Attachment -3

General Specification for C&I.

.0
1

Control and Instrumentation for Waste Water Treatment System

General Requirements
The Instrumentation and Control System envisaged shall be complete in all respect and
adequate for safe, reliable, efficient operation of the Waste water treatment system under
normal and worst service and environmental conditions specified. The scope of work shall
include detailed design, supply, testing and commissioning of Waste Water treatment plant
C&I system.
The design of C&I system shall be such that isolation of any piece of defective equipment
would be possible without shutting down the main equipment or disturbing the operation of
associated instrument and accessories.
All instruments i.e. Primary elements, transmitters, Switches, controllers, level transmitters,
Level switches, shall be electronic based on modular construction, while control actuators for
regulating duty shall be pneumatic. Satisfactory operation of the electronic equipment and
components for temperature and humidity shall comply with the site climatic conditions
specified under Section 1 of this specification.
For process variable viz. Flow, pressure, temperature, level etc. electronic signal transmission
from field to PLC shall be isolated 4-20 mA dc / Potential free contacts.
Complete instrumentation cables required for this System i.e. from field sensors / actuators to
JB's, JB's to PLC system, field sensors to Local control station and from MCC / switchgear to
PLC system i.e. where one end or both ends equipments is in bidder's scope, complete
Supply, laying, termination, etc shall be in bidder's scope.

Operation & Control Philosophy

The waste water treatment plant shall be fully automated, using the standalone PLC with Local
Control Panel. The PLC shall interface with the DCS via Modbus/OPC link such that the CCR
operator can monitor the operation of the plant and be aware of problems as and when they
occur.
A local control panel with Start/Stop Pushbutton, Selector Switch, LED type Status Indication
lamps & analog meters etc. shall be provided within waste water treatment area. A mimic
representation of the process shall be provided together with a suitable annunciator system to
alert the local operator to any system or process faults.
The PLC shall be interfaced with Plant GPS clock for time synchronization with the plant DCS .

Programmable Logic Controller (PLC) System for Fuel gas System

Separate independent PLC (Programmable Logic Controller) based control systems with dual
hot standby controller have been envisaged for control and monitoring of waste water treatment
plant. UPS (parallel redundant) for powering the controllers shall be provided by the Purchaser,
bidder has to provide power requirements for the system along with the bid.
(a) Design Criteria for Programmable Logic Controller (PLC) System

The PLC shall have Automation Monitoring Process control Management

Engineering features

Uniform operator machine interface

Reliable user guidance

Redundancy at Controller, Power supply & communication bus.

Modern object oriented software structure

Shall be able to communicate with external system and intelligent field equipment

Simple central project planning and configuration aids

Integrated documentation system

Integrated equipment capability curve and alarm analysis, Management

information system, diagnosis and service

Commissioning support

The Control System shall have on-line simulation & testing facility.

The system shall have the flexibility to easily reconfigure any controller at any time
without requiring additional hardware or system wiring changes and without
disabling other devices from their normal operation mode. Modifications shall not
require switching off power to any part of the system.

Fault Diagnostics.

(b) Technical Specification for PLC

The latest proven PLC system shall be provided. PLC should be sourced from original
manufacturers; PLC from system house shall not be acceptable. PLC system shall be complete
with redundant CPU of word length of 32 bits minimum, Input / Output modules, dual serial link
interface module, dual Communication Processors, Memory modules and redundant Power
supply units. PLC system will be interfaced with Owners DCS through redundant serial
communication gateway (to be provided at PLC end) with OPC / MODBUS protocol for important
process parameters.
Bidder shall make provision for receiving time signal for time synchronization of Separate
independent PLC (Programmable Logic Controller) based control system from Master clock
system.
The design of the control system and related equipment shall adhere to the principle of fail safe
operation at all system levels and provide reliable and efficient operation of the plant under
dynamic conditions and attainment of maximum station availability.
All the hardwares/softwares shall be latest and field proven.
(c) Processor
CPUs shall be in hot standby mode and CPUs shall not be loaded more than 70% in worst
condition. In case of failure of main processor the transfer from main processor to standby
processor shall be bumpless and within 50ms In the Event of the both the CPU failure, the
system shall revert to the Fail-safe mode.
(d) Input / Output Modules
Input/output cards shall receive signals from field and give output to/for field devices. These can
be analogue and binary type. The I/O cards used for control and interlock shall be nonredundant. All I/O cards shall be sourced from their original manufacturers/Principal. The salient
features of the Input / Output modules are as follows:
(i)
Digital Input/Output Cards

Ambient temp.

