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Extension of existing SCADA system

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GTCL/S&T/SPEC/01 Standards Specifications for Instrumentation


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1.0 GENERAL
1.1 Scope

1.1.1 This specification together with the attachments covers the design, engineering, supply,
Factory inspection and testing, field testing and calibration, installation and commissioning of
instrumentation and control systems on a turnkey basis for its successful operation.

1.1.2 The detailed scope of work, specific job requirements, design basis, exclusions, deviations,
additions etc. is indicated elsewhere in the bid document.

1.1.3 This specification provides only the qualitative specifications of commonly used
Instruments and systems, but by no means covers the specification of each and every item
covered in the bid document. Instruments specification for those items not covered in this
specification shall be submitted by the Contractor for approval.

1.1.4 Contractor shall be fully responsible for design, material selection, sizing and proper
Selection of the instruments and systems being supplied by them. Any approval or comment on
any document or guideline issued to Contractor before or after placement of contract or during
execution of the contract shall not absolve the Contractor of their contractual obligations and
responsibility with regards to completeness, proper selection, satisfactory operation and easy
maintenance of the unit.

1.1.5 All equipment supplied shall be of field proven quality both with respect to design and
materials. Prototype instruments or instruments of an experimental nature shall not be offered or
supplied. In general, all instruments and instrument control systems, like Remote Terminal
Unit(RTU), Flow computers, etc. offered by Contractor shall have a well proven performance
record of operating satisfactorily in the hydrocarbon industry like refinery, petrochemical, pipeline,
gas processing etc. for a minimum of 4000 running hours. No instrument requiring special
maintenance or operating facilities shall be offered or supplied as far as possible.

1.1.6 In the event of any conflict between this specifications, data sheets, related standards,
codes etc., the Contractor shall refer the matter to the purchaser /purchaser's representative for

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GTCL/S&T/SPEC/01 Standards Specifications for Instrumentation


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clarification and only after obtaining the same should proceed with the manufacture/engineering
of the item in question.
1.2 Applicable national/international standards.
1.2.1 Design and terminology shall comply, as a minimum, with the latest edition prior to the date
of purchaser's enquiry of following codes, standard practices and publications:

AGA American Gas Association, Gas Measurement Committee


- Report No.3 - National Gas Fluid Measurement- Orifice Metering of Natural Gas.
- Report No.7 - Measurement of Gas by Turbine Meters.

ANSI/ASME - American National Standards Institute/ American Society of Mechanical


Engineers.

B 1.20.1 Pipe Threads.


B 16.47 Steel Pipe Flanges and Flanged Fittings.
B 16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges.

API American Petroleum Institute


RP 520 Sizing, selection and installation of pressure relieving system in refineries.
Part-I Sizing and selection
Part-II Installation
RP 521 Guide for pressure relieving and depressurizing systems.
IEC International Electro technical Commission.
IEC 79 Electrical Apparatus for Explosive Gas atmosphere
IEC 85 Thermal Evaluations and Classification of Electrical Insulation.
IEC-332 Test on bunched wires or cables, Part 3 Cat. A
IEC 529 Classification of degree of protection provided by enclosures
IEC 534-2 Industrial Process Control Valves-Flow capacity
IEC 584-2 Thermocouples - Tolerances
IEC 60584-3 Thermocouples extension and compensating cables, tolerances and

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GTCL/S&T/SPEC/01 Standards Specifications for Instrumentation


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Identification system.
IEC-751 Temperature vs. Resistance curves for RTDs.

ISA Instrument Society of America.


S-5.2 Binary logic diagrams for process operations.
S-7.3 Quality standard for instrument air.
S-75.01 Flow equations for sizing control valves.
1.3 Drawing and Data
1.4.1 Bidder shall furnish all documents in A4 Size (210 mm x 297 mm) paper or folded in A4
size unless otherwise specified. All drawings and sketches shall be in multiples of A4 size like A3
(297 mm x 420 mm) or A2 (420 mm x 594 mm) etc., but folded to 'A4’ size. Final documentation
shall be submitted in bound volumes & Soft Copy on CD/DVD.

