pressure gauges.
4.4.24 Instrument impulse tube size shall be either or OD, SS316 MOC only.
4.4.25 Transmitters shall be mounted on nearest platform / grade level keeping in
view requirements of readability and accessibility.
4.4.26 All instruments shall have an integrally mounted terminal box to terminate
armored cables. Instruments with loose flying leads shall not be used.
4.4.27 Canopy made of bolted FRP sheets of min. 2 mm thickness shall be
provided for all transmitters, electronic instruments and local panels.
4.4.28 All remote seal diaphragm type Flow, Pressure and Level transmitters shall be
designed with 2flange size.
4.4.29 The local temperature gauges shall not be used in the whole project (including
any of the package unit also). All temperature points shall be provided with
either direct thermocouple (generally K type) or RTD (generally 3 wires,
PT100) sensors with flanged thermowell assemblies and field mounted 2 wire,
24 V DC, SMART with HART protocol Temperature transmitter with LCD for all
open and closed loops. No RTD and T/C signal will be interfaced with DCS.
4.4.30 All thermocouple/RTD sensors shall be duplex type with Flanged thermowell
along with nipple-union-nipple assly along with dual entry thermocouple head,
certified to weatherproof to IP65 as a minimum. Thermowell shall be
manufactured from drilled bar stock, tapered. MOC of thermo well shall be
suitable to process fluid and pressure/temperature conditions. The cable entry
shall be NPT(F) and complete assembly shall be provided with SS MOC,
double compression cable glands certified for weatherproof to IP65 with PVC
hood.
4.4.31 Displacer type level transmitters and float type level switches with external / side
mounted chambers shall have 2flanged tapping size. Irrespective of pressure
rating, the minimum flange rating shall be ANSI 300#.
4.4.32 All instruments / devices shall be immune to interference due to normal
walkie-talkies with output of 1W at UHF.

5.0 Accuracy and Repeatability

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5.1 Consideration shall be given to the relevant function of the instrument
and/or system, its required accuracy and repeatability, the maximum
obtainable industrial accuracy and its repeatability.
5.1 The characteristics of sensing devices shall be specified to meet the
following requirements:

Measurement error (accuracy) percent value of span, unless stated otherwise, not worse
than:
a. 0.075 % for all types of pressure transmitters, diff. pressure transmitters used
for Pressure, DP, Flow or Level measurement.
b. 0.5% for all Vortex and Magnetic Flow meters
c. 1.0% of calibrated range (acc.class 1) for pressure gauges.
d. 1.5% for (differential) pressure gauges.
e. 0.2% for multipath ultrasonic flow measurement for Gas services
f. 0.5% for Displacer type level transmitters.
g. 1.5 C between 40 C and 375 C Max. for TC with Class-1 accuracy
h. 0.004T C between 375 C and 1000 C Max. for TC with Class-1 accuracy
i. (0.15 +0.002*t)C or 100.00 0.06 at 0C for RTD, i.e. Class-A accuracy
j. 0.12 C for all temperature transmitters.
k. 1 mm for RADAR type tank Gauging systems for Custody transfer
l. 5 mm for General Purpose RADAR type level transmitters
m. 5% for all Gas Detectors
n. 0.75% for Annubar/Averaging Pitot tube flow meters
o. 1.5% for Critical flow measurement by Orifice Plate
p. 2% for General purpose flow measurement by Orifice Plate
q. For mass flow meters:
0.1% for liquid flow.
0.1 kg/m on liquid/gas density.
r. 0.5% for Belt weighers and Bagging machines
s. 5 kg for Weigh Bridges of a capacity up to 60 Ton and 10 kg for 100 ton
t. 20 gms for Bagging machine of 25/50 Kg bag

Note:-1 Hysteresis shall be maximum 0.1% of the range
Note:- 2 All dp transmitters shall have minimum static pressure rating of 250 kg/cm.
Note:- 3 Ambient temperature variation of 40 C shall not change output signals by
more than 1% of the range.

6.0 PROTECTION

6.1 Climate

Systems enclosures shall have a degree of protection in accordance with IEC 60529,
protection code IP 65 as a minimum. Preference is given to IP-65 due to heavy
rains/storms. Cable glands shall also be IP-65 to avoid ingress.
All field instruments shall be damp-proof and dust-proof, minimum protection class as
per IEC 529 shall be as follows:

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

6.2 Electromagnetic Compatibility (EMC)

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

6.3 Electrical Safety

Generally, PAC plant process is classified as general purpose, safe area. Hence
flameproof/explosion protection is not required at individual instrument level.

7.0 Instrument Air Suppl y

7.1 The quality of the instrument air and the air supply pressure range for
transmission devices shall be in accordance with IEC 60654.
7.2 Instrument air shall be used for the pneumatic operated actuators (e.g.
control, on/off valves).
7.3 Instrument air may be used for purging purposes, for pressurizing of
instrument enclosures and breathing (safety) masks.
7.4 All control valve actuators shall be sized at max. 4.0 bar g instrument air
available at control valve.
7.5 All the air to instrument control valves and individual consumer shall be
routed thru 10 way instrument air headers form the field. Air manifold,
instrument fittings, tubing and needle/ball valves shall be of SS316 MOC as
a minimum.
7.6 There shall be instrument air buffer vessel to cater to requirement of whole
plant during safe shutdown for a minimum of half an hour.

8.0 Instrument Power Supply:

8.1 The instrument power supply systems shall be used for instrumentation
purposes only.
8.2 Field instruments which are loop powered shall be used. Field instruments
requiring a separate power supply shall be avoided. The loop powered
transmitters shall be always 24 V DC, 2 wire, 4-20 mA DC signal type and
HART with SMART protocol.
8.3 Where two wire transmitters are not possible, 4 wire transmitters with 110 V
AC supply shall be selected. The supply to these instruments shall be fed
from central cabinet room located UPS PDB only.
8.4 All central cabinet room located instrument systems including DCS shall be
110 V AC UPS Power only.
8.5 All of above systems shall be capable of accepting dual redundant 110 V
AC UPS feeders, which will be fed power form two diff. UPS feeders The
feeders shall be connected to the UPS distribution boards in such a way
that at all times power will be available on at least one (1) feeder.
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8.6 The conversion to the required voltage level(s) shall be carried out by each
system vendor with dual redundant 24 V DC bulk power supply installed in
separate 24 V DC PDB. The same shall be used for 24 V DC Solenoid
Valves also.

9.0 Instrument Earthing

9.1 General

9.1.1 All equipment for electric transmission, including the enclosures as well as
the armoring, lead sheathing and screening of cables, shall be properly
earthed for personnel safety reasons and to obtain the maximum possible
rejection of interference.
9.1.2 Instruments and associated equipment requiring electricity with a potential
to earth greater than 50 V AC or 120 V DC shall be adequately earthed
(refer to IEC 60364 part 4, protection of safety, section 41, and protection
against electric shock.)
9.1.3 Unintentional interconnections between the two systems are not allowed to
occur.
9.1.4 All earth connections shall be protected against corrosion, which might
adversely effect the earth resistance.

9.2 General Earthing System

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

9.3 Instrument Earthing System

9.3.1 The instrument earthing system consists of one or more earthing electrodes
close to the control satellite building at a safe distance from any plant-
earthing electrode.
9.3.2 The resistance to earth is to be less than 1 ohm. To achieve this, an array
of parallel electrodes may be used.
9.3.3 The instrument earthing shall terminate in a copper bus, mounted centrally
to all instrument equipment, but electrically isolated from any other
equipment or structure.
9.3.4 The cable connections shall be easily accessible for testing facilities.
9.3.5 All connections between the copper bus bars and to the central earth bar
shall be individually connected via a separate, insulated, stranded wire
conductor of at least 4 mm.
9.3.6 To avoid undesired ground loops due to differences in earth potential or
influence of surface currents, the shield of signal wires shall be connected
to the instrument earth system only at one side (in the control room/satellite
building). The shielding shall be kept isolated from cable armoring and
instrument enclosures.

