02.Design Basis - Design Philosophy.pdf

DESIGN BASIS

SPECIFICATION NO.

A535-000-16-51-DB-02 Rev. 0

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0 03.07.14 Issued for tender MK NA RK

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DESIGN BASIS/DESIGN PHILOSOPHY

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SPECIFICATION NO.

A535-000-16-51-DB-02 Rev. 0

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Format No. 8-00-0001-F2 Rev. 0 Copyright EIL All rights reserved

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)

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

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ENGINEERING DESIGN BASIS

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0 22.02.05 CLIENTS COMMENTS INCORPORATED & ISSUED FOR APPROVAL MN AKG PM

B 8.02.05 ISSUED FOR CLIENTS APPROVAL ZH AKG PM

A 24.11.04 ISSUED FOR CLIENTS COMMENTS/APPROVAL JS AKG PM

Rev. No Date Purpose Prepared by Checked by Approved by


C2.10 INSTRUMENTATION

Format No. EIL 1641-1924 Rev. 1 JS

Copyright EIL All rights reserved

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1.0 Control Philosophy:

a) Mode of Plant Operation Centralised J

Unit wise F For all process units J Including Offsites Combined for For all utilities J (Note-1) all units F For all offsites F 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) Type of Plant Grassroot J Expansion F

Any Other F

1.1 Control Room Requirement:

Location Control Room Process Units Hazardous Area

Non-hazardous Area Floor

Main Control Room (CR#1)

NCU & its auxiliary units, PP, LLDPE, HDPE, MEG, Offsites, Utilities (Repeat Indications)

9 Ground

Power Plant Control Room (CR#2)

CPP

9 First Floor

Loading Control Room (CR#3)

Loading Gantry and associated Off-sites

9 Ground

Raw Water control Room (CR#4)

Raw water & Fire Water System, Flare

9 Ground

DM Plant control Room (CR#5)

DM Plant, CPU & RO system

9 Ground

WWTP Control Room

Local Control Room for WWTP

9

Ground

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

Location Satellite Rack Room Process Units Non-hazardous

Area Hazardous

Area SRR#1 NCP 9 SRR#2 MEG 9 SRR#3 PP 9 SRR#4 LLDPE 9 SRR#5 HDPE 9 SRR#6 Offsites 9

1.3 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 F for Supervisory computer F for

Other F for __________________

b) Local Electronic J Pneumatic F c) Final Control Element Pneumatic J Other________________

1.4 Interlock and Shut-down system: a) Logic Representation: As per ISA J Other ________________ b) Interlock Execution Independent of F With J

Shutdown System Shutdown system

Type of hardware DCS F Relay F PLC J

c) Shutdown System Dedicated Unit-wise J Common for all units F

Type of hardware-

Relay F PLC J

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d) PLC Configuration Dual Processor, Single I/O F for shutdown Dual Processor, Dual Tested I/O J (Note-2) & Redundant Power Supply as a minimum 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 ________________ e) TUV Classification Required J Not required F Class AK6

f) Process bypass switch Software F As per P&ID Hardwired with indication lamp F

g) ESD Switch location Local panel F (As per P&ID.) Control room F Field F Push Type F Pull Type J With mushroom head

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

a) Location Hazardous Area F Non-hazardous Area F b) Type Weatherproof F Flame-proof F Purged F NFPA 496 F

Type Z F Other___________ c) Instruments Type Pneumatic F Electronic F

2.0 Package Units Philosophy: 2.1 Operating philosophy: (Note-6)

Package Description Control & Monitoring Interlock & Shutdown

Local Panel

DCS

EM Relays DCS PLC

Process Package - 9 - - 9 Utility Package, Air Comp. & Air Drier Packages.

