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PROJECT TITLE
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND BRINE
DISPOSAL SYSTEM
BASIS OF DESIGN
PREPARED BY CHECKED BY APPROVED BY DOCUMENT NUMBER
SFF RAT PIC-E-NTV-627-003
DATE REVISION PAGE
2-2-2014 2-3-14 A 1 of 58
2 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
TABLE OF CONTENTS
SECTION ITEM PAGE NO.
Abbreviations, Definitions, Standards, References 4-8
1. INSTRUMENTATION
1.0 Introduction 9
1.1
Site Description 9
1.2
Environmental Condition 10
1.3
Measurement Units 10
2.0 Instrumentation System Requirements 10
2.1
Process Equipment 11
2.1.1 Separator 11
2.1.2 Scrubber 11
2.1.3 Flash Tank 12
2.1.4 Level Drum 12
2.1.5 Pump Motor 12-13
2.2
Field Instruments 13
2.2.1 Level 13-14
2.2.2 Pressure 15-16
2.2.3 Flow 16-17
2.2.4 Others 18-21
3 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
Doc. No. PIC-E-NTV-627-003
2.3
Control Room 21
2.3.1 Facility 21
2.3.2 Environment and Location 21
2.4
Junction Boxes 22
3.0 Instrument Material Selection 22-23
4.0 Supply System 23
4.1
Electrical 23
4.2
Pneumatic 23-24
5.0 Equipment Protection 24-26
6.0 Earthing System 27
7.0 Cable Requirements 27
7.1
Cable Types 28
7.1.1 Instrument Cable 28
7.1.2 System Cable 28
7.1.3 Signal Cable 29
7.1.4 Power Cable 29
7.1.5 Special Cable 29
7.1.6 Junction boxes Cable 29
7.2
Cable Identification 30
7.3
Cable Shielding 30
4 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
7.4
Cable Marking 31
7.5
Cable Runs 31
7.6
Cable Installation 32
7.7
Cable Termination 32-33
2. CONTROL
1.0 Introduction 34
2.0 Operation System 34-35
3.0 Safeguarding System 35
4.0 Equipment Locations 35
4.1
Methods 36
4.2
Elevation 36
4.3
Operating Convenience 36-37
4.4
Plant Equipment Layout 37
5.0 Basic Control and Monitoring 37-40
6.0 DCS and PLC Requirements 40-43
7.0 System Architecture 43
7.1
Narrative 44-45
7.2
Drawing 45
5 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
3. SAFETY
1.0 Introduction 46-47
2.0 Safety System (Fail Action) 47-48
2.1
System Architecture (DeltaV SIS) 48-49
3.0 Emergency Shutdown System 49-50
4.0 Fire Detection System 50-51
5.0 Gas Detection System 51-52
6.0 Audible and Visual Alarms 53
4. NAMING CONVENTION
1.0 Introduction 54
2.0 Naming Convention 54-58
DEFINITION
Engineering Procurement Construction Company or EPC
It is the contractor that will make the detailed engineering design and work of the
project. In this case the Process Instrumentation Company will provide for it.
ABBREVIATIONS
UPS Uninterruptible Power Supply
VIM Virtual I/O Module
6 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
PVC Polyvinyl Chloride
ESD Emergency Shut Down
IP Ingress Protection
HMI Human Machine Interface
NPT National Pipe Thread
AWG American Wire Gauge
AC Alternating Current
DC Direct Current
SS Stainless Steel
CS Carbon Steel
DCS Distributed Control System
PLC Programmable Logic Controller
VDU Visual Display Unit
MCC Motor Control Cabinet
SIS Safety Instrumented System
HART Highway Addressable Remote Transducer
AI Analog Input
AO Analog Output
DI Digital Input
DO Digital Output
7 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
FF Foundation Fieldbus
REFERENCES
The different standards reflected as references should be used upon the completion
of the project. The dated references shall be necessarily applied. If there are any
changes regarding on the dated references, the client and the contractor shall have an
agreement on whether they will apply it or not. The newest standards and codes shall
be used for the undated references.
International Electro technical Commission (IEC)
IEC 60331 Tests for Electric Cables under Fire Conditions
IEC 61131 Programmable Logic Controllers
8 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
IEC 61158 Industrial communication networks – Fieldbus specifications
IEC 61508 Functional safety of electrical/electronic/programmable
electronic safety-related systems
IEC 61511 Functional safety – safety instrumented systems for the
process industry sector
IP RATINGS (Ingress Protection)
IP 65 Totally protected against dust ingress, protected against low
pressure water jets from any direction.
