40 - Standard Specification For Programmable Logic Controller (PLC)

INDIAN OIL CORPORATION LIMITED DIGBOI
REFINERY (ASSAM OIL DIVISION)

Project : Wax Palletizer Unit IOT DESIGN & ENGINEERING
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STANDARD SPECIFICATION FOR
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DISCIPLINE: PROGRAMMABLE LOGIC ISSUE DATE : 24/02/2011
INSTRUMENTATION CONTROLLER
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PROGRAMMABLE LOGIC CONTROLLER
Prepared By Checked By Approved By

SD GP NM
CONTENTS
This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.
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Clause No. Items Page No.
1.0 Scope 03
2.0 Bids 04
3.0 Drawings and Data 05
4.0 Design and Construction 06
5.0 Meter electronics 08
6.0 Glass tube variable area flow meter 09
7.0 Metal tube Variable area flow meter 10
8.0 Purge Flow meter 10
9.0 Differential Pressure Regulator 10
10.0 Performance Requirements 10
11.0 Name Plate 11
12.0 Inspection and Testing 11
13.0 Shipping 12
14.0 Rejection 12
1.0 SCOPE
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1.1 This specification, together with the Material Requisition defines the minimum functional
requirements for the design hardware, software and firmware specifications, nameplate
marking, testing and shipping of Programmable Logic Controllers (PLC) designed for
reliable effective and optimum control and monitoring of a process plant (hydrocarbon and
non-hydrocarbon) and captive power plant.
1.2 The related standards referred to herein and mentioned below shall be of the latest editions
prior to the date of the purchaser’s enquiry:-
API RP 552 Systems Transmission
EEMUA 191 Alarm Systems – A Guide to Design Management and Procurement
EN 10204 Metallic Products – Types of Inspection Documents
EN 50039 Electrical Apparatus for Potentially Explosive Atmospheres:
Intrinsically Safe Electrical System ‘I’
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60529 Degree of Protection Provided by Enclosures
IEC 60584 Thermocouple Part 2: Tolerances
IEC 60617 Graphical Symbols for Diagram
IEC 60751 Industrial Platinum Resistance Thermometers and Platinum
Temperature Sensors
IEC 61000-4-3 Electromagnetic Compatibility (EMC) – Testing and Measurement
Techniques – Radiated, Radio Frequency, Electromagnetic Field
Immunity Test
IEC 61000-4-4 Electromagnetic Compatibility (EMC) – Testing and Measurement
Techniques – Electrical Fast Transients / Bust Immunity Test
IEC 61000-6-2 Electromagnetic Compatibility (EMC) – Generic Standards –
Susceptibility – Industrial
IEC 61508 Functional Safety of Electrical / Electronic / Programmable Electronic
Safety-related Systems
IEC 61131 Programmable Logic Controllers
IEC 61511 Functional Safety – Safety Instrumented Systems for the Process
Industry Sector
IEEE 802.3 Telecommunication and Information Exchange between Systems –
Local and Metropolitan Area Networks – Specific Requirements – Part
3: Carrier Sense Multiple Access with Collisions Detection (CSMA
/CD) Access Method and Physical Laver Specifications
IS 2148 Flameproof Enclosures of Electrical Apparatus
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IS 3043 Code of Practice for Earthing

IS 13947 Specifications for Low Voltage Switchgears and Control Gears
ISA 5.1 Instrumentation Symbols and Identification
5.2 Binary Logic Diagrams for Process Operations
5.3 Graphic Symbols for Distributed Control / Shared Display
Instrumentation, Logic and Computer System.
5.4 Instrument Loop Diagrams
5.5 Graphic Symbols for Process Displays
18.1 Annunciator Sequences and Specifications
71.01 Environmental Conditions for Process Management and Control
Systems: Temperature and Humidity
71.04 Environmental Conditions for Process Measurement and control
Systems: Airborne Contaminants
ANSI / ISA Security Technologies for Industrial Automation and Control Systems
TR 99.00.01 Manufacturing and Control System
ISO 216 Writing Paper and Certain Classes of Printer matter-Trimmed Sizes –
A&B Series
ISO 9241 – 5 Workstation Layout and Postural Requirements
ISO 9241 – 7 Display Requirements with Reflections
1.3 In the event of any conflict between this specification, data sheets, statutory regulations,
related standards, codes etc., the following order of priority shall govern:
a) Statutory regulations
b) Data Sheets
c) Standard Specifications
d) Codes and Standards
1.1.4 In addition to meeting purchaser’s specifications in totality, vendor’s extent of responsibility

shall also include the following:
a) Purchaser’s data sheets specify the minimum acceptable functional requirements for
the programmable logic controllers. It shall be vendor’s responsibility to select proper
hardware, software and firmware to meet the specified functional requirements.
b) Purchaser’s data sheets specify the scan time / cycle time / response time and loading
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requirements. Vendor shall be responsible for sizing and selecting their standard
product i.e. hardware, software and firmware to meet the requirements specified in the
purchaser’s data sheets.
c) Selection of proper and adequate hardware, software and firmware and to meet system
requirements specified in the purchaser’s specifications, keeping the integrity of
functional blocks specified in the configuration diagram attached with the material
requisition.
d) Adequacy of Bill of Material selected to meet purchaser’s requirements. Vendor to

note that bill of material shall not be verified by the purchaser’s during evaluation
stage. Any hardware, software and firmware required to meet the purchaser’s specified
requirements shall be provided by the vendor without any implication.
e) Providing adequate mandatory spares including consumable spares as specified in the

purchaser’s specifications. Vendor shall be responsible to meet mandatory spare
requirements specified by the purchaser.
2.0 BIDS
2.1 Vendor’s quotation shall be strictly as per the bidding instructions to vendor attached with
the material requisition. Vendor’s quotation shall enumerate and include the detailed
specification of each subsystem and each module of programmable logic controller, detailed
system configuration, hardware and software capabilities, programming aids, display
configuration, hardware and software capabilities, programming aids, display facilities and
other relevant information.
2.2 Whenever a detailed technical offer is required, vendor’s quotation shall include the
following:
a) Compliance to the specifications.
b) Detailed specification sheets for each sub-system. The specification sheet shall provide
information regarding hardware specifications, software specifications, redundancy
requirements, capacity, power consumption etc. of the programmable logic controllers
and its accessories. The material specifications and unit of measurement for various
items in vendor’ specification sheets shall be to the same standards as those indicated
in purchaser’s data sheets.
c) System security features and design details.
d) Proven references for each offered model in line with clause 1.2.4 of this specification
whenever specifically indicated in the purchaser’s specifications.
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e) A copy of approval for flameproof enclosure, intrinsic safety etc Whenever specified,
from local statutory authority, as applicable, like Petroleum and Explosive Safety
Organization (PESO) / Chief Controller of Explosives (CCOE), Nagpur or Director
General of Mines Safety (DGMS) in India along with:
i) Test certificate from recognized house CIMFR (Central Institute of Mines &
Fuel Research) / ERTL ( Electronics Research and Test Laboratory) etc. for
specified protection class as per relevant Indian Standard for all Indian
manufactured requirements or for equipment requiring DGMS approval.
ii) Certificate of conformity to ATEX or other recognized standards for all

equipments manufactured outside India.
f) Deviations on technical requirements shall not be entertained. In case vendor has any
valid technical reason to deviate from the specified requirement, the3y must include a
list of deviations item wise, summing up all the deviations from the purchaser’s data
sheets and other technical specification along with the technical reasons for each of
these deviations.
g) Certificate for specified SIL requirement (e.g. SIL-3) from Independent Testing
Agency.
h) Catalogues giving detailed technical specifications, model decoding details and other
related information for each item/ sub-system covered in the bid.
2.3 Vendor shall offer only their standard proven product i.e. system hardware, system software
and firmware, which shall be configured to meet the functional requirements specified in the
material requisition. Mor3eover, the equipment being offered / supplied shall be of latest
proven version available in the current manufacturing range and meeting the requirements
specified in clause 1.2.4 of this standard specification.
2.4 The system hardware, software and firmware as offered, shall be field proven and should
have been completed trouble free satisfactory operation for a period of minimum 4000 hours
on the bid due date in the similar application with equal or higher than the proposed system
size with respect to number of inputs outputs specified in the purchaser’s in the purchaser’s
data sheet. Items with prototype design or items not meeting proneness criteria specified
above shall not be offered or supplied.
2.5 The detailed scope of work, specific job requirements, exclusions, deviations, additions etc.
shall be indicated in the job specifications which shall be part of material requisition.
2.6 Whenever specified, vendor shall furnish tested valves of failure rates, probability of failure
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on demand and test intervals for safety level analysis.
2.7 All documentation submitted by the vendor including their quotation, catalogues, drawings,
installation, operation and maintenance manuals shall be English language only.
2.8 Vendor shall also quote for the following:
a) Two years operational spares for each sub-system and their accessories which shall
include the following as a minimum:
i) All type of electronic modules e.g. I/O modules, processor modules,