10.0 Package Unit Instrumentation
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10.1 There shall not be any local control panels with proprietary or 3
rd
party control
system like field mounted small PLC, etc. for any of the package unit or part
thereof, in the whole plant. All the controls and interlocks shall be realized in
PAC plant DCS system. No separate, small, skid mounted PLC systems,
dedicated controllers, or any other third party proprietary control systems are
acceptable, except the system as specified below. This includes various
machine safety interlocks and anti-surge controls also. There shall be no field
mounted control panels. Local panels at machine/package unit shall be used
only for Local Push Buttons and a few clustered LED type Lamps for start/stop
and health/running status indications of machine/peripherals and initial start up
procedure only. The field mounted Local Panel shall be weather proof to IP55
as a minimum. The panel make shall be RITTAL only and color shed shall be
RAL7032.
10.2 A common field alarm hooter at each package unit / local control panel shall be
generated from central control room DCS to alert the machine trip condition.
Complete control should be possible from central DCS for all the machines.
Also emergency shutdown of this entire machine/package unit shall be
governed by PAC plant DCS only.
10.3 Apart from field instrumentation philosophy, specified in these documents for
various field instrument specifications, for all package units field instruments,
the following minimum guide lines shall be followed, additionally.
10.7.1 All the instruments within package units shall be supplied as per Owners
specifications as per this ITB guide line applicable for main plant.
10.7.2 Approved vendor list for instruments shall be provided by OWNER. If a
package unit vendor wants to deviate from the approved vendor list, they have
to obtain prior approval from Owner.
10.7.3 The type of instruments shall be weatherproof to IP65 as per IEC529 and all
field panels shall be weatherproof to IP55 as a minimum.
10.7.4 Package unit vendor to lay branch cables from individual instrument to skid
mounted J unction box in closed FRP perforated cable trays. J unction box
segregation shall be maintained for various type of I/O signals like AI/AO can
be combined in common junction boxes, Digital inputs shall be wired in
separate junction boxes, Digital Output for lamps and Digital Output for
Solenoid valves shall be wired in separate junction boxes.
10.7.5 All branch cables shall be PVC sheathed and armored only. The broad specs,
mentioned in the field instrumentation specifications shall be strictly followed as
minimum. Other specs shall be as per IS1554 and shall be approved by
Owner.
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10.7.6 All cable glands shall be of double compression type with SS MOC and
weatherproof to IP65 as per IEC529, with PVC hood.
10.7.7 Package unit vendor shall maintain segregation of Electrical (all MCC related
I/O) and Instrument signals in diff. junction boxes. Electrical and instrument
interface junction boxes shall be a separate junction box in the package unit.
10.7.8 Power supply to individual shall be provided from UPS grade 110 V AC / 50 Hz
power supply at one location only per package unit from PDB panel located in
central cabinet room. Further distribution / voltage level conversions, Fuse co-
ordinations, etc. shall be performed by package unit vendors.
10.7.9 Package unit vendor to supply all drawings/documents in 4 sets of hard copy
and 2 sets in editable software like Microsoft Excel / AUTOCAD only. The
drawing and documents includes, various panel drawings, panel GA/IA
drawings, dimensional drawings, loop sheets, interlock and logic diagrams,
wiring diagram, cable schedule, PDB SLDs, J unction box schedule, instrument
list, Tag list, datasheets, sizing calculation sheets, etc.

11.0 Broad Specifications for Various type of Instruments power/signal and
control cables:

In addition to various cable manufacturing standards like IS1554 part-I,
BS/ IS5831, BS5308 and IS694-Part-I standards, the following basic
design criteria as per OWNERs standard shall be followed as a
minimum. All cables, color codes shall be strictly as follows. This
philosophy applies to package unit instruments also. The primary
insulation material shall be XLPE (cross linked polyethylene) for all types
of cables. The voltage grade shall be min. 600 V for all signal and control
cables and 1100 V for all 110 V AC/24 V DC power cable.

a. Single pair signal cable: ATC, Multi strand (Max 7 strands), 1 Pair, twisted pair, 1
sq. mm, white/black color, screened / armored/ FRLS cable, Outer J acket color
code: Grey for non-IS, Blue for IS. This shall be used for all 4-20 m amp. analog
inputs/outputs signals.
b. Multi pair signal cable: ATC, Multi strand (Max 7 strands), 12 Pair, twisted pair 1
sq. mm, white/black color, individual and overall screened / armored/ FRLS
cable, Outer J acket color code: Grey for non-IS, Blue for IS. This shall be used
for all 4-20 m amps. analog inputs/outputs signals. 6 pair multi pair cable shall
not be used.
c. 110 V AC Power cable Single Pair: - ATC, Multi strand (Max 7 strands), min.
1.5 sq. mm for 110 v ac, (2 core- Red / black, 3 core- Red / Black / Green,)
armored/FRLS, Outer jacket color code: Black. This shall be used for 110 V AC
power supply to field instruments, solenoid valves, etc. This shall be used for 110
V AC power supply as a minimum size. BIDDER to ensure correct size (cross
section area) for various requirements, to maintain 110 V AC -2% & +1% at 50
PAC PROJ ECT
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Hz -3/+1 Hz at field devices (wired from centrally located non-system UPS PDB
from central cabinet room only).
d. 110 V AC Power cable Multi Pair: - ATC, Multi strand (Max 7 strands), min. 1.5
sq. mm for 110 v ac, 2 C x 12 pair, (2 core- Red / black, 3 core- Red / Black /
Green,) armored/FRLS, Outer jacket color code: Black. This shall be used for
110 V AC power supply distribution to field instruments, solenoid valves, etc, via
power J B. This shall be used for 110 V AC power supply as a minimum size.
BIDDER to ensure correct size (cross section area) for various requirements to
maintain 110 V AC -2% & +1% at 50 Hz -3/+1 Hz at field devices (wired from
centrally located non-system UPS PDB from central cabinet room only).
e. 24 V DC Power cable, Single Pair: - ATC, Multi strand (Max 7 strands), 2.5 sq.
mm for 24 V DC, (2 core- Red/black) armored/FRLS, Outer jacket color code:
Black for non-IS and Blue for IS. This shall be used for all 24 V DC power supply
to field Solenoid Valves, Field Lamps/Alarms, etc. as a minimum size. BIDDER to
ensure correct size (cross section area) for various requirements to maintain
minimum 24 V DC at field device.
f. 24V DC Power Cable, Multi pair :- Single Pair:- ATC, Multi strand(Max 7 strands),
2.5 sq. mm, 2Cx12 Pair, overall screened, 2 core- Red/Black, armored/FRLS
cable, Outer J acket Color code: Black for non-IS, Blue for IS. This shall be used
for all 24 V DC Digital output signals for Solenoid valves, Field lamps/Alarms, etc,
as a minimum size. BIDDER to ensure correct size (cross section area) for
various requirements to maintain minimum 24 V DC at field device. Use of 6
pair/12 core cable is not allowed.
g. Control Cable for DI - Single Pair:- ATC, Multi strand(Max 7 strands), 1.5 sq. mm,
2Cx1Pair, overall screened, Red/Blue, armored/FRLS cable, Outer J acket Color
code: Black for non-IS, Blue for IS. This shall be used for all 24 V DC Digital input
signals.
h. Control Cable for DI - Multi pair:- ATC, Multi strand(Max 7 strands), 1.5 sq. mm,
2Cx12Pair, overall screened, Red/Blue, armored/FRLS cable, Outer J acket Color
code: Black for non-IS, Blue for IS. 6 pair multi pair cable shall not be used.
These shall be used for all 24 V DC Digital inputs.
i. Single Triad RTD cable ATC, Multi strand (Max 7 strands), 1 Triad, 1.3 sq. mm,
red/white/black color, screened / armored/ FRLS cable, Outer J acket color code:
Blue. This shall be used for all RTD input signals. Since no RTDs are required to
be wired up to Control room DCS/ESD, the specifications of 8 triad RTD cable is
not envisaged and not provided.
j. T/C single pair: 1 P x 18 AWG (Single) or 20 AWG (Duplex) as per IEC 60584-3,
Special compensating cable for particular type of thermocouple. Since no T/C are
required to be wired up to Control room DCS/ESD, the specifications for 12 pair
T/C cable is not envisaged and not provided.

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

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

PAC PROJ ECT
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a. All the field junction boxes shall be weatherproof to IP65, as per IEC529,
as a minimum.
b. All the field junction box shall be made of FRP Material.
c. There shall be diff. junction box for diff. type of I/O signals. As a minimum
the following segregation shall be maintained

Signal Category wise segregation

a. Analog Input and Analog output
b. 24 V DC Digital Input / NAMUR sensors
c. 24 V DC Digital Output used for lamps, etc.
d. 110 V AC power cables for field instrument power, SOV, etc.

d. The naming philosophy for junction box shall be adopted in such a way
that from the tag number of the particular junction box, it shall be evident
to decide type of signal and destination
e. All junction box MOC shall be of GRP / Polycarbonate material. Based on
requirement, there shall be diff. insulated shield and earth bus bars are to
be provided in the junction box. The individual branch cable shall be
brought to central cabinet room panel instrument shield bus bar via
insulated shield bus bars and multi pair shields from junction boxes.
f. All junction boxes shall have branch and multi pair cable entries from
bottom only.
g. All junction boxes shall be weather proof to IP65 as a minimum. Generally
12 branch entries of NPT and 1 no. of main multi pair cable entry type
junction boxes shall be used in the total project.
h. Each J unction box shall have 0.5 to 4.0 sqmm, screw less, WAGO make
terminals inside them. These shall be DIN rail mounted. The color code
shall be based on type of signals. The qty. shall be as required.
i. Each junction box shall have engraved/embossed SS tag plate with tag
number. This tag plate shall be screwed on the junction box.