Surge withstand capability

: IEC-255.4

No. of channels / card (Max.)

: 16

: 0-50 degree C

Interrogation voltage

Status Indicator

: LED Type.

Isolation

: Optical

(ii)

: 24 VDC

Analogue Input/Output Cards

Ambient temperature

Surge withstand capability

No. of channels/card (Max.)

: 8

Isolation

: Galvanic

Status Indicator

: LED Type.

: 0-50 degree C
: IEC-255.4

(e) Communication Network Bus System

Bus System
Basically bi-directional bus systems shall be envisaged to communicate the controllers
with work stations.
The bus system shall have the redundancy in the system for high reliability of
communication. All bus couplers, bus interfaces, other communication modules, etc. shall
also be redundant.
The characteristics of the control bus (Data highway) shall be as follows or better:

Redundant

Yes

Transmission rate

100 Mbps or better

Control

Masterless Token Passing

Transfer procedure

SDLC

Data Protection

16 bit CRC

Proprietary Bus

Yes

Standard

IEEE 802.4

Software License
The bidder shall provide software license for all software being used in PLC based control
system. The software licenses shall be provided for the project and shall not be
hardware/machine specific. All licenses shall be valid for the continuous service life of the
plant.
Software provided shall be latest, modular, upgradeable and industrially proven. It shall have
capability for multi tasking, multi programming, multi user operation in real time environment
and support for third party system.

Training
Bidder's experienced personnel/engineers shall provide training courses on offered PLC
system to Employer's engineers in the following areas:
(a)
Operator training
(b)
Hardware Maintenance training
(c)
Software training
(d)
Any other specialized training as required for system operation and
maintenance.

The maintenance training shall include lectures and hands on experience on similar type of
equipment / system at manufacturer works and recently commissioned operating plant and / or
training simulator. The details of hardware and software training shall be finalized during
detailed engineering and shall be subject to owner's approval.

Panels and Desks

(a) Constructional Features of Panels, Cubicles & Enclosures
All panels, cubicles, consoles and enclosures furnished as per this specification shall be of
free standing type and shall be constructed of specified gauge of steel plates. The panel
sheet thickness shall be 2 mm CRCA.
Neoprene Gasket, Exhaust Fans with louvers & filters shall be provided in all consoles and
panels.
All panels shall be mounted on vibration dampers, which are secured to channels mounted on
the floor. All panels shall have auto on/off switch for internal lighting.
The finish colours for exterior and interior surfaces shall conform to RAL 7032.
All panels and cabinets shall be provided with a continuous bare copper ground bus. The
ground bus shall be bolted to the panel structure and effectively ground the entire structure.
Nameplates of adequate size shall be provided for each panel on front and rear of the panel.
20% wired input/output spare channel should be provided for each I/O modules. In addition to
this, 20% spare relays of each type and rating, mounted and wired in relays cabinets. All
contacts of relays shall be terminated in terminal blocks of relay cabinets.
The spare capacity as specified above shall be uniformly distributed throughout all controller
systems. The system design shall ensure that above-mentioned additions shall not require any
additional controller/processor/Peripheral drivers in the system delivered at site. Further, these
additions shall not deteriorate the system response time/ duty cycle, etc. from those stipulated
under this specification and shall meet other redundancy / functional requirement.
Unless otherwise stated all apparatus shall be accommodated in cubicles. All the apparatus of
solid-state type shall be mounted on plug-in cards in racks. Similar racks or cubicles shall, as
far as possible, be employed for all apparatus. Cubicles, cabinets, racks and control panels
shall all conform to applicable IEC 60297 Standards.
They shall be of the free standing type, fabricated steel construction, and provided with
suitable equipment mounting fittings. Neither racks nor cubicles shall, unless otherwise
approved, exceed 2300 mm in height. The methods used for cubicle mounting, including the
provision of anti-vibration mounts, shall be to approval. Support steelwork shall be suitably
sized for the equipment weight with facilities for ensuring that the cubicles etc. are level.
(b) Cubicle Wiring
Cubicle wiring shall be of the flame-retardant/fire resistant. Wires shall not be joined or teed
between terminal points. Bus wires shall be fully insulated and run separately from one
another along the top or bottom of the cubicle. Fuses and links shall be provided to enable all
circuits in a cubicle, except lighting or heating circuit, to be isolated from the bus wires.
All wiring shall be terminated with approved crimped terminations. Other methods of wiring
termination shall be to the Owners/Engineers approval. Terminal blocks shall have separate
terminals for incoming and outgoing connections and no more than two connections shall be
permitted on any one terminal. Terminal blocks that rely on springs only for retaining the
terminations, and those which employ a pinch screw terminal are not acceptable.
It shall be possible to work on small wiring for maintenance or test purposes without making
the cubicle dead. Circuits working at different voltages shall be adequately segregated and
labelled.