1.4.2 Definitions of Deliverable Documents

1.4.2.1 Instrument work Specifications


This document details out the procedures and methodologies to be adopted by the Contractor to
carry out complete instrumentation work. The document apart from others shall include:
a) Agencies involved for carrying out design, detailing, engineering, procurement, installation,
loop checking and commissioning of Instrumentation with specific reference to various systems.
b) Scope of work and responsibilities of various agencies involved.
c) Interface requirement and co-ordination between various agencies.
d) Co-ordination between various engineering disciplines viz. Electrical, Mechanical Equipment,

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Piping, Process/Operations etc.


e) Experience of various agencies in carrying out respective jobs.
f) Inspection & testing requirements and co-ordination procedures for the same.
g) Co-ordination requirements & procedures for co-ordination with outside/statutory authorities.
h) Quality control and assurance procedures to ensure proper quality.

1.4.2.2 Drawing and Document Schedule


This document lists out drawings and documents prepared and/or submitted by Contractor to
Employer either during engineering or as a part of final documentation. Following information shall
be available in this document:
a) Name and number of each drawing and document listed.
b) The schedule for the document submission, Contractor shall follow as per the overall schedule.

1.4.2.3 Instrument Index


Instrument Index lists out all instruments those appear on the P&ID without any exception. It is a
basic instrument document, which is necessary for the smooth execution of a job and is also a
reference document after the completion of job. Instrument Index shall be prepared in Format. In
case, any other format is used, it must contain all information as listed in this format.

1.4.1.4 Sub Contractor / Vendor List (for Instruments and Accessories)


It is Contractor's responsibility to select correct make and model number to suit the requirements
and has requisite proven track record. Contractor shall list all sub contractors / vendors proposed
by him, meeting criteria specified in bidding document, for Employer’s approval.

1.4.1.5 Utility requirements


Contractor will provide calculation for AC Power the In-rush current with duration and
power factor required for each individual and all equipment in a panel and the total for the each
location.

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GTCL/S&T/SPEC/01 Standards Specifications for Instrumentation


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INSTALLATION MATERIALS

1.5 Contractor shall ensure and supply all erection hardware required for the installation of
complete instrumentation which form a part of the package unit. This includes items like
cables, cable glands, junction boxes, instrument valves and manifolds, mounting
accessories, impulse piping/tubing, pipe/tube fittings, pneumatic signal tubes, air line pipes
and fittings, filter regulators, steam/electrical tracing, insulation materials, cable duct and
trays, conduits, identification tags, structural material required for instrument supports and
trays etc.
.5.1 The Contractor shall supply all necessary items to make the installation and commissioning
work complete in all respects, irrespective of whether these have been explicitly included
in their scope or not.
.5.2 Salient features and minimum requirements for some of the main installation materials are
being described in the following paragraphs. For items for which no specifications have
been provided, Sub Contractor / Vendor may follow their own specifications and prevailing
international standards.
Pressure, Differential Pressure, Flow

01. Working Principle : Smart

02. Type : 2-Wire

03. Output signal : Simultaneous transmission of digital and 4-20 mA DC


signal, HART protocol.

04. Signal Processing Unit : Silicon solid-state electronic circuitry

05. Measuring element : Capsule/Diaphragm

06. Element material : AISI-316 (Stainless Steel) or better

07. Over Pressure : 150% of maximum pressure

08. Turn-down ratio : 10:1 for vacuum / very low pressure application.
30:1 for other application

09. Span and Zero : Continuous non-interacting tamper proof, remote as well
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as manual adjustable from instrument with zero


suppression and elevation facility.

10. protection : IP-67 NEMA X4 ( water and Explosion proof for NEC
Class-1, Division 1 area) with ½” NPT (F) cable entry.

11. Output Indicator : LCD type

12. Body : Forged Carbon Steel (SS for DM Water)

13. Operating Voltage : 24 V DC ± 10% intrinsically safe Type

14. Load : 600 Ohms (min.) at 24 Volts DC

15. Performance :-

a) Accuracy : 0.04 % of span or better

b) Repeatability :  0.05 % of span or better

c) Response time : 96 msec or better

d) Zero & Span drift : 0.015% per Deg.C at max span


0.11% per Deg.C at min span

e) Stability : 0.1% of calibrated span for six months for ranges upto
and including 70 Kg/ sq.cm.
0.25% of calibrated span for six months for ranges more
than 70 Kg/ sq.cm (g).

16. Process connection : ½” NPT (F)

17. Sealing / Isolation : Extended diaphragm with 5 meters SS armoured capillary


for corrosive, viscous and dirty fluid applications. Material
for separator diaphragm, depending on application.