13.0 Flow Measurement:

13.1 Orifice Plates:

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

13.1.1 Flow measurement shall be normally carried out using thin,
square edge, concentric orifice plate mounted between a pair of weld neck
flanges of minimum 300#rating, for line size 2" and above.
13.1.2 Flange taps shall be used for line sizes up to 12. D-D/2 taps shall be used
for line sizes 14" and above. For line sizes 1 and below and for conical
PAC PROJ ECT
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entrance orifices, corner taps shall be used. (In case of fouling of tapping
points w.r.t. to welding of flanges, flange tapings are to be used)
13.1.3 The material of the orifice plates shall be normally SS 316, as a min.
Flange, gaskets, bolts & nuts material shall be as per the relevant Piping
specifications.
13.1.4 Quadrant edge or quarter circle orifice plates shall be used for highly
viscous fluids for pipe Reynolds number below 10,000. The Beta Ratio for
these plates shall not exceed 0.6.
13.1.5 Conical entrance type of orifice plates shall preferably be used for highly
viscous fluid up to throat Reynolds number of 250. These shall be
fabricated as per BS1042 part I. The Beta Ratio for these plates shall not
exceed 0.3.
13.1.6 Eccentric orifice plates shall be used for fluids containing two phases.
Eccentric orifice plates shall have bottom of the orifice bore flush with the
bottom I.D. of the pipe. Eccentric or segmental orifice plates shall be used
in horizontal run only.
13.1.7 Vent and drain hole shall be provided for orifices where bore diameter is
more than 25 mm
13.1.8 Plate dimensions and machining tolerances shall be as per BS 1042 and
Sizing of orifice plates shall be carried out in accordance with ISO 5167.
13.1.9 Honed metering runs in accordance with AGA tolerances or integral orifice
type transmitter shall be used in lines with 1 (40 mm) nominal diameter.
13.1.10 Integral flow assembly shall be supplied as an integral assembly consisting
of upstream and downstream straight pipes, integral orifice of 316L SS (as
a minimum) installed along with manifold and SMART , 2 wire 24 V DC , DP
transmitters. End flanges shall be as per piping specifications. Upstream
and downstream pipes shall be honed from inside to achieve smooth
surface. Integral orifice meters, when used, shall be installed with block and
bypass valves.
13.1.11 Upstream and downstream straight length shall be provided based on
maximum d/D ratio of 0.75, in general. Where it is difficult to meet this
requirement, the actual d/D can be considered for reducing the straight
length as permitted by ' recommended practice shall be as per API-MPMS
Recommended Practices and AGA Report No.3. The piping layout, where
possible, shall be arranged such that straightening vanes are not required.
13.1.12 Orifice plates shall be installed on horizontal lines when practical. Vertical
meter runs may be used for down flow of vapor and up flow of liquids.
13.1.13 Meter taps shall be horizontal for liquids, condensable vapors and steam.
The tap shall be on top for gas, non-condensable vapor, or liquids, which
boils at maximum design ambient temperature at operating pressure.
13.1.14 Where piping clearance are a factor, taps may be located up to 45 below
the horizontal centre line for liquid and up to 45 above the horizontal centre
line for condensable vapor and may be located up to 60 from vertical for
gas and non condensable vapor.
13.1.15 Each orifice plate shall be provided with a tab that is clearly visible in
position. The tab will be stamped, or deep engraved, on the upstream with
the tag number, orifice plate material, measured bore, I.D. of the pipe,
flange size and rating. The tab shall also be in line with the Drain or Vent
hole and shall indicate the direction of flow
13.1.16 Flanges shall be as per ANSI B16.36 and shall generally be of weld-neck
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type only. Irrespective of pressure, the minimum flange rating shall be ANSI
300#.
13.1.17 Flanges larger than 3" shall have a pair of jack-screws. The mating flanged
shall be aligned in such a way that jack-screws will be diametrically
opposite.
13.1.18 Orifice flanges used at pressure ratings up to 600 Ib. shall be tapped
NPT(F) tap for 900 # above NPT(F). Orifice connections for Vena
contracta taps or pipe taps socket with schedule/MOC as per piping
specs.
13.1.19 The Meter Range flow shall be equal to the 1.5 times of normal flow or 1.3
times of the maximum flow.
13.1.20 Differential ranges for all liquid flow meters shall not exceed 5000 mm
water. Typical ranges for gas, steam or vapor meters are as follows:

Static Pressure Diff. Range
(in Kg/Cm2g) (in mmwc)

0.35 to 2.5 500-1200
2.6 to 6 1250-2500
Above 6 2500-5000

13.1.21 Where compressible fluids are measured using differential pressure
producing devices, the selected differential in mm of water shall be
preferably not numerically exceed 5.5 times the upstream static absolute
pressure in kg/cm2 x 100.
13.1.22 Though it is preferable to select diameter ratio between 0.3 to 0.65, The
diameter ratio of orifice plates shall be as follows:

Type Beta Ratio

Corner Tap 0.23 to 0.8
Flange Tap 0.2 to 0.75

13.1.23 Orifice bore with diameter less than 0.125 shall be avoided.
13.1.24 Orifice plates with RTJ flange connections above 2 shall be supplied with
Carrier rings.

13.2 Venturi Meters and Flow Nozzles:

Venturi meter & flow nozzles may be considered for gas/air flow
measurement in large size pipes / ducts, where high accuracy is required
with less permanent pressure loss
For high velocity steam or similar fluid, flow nozzles may be used in place
of orifice plates to avoid problems due to erosion.

13.3 Averaging Pitot Tubes:

Averaging pilot tubes shall be considered for low pressure loss, high
velocity, large diameter lines and air ducts. This shall be installed on 1
size nozzle for small lines and 3 for large lines or lines with large velocity.
PAC PROJ ECT
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The averaging pitot tube shall be of SS316 MOC as a minimum. It shall be
retractable with ball valve arrangement and shall be provided with end
supports.

13.4 Variable Area Flow meters:

13.4.1 Variable Area Flow meters or Rota meters shall be as per ISA-RP 16.1.
16.2, 16.3 16.5 and 16.6 and shall be used for viscous or corrosive services
or where rangeability of required flow precludes the use of an orifice.
13.4.2 Metal tube rota meters shall be used for all fluids. The devices for indicating
or transmitting shall be magnetically coupled with float or extension.
Magnetic coupling shall be glandless type.
13.4.3 The tube and flange be SS316 as a minimum. Flange connections shall be
as per piping specifications. \Rota transmitter shall be 24 V DC, 2 wire, 4-20
ma, SMART with local display type.
13.4.4 All the Rota transmitter shall be Weather proof to IP65.
13.4.5 Glass tube rota meters shall be used for low pressure utility services for
local and where line size is 1-1/2" (40 mm) or less. Glass tube rotameters
shall not be used if an outlet line is connected to a line or vessel containing
hazardous or toxic fluid unless a check valve is installed at the downstream
side of rotameter.
13.4.6 Glass tube meters mechanically protected and (may only be used on non-
hazardous fluid service up to temperatures of 130C, and on fluids always
above freezing.
13.4.7 Linearity should be better than 5% for indication-only rotameters and better
then 1% for rotameter transmitter. Accuracy shall be 2% (or better) of full
scale for general and metal tube rotameters.
13.4.8 Variable Area Flow meters (purge rotameters) fitted with a constant flow
regulators shall only be used for fixed rate flows such as flushing or
purging.
13.4.9 For low cost measurement of high flow rates generally 2" and larger size, a
by-pass rotameters shall be used.

13.5 Ultrasonic Flow Meters, Thermal Mass Flow meters, Turbine &
Positive Displacement type Flow meters:

Multi Path (min 5 path) ultrasonic flow meter for gas flow measurement
shall be used for high accuracy custody transfer application or for GTR
parameter measurements.

13.6 Coriolis Mass Flow Meters:

13.6.1 Coriolis mass flow meter shall be used for high-rangeabilty, high-accuracy
application requiring mass flow measurement or where plants input/output
fluid quantity is used for mass balance or custody transfer purpose. If mass
flow meter is not proven for the service, The Coriolis mass flow meters
shall be used at all those locations, where fluid physical property will vary. If
PAC PROJ ECT
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Mass flow meter is not proven for the service, Bidder may use high
accuracy Magnetic flow meter with GNFC approval.
13.6.2 The Coriolis mass flow meters shall be used for all density measurement
13.6.3 As a standard, sensor tube material to be SS 316L (a minimum). Better
MOC shall be provided based on process fluid/service conditions.
13.6.4 Mass flow meters end connections shall be flanged and meter size shall be
selected in such a way that pressure drop at max. flow / velocity shall be
minimum.
13.6.5 Mass flow meters shall be 4 wire transmitters and supply shall be 110 V AC
only.
13.6.6 All mass flow meters shall have accuracy of +/- 0.1% for both analog and
pulse output. It shall be possible to freely configure density or flow output
over any of these two available output options.
13.6.7 All mass flow meters shall be weather proof to IP67 as per IEC529.
13.6.8 Mass flow meters shall be supplied with Remote mount, SMART transmitter
with 4-20 ma output and pulse+RS485 outputs. The sensor/transmitter
cable shall be min. 15 meter long, laid in protective conduit. All mass flow
meters shall be suitable for 2 pipe mounting and shall be supplied with
Local LCD type display. All mounting bracket MOC shall be SS304.
13.6.9 While selecting mass flow meters, consideration shall be given to fluid
velocity max. limit ( 2 meter /second for liquids), pressure loss, etc.

13.7 Magnetic Flow Meters:

13.7.1 Magnetic type flow meters shall be used for electrically conductive slurry,
cooling water or corrosive services and shall be installed with line size
bypass, with block and cleaning valves, at the lowest point in piping to
ensure that meter run is always liquid filled.
13.7.2 Grounding ring or ground electrode shall be used in all the magnetic flow
meters.
13.7.3 If the electrical conductivity is equal to or more than 20 micro siemens/cm
most of the conventional magnetic flow meter can be used. While selecting
meter, effect of temperature on conductivity shall be considered.
13.7.4 Magnetic flow meter size shall be selected so that the measurement is
accurate.
13.7.5 Magnetic flow meters shall be installed with required straight lengths.
13.7.6 All magnetic flow meters shall be 4 wire transmitters. The power supply
shall be 110 V AC.
13.7.7 All Magnetic flow meters shall be supplied with Remote mount, SMART
transmitter with 4-20 ma output and pulse output. The sensor/transmitter
cable shall be min. 15 meter long, laid in protective conduit. All magnetic
flow meters shall be suitable for 2 pipe mounting and shall be supplied with
Local LCD type display.
13.7.8 All the magnetic flow meters assembly shall be weather proof to IP67. All
mounting bracket MOC shall be SS304. Flow tube and flange MOC shall be
SS316L
13.7.9 The end connections shall be flanged type and min. pressure rating for
flanges shall be as per pipe class.

