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SPECIFICATION NO.

A535-000-16-51-DB-02

DESIGN BASIS

Rev. 0
Page 1 of 2

DESIGN BASIS/DESIGN PHILOSOPHY

03.07.14

Issued for tender

MK

NA

RK

Rev.
No

Date

Purpose

Prepared
by

Checked
by

Approved
By

Format No. 8-00-0001-F2 Rev. 0


Page 1240 of 3574

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SPECIFICATION NO.

A535-000-16-51-DB-02
Rev. 0
Page 2 of 2

1. This document consist of design basis and design philosophy to be followed for C4
mix storage facilities. The design basis of Panipat naphtha cracker project shall be
followed for this job which is attached with this document (6556-01-16-51-DB-02)

Format No. 8-00-0001-F2 Rev. 0


Page 1241 of 3574

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 1 of 18

ENGINEERING DESIGN BASIS


C2.10 INSTRUMENTATION

22.02.05

8.02.05

A
Rev.
No

CLIENTS COMMENTS INCORPORATED


& ISSUED FOR APPROVAL

MN

AKG

PM

ISSUED FOR CLIENTS APPROVAL

ZH

AKG

PM

24.11.04

ISSUED FOR CLIENTS COMMENTS/APPROVAL

JS

AKG

PM

Date

Purpose

Prepared by

Checked by

Approved by

Format No. EIL 1641-1924 Rev. 1


JS
Page 1242 of 3574

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 2 of 18
1.0

Control Philosophy:
a)

Mode of Plant Operation

Centralised

Unit wise

For all process units J


Including Offsites
For all utilities
J (Note-1)

For all offsites

Combined for
all units
Any other

Note-1: This includes Raw Water, Fire Water & Flare. DM Plant and CPP shall be operated
from respective Control room. For Other utilities, local operation shall be considered.
b)

1.1

Type of Plant

Grassroot
Expansion
Any Other

J
F
F

Control Room Requirement:


Control
Room
Main Control
Room
(CR#1)
Power Plant
Control
Room
(CR#2)
Loading
Control
Room
(CR#3)
Raw Water
control
Room
(CR#4)
DM
Plant
control
Room
(CR#5)
WWTP
Control
Room

Format No. EIL 1641-1924 Rev. 1


Page 1243 of 3574

Location
Process Units

Hazardous
Area

NCU & its auxiliary units,


PP, LLDPE, HDPE, MEG,
Offsites, Utilities (Repeat
Indications)
CPP

Non-hazardous
Area

Ground
9

9
Loading
Gantry
associated Off-sites

and

CPU

Local Control
WWTP

First
Floor
Ground

Raw water & Fire Water


System, Flare
DM Plant,
system

Floor

&

Ground
9

RO

Ground
9

Room

for

Ground
9

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 3 of 18
1.2

Satellite Rack Room Requirement (SRR-Satellite Rack Room):


Satellite Rack
Room

1.3

Location

Process Units

Non-hazardous
Area

SRR#1

NCP

SRR#2

MEG

SRR#3

PP

SRR#4

LLDPE

SRR#5

HDPE

SRR#6

Offsites

Hazardous
Area

Type of Control and Monitoring:


a)

Centralised

Distributed Control System

J All units and critical parameters of


Utilities & Off-sites

Control panel with


micro-processor based
instruments

for

Supervisory computer

for

Other

for __________________

Electronic

Pneumatic

Pneumatic

b)

Local

c)

Final Control Element

Other________________
1.4

Interlock and Shut-down system:


a)

Logic Representation: As per ISA

b)

Interlock Execution

c)

Shutdown System

Independent of
F
Shutdown System

With
Shutdown system

Type of hardware
DCS
Relay
PLC

F
F
J

Dedicated Unit-wise

Type of hardwareRelay

PLC

Format No. EIL 1641-1924 Rev. 1


Page 1244 of 3574

Other ________________
J

Common for all units F

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 4 of 18
d)

PLC Configuration
for shutdown

Dual Processor, Single I/O

Dual Processor, Dual Tested I/O


& Redundant Power Supply as a
minimum

J (Note-2)

Triple Modular Redundant.