18. Nameplate : Tag number and Service engraved in stainless steel tag
plate

19. Accessories : a) Installation accessories such as mounting bracket,


high tensile carbon steel U-bolts suitable for pipe
mounting.

b) ½” NPT 2-valve stainless steel manifold, constructed

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from SS316 bar stock for pressure transmitter. In


case it becomes necessary to use a DP transmitter
for pressure measurement then a 3 valves manifold
should be used in place of 2 valve manifold.

c) ½” NPT 5-valve stainless steel manifold, constructed


from SS316 bar stock for DP transmitter. 3 valves
manifold for DP application in flue gas and air.

d) Companion flange with nuts, bolts and gaskets.


½” NPT cable gland

.6 TEMPERATURE TRANSMITTERS

.6.1 Thermowells

(1) Temperature measuring instruments shall be provided with thermowell. The boss on
the pipeline as a process connection for thermowell will be prepared by the Employer.
The Contractor shall verify the information of process connection and design suitable
thermowell.

(2) Thermowells shall be constructed from one-piece bar stock, and machined to get a
smooth and tapered profile with no sharp edges. All insertion type temperature
instruments and indicators shall be provided with a thermowell. The thermowell
immersion depth in the pipe shall be between one-third and two-thirds of the internal
diameter of the pipe.

.6.2 Temperature Transmitter

(1) Resistance temperature detectors (RTDs) shall be used for centralized and multi-
point indication. The RTDs shall be grade II. Platinum 100 ohms at 0 °C (32 °F).

(2) A detector with head mounted transmitters shall be used with dual output 4-20 mA
signal directly proportional and linear to temperature.

Resistance Temperature Detector

01. Type : Platinum (Duplex), Ungrounded

02. Resistance : 100 ohm at 0 deg C

03. Base : Wound on ceramic (anti-inductive)

04. Wiring : 3 /4 Wire


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05. Protecting Tube :-

a) O.D. : 8 mm
b) Material : SS-316, Seamless
c) Filling : Magnesium oxide (Purity above 99.4%).

06. Calibration : DIN 43760 Class A

07. Characteristics : Linear with respect to temperature within ± ½% of top


range value
08. Head :

a) Type : IP-67 universal screwed type. (Explosion proof for NEC


Class-1, Division 1 area)
b) Material : Epoxy coated Die cast aluminum or better
c) Terminal blocks : Nickel plated Brass-screw type / silver plated
d) Cable connection: ½” NPT gland and grommet.
e) Instrument connection : ½” NPT to well
f) Others : Terminal head cover with SS chain and suitable gasket

09. Accessories : a) Adjustable nipple-union-nipple [1/2” Sch 80 X ½”


NPT (M)] with thermowell connection
b) Compression fittings/unions
c) Flanges etc. (for flanged connections only)
d) Forged / barstock thermowell as per ASME PTC 19.3
code. Process connection M33X2 (M).
e) Material of construction of Thermowell: SS 316: In
general

10. Nameplate : Tag number, service engraved in stainless steel tag plate

Thermowell

01. Material : AISI 316 SS drilled from bar stock


02. Process connection : M33 X 2 (M).

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03. Max Internal bored dia : Shall match with temperature Element
04. Bore Connection : 5% wall thickness
05. Identification Mark : Tab Number punched on head
06. Surface Treatment : Polish after machining
07. Element Connection : ½” NPT (F)
08. Certification : ASME Performance Test Code 19.3
09. Accessories : Plug and chain for test thermo wells

Field Mounted Temperature Transmitters


01. Working Principle : Smart
02. Type : Two wire
03. Input : RTD (Pt 100)-3 / 4 wire
04. Isolation : 500V AC
05. Output Signal : Simultaneous transmission of digital and dual output 4-20
mA DC signal with HART protocol.
06. Signal Processing
Circuitry : Microprocessor based Solid State Electronic
07. Span and Zero : Adjustable in field, Non-interacting facility for elevation
and suppression of zero.
08. Enclosure Class : IP-67 (Explosion proof for NEC Class-1, Division 1 area)
09. Output Indicator : LCD type
10. Span Adjustability : Yes
11. Nameplate : Tag number to be engraved on metallic tag plate rigidly
fixed to the body.
12. Body : Die Cast aluminum
13. Operating Voltage : 16-48 V dc
14. Load : 600 Ohms at 24V DC (Min.)
15. Performance
a) Accuracy : 0.4% of span
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b) Repeatability : 0.05% of span