communication modules, memory modules, disc controller module, power
supply modules etc.
ii) All type of auxiliary items e.g. barriers / isolators, hardwired instruments,
enunciator modules, receiver switches, trip amplifiers, temperature element
converters etc.
iii) Switches, lamps, fuses, connectors, terminals, pre-fabricated cables, circuit

breakers, relays etc.
iv) Video display units, keyboards, disc drives, PC’s network items (e.g. switches,
hubs etc.) etc.
b) Any special tools and test equipments needed for the maintenance of PLCs and other
items being offered by vendor. Vendor must confirm in their offer if no special tools or
test equipments are needed for maintenance other than those specifically indicated in
purchaser’s data sheet.
3.0 DRAWING AND DATA
3.1 Detailed drawings, data, catalogues and manuals and manuals from the vendor are indicated
by the purchaser in vendor data requirement sheets. The required number of prints and soft
copies shall be dispatched to the address mentioned, adhering to the limits indicated.
3.2 Final documentation consisting of design manuals, installation manual, operation and
maintenance manual etc., submitted by the vendor after placement of purchase order shall
include the following, as a minimum:
a) Specification sheet for each sub-system, auxiliary instrument and bought out item.
b) Certified drawings for complete system including the following:
i) GA drawings for panels, cabinets, panels, marshalling racks, hardwire consoles,
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operator console, programming terminal etc with complete dimensional details,

internal construction and weight in kilograms.
ii) Control room layouts e.g. console room, rack room and engineering room layout
with all dimensions in millimeters.
iii) Chanel base frame drawing for console room, rack room and engineering room.
iv) Input / output assignment.
v) Logic / Ladder diagrams.
vi) Loop wiring diagram.
vii) Power supply distribution diagram.
viii) Mem0ory loading calculations / Scan time calculation.
ix) Protocol / Pin Details.
x) Dynamic graphic diagrams
xi) System grounding drawing.
c) Design manuals and functional design specifications which shall include hardware
design manual, software design manual and special software specifications.
d) Copy of type test certificates.
e) Copy of test certificates for all tests indicated in this specification.
f) Installation manual containing installation procedure for programmable logic

controllers and other items covered in the material requisition.
g) Power-on, start-up and internal testing procedures.
h) Software debugging system configuration procedures.
i) Calibration and maintenance manual containing maintenance procedures including

replacement of parts, application modification etc.
j) Any other drawings and documents specifically indicated in job vendor data
requirement enclosed with the material requisition.
All system manuals and documentation shall be supplied in hard cover loose ring folders in
‘A4’ size as per ISO 216 i.e. of size 210mm x 297mm. All drawings and sketches shall be in
multiple of ‘A4’ size like ‘A3’ (297mm x 420mm) or ‘A2’ type (420mm x 594mm) etc. but
folded to ‘A4’ size.
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4.0 DEFINITIONS
The various terms used in this specification are defined as follows:
4.1 Programmable Logic Controller
The class of control systems which can be programmed to execute plant shutdown
and / or interlock / sequence logics to the specified safety levels.
4.2 Accessible
A system feature that is viewable by and interactive with the operator and allows
the operator to perform user permissible control action e.g. set point change, auto-
manual transfers or on-off actions.
4.3 Assignable
A system feature that permits an operator to direct a signal from one device
another without the need for change in wiring, either by means of switches or via
other data entry devices like keyboard commands to the system.
4.4 Configurable
The capability to select and connect standard hardware modules to create a system
or the capability to change functionality or sizing of software functions by
changing parameters without having to modify or regenerate software.
4.5 I/O
Input / Output with respect to process / operator.
4.6 PLC Console (Operator)
PLC console (Operator) is the operator’s main plant interface device through
which operator can view, monitor and control the plant and can give instructions
to peripherals to execute commands, and shall have protective access to configure
and maintain the system.
4.7 PLC Console (Programming Terminal)
PLC console (Programming Terminal) shall be the engineer’s main interface

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device through which engineer can configure / program and maintain the system,
and shall have protective access to monitor and control the plant, give instructions
to peripherals to execute commands.
4.8 Local Level
All those sub-systems, which directly interface with field devices shall be referred
to as local level.
4.9 Central Level

Operator Console and Programming Terminal, which present data acquired from
local level devices, shall be referred as Central Level.
4.10 Database
Database shall be defined as the information stored temporarily or permanently in
the system which can be accessed by various programs to meet all its functional
requirements.
4.11 Loop Integrity
A system shall be said to have loop integrity if the failure of one component in the
system/sub-system does not affect more than one loop.
4.12 System Loading
System loading for a sub-system is defined as the percentage of time a sub-system

spends in carrying out various activities referred to the use of memory, CPU time
and communication capacity in the worst case of high sub-system operation out of
the designed / designated cycle time of the sub-system.
4.13 Redundancy
A system component shall be termed as redundant if it takes over automatically

the operation in the event of the failure of the main component without causing
any interruption in the system and upsetting the process. The repaired or replaced
devices shall be brought in-line only through operator action without upsetting
system operation.
4.14 Switchover Time
Timer required for a back up instrument / system to come on-line automatically in

case of the failure of the main instrument / system.
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4.15 Processor Cycle Time (tpc)
Processor cycle time is the measure of the processing speed of a processor.

Processor cycle time for a sub-system of the programmable logic controller shall
be defined as follows:-
Processor cycle time for programmable logic controller shall be defined as the
total time taken by the processor to read input supplied by input module, execute
all computations (analog as well as logic as configured) and write the outputs for
the output module.
4.16 Scan Time (ts)
Scan time of a logic loops is the end-to-end response time of a sub-system and
shall be defined as follows:
The scan time for a logic loop shall be defined as the total time taken by a sub-
system e.g. programmable logic controller to read input from the terminal, process
input, execute logic, updating logic output and write output at the output terminal
for all the logics configured within the subsystem.
4.17 User’s Memory
Free memory space available after utilization of memory required for system
operation, configuration and implementation of application and other system
related functions for implementation of user defined specific programs such as
plant calculations, process optimization or MIS (like free formatting of certain
logs). The programs shall either be written in high level language or system
specific language.
4.18 Event
An event shall be defined as any action taken by the operator via operator
keyboard or switches on hardwired console like change of set point, change of
control mode, start/stop of motor, open/close of shut down valves, alarm
acknowledge etc.
4.19 Sequence of Event (SOE)
Arranging events in the sequence of their occurrence in time with a specified time
resolution by a program is defiant as sequence of event.
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4.20 Sequence of Event Recorder (SER)
System or sub-system which presents and / or records the events in the sequence
of their occurrence in time with a specified time resolution utilizing its hardware
and software capabilities is termed as sequence of event recorder.
4.21 Real Time Trend
Real time trend shall be defined as a continuously progressing graphical record

showing updated parameter with most recent valve and a past record of minimum
of 10 minutes without pressing any additional key for moving backward in time.
4.22 Plant Information Network
High-level communication network which serves various users within a plant and
transfer information for the purpose of unit / plant monitoring. This network is
different than control network and is generally realized using open communication
protocol network e.g. OPC etc.
4.23 Tag
A Tag is a collection of attributes that specify either a control loop or a process

variable, or a measured input, or a calculated valve, or some combination of these,
and all associated control and output algorithms. Each tag is unique.
5.0 SPARES PHILOSOPHY
5.1 The system including sequence of event recorder, hardwired instruments etc. shall
meet the following spare philosophy. This philosophy shall also be applicable for
items like barriers, relays, terminals, lamps, push buttons etc.
5.1.1 Mandatory Spares
Vendor shall include following mandatory spares in their scope of supply:
5.1.1.1 Installed Engineering Spares
Installed engineering spares shall be provided in each sub-system for each type of
module to enhance the specified system functional requirements by 20%. The
basis of offering installed engineering spares shall include:
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a) For a system with conventional and / or smart analog input / output, discrete
(contact) input / output, 20% spare input / output of each type shall be
considered for calculating I/O modules and all other related accessories.
b) For all serial input / outputs to the system 20% spare serial I/O ports of each
type of serial input / output shall be provided.
c) 20% spare accessories like relays, switches, lamps, fuses, circuit breakers,
barriers, isolators, terminals etc.
d) The engineering spares shall be wired up to the field cable interface and
shall be in ready – to operate condition when field cable is connected to
spare assigned terminals.
e) Spare pairs of the incoming cables shall be terminated on spare terminals in

the marshalling / barrier cabinets as applicable.
f) The system shall be fully engineered considering 20% installed engineering

spares including processor loading.
5.1.1.2 Spare Requirement
In addition to installed engineering spares specified in Clause 3.1.1.1 of this

specification, the system shall be provided with following spare space:
a) I/O racks of programmable logic controller shall have 10% usable spare for
installing additional I/O cards of each type in future. However internal
wiring for the same shall be connected up to the I/O terminals.
b) Processor system of programmable logic controller shall have capability to

execute additional 20% logics.
c) Each operator console shall co0ntain 20% usable spare group and related
display capability in addition to as specified in para 3.1.1.1 of this
specification.
d) The system shall have capability to extend its historical trending, logging
and user’s memory by 20% to meet future expansion with/without adding
additional memory modules.
e) The communication sub-system shall have sufficient capacity to handle