9 (Note-5) - - -

9

All other Utility Packages

- - - - 9 (Note-6)


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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 F Dual Processor, Dual I/O J (Note-7) Vendors standard F Other _____________

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 Bentley Nevada series 3300 or equal F Machine monitoring Bentley Nevada series 3500 or equal J Other

2.5.1 Location of monitors Control room F SRR J Local panel F

2.5.2 Type of local panel Weather proof J Flame proof J Purged F As per NFPA 496 F Type Z F 3.0 DCS Requirements: 3.1 Functional Requirements: Control and Data Acquisition System J Data Logging and Report Generation J Management Reports J Advanced Control F Data Storage and Archival J Management Information System reporting F Note-8: History for all tags capability

Format No. EIL 1641-1924 Rev. 1 Copyright EIL All rights reserved (Inclusive of installed spares, spare space and additional 10% for soft tags)

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3.2 Operator Consoles:

a) Number of Operator Consoles for each Control Room:

Control Room Operators Consoles Number of

CRTs / console Process Units

Note-9 3 NCU & its auxiliary units

Note-9 3 PP

4 (Note-9) 2 LLDPE

Note-9 3 HDPE

Main Control Room(CR#1)

Note-9 3 MEG

1 3 Offsites


3 Console#1: 2 (UB) Console#2: 4 (HRSG) Console#3: 2 (STG)

CPP & DM Plant


Note-10 Note-9 Loading Gantry area

Raw Water control Room (CR#4)

1(HOLD) 2 Raw water & Fire Water

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.

b) Open system connectivity J

c) Assignable Recorders on each console Yes F No J

3.3 Engineering Consoles: Required J Not required F Number of consoles for each Control Room: (Note-11)

Name of Control Room

Number of Engineering

Consoles

Number of CRTs /

console Name of Units


1 1


- -

Raw Water control Room (CR # 4)

1 1

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


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Number of consoles for each SRR (Note-12):

Name of Control Room

Number of Engineering

Consoles

Number of CRTs /

console Name of Units

SRR#1 1 1 NCP

SRR#2 1 1 MEG

SRR#3 1 1 PP

SRR#4 1 1 LLDPE

SRR#5 1 1 HDPE

SRR#6 1 1 Offsites

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

3.4 Type of Reports Required Hourly J Alarm History J Shift wise J Alarm Summary J Daily J Shutdown Report J MIS reports J Others

3.5 Type of Controller Multi-loop J Single-loop F

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

3.8 Foreign Device Interface required for: Programmable Logic Controllers J Analyzer system J Chromatographs J Tank Gauging System J Computer F Package PLCs J Anti Surge Controller J Vibration & Temperature Monitoring System J Speed Governor J 3.9 Advanced Control Function Requirements- (Not Applicable) Through DCS F Through Dedicated F Supervisory Computer F 3.10 Training Kit Required F Not required J 3.11 Training Simulator Required F Not required J Format No. EIL 1641-1924 Rev. 1 Copyright EIL All rights reserved

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Process model required for________________ 3.12 Redundancy Philosophy: a) Controller Sub-system Redundant F 1:1 redundancy J b) Data Acquisition Redundant J System (if more than 16 AI or 32 DI per module) Non-Redundant J c) Communication Redundant J 1:1 redundancy J Sub-system d) Power supplies Redundant J 1:1 redundancy J Sub-system 3.13 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 F Closed back J Non-Graphic J Open back F Semi-Graphic F Console type F 4.2 For Control Room Instrumentation (As per P&ID) (Note-15) a) Indicators, Integrators, All F Critical J Indicating controllers, etc. (As per P&ID) None F Location Panel F Console J Size: Anti Surge Controller 6" x 3" F OEM standard J Speed Governor 6" x 3" F OEM standard J b) Recorders All F Critical F None J Location Panel F Console F Size: Assignable Trend Recorder 6" x 3" F

Other______________ c) Multipoint Temperature Critical Parameters F None J Recorders Location Panel F Console F Size: Large case F 6 x 6 F d) Alarm Annunciation All F Critical J

Format No. EIL 1641-1924 Rev. 1 Copyright EIL All rights reserved (As per P&ID)

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On panel F Hanging Type F On console as per P&ID J First out sequence Required J (As applicable) e) Multi-point Temperature Required F Not required J Indicator f) Auto Manual Station On Panel F On Console J (As per P&ID) g) Manual Loading Station On Panel F On Console F (As per P&ID) h) Selector Switch On Panel F On Console J (As per P&ID) i) Start/Stop, Emergency On Panel F On Console J Push Button (As per P&ID) j) Process Bypass Switch/ On Panel F On Console J Indication (As per P&ID) Note-15: Location shall be as per licensor requirement. k) Start up / shut down operation from control room: 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 l) 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