c) Cold Junction : Built-in
Compensation:
d) Calibration : As per N.I.S.T Monograph 125 for T/C and European
Curve Alpha = 0.00385 for RTD
16. Accessories : a) Universal mounting bracket suitable for pipe and
surface mounting.
b) Hi-tensile Carbon Steel U-bolts.
c) ½” NPT cable gland
Contractor will replace the single temperature element(RTD) with duplex element to
provide connection to panel mounted custody meter of station and dedicated flow
computer for SCADA. Contractor will provide one HART Communicator for configuration
of transmitters.

.7 FLOW COMPUTER

The flow computers shall be microprocessor based, with digital display, data entry keypad
and alphanumeric display with AGA firmware for natural gas flow measurement. Flow
computer electronics shall be protected from industrial interferences; and shall be shock
and vibration proof shall have low power consumption. Flow computer will be
Emerson/Florentino/ABB/equivalent make custody meter.

The flow computers shall compute and display the instantaneous and totalized flow rate
for each stream corrected for pressure and temperature variations. The flow computers
receive data from the Gas chromatograph for calculation of compressibility factor as per
AGA-8 detail method. The flow computers shall be linked to the RTU for providing the flow
measurements of the individual stream runs and related process variables.

The flow computer shall be certified for custody transfer applications by laboratory /
institutes authorized by weights and measures authorities of their country.

The flow computers shall have an audit trail facility. It should be able to store data for 30
days.

Contractor has to submit the flow chart for FDS (Functional Design Schematic) of the flow
computer.

All the licensed configuration software shall be supplied with flow computers.

Mounting shall be Flush panel type in General purpose enclosure or in RTU enclosure.
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POWER SUPPLY: 230 V AC ± 10%, 50 Hz ± 3% (UPS) or 24 VDC or in some cases Solar


powered with battery back-up suitable for 30 no-sunny days. The system shall be
designed for supplying power to field mounted electronic instruments like PTs, TTs, DPTs
etc.

INPUT SIGNAL CAPABILITY:


a) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from
‘SMART’ high differential pressure transmitter representing differential pressure
across orifice for flow measurement.
b) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from
‘SMART’ low differential pressure transmitter representing differential pressure
across orifice for flow measurement.
c) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from
‘SMART’ pressure transmitter representing line pressure.
d) 4-20 mA D.C. (2 wire) superimposed with digital signal (HART protocol) from
‘SMART’ temperature transmitter representing line temperature.
e) Other standard inputs available.

INTERFACE CAPABILITY:

Flow computers shall be interfaced with Employer’s RTU for flow metering and gas
composition data such as gas temperature and pressure, energy flow rate and total
energy, corrected volumetric flow rate and total flow, last day’s cumulative energy and
volume, current day’s running volumetric total and energy total, volume and energy
integrated at 6 a.m., gas composition (C1, C2, C3, iC4, nC4, iC5, nC5, C6+, Specific
gravity, Calorific value, mol% of N2, CO2) etc. Contractor to note that SCADA Sub
Contractor / Contractors shall provide RS 485 serial link at the RTUs for interfacing of
intelligent electronic devices like flow computers. For flow computer interface to RTU,
Contractor shall accordingly provide RS 485 link (Modbus-RTU protocol supporting IEEE
single precision floating point no. with user configurable register).

The digital and analog data shall be made available to RTU (SCADA) and it shall be
mapped in the contiguous registers so that data can be fetched / written in minimum
transactions. Flow computer shall have provision to configure an IEEE floating point in
two 16 bit modbus register. Provision shall also be kept at flow computer for writing data
from RTU e.g. orifice plate data and gas composition data can be upload to Flow computer
from SCADA control center through RTU.

Contractor shall furnish all details like pin configuration and signal wise MODBUS address
mapping list etc. for smooth interfacing of this communication link with RTU (SCADA).
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Contractor shall also furnish the details of implemented MODBUS protocol like function
codes for read and write, CRC implementation, BCC implementation, register addressing
methods / mapping etc. during detail engineering for serial interfaces to SCADA (RTU).

Contractor shall supply suitable length of interface cable between the Flow computers and
RTU along with connectors at both ends & necessary converters and other cables
accordingly for each flow computer.