J (Note-3)

Note-2: Dual processor, Dual I/O for Raw water, WWTP, DM Plant and Loading Control Room.
Note-3: TMR for Main plant, which includes Units & Offsites and Power Plant.
Other

1.5

e)

TUV Classification

f)

Process bypass switch Software


Hardwired with indication lamp

g)

ESD Switch location


(As per P&ID.)

Required
Class

Not required

J
AK6

Local panel
Control room
Field
Push Type

As per P&ID

F
F

Pull Type
With mushroom head

F
F
F
J

Local Panel Requirement (other than package units): (NOT APPLICABLE)


a)

Location

Hazardous Area
Non-hazardous Area

b)

Type

Weatherproof
Flame-proof
Purged

c)
2.0
2.1

________________

Instruments Type

Pneumatic

F
F
F
F
F

NFPA 496
F
Type Z
F
Other___________

Electronic

Package Units Philosophy:


Operating philosophy: (Note-6)
Package
Description

Process Package
Utility Package,
Air Comp. & Air
Drier Packages.
All other Utility
Packages
Format No. EIL 1641-1924 Rev. 1
Page 1245 of 3574

Control & Monitoring


Local
Panel

DCS

9
(Note-5)
-

Interlock & Shutdown


EM
Relays
-

DCS

PLC

9
9

9
(Note-6)

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ENGINEERING DESIGN BASIS

DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

Page 5 of 18
Note-5: Repeat Signals to DCS as per P&ID.
Note-6: Control monitoring shall also be from the dedicated PLC based system.
2.2

Logic implementation for package units through

Plant PLC
J
Package Vendors
J
PLC
(For proprietary /Utility Packages/Where
specifically required)
Any other_____________

PLC as per Clause no.2.1 above.


2.3

PLC configuration

Dual Processor, single I/O


Dual Processor, Dual I/O
Vendors standard
Other

F
J (Note-7)
F

_____________

Note-7: PLC configuration shall be dual processor, dual I/O as a minimum. TMR PLC as
required for proprietary equipments or specifically required as per Licensor.
2.4

Anti surge controller

Conventional Single loop Controller


F
DCS
F
Dedicated Special controller (CCC or equivalent)J
with serial interface to DCS

2.5

Vibration & Temperature


Machine monitoring

Bentley Nevada series 3300 or equal


Bentley Nevada series 3500 or equal
Other

F
J

2.5.1

Location of monitors

Control room
SRR
Local panel

F
J
F

2.5.2

Type of local panel

Weather proof
Flame proof
Purged
As per NFPA 496
Type Z

J
J
F
F
F

3.0

DCS Requirements:

3.1

Functional Requirements:
Control and Data Acquisition System
Data Logging and Report Generation
Management Reports
Advanced Control
Data Storage and Archival
Management Information System reporting
Note-8: History for all tags capability
(Inclusive of installed spares, spare space and additional 10% for soft tags)

Format No. EIL 1641-1924 Rev. 1


Page 1246 of 3574

J
J
J
F
J
F

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 6 of 18
3.2

Operator Consoles:
a) Number of Operator Consoles for each Control Room:
Control Room
Main Control
Room(CR#1)

Operators
Consoles

Number of
CRTs / console

Note-9

NCU & its auxiliary units

Note-9

PP

4 (Note-9)

LLDPE

Note-9

HDPE

Note-9

MEG

Offsites

Process Units

Console#1: 2 (UB)
Power Plant Control
3
CPP & DM Plant
Console#2: 4 (HRSG)
Room
Console#3: 2 (STG)
(CR#2)
Loading
Control
Note-10
Note-9
Loading Gantry area
Room
(CR#3)
Raw Water control
1(HOLD)
2
Raw water & Fire Water
Room
(CR#4)
Note-9: To be firmed up based on licensor as well as clients requirements and shall be defined
accordingly in the job specification.
Note-10: To be firmed up based on Gantry loading systems requirements and shall be defined
accordingly in the job specification.