Power supply bus bars in cubicles shall be carefully routed and each bus bar shall be
shrouded. It shall not be possible to inadvertently short bus bars either between themselves or
to earth.
(c) Marshalling Cubicles
Marshalling cubicles shall be of fabricated steel construction of minimum thickness 2 mm,
galvanized and painted, dustproof and vermin proof and so designed that condensation shall
not affect the insulation of the terminal blocks or cables.
Sufficient space shall be included in the cubicle for terminals and cable trunking. The trunking
shall not be overfilled and adequate space shall be allowed for easy removal of lower cables.
All spare cables shall be contained in the trunking.
Marshalling cubicles shall be complete with ail necessary terminal blocks, wiring, washers or
tags, wiring ferrules, labels and door locks. All marshalling cubicles shall accept a common
key for locking.
In each marshalling cubicle circuits shall be grouped and labelled according to function (i.e.
system control, alarm and tripping circuits, telephone circuits, etc), with the labels attached to
the fixed portion of the terminal boards. Terminals shall be provided for connecting the screens
of screened twisted pair cables or the overall screen on multicore cables and shall be adjacent
to the termination of the associated twisted pair.
(d) Earthing
Earthing of electronic equipment is required to reduce the effects of electrical interference and
for the safety of operation and maintenance staff. Where there is a conflict between the two,
personal safety shall always take precedence.
Earthing should be generally in accordance with BS 6739, BS 7671 and BS 7430 or
equivalent international standards unless otherwise approved.
Protective screens around insulated cables shall be insulated from field instruments,
connected through any field junction boxes, and be continuous up to the earthing point in the
destination cubicle or panel.
Cubicles, desks etc, shall be equipped with a "clean" instrument earth comprising an insulated
copper earth bar for the connection of cable screens. All "clean" instrument earth bars shall be
clearly labelled as such. Connection of the instrument earth to the site earth shall be by
separate conductor to the equipment safety earth.
All non-current carrying metallic parts of plant, equipment, components, enclosures, racks etc,
shall be earthed by connection to the main plant earth bar in an approved manner and all
earthing terminals and connections shall be of adequate dimensions.
For all panel, cubicle doors or swinging frames, flexible cable or braid shall be used for
earthing these items; the door hinges shall not be accepted as a means of earthing this part of
the equipment.
The design of equipment shall be such that cable screens and cable armouring are kept
electrically separate throughout the equipment installation so as to avoid the introduction of
earth loops and minimize interference pickup.

Technical Details for Measuring Instruments

(a) Pressure Gauge

Sl. No

Features

Minimum Requirements

01.

Type

Bourdon / Bellows / Diaphragm

02.

Sensing Element Material

SS 316

03.

Movement Materials

SS 304

04.

Case Material / Protection

Class

SS / IP 65

05.

Dial Size

150 mm

06.

Scale

Black lettering on white background in 270 C arc

Normally operate at 75% of its maximum pressure

07.

Range Selection

range. Instruments measuring varying pressures

shall operate in a band of 60% of its maximum
pressure range.
150% of maximum range by internal stop.

08.

Over range Protection

09.

Adjustment

10.

Stop at Max. Reading

Shall be provided

11.

Element Connection

Argon welding

12.

Process Connection

13.

Performance :a)

14.

Accuracy

Operating Ambient
Temperature

15.

Safety Feature

16.

Feature

External stop below zero.

External Micrometer screw for zero adjustment.
Internal micrometer screw for range adjustment.

