ENGINEERING DESIGN BASIS for INSTRUMENTATION, SCADA and TELECOMMUNICATION SYSTEM

ENGINEERING DESIGN BASIS for INSTRUMENTATION, SCADA and TELECOMMUNICATION SYSTEM

TABLE OF CONTENTS

GENERAL…………………………………………………………………………………..

PART A: INSTRUMENTATION…………………………………………………………..

PART B: SCADA SYSTEM………………………………………………………………

PART C: TELECOMMUNICATION SYSTEM…………………………..………….…..23

GENERAL

1 JOB DESCRIPTION

About Projrct..

2 PURPOSE

It is proposed to implement Instrumentation, SCADA and Telecommunication system for safe, efficient & reliable operation of the pipeline.

This document outlines the Design basis for the following systems:

PART A: Instrumentation

PART B: SCADA system

PART C: Telecommunication System

PART A: INSTRUMENTATION

1 INSTRUMENTATION

1.1 Control Philosophy

a) Mode of Plant/Pipeline Operation

Centralized SCADA (Through SCADA & APPS from SMCS, Refer PART B SCADA Design Basis)

Station Level (For manned stations only)

Intermediate Pigging Station Intermediate Tap-Off station

Sectionalizing Valve (SV) Station

Operated from SMCS only for ROV) Local Manual For all)

b) Type of projectGrass root Expansion Any Other

1.2 Control Room Requirements

1.3 Type of Control and Monitoring:

a) Station wise Control System

b) LocalElectronic  Pneumatic 

c) Final Control Element

For regulatory servicePneumatic` 

Electro Hydraulic actuated for Control Valves

(for all terminals)

d) For On Off serviceMotor Operated

Pneumatic Operated

One valve after metering system at all receipt & Dispatch terminal at Batter limit.

1.4Local Panel Requirement: (Not Applicable)

a) LocationHazardous Area

Non-hazardous Area

(For Fire Water System Fire water Pump House)

b) TypeWeather-proof

Flame-proof

Purged

NFPA 496 

Type Z

Other

c) Instruments TypePneumatic Electronic 

2 PACKAGE UNITS CONTROL PHILOSOPHY

2.1 Description

VFDs shall be provided accordingly redundant serial link shall be connected to PLC and breaker line up shall be done through PLC for starting of motor and relevant logic shall be developed in one PLC

2.2 Machine monitoring

Bentley Nevada series 3300 or equivalent 

Bentley Nevada series 3500 / Shinkawa or equivalent.

Temperature Monitoring Bentley Nevada Series 3500 / Shinkawa or

Equivalent

2.3 Location of monitors

Control room 

Local panel 

2.4 Integrated Machine monitoring system

Required Not Required

3 STATION CONTROL SYSTEM REQUIREMENTS

3.1 Type Of Control system

PLC Based atAll Despatch and Receipt Teminal 

Panel based Conventional hardwired instruments at IP/ station 

DCS Based 

Control logics at IP to be developed in RTU along with and Panel PC HMI

shall be provided

3.2 Functional Requirements( For PLC based Station control System)

Control and Data Acquisition System

Plant Operation and Monitoring

Data Logging and Report generation

Plant Safety shutdown/interlocks & sequencing

Data Storage and Archival 

3.3 Operator Consoles

a) No. of operator Consoles for each Control Room

Operator consoles should be integrated consoles i.e., Station PLC, Pipeline SCADA, Telecom NMS, VCS and CCTV Server and it should be open type console.

b) Console Screen Size 19” 21”

Console screen TypeLCD (TFT)CRTColor 

3.4 Type of Reports Required

Hourly Alarm History

Shift wise Alarm Summary

Daily Shutdown Report

MIS reports

Others

3.5 PLC Configuration

Dual Processor, single I/O, Redundant

Power supply, (Dual I/O for interlocks & trips and single I/O for others) 

Redundant Processor, Redundant Tested 

I/O & Redundant Power Supply and Communication as a

Minimum. (Note-2)

Triple Modular Redundant.

Quad 

Other ______

SIL Classification Required

Not required

ClassSIL 3 Note-2 (Before SIL

classification SIL study shall be done)

3.6 Type of Controller

Multi-loop (In PLC firmware)

Single-loop 

Panel Mounted Single Loop

3.7 Foreign Device Interface with station control system required for

RTU 

Flow Computers

Package PLCs

Vibration Monitoring System

TFMS (Existing)

VFD

Density Meter 

MOV bullet, MSV, etc 

CP System 

Solar system 

Battery Charger 

H2S Analyser 

Moisture Analyser 

Deluge valve indication 

Clean agent flooding system 

Fire alarm system 

The above link shall be redundant and in case of failure of one other shall take care Integration hardwire signal of level of bullet, MSV and status of tank MOV, ROV with pipeline PLC for interlock at dispatch and receipt terminal shall be considered and provided.