13.8 Vortex Flow Meters:
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13.8.1 Vortex flow meters shall be considered for following applications

- Where higher rangeability is required
- Where high accuracy is required
- Where no maintenance spare is expected
- Where process is a clean service
- Where mechanical vibrations are not existent in pipe and sufficient straight length
can be provided.

13.8.2 Size the meter so that its maximum permitted flow rate is as close as
possible application maximum flow rate.
13.8.3 Vortex flow meter shall not be used for the following services:

- High viscous and slurry service
- Liquids having large concentration of solids and two phase flow service.

13.8.4 Vortex flow meters shall be installed with required straight lengths.
13.8.5 All Vortex flow meters shall be 4 wire transmitters. The power supply shall
be 110 V AC.
13.8.6 Vortex flow meters shall be supplied with Remote mount, SMART
transmitter with 4-20 ma output and pulse output. The sensor/transmitter
cable shall be min. 15 meter long, laid in protective conduit. All vortex flow
meters shall be suitable for 2 pipe mounting and shall be supplied with
Local LCD type display.
13.8.7 Wetted part MOC shall be suitable for process fluid / temperature.
13.8.8 All the Vortex flow meters assembly shall be weather proof to IP67. All
mounting bracket MOC shall be SS304.

14. Level Measurement:
14.1 Level Gauge:

14.1.1 The Level gauge shall provide visible coverage of complete level
transmitter / controller range and the alarm/ trip level switches. In the case
of diff. pressure level transmitters where large spans are involved, a gauge
located at the top, centre and bottom of the installation with overlap in
visible area shall be acceptable.
14.1.2 All gauges glasses shall be steel armored reflex or transparent type with
body & cover material of forged carbon steel as a minimum and shall have
mechanical & thermal shock resistant type toughened borosilicate glass
with suitable gaskets. Bolting shall be of SAE 4140 steel.
14.1.3 Transparent type of gauges shall be provided with internal illuminators
operating at 240 V 50 Hz supply and suitable for electrical area class
specified. Illuminator shall be of the plastic solid wedge type designed to
give an even diffusion of light over the entire length of the gauge glass. All
gauge glasses must have a rating equal to or more than the vessel design
pressure and temperature and shall be provided with suitable metal guard.
Reflex type shall be used for clean and colorless liquids like water and
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hydrocarbon service, except liquids interlace level.
14.1.4 For low temperature, low boiling point services, large chamber type will be
used. Transparent type will be used for light fluids, acids, caustic, dirty or
viscous liquids, coloured liquids and liquids interface level. Transparent
type with Mica or Kel-F shields shall be used for treated water, boiler and
condensate services and for corrosive liquids which will attack glass.
Tubular gauge glasses shall, in general, not be used. They may be used for
non-hazardous services at ambient temperature and low .pressures.
14.1.5 AlI gauges shall have top and bottom chamber connections, unless
otherwise specified. Vent and Drain valves shall be fitted, as applicable.
Vent and drain valve shall be provided with nipple and end caps. Drain and
vent shall be of welded construction. Level gauges with side-side
connections shall be avoided. Each gauge shall be provided with ball check
valves & pipe union.
14.1.6 Large chamber gauges with frost shields shall be provided for cold
services, below 0C. Frost shield shall be transparent plastic type covering
full width of vision slot and suitably sealed to the glass.

Depth of Block Design Temperature

38 mm above-19 C
75 mm -20C to -49C
150 mm -50C to -99C
200 mm below-100C

14.1.7 Heating jacket shall be provided for viscous liquids.

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

14.1.9 In general, the visible length of the level gauges shall be selected from the
following.

Visible length (mm) Centre to Centre Length (mm)

220 470
470 720
720 970
980 1230

14.1.10 The maximum visibility length shall not exceed 1500 mm for a single gauge.
Multiple gauges with overlapping range shall be used for such cases. For a
given section, the visible length shall not be less than 90% of the total
length of section.
14.1.11 Float operated magnetically coupled gauges with 2" (50 mm) flanged end
connections shall be used, for level gauging in very viscous liquids, liquids
with crystals, sour services, toxic services and shall be of Bi-Color rolling
cylinders/Balls.
14.1.12 Bi-color type level gauges shall be used on steam drums. Larger chamber
PAC PROJ ECT
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gauge glasses and an expansion loop between the top of the gauge and
the top gauge valve shall be used. Level gauges on steam / boiler drums
shall be in accordance with the latest requirements of the IBR code.

14.2 Level Transmitters:

14.2.1 Displacer type instruments shall be used with displacer length varying from
350 mm to 1500 mm. for interface level measurement. In general, remote
seal type DP transmitters shall be used for level measuring application. For
condensable services, simple DP transmitter shall not be used with lag
filling. It shall be remote seal type DP transmitters only.
14.2.2 External displacer type instruments with side-side connections and
rotatable head shall be normally used for level measurement up to 1500
mm. Side-bottom are preferred when RTJ connections are required.
Internal displacer type of level transmitter shall not be used.
14.2.3 The process connection shall be 2 size.
14.2.4 Displacer type level transmitter shall be 2-wire, 24 VDC, 4-20 mA output
with LCD type local display.
14.2.5 The displacer type level transmitters shall be of LVDT / RVDT or strain
gauge type and the torque tube material of inconel, as a minimum.
14.2.6 All displacer type level transmitters shall be weatherproof to IP67 to
IEC529. Transmitter shall have remote mount facilities as an option, in case
of excess heat in the surrounding area.
14.2.7 Transmitters shall have NPT(F) electrical cable entry.
14.2.8 The standard materials for Displacer and displacer chamber shall be SS316
and Torque tube shall be Inconel, as a minimum. Based on process fluid
better options shall be selected.
14.2.9 Finned torque tube extensions shall be provided as necessary for
temperature service conditions.
14.2.10 Differential pressure transmitter shall be used for level measurement above
1500 mm for services requiring purge or where liquid might boil in external
portion. DP transmitters with lag filling mechanism shall not be acceptable.
14.2.11 Differential pressure transmitters for use on corrosive, condensable or
fouling service shall be diaphragm wafer with extended filled capillary type.
The length of capillary shall be 5 mtr. with SS armored in PVC sheath.
14.2.12 The process connection size shall be 2 Flanged for remote seal diaphragm
type Level Transmitters. All remote seal type instruments shall be supplied
with calibration ring with two blind plug/needle valves.
14.2.13 Flush or extended diaphragm type differential pressure transmitter shall be
considered for special applications only. Transmitters for closed vessel
shall have correction for suppression or elevation.
14.2.14 Dip Tube type level transmitters may be used on corrosive, congealing,
slurry services, where suitable diaphragm seal type transmitter is difficult to
obtain or where accuracy is not of prime importance.

14.3 Level Switch:

14.3.1 Level switches shall generally be external ball float type with flanged head.
14.3.2 External displacer type level switches can be considered for lighter fluids
where specific gravity is less than 0.5. Internal float / displacer type level
PAC PROJ ECT
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switches shall only be used if external type is not possible, like in viscous
services and in underground tanks / vessels.
14.3.3 The low-level switch shall be mounted directly on the column when the set
point is not less than 630mm. When level gauge and level switch are on the
same stand pipe, minimum allowable low level set point shall be 480mm on
the column.
14.3.4 Tuning fork, capacitance, or displacer type level switch may be used based
on application.
14.3.5 For all type of level switches, the micro-switches shall be hermetically
sealed, snap acting, with 24 V DC/2 Amps contact ratings with gold plated
contacts. Level switches with reed switch shall not be used.
14.3.6 For all type of Level switches, there shall be a SPDT with 2 NO/NC
contacts with adjustable differential.
14.3.7 For all type of level switches as specified above, the process connection
shall be flanged type and the flange size shall be 2 .

14.4 Tank Level Instruments:

14.4.1 There shall be NO Mechanical float type gauges, Servo controlled level
gauges or Ultra Sonic type level transmitters/switches for any of the level
measurement/trip/alarm application. For all type of tank level instruments, a
2 wire RADAR instrument shall be used. Measurement accuracy shall be
+/- 5mm or better for these RADAR type level instruments. Also, where
more than 2 level instruments are used on same location, one of them shall
be RADAR type.
14.4.2 All RADAR type instruments shall have Flanged process connections and
min. nozzle height for process connection shall be 150mm.
14.4.3 Irrespective of pressure rating, the minimum pressure rating for RADAR
flange shall be min. 3 ANSI. Flange MOC shall be same as that of wetted
parts.
14.4.4 RADAR type transmitter shall be standard 2 wire, 24 V DC, 4-20 ma,
SMART with HART protocol type with Local LCD display and with ROD
type antenna only.
14.4.5 Flange and wetted part MOC for RADAR and flange shall be min.
SS316/PTFE coated or better to suite process fluid/temperature.
14.4.6 Wherever, the range can not be covered with 2 wire, 24 V DC type RADAR,
a 4 wire transmitter with 110 V AC supply may be used. However, the
RADAR transmitter shall be SMART with all other specifications same as
above.
14.4.7 All RADAR type level transmitters shall be weatherproof to IP67 as per
IEC529.
14.4.8 RADAR shall be with various software features like empty tank spectrum,
dynamic error corrections, false echo filtering, Programmable range from 0-
100%, throughout out the tank height, SPAN/ZERO elevation/suppression,
programmable blocking window distance, etc.
14.4.9 For solid level measurement, type of instrument shall be RADAR only.
14.4.10 Standpipe shall be used for clean, non-viscous and non-crystallizing service
if more than 4 nozzles are required for level instruments, e.g. one displacer
instrument and one level gauge can be mounted directly on the equipment.
The size of Standpipe shall be 3" NB minimum and shall have valves at the
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instrument connections. Taping size on vessel for stand pipe shall be 2 as
a minimum.
14.4.11 Trip level switches should be directly mounted on vessel/column and not
with the standpipes.
14.4.12 Connection of standpipe from the bottom of vessel must be avoided.
14.4.13 On horizontal vessels with boot, a separate standpipe shall be used for
boot interface level measurement in addition to standpipe used for
horizontal vessel.
14.4.14 Level co-ordination sketches shall be produced showing all pertinent details
including nozzle locations, alarm levels, controlled level zones, shutdown
level, interface line, etc.
14.4.15 All displacer and float type instruments shall have provisions for on-site
calibration simulation check.