NPT(M) bottom connection for local mounting,

back connection for panel mounting

+1.0% of span or better

50 C (Max. continuous)
Neoprene Safety Diaphragm (Blowout disc) at the
back
Shatter-proof glass

17.

Chemical Seal Unit

SS 316 Flange and Diaphragm, PTFE coated /

block, Silicon Oil filling fluid
Snubbers for pulsating fluid applications / 3-way
gauge cock / 2-valve manifold / Gauge Saver, if

18.

Accessories

maximum or Design Pressure is very high than

the Operating Pressure / Counter Flanges / Bolts,
Nuts, Gaskets / SS Tag Plate

(b) Temperature Gauge

Sl. No

Features

Minimum Requirements

01.

Type

Gas filled

02.

Stem

SS 316

03.

Movement Materials

SS 304

04.

Case Material / Protection

class

SS / IP65

05.

Dial Size

150 mm

06.

Scale

Black lettering on white background in 270 C arc

07.

Adjustment

08.

Pointer

09.

Range Selection

10.

Stop at Max. Reading

Shall be provided

11.

Over range Protection

150% of FSD

12.

Instrument Connection

13.

Process Connection

Micrometer screw for zero adjustment. Internal

micrometer screw for range adjustment.
Externally Adjustable
Normal Process Temperature approximately two
third of Temperature range.

Bottom connection for local mounting, back

connection for panel mounting.
NPT with Thermowell

14.

15.

16.

Performance :a)

Accuracy

+1.0% of full scale deflection or better

b)

Repeatability

Less than 0.5% of full range

c)

Response Time

Operating Ambient
Temperature
Accessories

30 seconds (max.) with thermowell and 15

seconds Bare.
50 C (Max. continuous)
Counter Flanges / Bolts, Nuts, Gaskets / SS Tag
plate, SS Thermowell etc.

(c) Tubular Level Gauge

Sl. No

Features

Minimum Requirements

01.

Mounting

Side-Side

02.

End Block Type

Offset Needle Valve with Auto Ball Check

03.

Gauge Glass

Borosilicate

04.

Packing

As per process requirement

05.

End Block

SS

06.

Gland

SS

07.

Working temperature

As per process requirement

08.

Process Connection

As per requirement

09.

Vent

Plug

10.

Drain

Ball Valve

11

Accessories

All mounting accessories

(d) Ultrasonic Level Transmitter

Sl. No

Features

Minimum Requirements
Non contact Microprocessor based 2 wire type,

01.

Type

02.

Accuracy

0.25% of range or better

03.

Resolution

0.1% of range or better

04.

Repeatability

3 mm or better

05.

Local Indication

To be provided

06.

Temp. Compensation

To be provided

07.

Range

08.

Power Supply

09.

Sensor Material

HART protocol compatible Ultrasonic Transmitter

Capable of covering the complete level span of tank

taking care of blocking distance
24 VDC
Corrosion resistant material to suit individual
application requirement
Transmitter shall be capable of Tolerance ignoring

10.

False signal

false echoes from Tolerance ignoring false echoes

from such as pipes, heating coils or agitator blades.

11.

Outputs

4 20 mA DC with 600 ohms load

12.

Enclosure protection

Weatherproof IP 65

13.

Electrical connections

inch NPT

14.

Process connection

As per requirement

15.

Mounting accessories

All weather canopies for protection from direct

sunlight and direct rain and All mounting hardware
and

accessories

required

for

erection

and

commissioning.

(e) pH Meter

Sl. No
01.

Features
Type

Minimum Requirements
Cell - Flow through, Transmitter- Microprocessor
based

02.

Case

Die cast aluminium

03.

Electrode

pH Glass

04.

Analyzer output

4 to 20 m Amp DC

05.

Power supply

240V AC, 50 Hz

06.

Accuracy

+ 0.03 pH

07.

Repeatability

+0.02PH

08.

Type of contacts

Snap action microswitch

09.

No. of contacts

2 SPDT

10.

Rating of contacts

5 amp 240V AC 0.2 Amp 220V DC

11.

Electrical Connection

NPT(F)

12.

Enclosure Protection

IP 65

13.

Automatic temperature

Provided

compensation
14.

Chemical reagents for

Provided

12 month of operation
15.