IP 55 Limited protection against dust ingress, protected against
low pressure water jets from any direction.
IP 42 Protected against solid objects over 1.0mm e.g. wires,
protected against falling drops of water, if the case is
disposed up to 15 from vertical.
International Society of Automation (ISA)
ISA 5.1 Instrumentation Symbols and Identification
ISA 5.4 Instrument Loop Diagrams
ISA 5.7 Process and Instrumentation Diagrams
ISA 7.0.01 Quality Standards for Instrument Air
ISA 71 Environmental Conditions for Process Measurement and
Control
ISA 75.01 Control Valve Sizing Equations
9 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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ISA75.04, Control Valve Stability
ISA75.07, Control Valve Noise Measurement and Prediction
ISA75.08, Control Valve Face-to-Face Dimensions
ISA77.22, Power Plant Automation
ISA/ANSI –S 84.01 Application of Safety Instrumented Systems for the Process
Industry
National Electrical Manufacturers Association (NEMA)
NEMA 250 Enclosures for Electrical Equipment (1000 Volts maximum)
National Fire Protection Association (NFPA)
NFPA 70 National Electrical Codes
NFPA 1 Fire Protection Code
NFPA 67 Guides on Explosion Protection for Gaseous Mixtures in
Pipe Systems
NFPA 59A Standard for the Production, Storage, and Handling of
Liquefied Natural Gas (LNG)
NFPA 72 National Fire Alarms and Signaling Code
American Petroleum Institute (API)
API RP 505 Recommended Practice for Classification of Locations for
Electrical Installation at Petroleum Facilities Classified as
Class I, Zone 0, Zone 1 and Zone 2 (2002).
API RP 500 Recommended Practice for Classification of Locations for
electrical Installation at Petroleum Facilities Classified as
Class I, Division 1 and Division 2.
10 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
Doc. No. PIC-E-NTV-627-003
Indian Standard (IS)
IS 5831 PVC insulation
A. INSTRUMENTATION
1. INTRODUCTION
The basis of design for instrumentation shall discuss the considerations under
the scope of plant process instrument general requirement e.g. type of materials,
operating ranges, standards for equipment protection and even overview of the
geographic location of the process field. The pre-determined process conditions
such as exposure to corrosive and toxic gases, process ambient temperature and
other factors that may degrade the functionality of the instrument installed shall be
the foundation in selecting the right material to be used. The purchase of the right
equipment shall determine the efficiency of the instrument and the length of its
service.
The basis of design for instrumentation shall state the plant process instrument
general requirement e.g. type of materials, operating ranges, type of connections,
standards for equipment protection and even overview of the geographic location of
the process field. Pre-determined process conditions such as exposure to corrosive
11 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
and toxic gases, process ambient temperature and other factors that may degrade
the functionality of the instrument installed shall be the foundation and basis for the
purchase of materials to be used. The basis for instrumentation shall determine
which equipment is suitable for the given application and the length of its service.
1.1 SITE DESCRIPTION
The Tiwi field is located about 300-km southeast of Manila in the Albay
Province. The Tiwi geothermal field will be located on the northeast flank of Mt.
Malinao, an extinct Quaternary stratovolcano in the East Philippine Volcanic Arc.
This arc is a belt of upper –Miocene to Recent calc-alkaline volcanoes
associated with subduction along the Philippine Trench. Mt. Malinao is composed
dominantly of <0.5 million year-old andesitic lavas and lesser pyroclastic rocks.
Tiwi Geothermal Power Plant coordinates are 13°27'54" N and 123°38'55"
E in DMS (Degrees Minutes and Seconds) or 13.4649487555258 latitude and
123.648541284874 longitudes (in decimal degrees). It has an elevation of ~45
meters.
12 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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©googlemaps.com
1.2 ENVIRONMENTAL CONDITION
The geothermal plant geographical location has a humid subtropical
climate with 1, 850 – 2, 300 mm annual rain fall. The ambient temperature is
ranging from 75.38 °F to 82.58 °F with relative humidity at 83-96% and 3.6 km/h
North wind speed.