3.3

b)

Open system connectivity

c)

Assignable Recorders on each console

Engineering Consoles:

Required

Yes
No

F
J

Not required

Number of consoles for each Control Room: (Note-11)


Name of Control
Room
Power Plant Control
Room
(CR#2)
Loading
Control
Room
(CR#3)
Raw Water control
Room (CR # 4)

Number of
Engineering
Consoles
1

Number of
CRTs /
console

Name of Units

1
-

Note-11: The Engineering console shall be Engineering cum Operator station.


Format No. EIL 1641-1924 Rev. 1
Page 1247 of 3574

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 7 of 18
Number of consoles for each SRR (Note-12):
Number of
Engineering
Consoles
1

Number of
CRTs /
console
1

NCP

SRR#2

MEG

SRR#3

PP

SRR#4

LLDPE

SRR#5

HDPE

SRR#6

Offsites

Name of Control
Room
SRR#1

Name of Units

Note-12: SRR shall have engineering cum operator console for startup.
3.4

Type of Reports Required

Hourly
Shift wise
Daily
MIS reports
Others

J
J
J
J

Alarm History
Alarm Summary
Shutdown Report

J
J
J

3.5

Type of Controller

Multi-loop

Single-loop

3.6

Sequence of Event recording Required


J
Not required
F
In DCS
F
In separate unit
F
In PLC
J (Note-13)
Note-13: For all process units, SOE resolution time shall be as per PLC scan time.

3.7

Field Multiplexer

3.8

Foreign Device Interface required for:


Programmable Logic Controllers
Analyzer system
Chromatographs
Tank Gauging System
Computer
Package PLCs
Anti Surge Controller
Vibration & Temperature Monitoring System
Speed Governor

J
J
J
J
F
J
J
J
J

Advanced Control Function Requirements- (Not Applicable)


Through DCS
Through Dedicated
Supervisory Computer

F
F
F

3.10

Training Kit

Required

Not required

3.11

Training Simulator

Required

Not required

3.9

Format No. EIL 1641-1924 Rev. 1


Page 1248 of 3574

Required
F
Not required
i) 4 ~ 20 mA open loops
ii) Thermocouple (open loops)
iii) RTD (open loops)
iv) Contact inputs (open loops)

J
F
F
F
F

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 8 of 18
Process model required for________________
3.12

Redundancy Philosophy:
a)
b)

3.13

Controller Sub-system
Data Acquisition
System

Redundant
F
1:1 redundancy
Redundant
(if more than 16 AI or 32 DI per module)
Non-Redundant

J
J
J

c)

Communication
Sub-system

Redundant

1:1 redundancy

d)

Power supplies
Sub-system

Redundant

1:1 redundancy

Processor loading philosophy:


Control Processor
60%
J (Note-14)
Note-14: Ideal Loading to be assumed based on adding installed spare + spare space. Not
more than 80 closed loops per controller.

4.0

Control panel / Hard-wired console Instrumentation:

4.1

Type of control panel


Graphic
Non-Graphic
Semi-Graphic

4.2

F
J
F

Closed back
Open back
Console type

J
F
F

For Control Room Instrumentation (As per P&ID) (Note-15)


a)

b)

Indicators, Integrators, All


Indicating controllers, etc.