additional data contributed by addition of 20% I/O over and above installed
engineering spares.
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f) Usable spare space in panels and cabinets to install 10% spare hardwired
items like relays, switches, lamps, fuses, circuit breakers, barriers, isolators,
terminals, and panel mounted instrument etc. in future.
5.1.1.3 Spare Memory Requirement
a) The system shall be provided with a minimum of 40% spare memory

capacity, as required for application program and data base to meet specified
functional requirements.
b) It shall be possible to extend the memory by at least 20% over and above the
actual requirement at a later date.
5.1.1.4 Spare Software Capability
a) Sufficient additional softwar3e capacity shall be available in the system to

take care of spares requirement as specified in para 3.1.1.1. and 3.1.1.2. of
this specification to meet all functional requirements as per para 4.0 of this
specification.
b) Unless specifically indicated otherwise, the offered system shall have

software licenses to cover all the tag numbers indicated in the material
requisition, including installed engineering spares and spare space indicated
in clause 3.1.1.1 and 3.1.1.1 of this specification.
5.1.1.5 Predefined Mandatory Spares
a) Mandatory spares shall be ware-house spares and shall be supplied as loose

items.
b) Mandatory spare module of 5% or one module of each type, whichever is

higher, must be supplied for each type of modules being used excluding
modules used in consoles, servers, Personal Computers.
c) For items like, Video Display Units, keyboards, disc drives, network
components, hardwired instruments like barriers, lamps, fuses and circuit
breakers, complete item limited to 5% or minimum one of each type shall be
supplied as predefined mandatory spare. But this shall not include hardware
like hard discs, terminals.
5.1.1.6 Consumable Spares
Any paper, ribbon, printer heads, toner and ink required for printers, video copier
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or any other consumable item shall be supplied along with system required for
minimum of six months duration after system acceptance.
5.1.1.7 Commissioning Spares
Unless otherwise specified, vendor shall be responsible to supply all spares which
are found necessary to replace failed modules, failed sub-systems, or corrupted /
faulty software while performing pre-commissioning activities.
3.1.2 Two Years Operational Spares
Two years operational spares shall be as per Clause 1.2.8(a) of this specification
and shall be quoted separately.
4.0 DESIGN AND CONSTRUCTION
4.1 Design Requirements
4.1.1 Programmable logic controller shall be microprocessor based system which shall
be used to execute all the process and safety shut-down logic of the plant. When
specified, it shall also execute plant interlock logics and operation. Programmable
logic controller shall be an independent unit and shall not depend on any of its
functionality on any other system including Distributed Control System.
4.1.2 The system shall be of modular construction and expandable in future by adding
additional modules which shall be easily accessible in order to have
interchangeability and low inventory.
4.1.3 System Availability
a) The system shall be designed ‘fault avoidant’ as a minimum by selecting

high grade components of proven quality and proper design of system
electronics.
Redundancy shall be provided, as a minimum, as per this specification to

improve system availability and reliability. Due considerations shall be
given to the environmental conditions particularly for field mounted sub-
system, if specified in job specifications, during system design.
b) The system shall have a high MTBF value and shall have well proven record
of operating in hydrocarbon plants.
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c) The system shall be designed with 99.995% or greater availability. The

availability shall be defined as follows:
Availability = Mean Time Between Failure (MTBF)

MTBF + Mean time to repair (MTTR)
For the purpose of calculations, consider mean time to repairs as four (4)
hours unless the manufacture recommends higher value for MTTR. It is
therefore necessary that:
i) Vendor covers all necessary spare parts in 2 years recommended

operational spares which shall be necessary to meet specified MTTR
time.
ii) Vendor provides adequate training to owner’s personnel and cover all
necessary maintenance related topics in their training programmers to
ensure specified MTTR time.
4.1.4 Operating Environmental Conditions
4.1.4.1 Environmentally Controlled Location Installation
a) All subsystem of programmable Logic Controllers located in Control Room,

Local Control Room or in Satellite Rack shall be able to operate
satisfactorily from 150 C to 300C and 20% to 80% non condensing humidity.
b) In addition to above, all such sub-system shall also be able to operate

satisfactorily in case of air conditioning failure with ambient temperature of
500C and 90% non-condensing humidity until the system safe operating
limits are exceeded. The minimum period of continuous operation in such
condition shall be 48 hours at least once in a month without any damage or
degradation of system performance. Vendor, therefore, shall provided
continuous temperature monitoring for each enclosed cabinet housing
items / equipments generating heat, such as system cabinets, barrier
cabinets, relay cabinets etc and also provided alarm for operator alert in case
the safe operating temperature limits are exceeded.
c) Chemical filters have been provided in the incoming air conditioning air to
limit the concentration of contaminants below following limits:
Contaminants Concentration
(Corrosive Gases)
Sox < 0.01 ppm by volume

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NOx < 0.05 ppm by volume

H2S < 0.003 ppm by volume
Cl2 <0.001 ppm by volume
NH3 < 0.5 ppm by volume
SPM < 200 ugm/m3
RSPM < 100 ugm/m3
All sub-systems and system components shall be suitable for operating

continuously in the above mentioned corrosive environments.
4.1.4.2 Outdoor Installations
a) Sub-systems or system components which are installed outdoor shall be

suitable to continuously operate at ambient temperature and humidity
specified under ambient conditions. The heat generation effect of current
carrying for the electronic modules shall also be considered. for this purpose
the system shall be rated for minimum 5 deg C more than the maximum
ambient temperature specified. In case the system is not suitable for the
above conditions, necessary cooling arrangement shall be provided.
b) Unless otherwise specified, all PLC sub-systems or system components

installed outdoor shall have corrosive environmental protection coating
meeting the environmental classification class G3 as per ISA-S71.04.
4.1.5 Transient, Static and EMI / RFI Protection
4.1.5.1 The system shall be internally protected against system errors and hardware
damage resulting from:
a) Electrical transients on power wiring.

b) Electrical transients on signal wiring.
c) Connecting and disconnecting devices or removing or inserting printed
circuit boards in the Programmable Logic Controller (PLC).
4.1.5.2 All sub-systems and system components shall be capable of accepting various
signal inputs for its direct use while preventing noise errors due to electromagnetic
interference (EMI) or radio frequency interference (RFI) including nearby radio
stations, hand held two way radios, solenoids, relays or contactors carrying heavy
currents as per levels of Environmental electromagnetic phenomenon defined in
IEC-61000-6-2. The system shall have total noise immunity from UHF / VHF
radio communication equipments (RFI) and (EMI) noise generating equipments as
per IEC-61000-4.
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4.1.5.3 For interplant, inter unit and other system cables routed in the field, the level of
surge immunity required for equipment signal ports shall be increased to level 4 as
defined in IEC61000-4-5 and the system shall operate according to performance
criterion B as defined in IEC-61000-6-2
4.1.6 On-line Replacement
4.1.6.1 On- line replacement of any module of programmable logic controller Shall be
possible in Such a way that removal and addition of the module Shall be possible
and Safe without-energizing the System, Furthermore , there Shall not be any
interruption of the System While replacing a faulty module wherever redundant
modules are provide.
4.1.6.2 Apart from system modules, power supply units Shall be replaceable on-lion
without disrupting the process and without affecting the system redundancies. It
shall be possible to hot swap any faulty system module without degrading the
system safety or operation or freezing the output status. The switch over to the
health module shall be bump less. The swapped module shall take over the or the
failed module without any manual programming.
4.1.7 Electrical Isolation
Galvanic or optical isolation shall be provided for all field signals. The isolation
levels shall be as follows:
Analog I/O channel to system ground : 1500V AC
Discrete I/O channel to system ground : 500V AC
External isolator shall be provided, if necessary to meet the above.
Isolation shall also be provided between Engineering / operator console / PLC
programming terminal and related sub-systems connected to it if there is any
possibility of high voltage being transmitted to the sub-systems.
4.1.8 Design Requirements of Equipments in Hazardous Area
4.1.8.1 Unless specifically indicated, the field devices are beyond the scope of this
specification.
However vendor shall be fully responsible for integrating these devices with their
system.
4.1.8.2 General requirements
a) Unless otherwise specified, all instruments in hazardous area shall be