1.3 MEASUREMENT UNITS
2. INSTRUMENTATION REQUIREMENTS
Liquid Flow Rate = GPMgpm
Gases Flow Rate = Nm3/h
Steam Flow Rate = kg/hr
Temperature = °C0F
Pressure = lb/in2
Vibration = dB
Level Relative = 0-100 %
Level Absolute =iIn. or
mm
Gage Pressure = psig
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GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
This part contains the basic requirements of different instruments, and equipment
needed in the process of separator, scrubber and brine disposal system.
2.1 PROCESS EQUIPMENT
The selection of the process equipment shall be based on conditions and
the desired standards for which it is expected to comply. The main goal for
detailing these conditions is to be efficient in terms of equipment reliability.
2.1.1 SEPARATOR
The type of separator to be used is the Upgraded CE Natco. It
shall be constructed with 316L stainless steel to comply with the tank
design temperature and pressure which is 400 °F and 200 psi. The
diameter of the tank shall be 2743 mm and 7620 mm height. to
accommodate 600-800 kph flow rate capacity. Its operating parameters
shall range from130 – 180 psig at water level. Its two-phase entry will be
tangential. The height of steam outlet to inlet is recommended to be
positive with acceptable pressure drop of 7-10 psi.
Principle of Operation
The two phase fluid enters the separator through the two phase inlet
nozzle.
The separation process commences by utilizing the difference in
density of the liquid and the vapor phases of the two phase fluid.
14 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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It operates by using the centrifugal force of the spinning steam and
brine mixture inside the separator to force the brine to the wall of the
vessel.
The brine then drops to the bottom of the vessel exiting to the brine
outlet while the lighter steam and gas exits through a pipe extending
up the inside of the vessel.
The 2-phase phase fluid usually contains carryovers and impurities
present in the steam such as silica and chloride and non-condensable gas
(NCG). The carryovers can be removed by the centrifugal action possible
with the separator’s design while silica and chloride and non-condensable
gases are found to be difficult to remove, proper selection of materials that
can withstand their effects must be put into consideration.
2.1.2 SCRUBBER
The scrubber purifies the steam by separating the pure steam from
other impurities that the separator failed to remove. This is done to meet
the minimum requirements of the power plant. TheThe plant steam quality
requirements are as follows:
Silica Maximum of 1.0 ppm
Chloride Maximum of 1.0 ppm
Steam Quality Minimum of 99.75%
Non-Condensable gases Should be between 1.0 to 3.0 ppm
15 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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The steam quality can be achieved by using Porta-test scrubber. This high
pressure scrubber shall have an inner diameter of 3657 mm with 1066.8 mm
height. It s shall be built to operate atdesign temperature and pressure will be
405⁰F deg. Fahrenheit temperature and pressureand of 200 pPsig.
Principle of Operation
Primary separation takes place as gas enters through a tangential nozzle,
creating centrifugal force and forcing the heavier liquid particles to the vessel
wall. From there, the liquids drain to the stilled chamber in the bottom of the
vessel.
Secondary separation occurs as the spinning gas converges at the center
of the separator and enters the vortex finder tube. Inside the vortex finder tube,
the gas spins at a higher velocity and forces any remaining entrained liquid to the
tube wall. This liquid is swept upward toward the gas outlet. Prior to exiting the
vessel, the liquid and a 10% side stream of gas are drawn through a small gap in
the vortex finder tube and returned to the primary separation section. A low
pressure area in the primary separation section created by the spinning gas
provides the necessary differential pressure driving force.
2.1.3 FLASH TANK
Flash tank is where a pressurized high-temperature water enters,
as water enters the flash tank a sudden decrease in the pressure causes
the liquid to vaporize into steam. This vapor is released into the
atmospheresteam and the cois thendensate is disposed to the sumpuse
for power generation. Its material construction shall be the made with
carbon steel same with the scrubber since the pressure andwith design
temperature and pressure of experienced by the vessels is measured to
16 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
Doc. No. PIC-E-NTV-627-003
be around 200 psi at 400 °F and 200 psi. The flash tank parts are brine
inlet and outlet and vapor outlet for vapor venting, and manhole for
maintenance and inspection.The vessel must be made of corrosion
resistant materials.