KEYPAD CAPABILITY:

The data entry keypad shall have the provision to enter the following:
a) Pressure and temperature base factor
b) Specific gravity and scaling factor
c) Mol % or composition of the gas to be metered
d) Report headings, frequency and timing of reports
e) Selection of parameter to be displayed and on-demand printing of reports
f) Calorific value
g) Flow, pressure, temperature and density values and give compensated flow for
any external conditions
h) Gas Compressibility
i) Other standard features available

The flow computer shall have provision to enter default values of all inputs (inclusive of
gas chromatograph) low / high alarms for all inputs (inclusive of gas chromatograph) and
shall be user configurable. The flow computer shall use the default values in case any
input goes beyond low/high limit.

OUTPUT CAPABILITY:
a) 4-20 mA compensated volume flow rate output & Flow set point (as external
remote set point) for flow controller, energy rate (or mass flow rate),
b) Contact alarms output for unit malfunction, process alarm etc. (3 nos.).
c) RS 485 serial output link for telemetry link for all signals as specified
d) RS232C serial link for Employer’s PC for reports
e) Other standard outputs available (Minimum 2 nos. 4-20mA analog output for
pressure & temperature) (Galvanic isolation is required for all inputs and outputs)

COMPUTATIONAL CAPABILITY:
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a) Volume flow rate at standard, normal or operator specified base conditions


(Sm3/hr)
b) Integrated corrected volume
c) Mass flow rate and integrated mass
d) Energy flow rate and integrated energy.
e) Linearization of temperature input
f) Generation of standard and user defined reports at ticket printer. All reports shall
be user configurable.
g) Co-efficient of deviation from ideal gas law as per AGA 8 on the basis of specific
gravity, temperature, pressure and mol % of N2 and CO2 and other compositions
for all flow computers
h) Previous day’s flow / energy (i.e. yesterday’s 6.00 A.M total volume / energy to
today’s 6.00 A.M total volume / energy) & current running total for the day (i.e.
volume tantalizer/ integrator value at 6.00 A.M from first day) to be stored in a
separate location (register) and these shall be user configurable.
i) Today’s accumulated flow /energy (running total since morning 6.00 A.M to
current time) and shall be user configurable.
j) Generation of reports for totalized volume & energy at daily (6 am), weekly,
fortnightly & monthly intervals etc. shall be user configurable.
k) All the above data shall also be made available by Contractor to RTU through the
serial links.

STANDARDS USED:

For the above, applicable standards are:


a) AGA report 3 and 7 for flow rate and total flow for all tags for Orifice meter and
turbine type flow meter (as applicable).
b) AGA-8 characterization method to determine density, compressibility, super
compressibility factor etc. for flow computers
c) AGA Report 5 for energy rate and integrated energy & if any other statutory
standard required.

ENGINEERING UNITS:

Volume flow rate - MMSCFD, Mass - kg/hr, Pressure - PSIG / BARG, Temperature -°C /
°F, Energy - Kcal

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MEMORY TYPE : Non-Volatile

A/D AND D/A CONVERTORS:

Calculation accuracy shall be better than ± 0.05% of full scale including linearity,
Hysteresis, repeatability and resolution. Accuracy for analogue inputs to be minimum
0.05% and for analogue outputs accuracy shall be minimum 0.1%.

SCAN PROCESSING TIME:


a) The interval between computer readings of Process variables shall not exceed 1
sec.
b) The interval between each cycle for computation of instantaneous flow rate and
totalized flow shall be less than 1 sec.
c) Algorithm and rounding off error for computation shall be with in ± 0.001% of
computed value.

SECURITY:

Key lock shall be provided for prevention of unauthorized data entry. One hardware and
two software security levels shall be provided.

DISPLAY CAPABILITY:

The flow computer shall have the capability to display any two of the following parameters
at a time:

Uncompensated volume flow rate, Compensated volume flow rate, Integrated volume
(corrected and not corrected), Mass flow rate, Integrated mass, Density/Specific gravity,
Pressure, Temperature, Energy rate & total energy, Complete gas composition,
Calculated parameters (compressibility factor etc.), Current accumulation, previous day
accumulation, Data entry, Error codes, Selected parameter codes, Alarms (process and
systems) including diagnostic message, Engineering units as per selected parameter,
Other standard displays available, Custody transfer flow computers shall have audit trail,
All the above data shall also be made available by Contractor in the serial links to RTU.