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intrinsically safe type. Other concepts shall be used when specified.
b) For conventional instrumentation, entity concept shall be used for selecting

proper barriers / isolators.
4.1.9 Repeat Signals
4.1.9.1 Unless otherwise specified in the job specifications, following philosophy shall be
followed for repeat signals:
a) Whenever repeat contact outputs are required as per job specifications

following philosophy shall be followed:
i) For intrinsically safe input contacts, isolating barrier with dual contact
output shall be utilized.
ii) For all other contact inputs, repeat contact shall be provided using
electromagnetic relays.
4.1.10 The system shall be designed fault tolerant and shall utilize high quality
components of proven quality. Any single system fault shall degrade the system
safety or functionality or affect operation. The system shall have certified Safety
Integrity Level as per IEC 61508 / 61511 as applicable and specified in job
specification. Unless otherwise specified, it shall meet the availability requirement
specified in Clause 4.1.3 of this specification.
4.1.11 Unless otherwise specified, the scan time programmable controller shall be of the
order of 250 milliseconds for SIL certified PLCs. Scan time for a PLC shall be as
defined under para 2.16 of this specification.
4.1.12 Operation of the PLC shall be completely unaffected by a momentary power loss
of the order of 20 milliseconds.
4.1.13 The system shall be programmed in principle as per the logic diagrams furnished
during frailer engineering. Vendor shall prepare their own Logic/Ladder diagrams
depending upon the capability of the programmable logic controller offered by
them. Owner / Consultant reserve the right to revise or review the logic diagrams
even after acceptance of any offer. The programming language of offered PLC
shall be as per IEC 61131.
4.1.14 Whenever the requirement of SIL specified for the PLC, it shall meet the
requirements of SIL level specified and shall be certified by an independent body
(e.g.TUV) for complying requirements of IEC-61511 as specified. For shutdown
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application requiring SIL certification, PLC shall always meet SIL 3 requirements.
4.1.15 The system shall have extensive set of self diagnostics hardware and software for
easy and fast maintenance of PLC. Routine checks should run automatically at
frequent intervals for identifying any fault in software or hardware. Diagnostics
shall be required at local as well as console level.
4.1.16 Safety barriers shall be provided by the vendor for intrinsically safe input / output
circuits wherever specified. In such cases, the system shall be designed
intrinsically safe based on entity concept. The barriers shall be certified by a
statutory author like Baseefa, LCIE, CSA, UL, PTB, DCIMFR etc., for the use in
the area classification as specified elsewhere in the job specifications. The proper
selection of the safety barriers shall be the vendor’s total responsibility. In case of
smart transmitter, the entity parameters of the hand held terminals shall also be
considered while selecting proper barriers.
4.1.17 Unless otherwise specified all intrinsically safe barriers shall be 3 port isolating
type only providing isolation between;
i) Input and output (non-hazardous to hazardous side of barriers)
ii) Power supply and input
iii) Power supply and output
The minimum isolation level shall be 250V.
4.2 System Configuration
4.2.1 General
a) PLC system configuration / architecture shall be as specified in the job

specification. For emergency shutdown system application specified with
SIL classification, the system configuration shall be TMR or QMR or DMR
as per the job specification and shall be certified by independent agency e.g.
TUV.
b) Regardless of the action feature selected (except for single architecture of

single component shall not result in a failure of correctly executed safety
function. The degradation mode for the selected configuration e.g. 4-2-0 or
3-2-0 or 3-2-1-0, etc. shall be documented in SIL certification report.
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c) In general, the PLC system shall comprise of various sub-systems as

described in the subsequent clauses of 4.2.
4.2.2 Input/output Subsystem
4.2.2.1 Each I/O module shall have its own processor. I/O modules configured in
redundant configuration, shall have their processors properly synchronized.
4.2.2.2 Unless otherwise specified, system shall accept analog 4 – 20mA inputs and
contact inputs. The maximum number of Input / Output per I/O module shall be
limited as per the following table.
SI. Type of Configuration Maximum

No. No. of I/O Os
1 Single I/O system 8
2 Dual I/O system 16
3 Triple Modular Redundant system (TMR) 32
4 Quadruple Modular redundant System (QMR) 16
In case of PLC certified for SIL requirements, the maximum number of I/O’s shall
be governed by the SIL certification applicable for specified SIL level.
4.2.2.3 Each I/O shall be galvanically isolated from external control circuit by suitable
means. The minimum isolation level between I/O and logic circuit shall be 1000
volts DC.
4.2.2.4 Each I/O shall be protected against the reversal of polarity of the power voltage to
I/O.
4.2.2.5 Each input shall be provided with filters to filters to out any noise in the input line
and contact bouncing noise, as applicable.
4.2.2.6 All the inputs / outputs shall be double ended i.e. two wires per input / output and
not with common return for all inputs.
4.2.2.7 The interrogation voltage to the inputs and power supply for 2-wire instruments
shall be powered from separate redundant power supply / supplies and shall not be
a part of PLC, unless otherwise specified. This power supply shall be supplied at
one point and shall be distributed by the vendor.
4.2.2.8 a) Each I/O module shall have a LED per channel to indicate the status of each
Input / Output.
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b) when specified, input module shall be capable of monitoring the input

contacts for any wire open fault and short circuit.
4.2.2.9 Analog Input Module
a) Input module shall be able to accept 4-20mA DC input from smart

transmitters (e.g.4-20mA HART).
b) The module shall have 12 bit Analog to Digital resolution accuracy of ±

0.25% of full scale over the entire range, unless otherwise specified.
4.2.2.10
a) Output contacts from the PLC shall be potential free dry contacts with
contact rating as per para 4.2.2.10 b) of this specification. Vendor must
provide are suppression device for each output contract.
b) The output contact rating shall be as follows:
SI. APPLICABLE FOR VOLTAGE CURRENT

No. RATING RATING
1 All output cards driving solenoid valve
and alarm enunciator system unless
otherwise specified
Category – I 110 V DC 0.5 A
Category - II 24 V DC 2A
2 All motors / pumps / compressor output
cards unless otherwise specified.
Category –I 240 V AC 5.0 A
Category –II 220 V DC 0.2 A
c) The category of contracts shall be specified in the material requisition. Each
output shall be short circuit proof and protected by fuse. Visual indication of
fuse blown must be provided for each module.
d) When specified contact output module shall have monitored output features
like wire open and short circuit.
4.2.2.11 where inputs or outputs have multiple field devices for the same measurement or
device, the corresponding inputs / outputs shall be configured in separate I/O
modules.
4.2.2.12 where single input signal is available for QMR or TMR configuration, inputs shall
be multiplied to feed inputs to each input modules / channels.
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4.2.2.13 PLC shall be provided with Auto I/O testing facility as a standard diagnostics
features. PLCs which do not have auto I/O testing facility, manual testing facility
shall be provided to detect any system fault. For manual testing, manual switches
shall be provided to by pass each input at a time and its effect on the shall be
monitored.
4.2.3 Processor System
4.2.3.1 The processor shall have capability to implement all the control functions required
to implement the logic scheme as logic / ladder diagram.
4.2.3.2 The size of the memory shall be sufficient for storage of the program instructions
required by the logic schemes and other functional requirements. Offer shall
indicate the amount of memory capacity occupied by the actual program and
capacity available for future program modifications or additions.
4.2.3.3 Memory shall be non-volatile. However in case volatile memory is provided,

battery backup shall be provided with a minimum of 3 months lifetime to keep the
program storage intact. A battery drain indication shall be provided at least week
before the battery gets drained.
4.2.3.4 Watchdog timer shall be a software device. The healthiness of processors shall be
continuously monitored by watchdog timer. Any hardware or software problem in
the processor system, which shall include, CPU, memory, power supply,
communication interface etc. shall cause the watch dog timer to report processor
failure.
4.2.3.5 Wherever dual redundant processor is specified, redundancy shall be provided in

such a way that in case of failure of the main processor, the standby shall take
over automatically. The changeover shall be bump less. Redundancy shall be
provided for complete processor system including processor, power supply and
communication sub system.
4.2.3.6 In case of triple modular redundant system all the three processors shall execute
the same instructions/program and check their results and vote to correct any
faulty result. The faulty processor diagnostic shall be made available.
4.2.3.7 In case of QMR system, individual processor shall execute the same instructions /
programs and check their results within same CPU module and majority vote to
correct any faulty result. The fault processor diagnostic shall be made available.
4.2.3.8 Failure of a single processor in dual redundant, triple redundant system and two
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processors in QMR system shall not affect the system. In case of failure of
complete processor system i.e. processors in case of dual configuration, two or
more in case of triple redundant system and more than two in case of QMR
system, outputs shall take failsafe state automatically unless otherwise specified in
the data sheets.
4.2.3.9 In case multiprocessor configuration is offered, the processors must able to

communicate with each other over the interconnecting data link. Vendor must
ensure that system performance shall not be degraded by any means when such a
system ids offered.
4.2.3.10 It shall be possible to generate the first out alarm contact by the PLC in case
where a group of parameters are likely to trip a system.
4.2.4 PLC Console (Programming Terminal)
4.2.4.1 The PLC console (Programming Terminal) shall be used for programming
program storing, fault diagnostics and alarm monitoring. Whenever specified, it
shall also be possible to use this console for plant operation. The functionality to
operator as engineering / programming terminal or operator terminal or both shall
be as specified in the job specification.
4.2.4.2 It shall consist of at least one coloured 21” Flat screen LCD monitor with TFT
technology and one programming / operating keyboard, mouse and printer unless
specified otherwise.
4.2.4.3 PLC console when used for plant operation shall also meet the functional
requirements as per clause 4.2.5 of this specification.
4.2.4.4 The keyboard shall preferably be touch sensitive sealed type, easy to operate with
each key clearly identified.
4.2.4.5 All illegal entries shall be rejected by the terminal and shall be identified by
warning signal on VDU.
4.2.4.6 Manual forcing of any input or output contact connected to PLC shall be possible
from keyboard functions shall have an associated audit trail.
4.2.4.7 It shall be possible to modify, add or delete the application program on line
without affecting the outputs.
4.2.4.8 PLC Console shall display logic and / or ladder diagram indicating power flow
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and shall show description and status contact. It shall also be possible to display
process alarms and diagnostic messages as and when they appear. Further it shall
also be able to display I/O map in a user defined format.
4.2.4.9 It shall be possible to print out the ladder / logic diagram on the dedicated PLC
printer. The printer in addition shall also print out:
a) The diagnostic messages as and when generated and diagnostic reports,