2.1.4 LEVEL DRUM
Level drum is ashall hold condensate holding vessel acquired from
scrubber which is expected to hold liquid with high pressure and
temperature condensate and. low pressure vapors. The level drum
dimension shall be: 406.4mm inner diameter and height of 1524 mm
constructed with materials carbon steel designed with that are capable to
operate at 200 psi and 400°F.
2.1.5 Seal Water Tank
Seal water tank stores fresh water supply that is to be fed into the
brine pumps. The tank shall be constructed with carbon steel material and
shall be designed with low temperature and pressure.
2.1.65 PUMP MOTOR
The pump that will be used for saturate disposal must be able to
operate at 405°F temperature with low pressure head required. The
centrifugal pump used to drive brines and other fluids in geothermal
17 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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process shall adopt ISO 5199:2002 Technical specifications for centrifugal
pumps— Class II. Its casing is preferred to be made up of carbon steel
with hard iron impeller for erosion-corrosion and abrasion resistance. It’s
working parts including float, valves and mechanical linkage shall be 316L
stainless steel. Zinc anodes and epoxy paintings for protection shall be
considered. The pPump motor will be driven by 3-phase with YB-type –
explosion proof motor squirrel-cage induction motor.
2.1.6 PIPELINES
Pipelines shall be routed as short as possible to minimize turns and
incline. The most important aspect in its design is usually to keep the route
monotonic and the incline slight in order to minimize pressure drop and
slug flow conditions in the pipeline. Pipe insulation shall be designed to
lessen pressure drop during steam transmission.
For the separator and scrubber steam pipelines, stainless steel
shall be used where the properties of steel e.g. corrosion resistant, high
tolerance to pressure and temperature can increase productivity. The
pipeline for brine disposal shall be made up of carbon steel for a thicker
material selection.
The pipelines shall be according to its application. For steam
pipelines, the material construction shall be made up of 316L stainless
steel with design pressure and temperature of 200 psi and 400°F. As well
as the pipelines for brines with minimum material requirement of carbon
steel construction.
2.2 FIELD INSTRUMENTS
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GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
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All field instruments must withstand the extreme process for which they
are installed for. The highest range of pressure involved is at 200 psi while
temperature is expected to be at around 405 °F. The type of material
construction must protect the mechanical and electrical components of an
instrument to give accurate results and prolong its service.
2.2.1 LEVEL
The saturated fluid and condensate level shall be controlled using
equipment that determines the said process variable. This equipment
follows the standards that satisfy the requirement for which it is intended
to be use.
LEVEL TRANSMITTERS
Level transmitters are used to measure and indicate level in the
process. It shall have an electrical output signal of 4-20mA in order to
transmit signal to the controllers and other instruments. Transmitters with
flush flange connected both sides are used for direct mounting, capillary or
process connections.
The pipe size and fittings for the level installation shall be in inch
and threads in NPT. The transmitter shall use 1199 Remote Seal to form a
Tuned-System Assembly that improves performance and reduced cost.
Other installed components shall be 316 SST conduit plug. For process
connections, ½” NPT is used. The enclosure rating shall be IP66 for
ingress protection of the transmitter.
19 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
Doc. No. PIC-E-NTV-627-003
LEVEL GAUGES
Level Gauges are installed so that the liquid level in the transparent
sight tube is same as the liquid inside the tank. Level gauge shall
compose of the following parts: armored shield with two flanges, sight
tubing and two self-sealing Super-Seal inserts. Only the PTFE Teflon
Super-seal inserts and the borosilicate sight tubing are exposed to the
process fluids. The standard shields shall be epoxy-coated carbon steel.
For installation, the support brackets should be longer than 10 ft. or
heavier than 75 lbs. and the alignment should be in vertical position.
LEVEL SWITCHES
Level Switches sense high or low liquid levels. These shall operate
in safety shutdown systems and use a displacer-style sensor located in an
external cage. The displacer cage with 4” diameter shall have two NPT
pipe plugs for easy relocation. For electrical connections, the external size
shall be ½ NPT. The standard construction material of level switch shall
comply the metallurgical requirements of NACE MR0175-200.
2.2.2 PRESSURE
Pressure is measured to determine its effect to the process and for
the equipment safety monitoring. Turbines requires specific amount of
20 of 58BASIS OF DESIGN Sheet
GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
Rev. No. A
Doc. No. PIC-E-NTV-627-003
pressure to be applied, by measurements acquired from process
instruments, the operators can determine whether the amount of pressure
can drive the turbines or not.
