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A535-000-16-51-DB-02
DESIGN BASIS
Rev. 0
Page 1 of 2
03.07.14
MK
NA
RK
Rev.
No
Date
Purpose
Prepared
by
Checked
by
Approved
By
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)
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 1 of 18
22.02.05
8.02.05
A
Rev.
No
MN
AKG
PM
ZH
AKG
PM
24.11.04
JS
AKG
PM
Date
Purpose
Prepared by
Checked by
Approved by
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 2 of 18
1.0
Control Philosophy:
a)
Centralised
Unit wise
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
Location
Process Units
Hazardous
Area
Non-hazardous
Area
Ground
9
9
Loading
Gantry
associated Off-sites
and
CPU
Local Control
WWTP
First
Floor
Ground
Floor
&
Ground
9
RO
Ground
9
Room
for
Ground
9
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 3 of 18
1.2
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
Centralised
for
Supervisory computer
for
Other
for __________________
Electronic
Pneumatic
Pneumatic
b)
Local
c)
Other________________
1.4
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
Other ________________
J
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 4 of 18
d)
PLC Configuration
for shutdown
J (Note-2)
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)
g)
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
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
Process Package
Utility Package,
Air Comp. & Air
Drier Packages.
All other Utility
Packages
Format No. EIL 1641-1924 Rev. 1
Page 1245 of 3574
DCS
9
(Note-5)
-
DCS
PLC
9
9
9
(Note-6)
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
Plant PLC
J
Package Vendors
J
PLC
(For proprietary /Utility Packages/Where
specifically required)
Any other_____________
PLC configuration
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
2.5
F
J
2.5.1
Location of monitors
Control room
SRR
Local panel
F
J
F
2.5.2
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)
J
J
J
F
J
F
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
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
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)
c)
Engineering Consoles:
Required
Yes
No
F
J
Not required
Number of
Engineering
Consoles
1
Number of
CRTs /
console
Name of Units
1
-
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
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
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
3.7
Field Multiplexer
3.8
J
J
J
J
F
J
J
J
J
F
F
F
3.10
Training Kit
Required
Not required
3.11
Training Simulator
Required
Not required
3.9
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
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
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
4.0
4.1
4.2
F
J
F
Closed back
Open back
Console type
J
F
F
b)
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
None
Location
Size:
Large case
Alarm Annunciation
(As per P&ID)
Panel
Console
All
F
F
6 x 6
Critical
F
J
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 9 of 18
On panel
F
Hanging Type
On console as per P&ID
First out sequence
Required
F
J
J
e)
Not required
f)
On Panel
On Console
g)
On Console
h)
Selector Switch
(As per P&ID)
On Panel
On Console
i)
On Console
j)
On Console
(As applicable)
l)
Rotating Equipment
Shut down valves
Dampers & gates
As per P&ID
As per P&ID
As per P&ID
J
J
J
5.0
General:
5.1
Tolerance
Duration after
Mains Failure
110V 10%
50Hz 3%
30 Minutes
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 10 of 18
5.2
24V DC
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)
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
Control Rooms
MCT Blocks
Pipe Sleeves
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 11 of 18
b)
MCT Blocks
Pipe Sleeves
c)
MCT Blocks
Pipe Sleeves
d)
Analyser Rooms /
Houses
MCT Blocks
Pipe Sleeves
5.4
6 kg/cmg
5.5
5.6
Instrument Installation
Close coupled
J
Remote
J (Note-19)
Note-19: Remote for Utility lines / Offsites / Where close coupled not feasible.
b)
c)
Tubing
Piping
Any other_________
Fabricated
Fabricated
Fabricated
J
F
F
e)
F
J
J
F
J
Gate
Gate
F
F
Globe
Globe
J
J
5.7
f)
Steam Tracing
g)
J
F
Smart
Field Bus
Conventional
J
Smart
As per vendors standard requirement
Conventional F
Smart
b)
c)
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
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 12 of 18
5.8
Signal:
a)
b)
5.9
Pneumatic Signal
4- 20 mA DC with superimposed
Digital Engineering Data (HART)
0.2- 1 kg/cmg
Process Switch Type for shut-down (Not Applicable- refer note -36)
a)
For pressure
Direct actuated
b)
c)
Any other
___________
5.10
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
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)
b)
Signal earth
c)
Barrier earth
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
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
6.1
General service
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)
c)
Liquids
PD meter
Turbine F
Mass
J
(As per P&ID)
ii)
Gas
Orifice
Turbine J
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)
Ultrasonic type J
Other ________
g)
Flanged
J
D- D/2
J
(For 14" lines)
Corner
2D-8D
F
F
DOCUMENT No.
6556-01-16-51-DB-02
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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)
d)
6.3
RTD
F
J
Level Measurement:
a)
b)
c)
J
J
J
J
J
Radar
Radar
Radar
Radar
Radar
Hydrostatic
Hydrostatic
Hydrostatic
J
J
J
J
J
F
F
F
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
Silos
F
Any other ________
__________________
__________________
__________________
Crude Desalters
Filter Size
6.5
Desuperheater
5 micron Max.
J
F
J
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 15 of 18
vendors recommendation
6.6
6.7
CCTV System
a)
CCTV
Required
Not Required
Required
Not required
J
J
F
Monitor Location
Location
Number of Monitors
6.8
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
HC Detectors
Output
ii)
c)
H2S Detectors
i)
Automatic fire
detection
ii)
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)
e)
Required
F
F
F
F
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 16 of 18
f)
Requirement of monitors:
Location
Gas Detection
g)
6.9
Number of Monitors
Tags in DCS
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
Conductivity
DP
Safety valves
Section I
IBR
Level measurement
2 out of 3
J (Note-25)
6.12
6.13
Not required
Required
Not required
Meteorological Sensors
Required
Not required
Required
J
Not required
Separate for each stack (As per P&ID)
F
F
By Contractor
Required
J
F
Not required
DOCUMENT No.
6556-01-16-51-DB-02
Rev.0
Page 17 of 18
6.14
Spare Philosophy:
a)
Spare instrument as
Mandatory Spares
b)
Spare Parts
J
J
J
c)
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
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.
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.
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.