Plant ESD shall be linked with Pipeline ESD

4 CONTROL PANEL / HARD-WIRED INSTRUMENTATION

4.1 Type of control panel

Graphic Closed back

Non-GraphicOpen back 

Semi-GraphicConsole type 

4.2 For Control Room

a) IndicatorsAllCritical

Indicating controllers,

Integrators etc.NoneAs per P& ID

(At non PLC Location)

LocationPanel Console

b) Single Loop Indicating AllCritical

Controller (At all Locations)

None As per P& ID

LocationPanel Console

Single Loop controller shall be part of PLC. Separate loop controllers are not required in the control panel.

c) RecordersAll Critical

NoneAs Per P&ID

LocationPanelConsole 

Size:

Assignable Trend Recorder6" x 3" Other

Recorders are not required in the control panel. It shall be part of PLC

d) Multipoint Temperature Recorders

Critical ParametersNone

LocationPanel Console

Size:Large case Not Required

e) Alarm AnnunciationAllCritical

(As Per P& ID) On panelHanging Type

On Console(as per P&ID) First out sequencing Required 

f) Multi-point Temperature Indicator

Required Not required

g) Auto Manual StationOn PanelOn Console

h) Manual Loading Station On PanelOn Console

i) Selector SwitchOn Panel On Console(At PLC

(As per P&ID) UCP  location)

j) Start/Stop, Emergency On PanelOn Console

Push Button (As per P&ID)

UCP/Metering Panel 

k) Process Bypass Switch/ Indication (As per P&ID)

On PanelOn Console(At PLC 

Location)

l) Flow Computers/ Density meter converters/H2S analyzer/Moisture

Analyser

On Panel On Console

m) Status lamps in control room;

1 Rotating Equipment As per P&ID 

2 ROV/Shut down valves As per P&ID 

5 GENERAL

5.1 Units of Measurement to be included;

Flow Liquid Kg/Hr, ton/Hr & M3 / hr at (ambient & 15°c)

Density Kg/m3

Viscosity cst Level % & MM  Pressure kg/cm2 g 

Temp.°C

5.2 Type of Power Supply:

5.3 Power Supply requirement

230V AC415V AC24V DC110 V AC230 VAC

50Hz.UPS3PhNon UPSNon UPS 1Ph

a) Package Units

    

b) PLC

   

c) Alarm Annunciator

    

d) Relay based Interlock & Shutdown system

    

e) I/P Interrogation voltage

    

f) Level Gauge Illumination

  

g) Cabinets Lighting Control Room

  

h) F.W. Local Panel

  

i) Flow Computer

  

j) Electro Hydraulic Control Valve

  

k) Density Meter (Applicablity of same is to be checked)

 

l) ROV one at each station

  

m) H2S Analyser/ Moisture Analyser at dispatch station

  

5.4 Cable Entry to

Control RoomsMCT BlocksPipe Sleeves 

5.5 Air Supply at Battery Limit Same is to be considered as per requirement of ROV at each receipt and dispatch terminal

6.0 kg/cm 2 gNot Applicable 

5.6 Size of Instrument Nozzles As per 7-52-0001and7-52-0002 

5.7 Installation/Tubing hook-ups

5.8

a) Instrument Installation

Close coupledRemote 

b) Instrument impulse lines

Tubing  Piping 

(Note -6)

Any other______

c) Instrument valve manifolds

1. For pressure gaugesIntegral Fabricated(CS) 
2. For flow DP transmitterIntegral Fabricated(CS)
3. For OthersIntegral Fabricated(CS)

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

Isolation valvesGate Globe

Vent/drain valvesGate Globe

e) Signal and Air supply tubing

SS tubing (for Instrument air (ROV)) Applicable

PVC covered copper tubing  Not Applicable

(Instrument Air)

Bare copper tube  Not Applicable

(Steam Tracing)

Pneumatic air pressure of plant at each location shall be considered for IO

5.9 Field Transmitter Type:

a) For open and closed loopsConventional Smart 

b) For anti-surge loopsConventional Smart 

c) Not Applicable

d) For shut-down loopsConventional Smart 

5.10 Field Transmitter signal type:

a) For Smart transmitters4- 20 mA DC with superimposed

digital engg. data (HART)

LCD display in Engg. Unit

b) Pneumatic Signal0.2- 1 kg/cm²g(to be checked) (applicable) EIL to confirm from the PDB

5.11 Process Switch type for shut-down

a) For pressure and Level Direct actuated

b) For flow, pressure, temperature, Interface level and.