DIFFERENTIAL PRESSURE TRANSMITTER
The differential pressure transmitter shall consist of a mechanical
measuring system with elastic pressure element of magnetic-field-
dependent sensor with amplifier and case. The resulting differential
voltage from the coupled sensor is amplified to current signals. It shall
have a standard output signal of 4-20mA. The maximum working pressure
may be 100 up to 250 psig.
The pressure connections shall be 2xG ½ female. Wetted parts and
case shall be made of stainless steel and NiCrCo alloy. It shall meet the
standard for the ingress protection of the transmitter which is IP65.
PRESSURE TRANSMITTER
Pressure transmitters shall be in-line to the process pipeline and
shall provide gage pressure measurement and indication. It shall have an
output signal of 4-20mA based on HART protocol. A change in signal is
directly proportional to the pressure measured by the diaphragm sensor.
The pressure range shall be -14.7 to 300psi. The maximum measured
error shall have a tolerance of +/-0.15% of span. Isolating diaphragm and
wetted material parts shall be 316L SST and Alloy C-276. ½-14 NPT
female may use for the process connection.
PRESSURE INDICATORS
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GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Pressure indicators shall be used for local indication. The
measuring element shall be diaphragm seal to protect from slurry fluids.
Using this type of indicator, the size of flanged shall be 1 ½”. The range
shall read approximately 1/3 to 2/3 of full scale and its maximum error
shall not exceed 1% of the span. The window material shall be of Shatter-
proof glass.
Its process connection shall be bottom entry type of SS 316 and ½”
NPT. The indicators shall capable of withstanding 130% of maximum
range without affecting its accuracy. The enclosure shall be weather proof
to NEMA 4X/IP66.
2.2.3 FLOW
An instrument for flow determination is designed to compensate the
information that the level controllers cannot acquire from level instruments.
The accuracy of these instruments can be preserved by using appropriate
instrument material construction.
ORIFICE PLATE FLOW METER
Orifice flowmeter shall be comprise of a concentric square edged
orifice plate designed for flange tap and capable of withstanding
differential pressure equal to full line pressure without zero or calibration
change. Flange taps shall be of size ½” NPT.
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GEOTHERMAL POWERPLANT SEPARATOR, SCRUBBER AND
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Rev. No. A
Doc. No. PIC-E-NTV-627-003
It shall meet the requirements of BS 1042 and ISO 5167 in all
aspects in measuring flowrate. For two wires, the output signal shall be 4-
20mA. The wetted materials such as orifice assembly, stem, and manifold
shall be made of 316L stainless steel.
PITOT TUBE FLOW METER
The Pitot tube flow meter shall have cross-sectional T shape that
allows flow separation at a fixed point. It shall be comprised of high and
low pressure plenums and shall have the ability to accommodate RTD
integral to the sensor. Also, the sensor shape shall promote less turbulent
zones on the backside of the sensor.
These flowmeters shall be made in 316L stainless steel and
hastelloy 276, and can withstand in the maximum pressure and
temperature of 200 psig at 405 °F. The mounting material shall be
constructed from same material as process pipe. Threaded and welded
opposite side support assemblies shall be applicable.
2.2.4 OTHERS
This includes the other general instruments involved in the
separator, scrubber and brine disposal system such as valves, actuators,
etc. which are not classify in the four process variable measurement.
CONVERTERS
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Converters are used to change an analog signal (4-20mA) to a
proportional linear pneumatic output (3-15psig) or vice versa. For split
ranging, it shall be recalibrated to provide higher output signals.
The minimum supply pressure shall be 3 to 15 psig. For safety
purposes, it should be enclosed when installed in outdoor environment
with an enclosure rating of IEC standards IP65.
HAND SWITCHES
Hand Switches are electrical switches actuated by hand motion.
The switches shall have three position changeover sequence for open, off
and auto control. The position indexing options may be 900 or 450. The
current rating should be 6A with a rated voltage of 690V. Silver/Nickel
shall be the contact material. For finger terminal protection, IP2X standard
shall be used.
HAND CONTROLLERS
Hand Controllers shall be protected against transient voltages and
reverse polarity. The supply voltage and current may be 24V AC/DC at
250mA.The temperature operating condition may be 32°F to 122 °F.