Location

Panel

Size:
Anti Surge Controller
Speed Governor
Recorders
Location

Critical
(As per P&ID)
None
Console

6" x 3"
6" x 3"

F
F

OEM standard
OEM standard

J
J

All
None
Panel

F
J
F

Critical

Console

6" x 3"
Other______________

Size:
Assignable Trend Recorder
c)

d)

F
J

Multipoint Temperature Critical Parameters F


Recorders

None

Location
Size:
Large case
Alarm Annunciation
(As per P&ID)

Format No. EIL 1641-1924 Rev. 1


Page 1249 of 3574

Panel

Console

All

F
F

6 x 6
Critical

F
J

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 9 of 18
On panel
F
Hanging Type
On console as per P&ID
First out sequence
Required

F
J
J

e)

Multi-point Temperature Required


Indicator

Not required

f)

Auto Manual Station


(As per P&ID)

On Panel

On Console

g)

Manual Loading Station On Panel


(As per P&ID)

On Console

h)

Selector Switch
(As per P&ID)

On Panel

On Console

i)

Start/Stop, Emergency On Panel


Push Button (As per P&ID)

On Console

j)

Process Bypass Switch/ On Panel


Indication (As per P&ID)

On Console

(As applicable)

Note-15: Location shall be as per licensor requirement.


k)

Start up / shut down operation from control room:


i)
ii)
iii)

l)

Rotating Equipment
Shut down valves
Dampers & gates

As per P&ID
As per P&ID
As per P&ID

J
J
J

Status lamps in control room: (Note-16)


i)
Rotating Equipment
As per P&ID
J
ii)
Shut down valves
As per P&ID
J
iii) Dampers & gates
As per P&ID
J
iv)
Flame Scanners
As per P&ID
J
Note-16: Feed back for both state to be made available in control room as per P&ID.

5.0

General:

5.1

Type of Power Supply:


Type
110 V AC UPS

Format No. EIL 1641-1924 Rev. 1


Page 1250 of 3574

Tolerance

Duration after
Mains Failure

110V 10%
50Hz 3%

30 Minutes

Emergency Power Supply


Requirement
Required

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DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

ENGINEERING DESIGN BASIS

Page 10 of 18
5.2

Power Supply Requirement


110V AC 110V DC
50Hz.UPS

24V DC

110 V AC 230 VAC


Non UPS
50Hz

a)

Distributed Digital
Control system

b)

Supervisory
Computer

c)

Package Units

d)

Alarm Annunciator

e)

PLC

f)

Relay based
F
Interlock & Shutdown system

g)

Solenoid Valves

h)

I/P, Transmitters
Voltage

i)

Gas Detection System J

j)

Analysers and
Analyser System
(Note-17, 18)

J (for Non-UPS)

k)

Chromatographs
(Note-17)

l)

Training Kit
for DCS

m) Level Gauge
Illumination

J (Non-UPS)

n)

Cabinets Lighting
Control Room

J (Non-UPS)

o)

Local Panel

Note-17: Analyser /GC shelter shall be provided with 415 V AC supply for HVAC / air
conditioning equipment.
Note-18: 110 V UPS Supply for Process Analysers, 230 V AC Non-UPS for stack analysers.
Separate PDB cabinet for powering Analysers from Control Room Rack Room.
5.3

Cable Entry to:


a)

Control Rooms

Format No. EIL 1641-1924 Rev. 1


Page 1251 of 3574

MCT Blocks

Pipe Sleeves

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DOCUMENT No.
6556-01-16-51-DB-02
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ENGINEERING DESIGN BASIS

Page 11 of 18
b)

Satellite Rack Rooms

MCT Blocks

Pipe Sleeves

c)

Local control Rooms

MCT Blocks

Pipe Sleeves

d)

Analyser Rooms /
Houses

MCT Blocks

Pipe Sleeves

5.4

Air Supply at Battery Limit

6 kg/cmg

5.5

Size of Instrument Nozzles:


As per 7-52-0001,7-52-0002

5.6

Installation / Tubing hook-ups:


a)

Instrument Installation

Close coupled
J
Remote
J (Note-19)
Note-19: Remote for Utility lines / Offsites / Where close coupled not feasible.

b)

Instrument impulse lines

c)

Instrument valve manifolds

Tubing
Piping
Any other_________

i) For pressure gauges


Integral
ii) For flow DP transmitter Integral
iii) For Others
Integral
d)

Fabricated
Fabricated
Fabricated

J
F
F

Impulse Line valves (After first isolation valve provided by piping)