when called for.
b) Process alarms connected to the programmable logic controller as and when

they appear and alarm report whenever initiated. The choice of printing
alarms on this printer shall be operator selectable from a key / password
protected switch on PLC console.
c) The I/O maps showing status of all inputs and corresponding outputs in a
user defined format.
4.2.4.10 The PLC console shall be provided with self diagnostics feature which shall
display error messages and initiate an audible alarm if the fault is detected.
Wherever specified, a potential free contact for diagnostic group alarm shall be
provided which shall be connected to the hardwired alarm enunciator system.
4.2.4.11 The system shall be able to identify the failure at least up to the module level
including I/O system and redundant processor and print out.
4.2.5 PLC Console (Operator)
4.2.5.1 Where dedicated PLC operator console is specified, it shall be used for operation
of plant, fault diagnostics, alarm monitoring and report generation.
4.2.5.2 It shall consist of coloured 21” Flat screen LCD monitor with TFT technology,
operator keyboard and printer unless specified otherwise.
4.2.5.3 At least two number cursor control devices shall be provided in addition to
keyboard which may include touch screen, mouse, track ball etc.
4.2.5.4 PLC operator console shall have complete graphic capability and shall be able to
display process dynamic graphics, overview displays. It shall be possible to
operate the plant i.e. start and stop of rotating machinery, opening and closing of
valves, PID function etc. from dynamic graphics and group displays available on
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PLC operator console.
4.2.5.5 It shall be possible to monitor histories and print out all process alarms, diagnostic
alarms and alarm reports.
4.2.5.6 Unless otherwise specified, the time stamping of all alarms shall be as per PLC
processor time stamping.
4.2.5.7 The system shall be able to store and display stored data wherever required. The
minimum storage capacity shall be for 30 days at 1 minute sample rate for all the
inputs specified, diagnostic alarms, process and first out alarms, manipulation data
etc.
4.2.5.8 The system shall be able to generate shiftily, hourly, daily, weekly and monthly
reports. The log format shall be furnished during detailed engineering.
4.2.5.9 The system shall be supplied with first out alarm generation capability. The
resolution of alarm shall be as per processor cycle time, as a minimum.
4.2.6 Communication Subsystem
4.2.6.1 The PLC communication subsystem shall be a digital communication bus that
provides a high speed data transfer rapidly and reliably between the processor, I/O
sub-system, PLC console and other devices connected in the PLC system.
4.2.6.2 Redundancy in PLC communication subsystem shall be provided as follows

unless otherwise specified:
a) For single architecture, the communication subsystem between PLC

processor and I/O subsystem shall be single unless otherwise specified. This
shall include single communication bus and single interfaces / buffers.
b) for dual I/O configuration, each I/O sub set shall have separate
communication interfaces and bus for connecting to PLC processors.
c) For the triple redundant system, each processor shall have a separate set of
PLC communication subsystem.
d) For the QMR systems each I/O subset shall have separate communication
interface and bus for connecting to respective CPU module.
e) The communication subsystem between processor subsystem and PLC

console shall be dual redundant, consisting of two separate communication
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interfaces and two buses, each one configured in redundant mode, unless
this is only used as programming aid.
4.2.6.3 In case of redundant PLC communication subsystem, on the active device, the
redundant device shall take over automatically without interrupting the system
operation. Information about the failed device shall be displayed at local as well as
on PLC console. It shall be possible to manually switch over the communication
from main bus / device to redundant bus / device without interrupting any system
function.
4.2.6.4 The mechanism used by the system for error ch3ecks and control shall be
transparent to the application information / program. Error checking shall be done
on all data transfers by suitable codes.
4.2.6.5 In general, PLC shall provide data in a well established protocol format preferably
MODBUS protocol.
4.2.7 System Power Supplies
4.2.7.1 Unless specified otherwise, the programmable logic controller shall operate on
uninterrupted power supply (UPS). However the system shall be capable of
operating satisfactorily at the following power supply specifications:
Voltage 110 V ± 10%
Frequency 50 Hz ± 3 Hz
Harmonic contents Less than 5%
Power interruption 10 millisec
4.2.7.2 The power supply system shall be supplied with dual PLC feeders each capable of
handling 100% of the total power supply load requirements. In case of failure of
one feeder. Redundant feeder shall supply the total load.
4.2.7.3 Each I/O rack shall be provided with separate power supply unless otherwise
specified in job specifications. Each power supply shall be sized to take full load
of the I/O rack / signal conditioning panel. Each rack shall be provided with dual
redundant power supply.
4.2.7.4 Processor subsystem shall be provided with separate powers supply, as a

minimum, unless otherwise specified in job specification. Failure of one power
supply shall not affect the system operation / processor switchover in case of dual
processor system. Wherever triple redundant system is specified each processor
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shall preferably be provided with a separate power supply. Also separate power
supply must be provided for each multiplied process I/O channel.
4.2.8 Self Diagnostics
4.2.8.1 The system shall have an extensive set of self diagnostic routines which shall be
able to identify all permanent and transient system faults / failures at least up to
module level including redundant components and power supp[lies through
detailed VDU displays and report print out.
4.2.8.2 At the level, failure of a module in any subsystem shall be identified by an

individual LED.
4.2.8.3 Diagnostic software shall have the capability to provide information about the
failed module / system either in the form of a system configuration display or
provided information in the form of a “statement”.
4.2.8.4 Self diagnostic software shall have capability to detect faults which make the
system permanently close/open in the I/O modules or I/O signal conditioning
modules (in case of triple redundant system, whenever specified in the job
specifications, this may be achieved by automatically running the testing software
at cyclic intervals). The automatic cyclic testing feature shall also be provided for
dual I/O configuration and dual I/O signal conditioning for triple redundant
system. The testing software cycle time may be considered once in 30 minutes
however this shall be field adjustable by engineer. However, system performance
shall not be degraded whenever testing feature is specified.
4.2.8.5 System for the following functionalities shall be supplied when specified:
a) Long storage historisation
b) Log report generation
c) First out alarm generation
4.2.8.6 System diagnostics shall be capable of identifying, locating and reporting the
following faults, as a minimum:
a) Processor fault
b) Communication fault
c) I/O module fault

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d) Power supply fault
e) Over temperature monitoring
f) Permanently close /open (stuck on off) fault
g) Memory fault
h) Signal redundancy fault
Any other additional diagnostic alarm if available as a standard shall also be

provided by vendor.
4.2.8.7 Testing software shall be capable of detecting faults in case of normally closed
system as well as in normally open system.
4.2.8.8 Feedback must be provided in case of triple redundant system and QMR system
from the output voter system to detect any latest faults of the system in addition to
other diagnostic software.
4.2.9 System Software
4.2.9.1 The system software shall include all programs for the PLC and PLC console
which are required to perform all the PLC functions including communication and
self-diagnostics. Whenever PLC is specified for shutdown application with SIL
classification, the system shall be designed and engineered in full compliance with
the requirement of IEC-61511. Whenever different functional logics are combined
within a common PLC, the safety related I/O’s of each functionality shall be kept
segregated within the system.
4.2.9.2 Logic program shall also be recorded on the external electronic media like DVD
which shall be delivered in duplicate together with the system.
4.2.9.3 The PLC programming language for implementation of logic operation shall be
based on the following representations:
a) Logic diagrams - Binary logic symbols such as AND, OR NOT Gates,

Timers and Flip-Flops.
b) Ladder diagram - Series / parallel connection of relay contacts.
c) Combination of (a) & (b) above.
4.2.9.4 Diagnostic package and its related equipment and software shall be supplied. A
list of additional diagnostic packages available and the packages provided,
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including the description and capabilities, shall be provided with separate quote,
wherever asked.
4.2.9.5 It shall be possible to print out the ladder/logic diagram on a dedicated printer.
The printer shall also print out all diagnostic reports. Vendor must supply the off
line software package to enable the owner to modify / add / delete any part of
program and for documentation.
4.2.9.6 Software for the generation of various displays including dynamic graphics
wherever specified to be provided as per given below:
4.2.9.6.1 It shall be possible to display dynamic graphic of plant on the operator console
VDU screens. Graphic displays shall be field configurable only through PLC
Console (Programming terminal) with standard / user defined graphic symbols.
Dynamic graphic displays of different sections of the plant shall be displayed on
different pages.
4.2.9.6.2 The system shall have graphic symbol library as per ISA-5.1 and 5.3. In addition
standard industrial symbols like distillation columns, heat exchangers, pumps,
compressors, tanks etc. shall also be provided as a standard.
4.2.9.6.3 Graphic displays shall be interactive type through which it shall be possible to
control the process. It shall also be possible to send motor start/stop and shutdown
valve open/close commands, as specified in job specifications, from this display.
4.2.9..6.4 It shall be possible to view the process variable and alarm points and view and
change set point value, manipulated variable, controller mode etc. from the
graphic display. also rotating machinery (i.e. compressor / pump) status and valve
status shall be displayed on the graphic display with different colours.
4.2.9.6.5 Various colours used in the generation of graphics like colour of the process lines,
utility lines, Instrument signal lines and event modifier conditions shall be
finalized during detailed engineering. The colours used to identify event modified
conditions shall generally be as follows unless otherwise indicating during
detailed engineering.
Red : All points alarm