These controllers must be installed inside a NEMA 3 (IEC IP54), or
better enclosure and mount to standard 35mm DIN rail track.
ACTUATORS
The cylinder type actuators shall be used in the whole process.
These actuators shall be direct acting that provides fail-to-open for
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normally close valves. The standard pressure range shall be 3-15psig. Its
maximum operating pressure may be up to 150psig. The connection shall
be in NPT.
Cylinder actuators shall be supplied with a compound link and lever
arrangement designed to minimize water hammer by providing
characterized opening and closing. Each unit shall comply AWWA C540-
93 Standard for Power Actuating Devices. All wetted parts of the cylinder
shall be nonmetallic, except the cylinder rod which shall be chromium
plated stainless steel. The rod seals shall be of the nonadjustable, wear
compensating type.
CONTROL VALVES
The control valves body shall be made of high temperature cast
steel. The temperature range should be -320 to 800°F and its pressure
rating shall comply the ANSI Class 125-300. These control valves shall
consist of a body with trim, bonnet and pneumatic actuator with metal
bellows or insulating extension. Also, these valves shall have fail-safe
action upon loss of air supply. All control valves scale shall be calibrated
from 0-100% and may installed vertically and horizontally.
SOLENOID VALVE
The solenoid pilot-operated diaphragm valve is suitable for
controlling air pressure. For general atmospheres, the material shall be
brass body. It can be used to pilot large actuators for quick closing of
control valves. It shall be resilient seating for tight shutoff and can be
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mounted in any position. For pipe sizes from 3/8”-1” NPT, with pressure
ranges from 10psi to 250 psi.
PRESSURE SAFETY VALVE
Pressure safety valve with rupture disk housing shall be made of
316 SS base on IP 65, IP 66 IEC 61508. The size of the rupture disk
device is generally the same as the PRV inlet connection. It shall be loop
powered with the 4-20mA transmitter signal to the controller. Proper
cabling type and diameter shall be used for input power as well as for the
output signal. Shielded stranded copper shall be. It shall have a size
between 10 to 14 AWG.
2.3 CONTROL ROOM
The control room shall provide shelter for operators and workstations and
must be constructed with materials that do not easily corrode. It must be
enclosed to avoid exposure from hydrogen sulfide and other air contaminants
that may deteriorate control room facilities. Air filters can be installed to provide
total protection against air impurities.
2.3.1 FACILITY
The centralized control room shall consist of workstations, alarm
consoles, HMI- interface, ESD switches/pushbuttons and visual and
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audible alarms. Auxiliary power source such as gGenerators and
uninterruptible power supply will be considered in case of power failure
occurs. Air-conditioning units shall be installed to protect control facilities
from overheating and for operator comfort. Fire extinguisher must also be
available.
Marshalling cabinets will be located at an area opposite to the
operator consoles or workstations, as well as the system cabinets. The
preferred entry of wirings from the field to its designated cabinets is top
entry since the central control room will be designed to be at ground level
with certain elevation..
2.3.2 ENVIRONMENT AND LOCATION
The central cControl rooms will be located 1400700 m at most from
the process field to avoid being exposed from the heat released by the
steam and hydrogen sulfide which can cause severe corrosion. The
ambient temperature inside the control room must be maintained at 18
deg. Celsius with 50% relative humidity and 0.1ms-1 maximum air speed.
2.4 JUNCTION BOXES
Junction boxes provide termination of process instruments cables
because instrument wire cannot send signals at a further receiver. These boxes
are within process areas where nearby instruments are found and therefore
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exposed to hazardous and corrosive environment. The minimum standards for
junction boxes will be based on NEMA enclosure type which covers corrosion
resistance and ability to protect from rain and submersion or the NEMA 4x types.
The enclosure will be made up of 316L stainless steel with 1.5 mm thickness.
The cables that will be inserted into the junction box will be protected by epoxy
stainless steel cable glands to prevent entry of corrosive gases inside the
junction box.
All the wires of field instruments are terminated to the junction boxes. An
area in the fieldn area may consist of different junction boxes depending on its
capacitysignal type. Each instrument has input and output signals which can be
classified either Analog or Digital.Instruments with analog signals will be
terminated in analog junction boxes, while cables with digital signals are
terminated in digital junction boxes.