Tolerance

Duration after Mains Failure

Emergency Power Supply Requirement

110 V AC UPS 110V 10% 50Hz 3%

30 Minutes Required


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5.2 Power Supply Requirement 110V AC 110V DC 24V DC 110 V AC 230 VAC 50Hz.UPS Non UPS 50Hz a) Distributed Digital J F F F F Control system b) Supervisory F F F F F Computer c) Package Units J F F F F d) Alarm Annunciator J F F F F e) PLC J F F F F f) Relay based F F J F F Interlock & Shutdown system g) Solenoid Valves F F J F F h) I/P, Transmitters F F J F F Voltage i) Gas Detection System J F F F F j) Analysers and J F F F J (for Non-UPS) Analyser System (Note-17, 18) k) Chromatographs J F F F F (Note-17) l) Training Kit F F F F F for DCS m) Level Gauge F F F F J (Non-UPS) Illumination n) Cabinets Lighting F F F F J (Non-UPS) Control Room o) Local Panel J F F F F

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 MCT Blocks J Pipe Sleeves F


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b) Satellite Rack Rooms MCT Blocks J Pipe Sleeves F c) Local control Rooms MCT Blocks J Pipe Sleeves F d) Analyser Rooms / MCT Blocks J Pipe Sleeves F Houses 5.4 Air Supply at Battery Limit 6 kg/cmg J 5.5 Size of Instrument Nozzles: As per 7-52-0001,7-52-0002 J 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 Tubing F Piping J Any other_________ c) Instrument valve manifolds i) For pressure gauges Integral F Fabricated J ii) For flow DP transmitter Integral J Fabricated F iii) For Others Integral J Fabricated F d) Impulse Line valves (After first isolation valve provided by piping) Isolation valves Gate F Globe J

Vent/drain valves Gate F Globe J e) Signal and Air supply tubing SS tubing (for Instrument air) J PVC covered copper tubing F f) Steam Tracing Bare copper tube (3/8) J g) Seal pot required for Yes F No F steam / condensing Vapour instruments(as per Licensor requirement) 5.7 Field Transmitter Type: a) For open and closed loops Conventional F Smart J Field Bus F b) For anti-surge loops Conventional J Smart F As per vendors standard requirement F c) For shut-down loops Conventional F Smart J (Note-20) Note-20: For shutdown, smart transmitters configuration facility shall be kept inhibited by

default.


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5.8 Signal: a) For Smart transmitters 4- 20 mA DC with superimposed J Digital Engineering Data (HART) LCD display in Engineering Unit J and % for level in field b) Pneumatic Signal 0.2- 1 kg/cmg F 5.9 Process Switch Type for shut-down (Not Applicable- refer note -36) a) For pressure Direct actuated F b) For flow, temperature, Hardwired Receiver Switches F level and low pressure F c) Any other ___________ 5.10 Hazardous Area Protection: (Note-21) a) All field transmitters Intrinsically safe J Flame proof F b) Field switches Intrinsically safe J Flame proof F c) I/P converters Intrinsically safe J Flame proof F d) Solenoid valves Intrinsically safe J Flame proof F e) E/P Positioners Intrinsically safe J Flame proof 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 J Isolating type J Not required F 5.12 Analyser/GC Installation Analyser room F Analyser/GC Shelter J Type of HVAC Packaged J Separate Air conditioning F And ventilation 5.13 Earthing system: a) Panels, racks, cabinets, consoles Electrical earth grid J shelters etc. and all Junction boxes with power more than 110 V b) Signal earth Separate dedicated earthing pit J c) Barrier earth Separate dedicated earthing pit J


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5.14 Units of Measurement: Flow Liquid m3/hr J Gas Nm3/hr J Steam Kg/hr J Level % J Pressure kg/cm2 g J Temperature C J 6.0 Other Instrumentation and Systems: 6.1 Flow instruments: (Note-22) As per Licensors requirement a) General service For 2" lines and above Orifice plate J

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 F Turbine F Mass J (As per P&ID) ii) Gas Orifice F Turbine J (As per P&ID) d) Performance Orifice J Turbine F PD Meter F Metering Mass J Any Other (As per P&ID) e) High Rangeability Turbine J Vortex J Mass J applications (for gas) (for gas) (for liquids) (As per P&ID) Others_____ (As per P&ID) f) Flare Flow Measurements Ultrasonic type J Other ________ g) Type of taps for Orifice Flanged J Corner F assembly D- D/2 J 2D-8D F (For 14" lines)