Blue : Valve open, pump running
Green : Valve closed, pump stopped
Flashing green : Shut down valve transition state
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4.2.9.6.6 It shall be possible to go from any graphic page to related graphic or any group
view or alarm summary in single key stroke using soft key function.
4.2.9.7 The software for printing alarms, system as well as process, and events on the
PLC printer must be provided. All alarms must be printed as and when they
appear.
4.2.9.8 Software package for displaying I/O map showing status of inputs and
corresponding output providing tag numbers as per logic diagram shall be offered.
The I/O map format shall be user definable.
4.2.10 Power Supply Distribution
4.2.10.1 All type of power supplies shall be made available at one point. Further
distribution of power supply shall be in vendor’s scope.
4.2.10.2 In general, all output contacts and solenoids shall be powered with 110 V ± 10%
DC/ 24V±10% DC power supply. However, the actual interrogation voltages shall
be as per job specifications and logic diagrams.
4.2.10.3 The distribution network for interrogation voltage shall be designed such that a
single fault in any branch shall not cause trip of the logic other than where the
fault has occurred.
4.2.10.4 Sequential starting of various load centers shall be provided whenever specified.
4.2.10.5 Power distribution network must use bus bars of adequate capacity with DPDT
(Double Pole Double Throw) switches and HRC (High Rupture Capacity) fuses in
each branch network. Vendor may select circuit breaker if short circuit
characteristics do not match the HRC fuse.
4.2.10.6 All cubicles lighting shall be on 240 V, 50 Hz AC normal power supply.
4.2.11 PLC System Cabinets
4.2.11.1 All PLC system cabinets shall be completely wired with all modules in place.
Inside cabinet wiring shall preferably be done using ribbon type pre-fabricated
cables.
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4.2.11.2 All the cabinets shall be free standing, enclosed type and shall be designed for
bottom entry of cables. Cabinet structure shall be sound and rigid. Cabinet shall be
provided with removable lifting lugs to permit lifting of the cabinets.
4.2.11.3 Cabinet shall be fabricated from cold rolled steel sheet of minimum 2 mm
thickness suitably reinforced to prevent warping and buckling. Doors shall be
fabricated from cold rolled steel sheet of minimum 1.6 mm thickness. Cabinets
shall be thoroughly debarred and all sharp edges shall be grounded smooth after
fabrication.
4.2.11.4 Cabinet finish shall include sand blasting, grinding, chemical cleaning, surface
finishing by suitable filter and two coats of high grade lacquer with wet sanding
between two coats. Two coats of paint in the cabinet colour shall be given for non-
glossy high satin finish. Colour of the cabinets shall be as per job specification.
Final coat shall be given after assembly at site when specified in the job
specifications.
4.2.11.5 Each cabinet shall be maximum 2100 mm high (excluding 100 mm channel base),
800 mm wide and 800 mm deep, in general. Construction shall be modular
preferably to accommodate 19” standard electrical racks. All cabinets shall be of
same height.
4.2.11.6 Cabinets shall be equipped with front and rear access doors. Doors shall be
equipped with lockable handless and concealed hinges with pull pins for easy door
removal.
4.2.11.7 In order to effectively remove dissipated heat from the cabinets, ventilation fans
along with vent louvers backed by wire fly screen shall be provided as required.
Ventilation fans shall be provided in all cabinets where the temperature rise with
all doors closed and all internal and external loads energized shall exceed 10 0 C
above the ambient temperature. A temperature element (resistance temperature
detector) shall be provided in each cubicle for temperature measurement.
Ventilation fans shall be provided in dual configuration, as a minimum.
Each fan shall have a separate dedicated assembly and shall be replaceable on-line
without shutting down any equipment / panel / cabinet / console in part or in
complete.
Ventilation fan assembly shall operate at 240 V AC power supply. Each fan shall
have its own dedicated circuit breaker.
Each ventilation fan shall be fitted with a protection type finger guard. Whenever,
the numbers of cabinets are compacted (supplied in mechanical joined
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conditions), each cabinet shall be provided with separate ventilation fan assembly.
The maximum noise level with all fans operating and cubicle doors open shall not
exceed 85dBA.
Following signals and alarms shall be provided for each cabinet:
i) Fan failure alarm for each cubicle in PLC.

ii) Temperature indication of each cabinet or compacted combination, as
applicable in PLC.
iii) A common alarm each for high temperature and fan- failure shall be made
available.
4.2.11.8 Internal illumination shall be provided for cabinets to ensure proper illumination
level of 250 lux for performing maintenance activities. Illumination shall be
provided for all cabinets by incandescent lamps, which shall be activated
individually by door operated magnetic switches. The lamps shall activate when
door is opened and deactivate when the door is closed. The magnetic switches
selected shall have undergone life cycle test of at least 1000000 operations. A
manual over-ride switch shall be provided inside the cabinet which shall keep the
lamp deactivated even when the door is open.
4.2.11.9 Equipment within the cabinet shall be laid out in an accessible and logically
segregated manner. Cable glands shall be provided and supplied by vendor for
incoming and outgoing cables to prevent excessive stress on the individual
terminals. All metal parts of the cabinet shall be electrically continuous and shall
be provided with a common grounding lug.
4.2.12 Control Panels / Hardwired Console
4.2.12.1 Control panels, if required, shall be non-graphic self supporting, free standing
cubicle with back doors made up of sectional steel panels. Each section shall be
maximum 2100 mm high, 1200 mm wide and 1000 mm deep and shall be
mounted on 100 mm high channel base. Care shall be taken to ensure that the face
of the panel is truly flat and smooth.
4.2.12.2 Panels / hardwired console shall be fabricated from 3.0 mm thick cold rolled steel
sheet. Angle iron frame shall use a minimum section of 50x50x4mm angle.
4.2.12.3 Front of panel / console instrument nameplates shall be black laminated plastic
with white core. Nameplate shall be provided on the rear of the panel also for each
instrument.
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4.2.12.4 Document pocket / wallet shall be provided on the inner side front and rear doors
of each cabinet and on the inner side of the door of each panel. Similar
arrangement shall also be made on the inner side of doors of console.
4.2.13 Wiring Requirements
4.2.13.1 All wiring shall conform to API RP 552- Transmission Systems. Different signal
level cables shall be routed with separation distances as recommended by this
code.
4.2.13.2 All wiring inside racks, cabinets, and back of the panels shall be housed in
covered, non-flammable plastic raceways arranged to permit easy assembly to
various instruments for maintenance, adjustments, repair and removal.
4.2.13.3 All wiring in the raceways shall be properly clamped. All incoming cable and
outgoing cables shall be terminated by vendor at marshalling rack. Total wring
cross-sectional area shall not exceed 50% of the raceway cross sectional area.
4.2.13.4 Separate wiring raceways shall be used for power supply wiring, DC and low
level signal wiring, and intrinsically safe wiring. Parallel runs of AC and DC
wiring closer than 300mm shall be avoided.
4.2.13.5 Vendor can alternate offer prefabricated cables for interconnection between
different cabinets and panels.
4.2.13.6 Wire termination shall be done using self insulating crimping lugs. More than two
wires shall not be terminated on one side of single terminal. The use shorting links
for looping shall be avoided.
4.2.13.7 Terminal housing shall be strictly sized with considerations for accessibility and
maintenance. Minimum distance required between various components is listed
below. These distances are clear distances and are excluding the width of the
raceways or any other component / item mentioned herein. Following clearances
should be considered:
a) Distance between terminal strip and side of the cabinet parallel to the strip,
up to 50 terminals, shall be minimum 50 mm.
b) Distance between terminal strip and, top and bottom of the cabinet shall be
minimum 75 mm.
c) Distance between two adjacent terminal strip shall be minimum100 mm.
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d) Additional distance for each additional 25 terminals shall be minimum 25

mm.
e) Distance between cable gland plate and the bottom of the strip shall be
minimum 300 mm.
4.2.13.8 All terminal / terminal blocks shall be DIN Rail mounted type and shall be easily
removable. The size of the terminal blocks / terminals of different types shall be
consistent and identical. All terminal blocks shall be mounted on suitable anodized
metallic or plastic stand-off.
4.2.13.9 No splicing is allowed in between wire / cable straight run.
4.2.13.10 Terminal strips shall be arranged group-wise for incoming and outgoing cables
separately. Terminal blocks for intrinsically safe wiring shall be separate. 20%
spare terminals shall be provided, as a minimum, preferably in each terminal strip.
Terminals shall be suitable for wires up to 2.5 sq. mm base solid or stranded
conductor in general. For power cables, higher size terminals shall be used.
4.2.13.11 Cabinet and rack layout shall be made considering proper accessibility and
maintenance.
4.3 Earthing
4.3.1 All system equipments such as panels, marshalling cabinets, system cabinets and
other powered equipments shall be provided with following type grounding
system:
a) Protective Earth / Electrical Earth