Hardwired receiver switches ( at Non PLC locations) Field Transmitter Connected  ( at PLC locations)

through PLC

c) Any other______

5.12 Hazardous Area Protection

a) All field transmittersIntrinsically safe Flame proof 

b) Field switchesIntrinsically safeFlame proof 

c) I/P convertersIntrinsically safe Flame proof  Not Applicable

d) Solenoid valvesIntrinsically safe Flame proof 

e) Smart Positioner Intrinsically safeFlame proof 

5.13 Intrinsic safety BarriersRequiredIsolating type

Not required

5.14 Earthing System:

a) Panels, racks, cabinets, consolesElectrical earth grid 

shelters etc. and all Junction boxes

with power more than 110 V

b) Signal earthSeparate dedicated earthing pit

c) Barrier earthSeparate dedicated earthing pit (Only for Zener barriers)

5.15 Lightening surge protection Required Not required

(For main feeder from UPS to control room Instruments)

5.16 Type of Cable

Flame Retardant

Flame Retardant and Low Smoke Flame Retardant and Fire Resistance 

6 OTHER INSTRUMENTATION AND SYSTEMS

6.1 Flow Instruments:

a) General service

For 2" lines and aboveOrifice plate

Other _

For 1½" lines and belowVariable Area meter

Meter Run

Integral Orifice Other _

b) Custody and Product Metering & Metering for leak detection

1. LiquidsPD meter Turbine Ultrasonic Mass 

1. GasOrifice Turbine 

Meter Prover at KR , Each proper handling system for lifting and loading of meter at each station in to truck for taking it to KR for calibrations as per statutory requirement

6.2 Temperature Measurement:

a) Temperature gaugesBimetallicFilled system 

b) ThermocoupleGroundedUn-grounded 

Not applicable

c) Temperature ElementRTDThermocouple

Temperature TransmitterRequired Not-required

For all Only for control

and shut-down

LocationControl-RoomField

Head-mounted

Remote-mounted

d) Thermo well flange ratingAs per piping specifications

Minimum 300# rating

6.3 Level Measurement:

a) Level Stand-pipe philosophyAs per EIL standard

b) Tank Level Gauging : Fire Water System

Fixed TanksServoFloatRadarHydrostatic 

Intermediate TanksServoFloatHydrostatic

Product TanksServoFloatHydrostatic Radar

Potable Water Tanks Capacitive  Float Hydrostatic  Radar 

c) Tank Farm Management System : Not Applicable

Tank Farm ManagementDedicatedWith DCS

RedundancyRequiredNot reqd. No. Of CRT’s Two  Three 

(One TFM PC Console)

Display LocationControl room

Satellite room

Any Other______

6.4 Fire and Gas Detection (F & G) System

a) F & G System Required Not required

(Shall be integrated in to same PLC, separate F&G system not required)

b) Gas detection system Required Not required

Note 5

1. HC DetectorsCatalytic diffusion IR Type  Any other ______
2. Output4-20 mAVendor standard

1. H2S DetectorsElectrochemical 

Semiconductor Any other ______

1. Toxic gas detectors______

c) Fire detection system

1. Automatic fire detectionRequired Not required

1. If yes, any specific areas to be coveredAs per POSD

1. Plant / Non plant building ( By Electrical For details, refer Electrical design basis)

Fire detection required  not required

To be provided as per OISD requirement (Fire alarm system shall be Integrated with Our Station PLC as well terminals fire fighting system)

6.5 Safety valve testing at site

At SiteBy Client

Testing jigRequiredNot required

(To be arranged by contractor for testing)

6.6 Spare Philosophy

a) Spare Instrument as20% or minimum one of each typefor each station (Level transmitter shall also be considered) 

Engineering Spares (range, type & material of construction, Except for control valves, Pressure relief valves, Displacer type Instruments, Level Gauge, And Special Instruments).

b) Spare Parts

For two years operation (as per vendor recommendations)

For Startup and Commissioning (as required)

Consumable spares for one Year operation (as per vendor

recommendations)

c) PLC Spare Philosophy

System Spares (Control Room wise)

Bus Capacity:40 %

No. of Nodes: 30 %

Installed Engineering Spares (Control Room wise)

I/O Level: 30 % Module wise

Spare Space (Control Room wise)