Accessories

C&I Cables

(a) General Technical Requirements

All mounting accessories

All cabling and wiring shall be of the flame-retardant and fire-resistant type in accordance with
BS 5467, BS 5308, and relevant IEC.
Multicore cables shall have stranded copper conductors of 1.5 mm2 minimum cross sectional
area, thermoplastic insulation and an overall thermoplastic sheath. These cables shall have an
overall metallic shield. There shall be a minimum of 20% spare cores, but no less than two
cores, for future use.
Multipair cables shall have twisted pairs of stranded copper conductors of 1 mm2 minimum
cross sectional area, thermoplastic insulation and an overall thermoplastic sheath. These
cables shall have an individual insulated metallic shield applied to each pair and an overall
metallic shield. There shall be a minimum of 20% spare pairs, but no less than 1 pair, for
future use.
Optical fibre cables shall have a minimum of 4 fibres. There shall be a minimum of 20% spare
fibres, but no less than 2 fibres, for future use. All fibres to be terminated in approved terminal
boxes.
The cables shall be protected from physical abuse and attack from rodents/insects. The
Bidder shall advise his proposed methods for the physical protection of the cables and these
shall be subject to the approval of the Owner/Engineer.
Multipair cables shall be employed for the majority of l&C applications including analogue
circuits, up to a maximum of 20 mA, and digital circuits up to a maximum of 50 V dc. This shall
include 24 V dc solenoid valves.
(b) Cable Installation
(i) Separation
Running l&C cables along the same route as power cables shall be avoided. Where this
is not possible, the cables shall be segregated as fully as possible. It is not permissible
for power and l&C cables to share the same tray/rack/trun king/conduit.
l&C cables shall be run on dedicated trays with a minimum separation between the l&C
trays and ail other trays.
If l&C cable trays are to be installed in the same routes as power cable trays then the
l&C trays are to be installed at a lower level than the power cable trays to ensure that
heat generated by the power cables does not travel through the l&C cables.
A closed conduit l&C cabling system shall be used for individual field devices up to the
local junction box.
(ii)
Segregation
All l&C cables from one unit shall be segregated from those for any other unit. The
cables for common or station equipment shall be segregated from any unit cabling.
Cabling for redundant equipment shall be installed over separate routes. Cabling for
redundant instrumentation (e.g. two-out-of-three voted signals) shall be installed over at
least two separate routes.
(iii)
Laying and Terminating
l&C cables shall be fully supported either in conduits, on tray, racks or other support
systems subject to the Owners/Engineers approval. The cables shall be adequately
supported and clamped to prevent excessive sagging. Cable routes shall be such that
the cables are not exposed to extremes of temperature from the plant processes and
prolonged exposure to direct sunlight without some form of thermal protection.
The installation of the cable cores/pairs within the plant equipment, adaptable boxes,
junction boxes and marshalling boxes shall be such that a core/pair can be moved from
one extreme end of the terminal rail to the other end. In addition the core/pair shall be
capable of being re-terminated a minimum of three times.
All spare cores/pairs shall be tied back with a length capable of being terminated as
above.

(iv)
Identification
Each cable shall be identified with a cable number approved by the Owner/Engineer.
Each cable core shall be uniquely identified using interlocking ring plastic ferrules or
similar. Clip on or 'c' type ferrules shall not be used. The core identifier shall be to the
approval of the Owner/Engineer.
Where the route of the cable is through junction boxes, marshalling boxes, etc both the
incoming core and the outgoing core shal! carry the same unique core identification.
(v)
Cable Screens and Armouring
The design of equipment shall be such that cable screens and cable armouring are kept
electrically separate throughout the equipment installation. This separation shall be
maintained throughout by the installation of a suitable earth system subject to approval.