b) System Earth / Signal Earth
c) Safety Earth / Barrier Earth (when required)
Both system earth and safety earth shall be totally separate from protective earth.
4.3.2 Protective Earth / Electrical Earth
a) Each metallic enclosure / cabinet / panel / console etc. shall be provided

with electrical earth lug, as a minimum.
b) Unless recommended otherwise by vendor, all earthing lugs of metallic

equipments indicated in Clause 4.3.2 (a) above shall be connected
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individually to electrical protective earthing system bus – bar / earthing

station using a maximum of 10sq mm solid copper conductor PVC insulated
wires.
c) Where multiple cabinets are multiplexed together, earth looping with

permanent shorting link cables shall be acceptable. Two earthing connection
wires as indicated in Clause No. 4.3.2 (b) above shall be used for connecting
multiplexed cabinets to protective earth station / bus-bar.
4.3.3 System Earth
a) System earth be totally noise free dedicated earthing system and shall be
fully isolated from electrical protective earth. This earth must be very high
integrity system and shall be used to ground zero volt references and signal
cable grounds.
b) System earth shall be less than one (1) ohm grounding system with its own
dedicated earthing pits. These earth pits shall be away from noise plant
equipment. Outside the control room building is the most appropriate
location.
c) Wherever supply of earth pit is kept in vendor’s scope in the Material

Requisition, the earth pit design shall be as per IS-3043 code of practice for
earthing. A minimum of four (4) number of earth pits shall be provided for
grounding system integrity. In case number of pits required to meet 1 ohm
resistance are more than (2), the number of earth pits shall be two times the
actual number of pits required to meet resistance criteria. All these pits shall
be securely connected with each other to from a one homogenous system
earth grid.
d) Earth marshalling / system cabinet / panels etc shall be provided with

system earth bus-bar which shall be insulated from the metallic body frame.
This bus-bar shall be used to earth also signal zero volt references and signal
cable screens. Terminals used for termination of spare conductor pairs /
cores of multi-pair signal / control cables shall be connected to system earth
bus-bar. Shorting links shall be used for spare terminal looping.
e) System bus-bars in the multiplexed cabinets can be joined together by

permanent shorting links. System bus-bars of other cabinets can also be
connected together provided they are permanently joined using 35 sq mm
stranded copper conductor cable.
4.3.4 Safety Earth / Zener Barrier Earth

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a) Whenever Zener barriers are selected or used to meet intrinsically safe

requirements, the earthing terminal of the zener barriers shall be connected
to a separate earth bus bar.
b) This earth shall meet all the requirements specified in Clause 4.3.3 of this
specification.
c) Safety earth bus bar shall be directly connected to earth pits using dual
insulated cable. Cable conductor size shall be minimum 95sq. mm (copper).
4.4 Interface with DCS
The PLC shall be required to be interfaced to the Distributed Control System bus
whenever specified. A suitable interface shall be offered in order to achieve the
following function:
a) Display of all input points under alarm / first out connected to PLC
generated by PLC, continuous indication for analog signal on the main DCS
operator console.
b) Generate shutdown reports on the logging printer of Distributed Control

system.
c) To receive certain operational commands from the operator console for the
operation of certain output devices connected to PLC
d) To display diagnostic message of PLC.
In general, PLC shall provided data in a well established MODBUS protocol

format.
The interface shall be dual redundant unless otherwise specified.
The speed of data transfer shall be such that any change in I/O which is to be
updated on the operated console shall not exceed 3 second from the time event to
update on the operator console screen considering one second standard update rate
in DCS operator console.
4.5 Sequence of Event (SOE) Function Requirement
Sequence of Event, whenever specified, for analog and digital inputs shall be
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generated and time stamped in PLC. The maximum resolution between two events
shall not exceed specified PLC scan time unless specified otherwise. A separate
SOE PC with 21” size TFT screen and printer shall be provided for PLC sub-
system unless specified otherwise.
5.0 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE
5.1 General
5.1.1 This specification defines the basic guidelines to vendor for factory testing and
acceptance, installation, commissioning and field acceptance of the complete PLC
system. On the basis of this specification, vendor shall submit their own detailed
testing, installation, commissioning and acceptance procedure. For hardware, the
procedure shall include test name, purpose of test, test equipment / set up,
definition of input, test procedure, results expected and acceptance criteria.
Similarly for software, it shall include test name, details of the method, list of
tests, sequence of execution, results expected and acceptance criteria. For PLC
system with SIL 3 requirement, certificate for hardware & software (Like TUV
etc.) shall be verified.
5.1.2 The testing and acceptance of the system shall be carried out on the approved
testing procedures and criteria based on this specification and vendor’s standard
testing requirements and procedures.
5.2 Factory Acceptance Teats (FAT)
5.2.1 Vendor shall test and demonstrate the functional integrity of the system hardware
and software. No material or equipment shall be transported until all required tests
are successfully completed and certified “Ready for Shipment” by the owner /
consultant.
5.2.2 The purchaser reserves the right to be involved and satisfy himself at each and
every stage of inspection. The purchaser shall be free to request any specific test
on any equipment considered necessary by him although not listed in this
specification, as a part of approval of factory testing procedure. The cost of
performing all tests shall be borne by the vendor.
5.2.3 Vendor to note that acceptance of any equipment or the exemption of inspection or
testing shall in no way absolve the vendor of the responsibility for delivering the
equipment meeting all the requirements specified in Material Requisition.
5.2.4 It shall be vendor’s responsibility to modify and /or replace any hardware and
modify the software if the specified functions are not completely achieved
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satisfactorily during testing and factory acceptance.
5.2.5 Schedule of FAT shall be included in the Vendor’s proposal.
5.2.6 Vendor shall not replace any system component / module / subsystem unless it is
failed. A log of all failed components / modules in a sub-system shall be
maintained which shall give description of the failed component / module, effect
of failure on the sub-system, cause of failure and number of hours of operation
before it failed. If malfunction of a component / module in a sub-system repeats,
the test shall terminate and vendor shall replace the faulty component /module.
Thereafter the test shall commence all over again. If even after this replacement,
the sub-system fails to meet the requirements, vendor shall replace the full sub-
system by the one meeting the requirements and the system shall be tested all over
again. If a sub-system fails during the test, which is not repaired and made
operational within four hours of active repair time after the failure, the test shall
be suspended and restarted all over again only after the vendor has replaced the
device in the acceptable operation.
5.2.7 Testing and FAT shall be carried out in two phases. The minimum requirements
for testing during these two phases shall be as follows:
5.2.7.1 Under the first phase, vendor shall perform tests at his works to ensure that all
components function in accordance with specification for each type of test. A test
report shall be submitted for purchaser review within one week of completion of
this test. Phase II testing (witness inspection) shall start only after this.
All subsystem shall undergo a minimum of 30 days burn in period. The burn-in
time shall start after the sub-system is fully assembled and is powered up. It may
include any such time for which the system has been kept powered on even for
system generation and Phase I testing.
Following tests shall be performed by the vendor and reports shall be forwarded to
purchaser:
a) Quality control test which shall be carried out to assure quality of all
components and modules in accordance with vendor’s quality control and
assurance procedures.
b) System pre-test which shall be physical check of all modules, racks, cabinets
etc.
c) System power-up test which shall test functionally all hardware and software.
This shall include testing of redundancy, System performance on power
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supply variations, application software testing and system diagnostic

verification.
5.2.7.2 The second phase of testing shall systematically, fully and functionally test all
hardware and software in the presence of purchaser representatives. All subsystems
shall be interconnected to simulate, as close as possible, the total integrated system.
Following minimum tests shall be carried out:-
a) Visual and mechanical testing, which shall be carried out in principle to

assure correct, proper, good and neat workmanship by the vendor This testing
shall include dimensional verification, Layout verification as per approved
GA drawings, Verification of Sheet thickness / quality of painting (outer and
inner) / Nameplates, identifiers and tag plates / Adherence to ferruling
philosophy / Dressing of wires / prefabricated cables and clearances / Locks
and handles as a minimum.
b) Verification of Bill of Material. The Bill of material verification shall

include both hardware and software.
c) Functional testing:
This shall include the simulation of each input and output to verify proper system
response. The testing as a minimum shall include:
i. Complete system configuration loading.
ii. Demonstration of all PLC system builder functions

including addition / deletion of an input / output, addition of a rung or an
element in a rung, generation of dynamic graphics and other views, report
generation etc.
iii. 100% checking of logics configured in the PLC by

connecting switch / lamp at input / output, by simulating inputs and verifying
outputs preferably using simulator, other related functions like forcing, first
out shall also be verified.
iv. Checking of scan time. Scan time verification shall be

carried out using high resolution storage oscilloscope during Factory
Acceptance Test based on the specified requirements considering discrete
input by given step change. The scan time values so observed shall be within
90% confidence level. Incase of analog inputs, input shall be ramp or
minimal step, however such reading for analog inputs should be noted only
for reference.
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v. Checking of all PLC console displays, keyboard and