DISPLAY TYPE: Alphanumeric LCD display

DIAGNOSTICS:

Flow computers shall have elaborate and sufficient on-line diagnostics to ascertain
accurate and proper functioning of the flow computer. Results of diagnostics / checking
shall be displayed. Facility for easy testing of the accuracy shall be provided. Provision for
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high and low limit check for each input, sensor break, saturation and alarms shall be
provided.

.8 LIMIT SWITCH

Limit switches for open / close valve position indication shall be of proximity type. The
switch enclosure shall be copper free cast aluminum, weather proof (NEMA 4X) and it shall
be intrinsically safe.

.9 Cables
.9.1 All cables shall have PVC insulated primary insulation of 85ºC PVC as per IEC 502. Inner
and outer jacket shall be made of extruded flame retardant 9CTC PVC to IEC 502. Oxygen
index of PVC shall be over 30% and temperature index shall be over 250ºC.
.9.2 All cables shall be fire retardant as per standard IEC 332-3 Part 3 Cat.A. Fire resistance
cables whenever specified shall be as per IEC 331 Cat. A.
.9.3 The insulation grade shall be 600 V/1100 V as a minimum and shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-2.
.9.4 All cables shall be armored. Amour over inner jacket shall be of galvanized steel wire/flat
as per IEC 502.AII the cores of single pair or multi pair shall be twisted and numbers of
twist shall not be less than 10 per metre.
.9.5 For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall
be light blue for intrinsically safe application and black for others. For thermocouple
extension cables the inner and outer jacket colour shall be as per IEC standard

1.9.6 Maximum DC resistance of the conductor of the completed cable shall not exceed the
following: -
i. 12.3 Q/km at 20ºC for cables with 1.5 mm conductor.
ii. 39.7 Q/km at 20ºC for cables with 0.5 mm conductor.

1.9.7 The mutual capacitance of the pair or adjacent cores shall not exceed 250 pF/m at a
frequency of 1 KHz. The capacitance between any core and screen shall not exceed 400 pF/ m

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at a frequency of 1 kHz.

 L/R ratio of adjacent cores shall not exceed 40 uH / Q for cables with 1.5 mm conductor and
25 uH / Q for cables with 0.5 mm conductor.

 The drain wire resistance including shield shall not exceed 30 Q/km. Electrostatic noise
rejection ratio shall be over 76 dB.

 A pair of communication wire shall be provided for multi-pair/ multi-triad cables. Each wire
shall be 0.5 mm of plain annealed single or multi-strand copper conductor with 0.4 mm thick
85ºC PVC insulation. Insulation shall be green and red colour coded.

 Contractor shall ensure a minimum of 20% of quantity of each type of cables supplied as
spare including any special cable. And in each multi-pair cable 20% pairs shall be kept as
spare.

 Running length of the cable shall be printed at least at every 3 metre interval. For multi-pair
/multi-triad cables, pair identification shall be provided with numbers at interval of not more
than 250mm as per Sub Contractor / Vendor's standard.

1.10. Signal Cables


a. Single pair shielded signal/alarm cables shall be used between field instruments/ switches and
junction boxes/local control panels.
b. Multi-pair individually and overall shielded signal/alarm cables shall be used between junction
boxes/local control panels and control room / satellite rack room as the case, in general.
c. The single pair/triad cables shall be 1.5 mm conductor size made of annealed electrolytic
copper conductor of 7 strands with each strand of 0.53 mm diameter. Multi-pair cables with 1.5
mm conductor size shall have 7 strands of annealed electrolytic grade copper conductor with
each strand of 0.53 mm diameter. Multi triad cable or multi pair cable with 1.5 mm² conductor
shall have 7 strands with each strand of 0.53 mm diameter. Colour of core insulation shall be
black blue in pair and black, blue and brown in a triad.
d. Shield shall be aluminium backed mylar/polyester tape bonded together with the metallic side
down helically applied with either side having 25% overlap and 100% coverage. The minimum
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shield thickness shall be 0.05 mm in case of single pair/traid and 0.075 mm in case of multi-
pair/triad cable.
e. Drain wire shall be provided for individual pair and overall shield, which shall be 0.5 mm multi
stranded bare tinned annealed copper conductor. The drain wire shall be in continuous contact
with aluminium side of the shield.
f. All multi pair cables shall have 6 pair/12 pairs only while multi-triad cable shall have 6 triads/8
triads only.