Instrument Installation
(a) General
All the instrumentation shall be installed so that it complies with BS 6739 and the
recommendations of the manufacturer. Only one instrument shall be fitted to each tapping
point.
(b) Local Measuring & Control Elements
Sensing elements shall be suitable for service fluid, temperature and pressure.
For sea water or brine service the wetted parts shall be Hastalloy C or Monel.
The body, Flanges, bolts and housing shall be stainless steel 304, 316L to suit the application
at the discretion of the Engineer.
Field instruments shall be located away from equipment/location where severe/continuous
vibrations or shocks occur or are expected.
Temperature and pressure compensation shall be provided, especially for steam/variable
specific gravity applications.
(c) Hazardous Areas
All l&C equipment shall be suitable for the specific area in which it is located. This shall take
into account the presence of any potentially hazardous conditions or substances.
If equipment is expected to operate in the presence of flammable or explosive materials
explosion proof construction is the preferred method of protection. All equipment offered for
use in such areas shall have the necessary certification by the appropriate Certification
Bureau and its proposed application shall fully comply with all conditions of the certificate.
The design and installation of the equipment shall take into account fully the appropriate
sections and requirements of BS EN 50014/BS EN 60079.
The Bidder shall provide a plant layout drawing and list defining the classification of all plant
areas taking into account all appropriate physical parameters including ambient and surface
temperatures of plant, dust/liquid/gas/water conditions, risk of fire and explosion.
(d) Primary Isolation and Instrument Valves
All instrument valves, proposed for use on this project, shall be approved by the
Owner/Engineer. All primary isolating and blow down valves shall be capable of being locked
in the open or shut positions. The direction of rotation shall be clearly marked on the handwheel.
The primary isolating valve shall be located at the tapping point, be of the parallel or globe
type and rated for the temperature and pressure of the main line. The primary isolation valve
shall be compatible with the system material to which it is connected.

Double isolation shall be provided for pressures above 40 barg and hazardous services.
Instrument isolating, equalizing and vent valves shall preferably be incorporated in a single
manifold, i.e. two/three way manifolds for pressure measurements and five way manifolds for
differential measurements. The instrument manifolds/valves shall be manufactured in stainless
steel unless the process conditions require different materials. Valve seatings and seals shall
be suitable for the process conditions.
Locking facilities for primary isolation valves and instrument valves/manifolds shall be
provided for l&C, related to safety/reliability of Unit/Plant.
(e) Impulse Pipe Work
Connections to instruments after the primary isolating valve shall normally be made using
stainless steel (316L) piping or piping suitable for the process conditions.
Instrument isolating valves, vent/test valves and instrument manifolds shall be attached to
measuring devices so that it is possible to disconnect the device from the connecting pipe
work without having to disconnect or drain the pipe work.
All instrument vent/drain points shall be directed to a safe position away from site personnel.
The primary instrument piping shall be 12 mm NB stainless steel piping. For applications up to
40 barg pressure, schedule 40 shall be used. For pressures above 40 barg, schedule 80 shall
be used.
(f) Pneumatic Pipe Work
Each individual air user shall be provided with an air filter regulator set with a lubricator to the
approval of the Owner/Engineer. A line size lockable isolating valve shall be provided
immediately upstream of the filter regulator.
The connection to the air user at the air supply manifold shall be supplied with an isolation
valve that shall have a locking facility. 20% spare connections, with isolating valves, shall be
supplied at each manifold.
The air supply pipe work and tubing shall be suitably sized to ensure that there is negligible
pressure drop during peak consumption of instrument air.
(g) Instrument Mounting
All indicating instruments and controls shall be grouped together, where possible, in suitable
housings and gauges shall be installed. They shall be readable and accessible from floor level
or permanent platforms. Gauge glasses shall be visible from any control valve that controls
the vessel level. Where gauge racks are used suitable sunshades shall be provided.
Transmitters and process switches shall be located in instrument housings containing up to six
instruments. Clearance shall be allowed for servicing and access to all items. Instrument
housings shall be provided with internal illumination, heaters, and a maintenance power
socket with an RCD and a communications jack socket.
Instruments, housings and gauge racks shall be positioned so that exits are not obstructed.
Post or bracket mounts for instruments shall not be attached to pipework, removable flooring,
handrails, or be directly affixed to machinery and equipment subject to vibration.
(h) Climatic Protection, Sealing and Purging
Instruments and their associated pipe work shall be mounted in heated or protected locations
wherever possible in order to minimize the effects of ambient weather conditions. Were this is
not possible a suitable means of ensuring and/or minimizing such effects shall be applied.
Instruments in liquid services, which solidify at ambient temperature, shall be provided with
diaphragm seals.
Seal chambers or diaphragm seals shall be used where fluid services are corrosive, viscous,
congealing, deposit forming, or dangerous. Seals shall be located as close as possible to the
primary isolating valve.