touch-screen operation (wherever specified), printer/ hard copier functions
etc.
vi. System redundancy checks including correct change over

of the back-up unit in case of failure of main unit.
vii. System diagnostic checking for all subsystems on local

level as well as on console, including checking of the testing software for I/O
modules / signal conditioning modules, when specified.
viii. Checking of output status on processor failure.
ix. Checking of first-out alarm generation.
x. Simulation of power failure and system restart auto boot-

up of system configuration and program after power restoration.
5.2.8 Vender shall notify the purchaser at least three (3) weeks prior to factory
acceptance test. In the event that representative
arrives and system is not ready for testing, vender shall be liable for back charges
for any extra and incurred.
5.3 Installation, Testing and Commissioning
5.3.1 Vender shall offer the services of an installation team which would install the
equipment in the control room lay the interconnecting cables inside control room,
check-out, test and commission the system.
All technical personnel assigned to the site by the vendor shall be fully conversant
with the supplied system and software package, and shall have both hardware
software capability to bring the system on line quickly and efficiently with a
minimum of interference with other concurrent construction and commissioning
activities.
5.3.2 Vendor’s responsibility at site shall include all activities necessary to be performed
to complete the job as per material requisition including:
a) Receipt of hardware / software and checking for completeness of supplies.
b) Installation of the system including for free supply equipment, if any.
c) Field cable termination and inter-cabinet cabling and termination.

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d) Check out equipment installation.
e) Checking of interconnections, hardware and software configuration, overall

system functioning etc.
f) Loop checking.
g) Field tests.
h) Commissioning and on-line debugging of the system.
i) Involvement during plant commissioning and performance of final

acceptance test.
j) Co ordination for integration with DCS / other third party system.
5.3.2 Field Inspection
5.3.3.1 All equipments shall be inspected thoroughly by vendor after its receipt at site for
completeness and proper functioning. Vendor must initiate the remedial action, in
case unsatisfactory operation of any item is observed, with intimation to Engineer-
in charge.
5.3.3.2 Vendor must document all observations including details of any malfunction
observed. Items enquiring total replacement must document the reasons for the
same.
5.3.4 Loop Checking
5.3.4.1 Loop checking shall be carried out by vendor including checking the
interconnections, configuration and overall system functioning.
5.3.4.2 Vendor’s scope of work as a part of system installation and loop checking shall
include termination of field cables in the control room, checking of interconnection
between instrument / equipment, glanding, ferruling / tagging of interconnecting
cables in control room, ferruling of field cables in control room and performing
overall loop performance check.
5.3.4.3 Vendor shall coordinate with the field contractor for smooth and proper loop
checking. Any discrepancy found during checking shall be brought to the notice of
the Engineer-in-charge. Complete loop checking shall be performed in his/her or
his /her authorized representative’s presence.
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5.3.4.4 The input signals shall be simulated by disconnecting the field wires for all field
switches connected to PLC. All field transmitters connected to control room shall
be loop checked at 0%, 50% & 100% of full scale (for both increasing and
decreasing signals). Wherever receiver cards are used, the set point shall be
generated by giving the input signal to receiver card. All outputs shall be checked
in field, either for actual operation of solenoid valve or actual pick-up of electrical
contactor for rotary equipments. Shutdown schemes shall be checked for proper
functioning, configuration and actuation.
5.3.4.5 After loop checking is completed, vendor shall connect back any terminals and
connections removed for loop checking.
5.4 System Acceptance
5.4.1 The owner shall provisionally takeover the system from vendor after System after
acceptance test. System acceptance test shall be started only after the satisfactory
performance of loop checking and verification of all loop checking by Engineer-in-
charge.
5.4.2 The system acceptance test shall be carried out in the presence of owner’s
representative and Engineer-in-charge or his authorized representative. The tests
carried out in System acceptance test shall be fully recorded and duly signed by all
representative participating in the System Acceptance Testing.
5.4.3 Vendor shall carry out the following functional tests, as a part of system acceptance
test, as a minimum:-
a) Hardware verification as per final Bill of Material.
b) Visual and mechanical check-up for proper workmanship, identification,

ferruling nameplates etc.
c) System configuration as per approved configuration diagram.
d) Demonstration of all system function, display and diagnostics.
e) Checking of correct change-over of redundant devices.
f) Checking of various peripheral devices like printers and printing of all

reports.
g) Complete checking of logic system, loading of user’s program and checkout

of results.
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h) Checking of proper functioning of all disc drives, alarm summary, alarm

history etc.
i) Proper information transfer on the information network by verifying system

displays and printout.
5.5 Final Acceptance Test
The owner will take over the system from the vendor after the final acceptance test,
which is defined as successful uninterrupted operation of the integrated system for
three weeks. Vendor’s personnel shall be present during the test. Any
malfunctioning of the system components shall be replaced / required. Once the
system failure is detected, the acceptance test shall start all over again from the
beginning. The warranty period commences from the day owner takes over the
system.
6.0 GENERAL REQUIREMENTS
6.1 Vendor shall comply fully with the general requirements, of PLC system including
logistic support services, documentation, warranty, maintenance contract and
shipping instructions.
Post Warranty Maintenance Contract
Vendor shall quote separately for post warranty maintenance contract after
warranty period for five years for the complete system as per commercial terms
and condition of the requisition and the type (i.e. comprehensive or non-
comprehensive) of post warranty maintenance shall be as specified in job
specification. The personnel deployed during post warranty maintenance shall have
though knowledge of the system and at least two years of experience on the
maintenance of similar system. Any other conditions of contract required by
vendor shall be explained in the offer.
7.0 SHIPPING
7.1 All the materials used for packing, wrapping, sealers, moisture resistant barriers
and corrosion preventers shall be of recognized brands and shall conform to the
best standards in the areas for the articles which are packed.
7.2 Workmanship shall be in accordance with best commercial practices and

requirements of applicable specification. There shall be no defects, imperfections
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or omissions which would tend to impair the protection offered by the package as a
whole.
7.3 The packing shall be suitable for storing in tropicalised climate, the ambient
conditions, being specified in job specifications.
7.4 Shipment shall be thoroughly checked for completeness before final packing and
shipment. Vendor shall be responsible for any delay in installation or
commissioning schedule because of incomplete supply of equipments.
8.0 REJECTION
8.1 Vendor shall make his offer in detail with respect to every item of the purchaser’s
specifications. Any offer not conforming to this shall be summarily rejected.

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INDIAN OIL CORPORATION LIMITED DIGBOI

REFINERY (ASSAM OIL DIVISION)

STANDARD SPECIFICATION FOR

Prepared By Checked By Approved By

Clause No. Items Page No.

3.0 Drawings and Data 05

4.0 Design and Construction 06

5.0 Meter electronics 08

6.0 Glass tube variable area flow meter 09

7.0 Metal tube Variable area flow meter 10

8.0 Purge Flow meter 10

9.0 Differential Pressure Regulator 10

10.0 Performance Requirements 10

11.0 Name Plate 11

12.0 Inspection and Testing 11

IS 3043 Code of Practice for Earthing

d) Codes and Standards

1.1.4 In addition to meeting purchaser’s specifications in totality, vendor’s extent of responsibility

d) Adequacy of Bill of Material selected to meet purchaser’s requirements. Vendor to

e) Providing adequate mandatory spares including consumable spares as specified in the

a) Compliance to the specifications.

c) System security features and design details.

ii) Certificate of conformity to ATEX or other recognized standards for all

on demand and test intervals for safety level analysis.

2.8 Vendor shall also quote for the following:

i) All type of electronic modules e.g. I/O modules, processor modules,

iii) Switches, lamps, fuses, connectors, terminals, pre-fabricated cables, circuit

3.0 DRAWING AND DATA

operator console, programming terminal etc with complete dimensional details,

d) Copy of type test certificates.

e) Copy of test certificates for all tests indicated in this specification.

f) Installation manual containing installation procedure for programmable logic

g) Power-on, start-up and internal testing procedures.

h) Software debugging system configuration procedures.

i) Calibration and maintenance manual containing maintenance procedures including

The various terms used in this specification are defined as follows:

4.1 Programmable Logic Controller

Input / Output with respect to process / operator.

4.6 PLC Console (Operator)

4.7 PLC Console (Programming Terminal)

PLC console (Programming Terminal) shall be the engineer’s main interface

4.8 Local Level

4.9 Central Level

4.12 System Loading

System loading for a sub-system is defined as the percentage of time a sub-system

A system component shall be termed as redundant if it takes over automatically

4.14 Switchover Time

Timer required for a back up instrument / system to come on-line automatically in

4.15 Processor Cycle Time (tpc)

Processor cycle time is the measure of the processing speed of a processor.

4.16 Scan Time (ts)

4.17 User’s Memory

4.19 Sequence of Event (SOE)

4.20 Sequence of Event Recorder (SER)

4.21 Real Time Trend

Real time trend shall be defined as a continuously progressing graphical record

4.22 Plant Information Network

A Tag is a collection of attributes that specify either a control loop or a process

5.0 SPARES PHILOSOPHY