15 Pressure/Diff. pressure measurement:

15.1 Pressure & Differential Pressure Transmitters:

In addition to the general field transmitters specified in Section 4.0, the following
minimum guide lines shall be followed for all the temperature transmitters used through
out in the project, including the package unit instruments.

15.1.1 All the field transmitters for flow, pressure, differential pressure and level
applications shall be yoke mounted, 2 wire, 24 V DC, 4-20 ma dc, SMART
with HART protocol.
15.1.2 All these transmitters shall be weatherproof to IP67 as per IEC529.
15.1.3 The min. loop load shall be 600 ohm for 4-20 ma output circuit of
transmitters. Transmitters shall be able to work between 12 to 35 V DC with
600 ohm loop impedance.
15.1.4 Transmitter lower housing shall be of SS316 unless otherwise specified.
The upper housing of transmitter shall be of die cast aluminum with Epoxy
paint as a minimum.
15.1.5 Pressure/ Differential Pressure Transmitter shall have electronic
capacitance, silicon resonant wire, piezo crystal or any other type of proven
sensor technology meeting all functional specifications. Inductive type
measuring principle is not acceptable.
15.1.6 Diaphragm, Element material for transmitter shall be SS316L as a minimum
for and shall be able to withstand over pressure of at least 1.5 times the
maximum working pressure. Other wetted part MOC shall be selected
based on process requirement.
15.1.7 All remote seal diaphragm type pressure/diff. pressure transmitters shall
have 2 Flanged diaphragm as process connection. For very low range
pressure/diff. pressure measurement application, diaphragm size shall be
3 ANSI.
15.1.8 The transmitter shall be so constructed that in case of a pressure sensing
diaphragm /element failure, the process material will not enter the electronic
portion of transmitter or wiring conduits
15.1.9 Transmitters shall be provided with external zero adjustment and shall have
integral vent/drain.
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15.1.10 All the transmitters shall be quipped with Local LCD type digital indicator
capable of indicating engineering unit display.
15.1.11 The transmitter shall be microprocessor based and it shall incorporate a
non-volatile memory, which shall store complete configuration data of
transmitter. All necessary signal conversions, including conversion to
produce output with the required protocol shall be carried out in the
transmitter electronics. The design of electronic parts shall be in
compliance with the electromagnetic compatibility requirements as per IEC
801
15.1.12 Transmitter shall also run complete diagnostic routine. In the event of
detection of failure, the output shall be driven to predefined value, which
could be either minimum (4 ma) , maximum(20 ma) or last good value. This
feature shall be programmable.
15.1.13 Built in temperature sensors shall be provided to compensate for process
temperature and ambient temperature variations.
15.1.14 Transmitter rangeability shall be 100:1. The transmitter shall be able to
assure an accuracy of +/- 0.1% of span for a rangeability of 1:30. The
accuracy shall include the combined effect of linearity, hysterisis and
repeatability. Effect o
f
static pressure on the transmitter in either direction
shall be negligible.
15.1.15 Care shall be taken while selecting the transmitter models that there shall
be minimum type of diff. models of the same category of transmitters to
reduce spare/inventory.
15.1.16 Transmitter shall be selected so as to have calibrated range within
turndown ratio of 1:10. The normal pressure shall be read at no greater
than 75 percent of the calibrated range for transmitter reading steady
pressures. For fluctuating services the normal pressure shall be read at 60
percent of the range.
15.1.17 In case of differential pressure transmitter with remote seals, adequate care
shall be taken to consider head pressure effect of capillary fill fluid while
selecting the transmitter.
15.1.18 The response time of smart transmitters shall commensurate with process.
It shall be equal or better than the half of the total scan time of any critical
loops for process requirement like anti surge controllers. In any case, this
shall not be less than 30 updates per second.
15.1.19 HART protocol of latest version shall be used and shall be suitable for
HART maintenance system with corner stone or AMS like software with the
following features as minimum:
o It shall allow multi masters (two for example, primary and secondary) for
configuration, calibration, diagnosis and maintenance.
o The primary could be control system or host computer and the secondary
could be the hand held communicator or a maintenance computer.
o It shall be capable of implementing universal commands. It must be
possible to communicate all the commands of HART maintenance system
to field transmitter and smart transmitters shall be selected accordingly.

15.1.20 Unless recommended otherwise by compressor manufacturer, field
transmitters used in anti-surge control loop shall be non-smart and
weatherproof types with IP67 protection.
15.1.21 The transmitters shall have their calibration adjustment from out side
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without any need to remove the cover of electronic enclosure.
15.1.22 Retrofit type SMART transmitters are not acceptable. The model selected
shall be the latest from the vendors product range and proven in the field
for minimum of 1 year of operation.
15.1.23 For hydrogen gas service transmitters, Hastelloy wetted parts shall not
used to avoid damage due to hydrogen ion permeability. It shall be SS316L
only.
15.1.24 Process connection for standard pressure & differentia! pressure
transmitter shall be NPT(F) and 2 " flanged for diaphragm seal type.
15.1.25 Diaphragm seal element with capillary shall be used for congealing,
corrosive and highly viscous services at high operating temperatures. Filled
fluid shall be capable of withstanding the process
temperature/pressure/fluid.
15.1.26 Capillary shall be SS armored with PVC cover and 5 meter in length. Its ID
shall be selected to have minimum lag.
15.1.27 For all the diaphragm type pressure and diff. pressure transmitters, a
Flushing rings with MOC suitable to process conditions, shall be provided
with screwed vent & drain connections duly plugged.
15.1.28 All transmitters shall be provided with integral two valves / three valves /
five valves manifold as per the specific requirements. MOC of manifolds
shall be same as those of wetted parts.
15.1.29 Oxygen service pressure/diff. pressure transmitters shall be supplied with
special inert fluids (including diaphragm type with remote seal and capillary)
and shall be free from grease/oil. These shall be clearly marked with For
use in Oxygen services.
15.1.30 Design materials, connections and accessories not specified herein shall be
in accordance with the vendor's standards, suitable for the specified service
conditions.

15.2 Pressure Gauges & Diff. Pressure Indicators:

15.2.1 Gauges shall conform to the requirements of BS 1780 gauges of the elastic
element type, unless-otherwise specified.
15.2.2 All the Pressure gauges dial shall be white, non-glaring and non-rusting
plastic with black figures. Dial size shall be 150 mm. Dial cover shall be of
shatterproof glass. The dial face shall be marked with pressure element
material. Pointers shall have micrometer adjustment. Pressure gauges shall
have feature like screwed bezels, externally adjustable zero, over range
protection and blowout disc.
15.2.3 Pressure gauge sensing element shall be of SS 316 and movement of SS
304, as a minimum except where the process requires a special material.
For general use gauges shall use a bourdon tube as measuring element.
The movement shall be either rotary geared or cam and roller type. The
movement mounting shall be integral with the bourdon tube socket.
15.2.4 For low pressure and vacuum services pressure gauges with capsule
sensing element to be used.
15.2.5 The elastic element material, unless specified otherwise, shall be as
follows:

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- For ranges 60 kg/cm2 g and less, AISI-316 seamless drawn stainless
steel tube, argon arc welded at AISI-316 forged or wrought stain less steel
tube anchorage and tube end piece.
- For ranges above 60 kg/cm2 g, AISI-316 bored stainless steel otherwise
as above.