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6.2 Temperature Measurement: a) Temperature gauges Bimetallic J Filled system F b) Thermocouple Grounded J Un-grounded F Temperature Required J Not-required F Transmitter For all J Location Control-room F Field J Head-mounted F Remote-mounted J c) Thermowell flange rating As per piping specifications/ Vessel Nozzle rating J Minimum 300# rating for F Equipments d) RTD PT-100, 3 Wire, calibration as per DIN 43760 J 6.3 Level Measurement: a) Level Stand-pipe philosophy As per 8-52-0002 J b) Tank Level Gauging Field Tanks Servo J Radar J Hydrostatic F Intermediate Tanks Servo J Radar J Hydrostatic F Product Tanks Servo J Radar J Hydrostatic F Highly viscous Services Servo J Radar J Spheres Servo J Radar J Any Other ____

c) Tank Farm Management System

Tank Farm Dedicated J With DCS F Management Redundancy Required J Not required F No. Of CRTs Two J Three F Display Location Control room J Satellite room F Any Other __________ d) Special Level Instrumentation (If required): (As per P&ID) RF Type for Silos F Crude Desalters F Any other ________ Capacitance Type __________________ Ultrasonic Type __________________ Any Other __________________ As per Licensor requirements 6.4 Air Filter Regulator Filter Size 5 micron Max. J 6.5 Desuperheater Separate Water control valve F As per requirement and J


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vendors recommendation 6.6 Test /Lab equipment Required F Not Required J 6.7 CCTV System a) CCTV Required J Not required F For Process units J Flare J Plant surveillance F Any other ______________ b) Monitor Location

Location Number of Monitors

MAIN CONTROL ROOM One for each Unit, offsite & Poly-Propylene

c) Recording facility Required J Not required F All cameras F Selective J Number of points (If selective) 6.8 Fire and Gas Detection (F & G) System: As per Licensor requirement.

a) F & G System Required F Not required J b) Gas detection system i) HC Detectors Catalytic diffusion J Only for H2 IR Type J Any other ______ Output 4-20 mA J Vendor standard F ii) H2S Detectors Electrochemical J Semiconductor F Any other _________ 4-20 mA J Vendor standard F iii) Toxic gas detectors As per process package J c) Fire detection system (For details, refer Electrical Design Basis) i) Automatic fire Required F Not required F detection If yes, any specific areas to be covered__________ ii) Plant / Non plant building Fire detection Required F Not required F (For details, refer Electrical Design Basis) d) Separate F & G LAN Required F e) Type of F&G PLC TUV Class AK5 F As per Licensor requirement F


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f) Requirement of monitors:

Location Number of Monitors

Gas Detection Tags in DCS

g) Gas cloud movement software Required F Not required J 6.9 Integrated Machine Monitoring System: Required J Not required F

For monitoring J For predictive maintenance 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 J DP J Safety valves Section I J IBR J Level measurement 2 out of 3 J (Note-25) Any other __________ Note-25: Level Measurement as per P&ID. 6.11 Ambient air monitoring system (NOT APPLICABLE) Required F Not required F No. of fixed stations ___________ No. of mobile stations ___________ Mobile van Required F Not required F Meteorological Sensors Required F Not required F 6.12 Stack Monitoring System: Required J Not required F Separate for each stack (As per P&ID) F Common for all stacks (As per P&ID) F 6.13 Safety valve testing at site: At Site By Contractor J Testing jig Required J Not required F


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6.14 Spare Philosophy: a) Spare instrument as 10% or minimum one of each type J Mandatory Spares (range, type & material of construction) b) Spare Parts For two years operation J For Startup and Commissioning (As required) J Consumable spares for six months operation J c) DCS and PLC Spare Philosophy: (Note-35) System Spares Bus Capacity 40% (Control Room wise) Number of Nodes 30% Installed Spares I/O Level 10% Marshalling 10% Spare Space I/O Level 10% Marshalling 10% Rack Mandatory spares 5% or minimum one of each type of module J

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.

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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.


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