1.11 Thermocouple Extension Cables


a. Single pair shielded thermocouple extension cables shall be used between thermocouple head
and junction boxes.
b. Multi-pair individually and overall shielded thermocouple extension cables shall be used
between junction boxes and control room mounted devices.
c. The type of thermocouple extension cables shall be compatible with thermocouple used. In
addition the colour coding of the primary insulation shall be as per IEC 60584-3.
d. The cable shall have 16 AWG and 20 AWG solid conductors for single and multi-pairs
respectively.
e. All thermocouple extension cable shall be matched and calibrated in accordance with IEC-584-
2.
f. Shield shall be aluminium backed by mylar/polyester tape bonded together helically applied
with the metallic side down with either side having 25% overlap and 100% coverage. Minimum
shield thickness shall be 0.05 mm for single pair and 0.075 mm for multi-pair cable. Drain wire
shall be 0.5 mm multi-strand bare tinned annealed copper conductor. The drain wire shall be in
continuous contact with the aluminium side of the shield.
g. Core inductance shall not exceed 4 mH/km. However for J-type thermocouple inductance
could be 8 mH/km.
h. All multi-pair cables shall have 6 pairs/12 pairs only,
i. For units with IEC Gr.IIC hazardous area classification of gas grouping, polyethylene insulated
cables with 70EC Polyethylene (PE) as per applicable international standard shall be used in

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general with all other specification same as (a) to (h).

1.12 Power Supply and Other Cables


a. All power supply cables shall have copper conductors depending on conductor size. Minimum
conductor size shall be 2.5 mm² of copper conductor. All these cables shall be PVC insulated and
armoured.
b. Any other special cable required for instruments shall also be supplied as per requirements.
Sub-Contractor / Vendor shall ensure that these cables are armoured type and shall meet all other
requirements specified in para 10.4.1 through 10.4.12, as applicable.
c. All cables in Control room building & enclosed area / compartment shall be FRLS type only.

2 Impulse Piping/Tubing

2.1Tubing
a. Contractor shall supply 1/2" OD x 0.065" thick ASTM A 269 TP 316 stainless steel fully
annealed, cold drawn and seamless tubes as a minimum for impulse lines upto 600 # class.
Higher thickness according to pressure rating shall be considered for higher pipe classes.

b. Monel or any other tubing shall be used where SS316 is not suitable for the service.

c. The hardness of SS tubes shall be Rockwell RB 70-79.

d. Steam tracing shall be 10 mm OD soft annealed copper tubes of electrolytic grade copper with
wall thickness of 1 mm as per ASTM B 68M copper no. C 12200.

e. Instrument air/gas distribution shall be with 6 mm soft annealed copper, 1 mm thick PVC coated
as per ASTM B 68M copper no. C 12200

f. Sub Contractor / Vendor shall supply a minimum of 20% of pipe/tubes as spare.

2.2 Tube Fittings


a) Contractor shall supply flareless compression type of tube fitting and of three-piece
construction with design similar to Swagelok/Parker Hannifen etc.

b) The fitting/ferrule hardness shall be in the range of RB 85-90 so as to ensure a minimum

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hardness difference of 5 to 10 between tube and fittings. The ferrule shall be of stainless steel
material, in general.

c) Instrument air brass fittings shall be suitable for use on copper tubes conforming to ASTM B
68/B 68 M hardness not exceeding RB 50. All fitting parts shall be manufactured from Brass bar
stock and shall be nickel plated.

d) All threaded fittings shall have NPT threads as per ANSI/ASME B16.ll only.

e) Installation of support materials/stands, clips as required for supporting aboveground


instrument tube, cable at 300 mm intervals. Cable tray with base foundation can be used for
supporting the impulse tubes.

f) Sub Contractor / Vendor shall supply a minimum of 20% of each type of pipe/tube fittings as
spare.

2.3 Cable Trays


a) All cables shall be laid in cable tray.
b) All branch cables/tubes shall run on cable trays.
c) These cable trays shall be made out of M.S steel sheets of 2.5 mm thickness unless galvanized
mild steel is specified. Ladder trays shall be of mild structural steel and shall be painted with red-
oxide primer. 50 mm x 50 mm angle shall be used as a minimum.
d) The width shall be so selected that 50% of tray space is available for future use.
e) Suitable cable clamps shall be supplied for binding the cables/tubes at every 500 mm.

a) Contractor shall supply instrument stands, stanchions and other structural steel material
required for supporting the cable trays, impulse lines and instruments.