15.2.6 All pressure gauges and diff. pressure gauges Cases shall normally be of
304SS and weatherproof to IP-65 as per IEC-529 / IS-2147.
15.2.7 Safety blow out discs shall be provided for all gauges and shall be located
in the back or side of the case. For pressure gauges with maximum
operating pressure below 60 Kg/cm2g, the minimum size of blow out disc
shall be 1" and for maximum operating pressure of 60 Kg/Cm2 and above,
pressure gauge shall be safety type with solid front where pointer and
gauges are partitioned from the sensor by a solid disc of 316SS material.
15.2.8 Pressure gauges shall have an accuracy of 1% of full scale as a
minimum. Differential pressure gauges may have an accuracy of 2 % of full
scale.
15.2.9 Gauges shall be able to withstand, over-range pressure of 1.3 times the
calibrated range for at least 30 minutes as standard without zero or
calibration shift.
15.2.10 Over-range protection such as gauge savers shall be provided where the
process pressures may exceed 1.3 x full scale deflection. Gauge savers if
provided shall be of non bleed type with internal pressure release/block.
15.2.11 Ranges shall be so specified that the gauge normally operates in the
middle third of the scale and shall conform to IS-3624 standard dials,
wherever possible.
15.2.12 Process connection shall normally be 1/2" NPT(M) bottom, except for
diaphragm seal where 2flanged connection shall be used in general.
15.2.13 Connection ( including flange MOC) shall normally be 316SS unless
otherwise the special material is required.
15.2.14 Socket stem shall extend a minimum of 1 beyond gauge case and shall
be provided with wrench flats.
15.2.15 Diaphragm seals, filled type shall be furnished where plugging of the
element may occur or where suitable material is not available in highly
corrosive services. When chemical seals are required, they shall be
provided with fabricated vent and drain arrangement. Diaphragm seal
device shall be furnished completely assembled with the pressure gauge.
15.2.16 Remote seal Diaphragm type pressure gauges with capillary shall be used
wherever required for access and visibility. Use of Schaffer diaphragm type
gauges will be avoided as far as possible.
15.2.17 The diaphragm seal devices shall be stainless steel SS316. The MOC for
the flanges, rings and top housings shall be of SS304, unless a special
material is required.
15.2.18 Liquid filled gauge shall be used where extreme vibration of the gauge is
expected. Glycerin or other suitable case filling liquid with non coloring
property shall be used.
15.2.19 An inert liquid shall fill the entire system between the diaphragm of the
diaphragm seal device and the elastic element. Unless otherwise specified,
filling liquid shall be suitable for an ambient temperature range of -18C to
204C.
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15.2.20 Oxygen service pressure/diff. pressure gauges shall be supplied with
special inert fluids and shall be free from grease/oil. These shall be clearly
marked with For use in Oxygen services.
15.2.21 Receiver pressure gauges for local/ local panel or those of electro-
pneumatic positioners input/output indication shall have 100 mm dial with
stainless steel element and 1/4" NPTM back side connection.
15.2.22 Pneumatic indicating receiver gauges shall conform to the applicable parts
of this specification except as follows:
- Elastic elements shall be SS designed for a 0.2 to 1 kg/cm2 g (3 to
15psig) pressure range, but shall be able to withstand 1.4 kg/cm2 g (22
psig).
- Dials shall be graduated for the range specified on the data sheet, with an
additional scale graduated 0.2 to 1 kg/cm2 g (3 to 15 psig) linear.
- The dial range shall correspond to the 0.2 to 1 kg/cm2g (3 to 15 psig)
element range in the data sheet specified. (For example, when the range
specified is 0-100, the "0" marking on the dial shall correspond to 0.2
kg/cm2 g (3 psig) and the "100" marking to 1 kq/cm2 g (15 psig).

15.2.23 Over range protector and pulsation dampener, whenever used, shall be of
SS 316 as a minimum. Pulsation dampener shall be used for all pulsating
services. It shall be floating pin type, externally mounted and externally
adjustable.
15.2.24 Gauge savers shall be used in all pump service applications.
15.2.25 Pig tail siphons with SS304 MOC shall be provided for steam applications
unless liquid filled impulse line is used.
15.2.26 All type of Gauges shall be supplied with engraved labels stating tag no.
15.2.27 Design materials, connections and accessories not specified herein
shall be in accordance with the Vendor's standards, suitable for the
specified service conditions.

15.3 Pressure & Differential Pressure Switches:

Generally pressure and diff. pressure switches shall be used only for alarm purpose and
shall be connected with DCS. Generally, all interlocks/logic shall be realized via 2 wire,
24 V DC, SMART pressure/diff. pressure transmitters connected to DCS for pressure,
diff. pressure and level application.

15.3.1 However, in special case, when required by machine vendors for machine
safety, for few critical applications, use of pressure and diff. pressure
switches shall be allowed with due justifications.
15.3.2 All the Pressure/Diff. pressure switches shall have either diaphragm or
bellow type of primary element with SS316 material of construction as a
minimum. Switch shall be hermetically sealed, snap acting micro switch
with SPDT contacts.
15.3.3 The contact rating shall be 230 V AC/ 2 amp or 24 V DC/2 Amp as a
minimum.
15.3.4 The switch mechanism shall be designed to prevent spurious operation by
vibration.
15.3.5 Pressure/DP switch design with Reed type switches shall not be selected.
PAC PROJ ECT
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15.3.6 The primary element and the diaphragm shall be made of 18 Cr/8 Ni.
Stainless steel, unless otherwise specified.
15.3.7 Receiver pressure switches shall have SS316 bellows as primary element
with NPT (F) connection.
15.3.8 The primary element shall be designed to withstand an over-range pressure
of 25% greater than the full scale.
15.3.9 Pressure switches shall be provided with a positive means of protection
against process fluids entering the electrical housing in the event of
element failure.
15.3.10 Pressure switches shall be blind type with NPT (F) process connection
and shall be operative in full specified range. The switch differential shall be
selected as per operating conditions; it shall be less than 60% of difference
between set value and operating value.
15.3.11 Diaphragm seal type pressure switches with flanged end connections shall
be specified for applications on corrosive / congealing services. In all these
case, the diaphragm flange size shall be min. 2 x 300 #ANSI ratings and
MOC shall be SS316 for flange and MOC. Better MOC shall be opted
based on process requirement.
15.3.12 All diaphragm type pressure / diff. pressure switches with flushing
connection. Diaphragm seal device shall be furnished completely
assembled with the pressure switch.
15.3.13 Pressure switches shall have repeatability of 0.5% of full scale as a
minimum.
15.3.14 The switching set point shall be adjustable over the whole range, with an
internally calibrated scale.
15.3.15 Switches shall be specified such that the on/off differential does not prevent
the switch resetting inside normal operating pressure ranges.
15.3.16 Over range protection and pulsation dampener requirements and design
shall be as per as specified above.
15.3.17 Design materials, connections and accessories not specified
herein shall be in accordance with the vendor's standards, suitable for
the specified service conditions.
16 Temperature Measurement:

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

16.1.2 All open loop/closed loop temperature shall be carried with
Thermocouple/RTD elements and field mountable 2 wire SMART
temperature transmitters. Hence in DCS, there shall not be any RTD or T/C
input cards.
16.1.3 All open/closed loop temperature measurement shall be carried out with the
help of Thermocouple / RTD elements along with field mounted ,2 wire, 24
V DC, 4-20 ma, SMART temperature transmitters. No head mounted
transmitters shall be used throughout the project or any part thereof,
including package unit instruments.
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16.1.4 All temperature interlocks/logic related measurement shall be carried out
with the help of Thermocouple / RTD elements along with field mounted ,2
wire, 24 V DC, 4-20 ma, SMART temperature transmitters. No head
mounted transmitters shall be used throughout the project or any part
thereof, including package unit instruments.
16.1.5 By default all temperature elements shall be duplex, unless otherwise
specified.
16.1.6 Irrespective of design pressure rating, the minimum pressure rating of
Thermowell flange shall be ANSI type as per piping class rating.

16.2 THERMOWELLS

16.2.1 All temperature elements shall be provided with thermowells. The flange
MOC shall be SS316 as a minimum. In case of corrosive and erosive
services Titanium/ Hastalloy C bar-stock thermowell shall be provided. The
thermowell design shall ensure no air gap between the tip of the element
and thermowell to minimize measurement lag. The internal diameter of
thermowell shall be suitable for sensing element /bulk OD of mm or 8 mm.
16.2.2 Thermowells shall be assessed for resonance effects. Where Thermowells
in lines subjected to high fluid velocities (exceeding 6 m/s for liquid and 120
m/s for vapors, gases), combined stress and frequency calculation shall be
carried out by a proven method. In case the thermowell design fails
vibration analysis , alternate design may be used by the contractor. All such
design along with calculations shall be submitted for purchaser's review.
16.2.3 Immersion length U of the thermowell shall be as follows.

Line Size Immersion length

From 4' to 6" 280 mm
From 8" onwards 320 mm
Vessels / columns 400 mm

16.2.4 Immersion length is based on 200 mm length between flange face and
inner wall of pipe. In special applications, where thermowell nozzle sizes
are larger or where temperature is to be measured at any specific location,
contractor shall decide the immersion length based on actual requirements.
16.2.5 All skin temperature elements and flue/fuel gas path elements shall be with
Inconel capillary with proper wedge element for proper sensing of exact
location temperature.
16.2.6 Any pipe line less than 4" nominal bore shall be blown to 4" size to installing
the thermowells.

16.3 Temperature Gauges:

No local temperature gauges/thermometers or any type of local
temperature gauges shall be used in main plant as well as any of the
package unit instruments.

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All temperature measurement points shall be through either T/C or RTD
type element only with field mounted 2 wire, SMART with HART protocol
Temperature Transmitters.

16.4 Temperature Elements:

16.4.1 For all type of temperature measurement, either thermocouple or RTD
elements shall be used depending on the requirements.
16.4.2 All the temperature Elements shall be spring-loaded, duplex, mineral
insulated and sheath MOC as SS316 as a minimum.
16.4.3 Bulb OD of all the elements shall be 8 mm and the overall diameter of the
sheathed element shall not deviate by more than 2%.
16.4.4 RTD and Thermocouple metallic head assemblies shall be furnished with
screwed in type heads / enclosure certified as Weatherproof to IP65 as a
minimum, irrespective of plants hazardous area classifications. All head
assembly shall have two NPT (F) cable entries. All assemblies shall be
supplied with either 1 no. of two nos. of double compression type SS MOC
cable glands certified for weatherproof to IP65. Wherever second element
is not in use, the spare cable entry shall be provided with NPT SS304
blind plug.
16.4.5 MOC for head assembly shall be die cast aluminum.
16.4.6 The terminals shall be color coded as per elements color code.
16.4.7 Thermocouples shall comply with ANSI MC 96.1 and IEC 584, Eidtion-2,
IS7358. They shall have wire size of 18 AWG for single and 20AWG for
duplex elements.
16.4.8 In general, the following guidelines shall be used for selecting thermocouple
elements/wire size, as a minimum.