Isolation valves
Vent/drain valves

e)

F
J
J

F
J

Gate
Gate

Signal and Air supply tubing

F
F

Globe
Globe

J
J

SS tubing (for Instrument air) J


PVC covered copper tubing F

5.7

f)

Steam Tracing

Bare copper tube (3/8)

g)

Seal pot required for


Yes
F
No
steam / condensing Vapour instruments(as per Licensor requirement)

J
F

Field Transmitter Type:


a)

For open and closed loops Conventional F

Smart
Field Bus
Conventional
J
Smart
As per vendors standard requirement
Conventional F
Smart

b)

For anti-surge loops

c)

For shut-down loops

J
F
F
F
J (Note-20)

Note-20: For shutdown, smart transmitters configuration facility shall be kept inhibited by
default.
Format No. EIL 1641-1924 Rev. 1
Page 1252 of 3574

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DOCUMENT No.
6556-01-16-51-DB-02
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ENGINEERING DESIGN BASIS

Page 12 of 18
5.8

Signal:
a)

b)
5.9

For Smart transmitters

Pneumatic Signal

4- 20 mA DC with superimposed
Digital Engineering Data (HART)

LCD display in Engineering Unit


and % for level in field

0.2- 1 kg/cmg

Process Switch Type for shut-down (Not Applicable- refer note -36)
a)

For pressure

Direct actuated

b)

For flow, temperature,


level and low pressure

Hardwired Receiver Switches

c)

Any other

___________

5.10

Hazardous Area Protection: (Note-21)


a)
b)
c)
d)
e)

All field transmitters


Field switches
I/P converters
Solenoid valves
E/P Positioners

Intrinsically safe
Intrinsically safe
Intrinsically safe
Intrinsically safe
Intrinsically safe

J
J
J
J
J

Flame proof
Flame proof
Flame proof
Flame proof
Flame proof

F
F
F
F
F

Note-21: If Intrinsically safe item is not available for any instruments, then it must be explosion /
flame proof. Only MCC I/Os shall be non-intrinsically safe.
5.11

Intrinsic safety Barriers

Required
Not required

J
F

Isolating type

5.12

Analyser/GC Installation

Analyser room

Analyser/GC Shelter J

Type of HVAC

Packaged
J
Separate Air conditioning F
And ventilation

5.13

Earthing system:
a)

Panels, racks, cabinets, consoles


shelters etc. and all Junction boxes
with power more than 110 V

b)

Signal earth

Separate dedicated earthing pit

c)

Barrier earth

Separate dedicated earthing pit

Format No. EIL 1641-1924 Rev. 1


Page 1253 of 3574

Electrical earth grid

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DOCUMENT No.
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Page 13 of 18
5.14

Units of Measurement:
Flow

Liquid
Gas
Steam

m3/hr
Nm3/hr
Kg/hr
%
kg/cm2 g
C

Level
Pressure
Temperature
6.0

Other Instrumentation and Systems:

6.1

Flow instruments: (Note-22)


As per Licensors requirement
a)

General service

For 2" lines and above

J
J
J
J
J
J

Orifice plate

Other ______________
For 1" lines and below
Variable Area meter F
Meter Run
F
Integral Orifice
J
Other as per licensor
b)

For highly viscous and fouling service


Mass Flow
J
(Coriolis type)
PD meter
F
Wedge
F
Orifice
F
Target
F
Other ______________
Note-22: For licensed units, licensors requirements shall be met

c)

Custody and Product Metering


i)

Liquids

PD meter

Turbine F

Mass
J
(As per P&ID)

ii)

Gas

Orifice

Turbine J

(As per P&ID)

d)

Performance
Metering

Orifice
Mass

J
J

Turbine F
Any Other

PD Meter
F
(As per P&ID)

e)

High Rangeability
applications
(As per P&ID)

Turbine
(for gas)

Vortex J
(for gas)
Others_____

Mass
J
(for liquids)
(As per P&ID)

f)