2.4 Cable Glands


a. Contractor shall supply all cable glands required for glanding the above mentioned cables both
at field instrument and local control panel side, junction boxes side and at control room side.
b. All cables glands shall be of nickel-plated brass and they shall be double compression type

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suitable for armoured cables.


c. Flame proof glands wherever required shall be supplied with EXd certification.

2.5 Junction Boxes


2.6 Contractor shall supply junction boxes as per the cables selected, wherever required. These
shall be of die cast aluminium alloy (LM-6) body and shall be weather proof to IP 65, as a
minimum.
2.7 These boxes shall have terminals suitable for minimum or 4 mm5 or less cable termination
mounted on rails. 20% spare terminals shall be supplied in each junction box.
2.8 Telephone sockets and plugs shall be provided in junction boxes.
2.9 Flame proof junction boxes wherever required shall be supplied with Exd certification. All
such boxes shall be weatherproof to IP 65 also.
2.10 Each junction box shall have a minimum of 2 Nos. for 6P/12C and 2 numbers for 12P/24C
spare entries. All spare entries shall be provided with plugs certified Exd for flameproof junction
boxes.

3 Instrument Valves and Manifolds


a. Contractor shall supply instrument valves (miniature type) and valve manifolds wherever
required of Swagelok / Parker or equivalent only.
b. Body rating shall be as per piping class or better. All valves and manifolds shall be forged type
only.
c. Valve body and trim material shall be SS 316 unless otherwise specified. Superior trim material
shall be selected as required by process conditions. Packing material in general shall be of PTFE.
d. For instrument air/gas isolation valves, body material shall be SS316.
e. Contractor / Sub Contractor / Vendor shall supply a minimum of 20% instrument valves and
manifolds as spare.
4.0 Condensate trapper
a) Contractor will supply condensate trapper for each single transmitter installed at inlet pressure
point in the mainline valve and for the set of transmitters installed at each meter run at

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TBS/metering stations. Condensate trap shall be of class #600 and with suitable material.

5.0 INSTRUMENT STAND WITH SUNSHADE

a) Transmitters / instruments / devices located in the field shall be grouped together and shall be
installed in Open Type Rack with canopy. Racks shall be factory prefabricated & painted and
complete with internal piping, tubing, manifold valve, isolation valves, blowdown valves,
condensate trapper, integral explosion-proof junction box, wiring, illumination etc.

b) The local instrument racks shall be constructed from suitable 3 mm thick channel frame of
steel and shall be provided with a canopy at top to protect the equipment mounted in racks from
falling objects, direct sun and water etc. The canopy shall not be less than .65 mm thick steel
and extended beyond the ends of the rack as attached drawing in the document.

6.0 INSTALLATION

6.1 Contractor shall be responsible for installation of all the items in their scope of supply including
supply, fabrication and erection of all installation / erection material. The scope of installation shall
include all field instruments, i.e remote panels including supply / fabrication / erection / installation
of all erection material i.e. cables, cable glands, junction boxes, cable ducts, Trays, conduits,
instrument supports, trenches, instrument road crossing as required completing the job in all
respect.

6.2 Supply / fabrication and installation of instrument mounting posts, support stands / frames,
fittings, brackets and other consumables for mounting and supporting all instruments, instrument
system components and fixing the same drawing attached in the document.

6.3 Installation of any underground cables shall include excavation and laying cable to 3 feet
depth, cable segregation, support, back filling with grades of sands, tiling, trench makers etc .After
laying of cable sand will be filled then two layer of bricks will be put on top of the sand layer. In
case of underground cables are required to be in RCC trenches, all installation shall be carried
out except excavation. Suitable cable markers made of MS shall be provided for all underground

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cabling at 200-meter interval and turning points.

7.0 SITE TESTING AND CALIBRATION

7.1All impulse lines shall be tested hydrostatically at 1.5 times the maximum operating pressure.
Ensure that instrument /piping is isolated during this test.

7.2 In case of special instruments/items where hydro testing is not permitted due to service
conditions, the impulse lines testing shall be carried out by using air or nitrogen.

7.3 After pressure testing, all these impulse lines shall be drained and dried with dry air to remove
any traces of moisture, oil and dust.

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