Type 8 AWG 14 AWG 18 AWG

T - >37 C For all other

E >871 C >649 C -do-

K >1260 C >1093 C -do-

S - - <1500 C

16.4.9 Thermocouples shall be compact Magnesium Oxide (MgO) filled and
ungrounded, unless specified. Grounded junctions are to be used where
fast response is required, if secondary system allows the use of grounded
T/C elements. The insulation resistance shall be >100 Mega Ohm. The
thermocouple wires shall be joined together by welding to form a hot
junction. Bulb / Sheath diameter shall be 8 mm and the overall diameter of
the sheathed element shall not deviate by more than 2%.
16.4.10 The type of thermocouple shall be selected based on the following
guidelines as minimum
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Copper-Constantan (ISA-Type-T) (-) 200 to 200C

Chromel-Constantan (ISA-Type-E) 200 to 600C

Iron-Constantan (ISA-Type-J ) 0 to 600C

Chromel-Alumel (ISA-Type-K) 600 to 1200C

Platinum Rhodium-Platinum (ISA-Type-S or B) 600 to 1600C

16.4.11 The design of thermocouple assemblies shall be such that replacement of
elements shall be possible on-line. It shall be equipped with SS304 MOC
Nipple-Union-Nipple J oints. Assembly shall include nipple-union-nipple
(1/2" NPT threaded) to allow approximately 150 mm between top of well
and bottom of head, when made up.
16.4.12 Thermocouple sheathing material shall be 316 stainless steel as a
minimum and are constructed from a seamless tube with a wall thickness of
at least 1 mm. Inconel 600 sheath shall be used for all application, where
the temperature is above 600C.
16.4.13 RTD (Resistance Temperature Detector) shall be 3 wire type platinum
elements with 100 ohms resistance at 0C. RTD shall be calibrated as per
IEC 751 / DIN 43760.
16.4.14 RTD shall be used for a temperature range of -200 to 650C. Three-wire
system shall be the element.
16.4.15 RTD shall generally be selected for applications requiring low temp with
comparatively shorter temperature span requiring accuracies of better than
+/-0.25%.
16.4.16 All RTD elements shall be duplex by default. It shall be compact
Magnesium Oxide (MgO) filled. The insulation resistance shall be >100
Mega Ohm.
16.4.17 The design of RTD assemblies shall be such that replacement of elements
shall be possible on-line. It shall be equipped with SS304 MOC Nipple-
Union-Nipple J oints. Assembly shall include nipple-union-nipple (1/2" NPT
threaded) to allow approximately 150 mm between top of well and bottom
of head, when made up.
16.4.18 RTD bulb sheathing material shall be 316 stainless steel as a minimum and
are constructed from a seamless tube with a wall thickness of at least 1
mm. Bulb / Sheath diameter shall be 8 mm and the overall diameter of the
sheathed element shall not deviate by more than 2%.
16.4.19 The special thermocouples such as reactor thermocouples, etc. shall be
designed by BIDDER and needs purchasers approval.
16.4.20 For Reactor / heater tube skin thermocouple, wherever applicable,
assembly shall meet the equipment design requirements and shall be
provided with expansion loops. The sheath MOC shall be selected based
temperature.
16.4.21 Flare application or Reactor thermocouples shall be Pad / Knife-edge type
with Inconel sheath.
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16.4.22 Class 'A' / Class '1 tolerance as per IEC 751 / 584-2 shall be specified for
all RTD and thermocouple sensors in complete temperature measurements
for all open/closed loops and interlocks.

16.5 Temperature Transmitters:

16.5.1 In addition to the general field transmitters specified in Section 4.0, the
following minimum guide lines shall be followed for all the temperature
transmitters used through out in the project, including the package unit
instruments.
16.5.2 Head mounted temperature transmitters are not allowed at any location,
through out the project or part thereof. Field mounted transmitters shall be
used for all temperature transmitters.
16.5.3 All Field mounted temperature transmitters shall be specified for all closed
and open loops in DCS, for all interlock inputs to DCS, which are taking part
in Flow correction or any other calculations. Remaining all other T/C & RTD
for open loops, which are only for monitoring purpose shall be directly
connected to DCS without temperature transmitters.
16.5.4 All the Temperature transmitters shall be 24 V DC, 2 Wire, 4-20 m amp dc
output with SMART with HART protocol.
16.5.5 Temperature transmitters shall be suitable for 2 pipe mounting and shall be
supplied with all SS304 mounting brackets/nut/bolts, etc.
16.5.6 All temperature transmitters shall be equipped with local, LCD type digital
indication which shall be configurable in engineering unit.
16.5.7 Temperature transmitters shall have a built-in linearising function.
16.5.8 The minimum accuracy of all the temperature transmitters shall be 0.1% of
FSD
16.5.9 All transmitters shall be of universal input type, so that it can accept all type
of Thermocouples or all type of RTD inputs with 2/3/4 wire options. This
feature is a must to reduce inventory and have interchangeability of various
transmitters.
16.5.10 All the transmitters shall be provided with min. two cable entries with
NPT(F) size. One entry shall be used for sensor cable input and other shall
be for 24 V DC/2 wire output cable.
16.5.11 All temperature transmitters shall weatherproof to IP67 as per IEC529.
16.5.12 Transmitter housing MOC shall be die-cast aluminum with epoxy paint as a
minimum.
16.5.13 Each temperature transmitters shall be supplied with min. of two nos. of
double compression type, SS304 MOC, cable glands with PVC hood. Cable
glands shall be Weatherproof to IP65 as per IEC529.

17 Limit switches / Position Switches:
17.1 All type of limit switches shall be 2 wire, proximity type, and NAMUR sensors
only.
17.2 The make shall be P+F only. The sensor shall be generally cylindrical NAMUR
sensor type proximity switch. The diameter and sensing range shall be
selected based on application.
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SECTION-II
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17.3 The MOC of sensor shall be SS316. Krastin type probes shall not be used,
unless surrounding atmosphere heat permits the use of the same under worst
condition.
17.4 All limit switches sensor shall be adjustable with the threaded length and check
nut arrangement.
17.5 Flying lead type loose connections for NAMUR sensors are not acceptable. All
these NAMUR sensors installed on any instruments to sense the position shall
be housed in a closed box certified for weatherproof to IP67. The gland size
shall be NPT(F).
17.6 All ON-OFF type application valves taking in part in interlock/shutdown shall be
provided with Open and Close type NAMUR sensor as limit switches. The
sensors along with enclosure shall be installed in control valve in such a way
that it can be removed with ease for maintenance.
17.7 Limit switches shall not be used for Control Valves. All controls valves shall be
equipped with SMART positioner, from where the analog output for continuous
position is available, which shall be used for interlock/control purpose.
17.8 NAMUR type Proximity switches shall not be directly wired to DCS Digital input
cards. These shall be connected with Isolation Amplifier of P+F make, located
in auxiliary cabinet/panels in central cabinet room. The isolation amplifier shall
provide potential free contact for further use in DCS. The isolation amplifier
shall be suitable for 110 V AC power supply , mountable on DIN rail.
18 Control Valves
18.1 The control valves shall be designed based on following guide lines, as a
minimum.
18.1.1 Control valve type / design selection shall be made with considering the
following conditions

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

18.1.2 Control valves shall normally be globe type, top guided (up to 10 Kg/Cm2
Delta P) or cage guided (more than 10 Kg/Cm2 Delta P), single seated,
non-pressure balanced type only. Other valves like butterfly, ball, rotary,
angle or 3 way valves shall be selected based on application. All control
valves shall be flanged end type only the control valve Body material and
Body rating shall be as per piping specifications. Valve bodies and other
pressure parts, except diaphragm and housing shall be of forged or cast
type conforming to ASTM standards, unless otherwise specified.
PAC PROJ ECT
SECTION-II
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18.1.3 The Minimum control valve body size shall be 1" in general. Body size shall
be limited to 1", 1-1/2". 2", 3", 4", 6", 8', and 12. Higher size may be used
if required. The flanged connection dimensions and pressure temperature
ratings shall be as per ANSI B16.5.
18.1.4 The accessories like Air Filter Regulator, Solenoid Valve, Limit switches,
Positioners, etc. shall be pre-tubed with actuator so that they can be
removed easily for maintenance purpose.
18.1.5 The max. allowable noise shall be 85 DB SPL (Sound Pressure Level).
Control valves at a 1 meter distance, exceeding this limit will be provided
with special precautions.
18.1.6 Leakage class VI shall be considered, where tight shutoff is specified. If no
leakage class is specified, min. leakage class V is to be considered.
18.1.7 For all interlock/shutdown valves, the minimum leakage class shall be
Class VI as per ANSI B16.104.
18.1.8 Control valve sizing shall be carried out as per ISA S75.01. The selected
CV shall permit up to 150% of normal flow or 110 % of maximum flow,
whichever is higher. In general, control valves shall be sized so that the
valve opening is as mentioned below.