Flare Flow Measurements

Ultrasonic type J

Other ________

g)

Type of taps for Orifice


assembly

Flanged
J
D- D/2
J
(For 14" lines)

Corner
2D-8D

Format No. EIL 1641-1924 Rev. 1


Page 1254 of 3574

F
F

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DOCUMENT No.
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ENGINEERING DESIGN BASIS

Page 14 of 18
6.2

Temperature Measurement:
a)

Temperature gauges

Bimetallic

Filled system

b)

Thermocouple
Temperature
Transmitter

Grounded
Required

J
J

Un-grounded
Not-required

F
F

For all

Control-room
Head-mounted

F
F

Field
Remote-mounted

J
J

Location
c)

Thermowell flange rating

As per piping specifications/


Vessel Nozzle rating
J
Minimum 300# rating for
Equipments

d)
6.3

RTD

PT-100, 3 Wire, calibration as per DIN 43760

F
J

Level Measurement:
a)

Level Stand-pipe philosophy

b)

Tank Level Gauging


Field Tanks
Servo
Intermediate Tanks
Servo
Product Tanks
Servo
Highly viscous Services Servo
Spheres
Servo

c)

J
J
J
J
J

Radar
Radar
Radar
Radar
Radar

Hydrostatic
Hydrostatic
Hydrostatic

J
J
J
J
J

F
F
F

Any Other ____

Tank Farm Management System


Tank Farm
Management
Redundancy
No. Of CRTs
Display Location

d)

As per 8-52-0002

Dedicated

With DCS

Required
Two
Control room
Any Other

J
Not required
J
Three
J
Satellite room
__________

F
F
F
F

Special Level Instrumentation (If required): (As per P&ID)


RF Type for
Capacitance Type
Ultrasonic Type
Any Other

Silos
F
Any other ________
__________________
__________________
__________________

Crude Desalters

As per Licensor requirements


6.4

Air Filter Regulator

Filter Size

6.5

Desuperheater

Separate Water control valve


As per requirement and

Format No. EIL 1641-1924 Rev. 1


Page 1255 of 3574

5 micron Max.

J
F
J

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ENGINEERING DESIGN BASIS

DOCUMENT No.
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Page 15 of 18
vendors recommendation
6.6

Test /Lab equipment

6.7

CCTV System
a)

CCTV

Required

Not Required

Required

Not required

For Process units


Flare
Plant surveillance
Any other ______________
b)

J
J
F

Monitor Location

Location

Number of Monitors

MAIN CONTROL ROOM

6.8

One for each Unit, offsite & Poly-Propylene

c)

Recording facility

Required
All cameras

J
F

Not required
Selective
Number of points
(If selective)
Fire and Gas Detection (F & G) System: As per Licensor requirement.

F
J

a)
b)

F & G System
Gas detection system

Required

i)

Catalytic diffusion J
IR Type
J
Any other ______
4-20 mA
J

Only for H2
Vendor standard

Electrochemical J
Any other _________
4-20 mA
J

Semiconductor

Vendor standard

iii) Toxic gas detectors


As per process package
Fire detection system (For details, refer Electrical Design Basis)

HC Detectors
Output

ii)

c)

H2S Detectors

i)

Automatic fire
detection

ii)

Plant / Non plant building

Not required

Required
F
Not required
F
If yes, any specific areas to be covered__________

Fire detection
Required
F
Not required
(For details, refer Electrical Design Basis)
d)

Separate F & G LAN

e)

Type of F&G PLC


As per Licensor requirement

Format No. EIL 1641-1924 Rev. 1


Page 1256 of 3574

Required

F
F

TUV Class AK5

F
F

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ENGINEERING DESIGN BASIS

DOCUMENT No.
6556-01-16-51-DB-02
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Page 16 of 18
f)

Requirement of monitors:
Location
Gas Detection

g)
6.9

Number of Monitors
Tags in DCS

Gas cloud movement software

Required
Integrated Machine Monitoring System:

Not required

Required
J
Not required
For monitoring
For predictive maintenance

J
F
J
J (Note-23)

Note-23: Predictive maintenance system shall be provided for each process unit and power plant.
6.10

Boiler drum Instrumentation (Note-24)


Note-24: Hydrastep (Red-Green) type local indication as well as 4-20mA signal to DCS.
Type of level instrument

Conductivity

DP

Safety valves

Section I

IBR

Level measurement

2 out of 3

J (Note-25)

Any other __________


Note-25: Level Measurement as per P&ID.
6.11

6.12

6.13

Ambient air monitoring system (NOT APPLICABLE)


Required
___________
___________

Not required

No. of fixed stations


No. of mobile stations
Mobile van

Required

Not required

Meteorological Sensors

Required

Not required

Required
J
Not required
Separate for each stack (As per P&ID)

F
F

Common for all stacks (As per P&ID)

By Contractor
Required

J
F

Stack Monitoring System:

Safety valve testing at site:


At Site
Testing jig

Format No. EIL 1641-1924 Rev. 1


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Not required

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ENGINEERING DESIGN BASIS

DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

Page 17 of 18
6.14

Spare Philosophy:
a)

Spare instrument as
Mandatory Spares

10% or minimum one of each type


(range, type & material of construction)

b)

Spare Parts

For two years operation


For Startup and Commissioning (As required)
Consumable spares for six months operation

J
J
J

c)

DCS and PLC Spare Philosophy: (Note-35)


System Spares
(Control Room wise)

Bus Capacity
Number of Nodes

40%
30%

Installed Spares

I/O Level
Marshalling

10%
10%

Spare Space

I/O Level
Marshalling
Rack

10%
10%

Mandatory spares

5% or minimum one of each type of module

Other Notes :26.

PLC based control system (Dual Processor, Dual Power Supply & Redundant I/Os)
shall be provided for controls and monitoring of Effluent Treatment Plant, Reservoir Raw
Water / Service Water System / Integrated Drinking water System, DM Water. For Logic
implementation of Instrument Air Dryer & HP Air Compressor Packages, Fire water
system PLC with dual processor, dual power supply & dual I/Os shall be provided. TUV
certification is not envisaged for these PLCs. For LP Air Compressor & VAR system,
vendors standard microprocessor based control system also acceptable.

27.

In case of contradiction between licensor specifications and this design basis, licensor
specifications shall prevail unless waiver to that specific requirement has been identified
in the job specifications. In case, job specifications categorically identifies requirement
which is in contradiction to this, job specification will prevail.

28.

HART maintenance system shall be provided for each of the process units.

29

All cables shall run through overhead cable ducts between unit to SRR and SRR to
main control room. For offsite/utilities areas, cables shall run on piperack / sleepers as
far as possible. RCC trench shall be used only where piperacks / sleepers are not
possible or not available.

30.

Orifice Sizing shall be as per ISO 5167 unless otherwise specified by licensor.

31.

Mandatory spares for critical/special instruments specified separately.

32.

Smart positioners shall be considered for control valves in critical loops and as per
Licensors requirement.

33.

Only copper cables termination inside control room for UPS ACDB to PDB.

34.

Provision in DCS shall be kept for connecting wide area network by Owner for remote
viewing of plant data for Management Review.

Format No. EIL 1641-1924 Rev. 1


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ENGINEERING DESIGN BASIS

DOCUMENT No.
6556-01-16-51-DB-02
Rev.0

Page 18 of 18
35.

100+10% installed +10% additional free spaces (with termination, barriers etc. included.
Only I/O Cards shall not be installed).
Software Licenses: 100+ 10% installed + 10% free spaces + 20% (future expansion). i.e
140% of total tags.

36.

No switches will be used for flow, temperature, level and pressure applications except
for statutory / special applications. The field transmitters shall be used for all such
applications, which shall be directly connected to DCS/PLC.

Format No. EIL 1641-1924 Rev. 1


Page 1259 of 3574

Copyright EIL All rights reserved