I/O Level: 30 %

Marshalling Rack : 30%

6.7 Any Other Special Instruments

a) Liquid metering system:

Type of Meter: Mass Flow Meter (For SCADA / APPS Metering for Leak

Detection

Mass flow meter are envisaged as per P&ID. Common Flow Computers shall be provided for two mass flow meter for computing flows at standard conditions and will provide corrected volumetric flow rates/ totalized flow. Accuracy of meters shall be 0.15% or better. Flow computers will be with serial link interface to station PLC.

b) Meter Prover:

One number fixed type skid mounted meter prover shall be considered for the Mass flow meters.

c) Control Valve ( for flow control and Pressure control):

Control valves shall be of Globe type with electro-hydraulic actuators and actuator control system integrally mounted on valve actuator. Control valve body rating shall be minimum 300# .

d) ROV (pneumatic control) at station battery limit

Notes:

1. The Pipeline Centralized operation is Through SCADA & APPS system to ensure effective and reliable control, management & supervision of the Entire Pipeline from existing centralized SCADA master control station located at Kochi.

1. The station PLC shall be dual redundant with redundant processor, redundant Power supply and redundant tested I/O. PLC configuration shall be SIL-3 certified as per IEC 61508. SIL validation for critical loops shall be considered as per licensor / process requirement, if any. The SIL-3 complete system architecture shall be approved by TUV and proposed for the implementation. The station PLC at Pump stations shall be used for interlocks, control, monitoring of all the station parameters including pump logic and CDL logic. Two nos. of PC based Operator cum Engineering console shall be provided at each station.

For IPS (Intermediate pigging stations), control panels with receiver instruments/annunciations/ lamps/PBs etc. will be provided for interlocks, control, monitoring of all the station parameters. Logic shall be modified in the RTU which is accessible through Touch panel screen (PC based) shall be installed on panel with HMI and relevant software. Relay based panel shall be avoided. At each IP one spare touch panel screen shall also provided

1. Station PLC shall be used for necessary Operation & control and logic of Mainline pumps and its auxiliaries. Pump auxiliaries controls, Vibration & temperature monitoring required for Pump and its motors will be provided on station PLC. Pump Station start-up sequence, stop & tripping interlocks relating to process shall be implemented in station PLC.

1. Station Operator consoles shall be with latest PC based computer machines with 21” colour monitor, Window based operating system. MMI software shall have real time dynamic graphic, group displays, alarm displays, real time and historical trend display and log report generation facilities. Engineering Functions shall be done from one of the operator console.

1. Fire and Gas detectors shall be connected to station PLC. A separate marshalling cabinet will be provided to be hooked up with station PLC.

1. For line rating up to 600#, instrument installation shall use piping with ½” SS tubing near to instrument. For line of any rating# instrument installation shall use pipe and pipe fittings.

1. All the vent & drain line of the Instrument tapping should be connected to cold / hot flaring system

1. All PLC link shall be extended through OFC network at Kochin & Coimbatore for remote viewing and diagnostic of PLC system.

1. In case of SIL PLC (hardware and software provided from same OEM only)

1. Warranty of SIL PLC system shall be supported by OEM in case offer is received from PLC integrator.

1. Warranty for all equipment should be period of 36 months from the date of supply or 24 months from the SAT (site acceptance test) whichever is earlier.

Attachments:

1. 7-52-0001Instrument connections on Vessels, standpipes and tanks
2. 7-52-0002Instrument connections on piping

PART B: SCADA SYSTEM

1. BPCL station-in-charge room at Kochi refinery- 1 no. (SCADA)- 1
2. New Control room at IOCL IMPORT TERMINAL, Puthuvypeer– 1 no. (SCADA),1 No.( APPS).
3. New Control room at IOCL BOTTLING PLANT RT, Udayamperoor– 1 no. (SCADA). 1 No.( APPS).
4. New Control room at BPCL COIMBATORE RT TERMINAL– 1 no. (SCADA) 1 No.( APPS).
5. New Control room at IOCL COIMBATORE RT– 1 no. (SCADA) 1 No.( APPS).
6. New Control room at IOCL ERODE RT– 1 no. (SCADA) 1 No.( APPS).
7. New Control room at IOCL SALEM RT– 1 no. (SCADA) 1 No.( APPS).

1. ECS (Emergency control station)

1. SCADA Server

1. SCADA MMI WS

1. SCADA EWS

1. Web server system

1. WAN Routers

1. Ethernet Switch

1. OPC Server

1. Large Video Screen

1. Printer

1. LAN

1. Any other

Third party interface at SV and manned locations for