At Max. Flow :- 80% Open
At Normal Flow :- 70% open
At Min. Flow :- 20% open

18.1.9 Equal % control valve shall be sized for 60% to 80% opening for normal
flow. For two phase flow, both phase CV is to be considered with relevant
process condition while sizing the valve.
18.1.10 Flanged bolted type gland packing boxes shall be used, unless other
specified. Gland packing shall normally be self-lubricating type. Packing
shall be PTFE type up to 200C. For temperature above 200 C, grafoil is
to be used. Usage of asbestos is not allowed in any part.
18.1.11 Bellows seals shall be used wherever gland leakage is not permissible like
toxic / hazardous product like carbon monoxide gas, etc.
18.1.12 As a minimum, trim MOC shall be SS316. By default, all Guide MOC shall
be hardened stainless steel like 440 C, 17.4 PH. For corrosive services
PTFE lined globe / ball valves shall be used.
18.1.13 Where tight shutoff is required, fire safe type soft seat trims shall be used,
provided pressure/temperature of service permits the use of this.
18.1.14 Trim characteristics shall be equal percentage, unless otherwise specified.
For high erosion service or in steam service where, the delta P is higher
than 5 Kg/Cm2, hardened trim with stelliting shall be used. When this is not
sufficient, in such cases, special Anti-cavitating trim or shall be selected
18.1.15 The allowed stroking time shall be governed by process requirement.
Generally, for control valves, equipped with positioner, max. stroke time
shall be 10 seconds up to control valve size 4 or smaller. And shall be
max. 15 second for control valve with size 6 and above. For critical control
valves, like anti surge control valve, stroke time may be in the range of 2-5
seconds. For interlock valves, this could be in the range of 1 to 2 seconds.
18.1.16 PCV shall be used only when load is constant and precise control is not
required like nitrogen blanketing system for storage tanks, etc.
PAC PROJ ECT
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18.1.17 All shutdown valves shall be floating ball design with full bore design,
unless otherwise specified.
18.1.18 All valves with flow tends to open design, shall be used.
18.1.19 Oxygen service valves shall be de-greased completely and certified for
oxygen service use. MOC for body shall be Monel and trim shall be Inconel
600 only.
18.1.20 For all steam service valve, BIDDER to ensure submission of IBR FORM
IIIC certificate in original.
18.1.21 For all shutdown valves on fire safe applications, air volume tank shall be
supplied for the storage of air volume for minimum 3 stroke operation.
18.1.22 For steam de-superheating, single valve is not acceptable. Both valve for
water injection and pressure reduction shall be separate.

18.2 ACTUATORS

18.2.1 Generally all actuators shall be single acting, spring return, diaphragm or
piston type only. Use of double acting piston actuator is not allowed. If
thrust requirement is more, a spring return piston actuator shall be used.
Also the usage of Hydraulic or Motorized actuators is not acceptable.
18.2.2 All actuators shall be designed with max. 4 kg/cm2g air pressure availability
only. The actuator shall be sized in such a way that it should be able to
open the valve when full static upstream pressure is acting on upstream in
valve full closed condition and down stream pressure is atmospheric
pressure. Actuator shall be oversized to 125% of the thrust required for DP
Shut off, as specified above. In short, actuator shall be able to with stand
max. shut off static pressure with down stream atmospheric pressure, when
available instrument air pressure to actuator diaphragm is minimum
specified. Spring shall be painted with corrosion resistant paint. All actuator
open/vent port shall be provided with breathers. Paint shall be min. epoxy
type.
18.2.3 Actuator case MOC shall be Steel and Yoke MOC shall be high tensile
ductile iron as a minimum. Diaphragm shall be of nylon reinforced neoprene
or Buna N rubber. Extended bonnet shall be selected based on high
temperature or cryogenic services.

18.3 POSITIONERS

18.3.1 By default, all the control valves positioners shall be SMART with HART
protocol, Electro-pneumatic type, accepting 2 wire, 4-20 m amp input
signals from central DCS system.
18.3.2 All the positioners shall be weatherproof to IP65.
18.3.3 There shall be min. two NPT (F) cable entries in each SMART
positioner, from where input signal and position output feedback signal
wires can be terminated separately.
18.3.4 Air consumption of the SMART positioner shall not be more than 0.3
NM3/Hr. Positioner shall be having AUTO STROKE functionality, Self
Diagnostic, etc. features in built with local push button and LCD display.
18.3.5 Positioner shall be mounted on control valve so that it can be removed with
ease during the maintenance.
18.3.6 Positioner feedback link with control valve shall be fixed with 100% secure
PAC PROJ ECT
SECTION-II
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mechanism so that there is no backlash in motions, resulting hysteresis or
chance of dis-engagement of the link while the control valve is installed with
severs pipe vibrations.

18.4 OTHER ACCESSORIES

18.4.1 Hand wheels shall be provided as per requirement indicated the data sheet.
18.4.2 Valve stem position indicators shall be fitted as standard, showing
incremental stroke positions.
18.4.3 Direction of flow indication shall be engraved or embossed on the body.
18.4.4 Limit switches, if specified in datasheets, shall be 2 wire, NAMUR sensor,
proximity type and P+F make only. This shall be installed in weatherproof
IP65 box. No flying lead type connections are acceptable.
18.4.5 All Solenoid Valves used in the whole plant (including those being supplied by
package unit vendors) shall be of either ASCO or HERION make only.
18.4.6 It shall be 110 V AC/50 Hz, 3/2 way, NPT(F) or NPT(F) process
connections based on Kv/Flow requirement of control valve actuator and stroke
speed requirement, SS 316 MOC body, weatherproof to IP67, NPT(F) cable
entry. The make of all the solenoid valves shall be Herion Only.
18.4.7 The max. working pressure for all Solenoid valve shall be 10 kg/cm2g. There
shall be only two types of common models of Solenoid valves shall be used (
and Process connections) through out the complete plant design to maintain
fewer inventories and have interchangeability at any time.
18.4.8 This philosophy shall be extended for all the package unit instruments too.
BIDDER to ensure the same type/model of solenoid valves along with each
package unit instrumentation also.
18.4.9 All solenoid valves shall be supplied with NPT, SS MOC, double
compression Cables glands, weather proof to IP65 with PVC hood.

18.5 INSPECTION & TESTING

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

- Dimensional /Physical Test
- Hydrostatic Body Test. - Duration 3 min. ( including all parts in assembled condition like
body, gland, all joints)
- Seat leakage as per ANSI B16.104/FCI 70.2
- Diaphragm head test
- Complete actuator leak test
- Helium leak test for control valve with below seals
- Stroke calibration
- Stroke speed test

18.6 Documents/Test Certificates

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

- MOC certificate for control valve, all accessories and other bought out items
- GA Drawings, including all accessories
PAC PROJ ECT
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- Dimensional Cross sectional drawings of complete control valve/accessories
- All type of tests certificate like Hydro test / seal leakage test certificates
- Radiography test
- IGC test as per ASTM A262, Practice A, Fig. 1
- DP Test
- Stroke calibration and stroke time test certificates
- Operation and Maintenance manual of control valve and all accessories
- Product catalog of control valve and all accessories
- Functional test certificates for all accessories

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

- Instrument Tag Number
- Vendor's Name
- Valve Model Number
- Order/Requisition Number
- Body & Trim Material
- Stem Packing
- Material Body Size and Rating
- Design CV (For Control valve and Regulator)
- Trim Characteristic or Cam Code/type as necessary
- Air-Fail Action
- Hazardous Area Class
- Actuator size
- spring range
- air supply pressure

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

- ANSIB16.10 - Control valve dimension
- ANSI / ISA S75.C1 - Flow equation for sizing of control valves
- ANSI / ISA S75.02 - Control valve capacity test procedure
- ANSI / ISA S75.03 - Face to Face dimension for flanged type control valve
- ANSI / ISA S75.04 - Face to Face dimension for flange less control valve
- ANSI / ISA S75.05 - Control Valve Terminology
- ANSI / ISA S75.11 - Flow Characteristic and rangeability
- API Std. 598 ISA - Test procedure.

19 pH / Conductivity Anal ysers:

All pH and conductivity analysers shall be 2 wire, 24 V DC, SMART with
HART protocol and with local display. The pH transmitter electrode shall not
have inbuilt preamplifier. This will be a part of pH transmitters. Adequate
sample handling system shall be designed with pH /Conductivity meters.

20 Material Handling Systems
Bidder to include min. 1 running + 1 stand-by fully automatic bagging
machine with integrated PLC control and interface the same to DCS over
OPC interface. The capacity of one machine shall be equal to 150 tons of
PAC PROJ ECT
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complete product in 25 kg bags with max. 18 working hours a day. The
accuracy of bagging machine shall be +/-20 gms per bag. The baging
machine shall be fully automatic with empty bag placement, automatic filling
of required qty with min. 3 nos. of gates, i.e. coarse, fine and dribble and
cross check of weight at regular interval and auto correction of timings and
movement of bags along with automatic stitching and stacking. The
complete operation shall be unmanned with one person supervising
complete bagging, stacking activities without any human intervention.

There shall be a full-fledged terminal automation system (TAS) for 1 no. of
road tanker filling product gantry along with all required mass flow meter,
digital set-stop valves, batch controller and remote interface unit with local
push button stations, terminal server, load rack server and related hardware
software required for its interconnectivity with new PAC project DCS via
OPC and existing Terminal Automation System/ SAP interconnectivity. This
will be an augmentation of existing main TDI project TAS. The detail
specifications of existing TAS shall be made available to all prospective
bidders.

Additionally, there shall be 1 no. of carboy/drum filling station with electronic
check weigh machine facility for PAC liquid product. The carboy filling
station is envisaged with mass flow meter, batch controller, RIT with local
push button station and on-off valves.

21 Other instrumentation Items

Any other instrumentation items, which are not covered in these general
minimum specifications, shall be as per GNFC requirement and technical
specifications shall be approved by GNFC along with vendor list approval.

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