These boxes shall be elevated with minimum elevation of 1.5 feet,
depending on its size and capacity.
There are cases considering the assigned I/O signal type to the field instruments. If the
accessories are separated from its main field device, then the I/O signal type is
assigned to the accessories instead to the main field device. For example, if the
transducer (I/P Converter) is separated to the control valve, then the Analog Output
signal from the control valve is assigned to the transducer (I/P Converter).
3.0 INSTRUMENT MATERIAL SELECTION
Instrument material selection must be according to its application. In geothermal
process where critical and extreme conditions are involved, material selection must
always consider the process temperature and pressure to prevent degradation of the
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instrument’s accuracy. Instruments that havewhich involve direct contact with
superheated fluid or steam must have an operating range prior to actual measurements
with additional tolerance. for fluids at 400 °F and can handle pressure at 200 Psi. Also,
materials should be corrosion resistiveresistant to corrosion since the underground
steam releases hydrogen sulfide which reacts fast with metals with no corrosion proof.
The manufacturers below are expected to meet or supply the instruments required in
the production of steam.
List of Manufacturers/suppliers: to follow
For the selection of instruments,
Rosemount instruments are taken into consideration as well as Fisher in
selecting the appropriate valves for the process.
4.0 SUPPLY SYSTEM
Power supply of the control system shall be of highest available quality for
reliability and long service life. Power supplies for all transmitters, controllers, signal
converters, electric system and components in shutdown system shall be supplied from
UPS. Power distribution to each instrument shall be through proper, independent switch
and fuse. Protective fuses shall be of indicating cartridge type mounted in fuse holders.
4.1 ELECTRICAL
In general, the following Power Supplies shall be used for instrumentation
and Control: -For Process Platforms: 220V AC + 5%, 60HZ + 1% (UPS) for all
instruments control. However, all components e.g. instruments, system shall be
suitable for 220 V + 10% AC, 60 Hz + 3%; For Process & Well Platforms: 24V
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DC + 5% Battery Negative earthed for Platform interlock system, solenoid valves,
fFire and gGas system and status lamp.
. 4.2 PNEUMATIC
For pneumaticPneumatic instruments, dry instrument gas / air supply
compressor output shall range from shall 100 psi minimum to 200 psi. For
pneumatic valve actuation, the operating air supply pressure shall range from
120 psi to 150 psi.be as follows:
100 psi (minimum)
200 psi (normal)
300 psi (maximum)
5.0 EQUIPMENT PROTECTION
Since a process involving geothermal is hazardous, all aspects involve in here
must be clearly stated and finalized. One of the most important parts of a system is the
equipment. Without these equipments, a system can’t be operational and so, for the
safety of this equipment, certain protection is defined.
5.1 ENVIRONMENTAL PROTECTION
All instruments/equipments must be suitable with the working environment
as well as its position whenn the installed. The basis for installation should also
consider equipment exposure to several factors like wind, temperature, vibration,
shock and many others. It must also withstand these conditions during shipment
or storage.
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5.2 INGRESS PROTECTION
All field instruments shall have ingress protection to IP 65 or better.
Pneumatic field instruments used for control applications shall have ingress
protection to IP 55 or better. All instruments installed inside pressurized
equipment / control rooms shall have ingress protection to IP 42 as a minimum.
5.3 TROPICALIZATION
All electrical components shall be tropicalized to protect against humidity,
moisture and fungal growth by means of hermetically sealed units, protective
coating on circuit boards, gold plated edge connectors, etc.
5.4 HERMETIC SEALING
All relays and switches shall be hermetically sealed, and those utilized in
24 V DC control logic circuits shall have gold plated contacts rated 0.5 Amp at 24
V DC. Those interfacing with field equipment shall be rated 2 Amp 24 V DC.
5.5 HAZARDOUS AREA INSTRUMENTATION
The Contractor shall classify hazardous areas in accordance with API 500
and specify various equipments accordingly. All instruments which are mounted
outside of normally pressurized control / equipment rooms shall be certified by
bodies such as FM / UL / BASEEFA / CSA / DGMS / CMRS for use in Class I,
Division I, Group D, T3 hazardous area, even if the instrument’s location is
classified as a normally non-hazardous area. Intrinsic safety approval shall be
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based on entity concept and necessary compatibility checks shall be carried out
by Contractor before selecting any equipment. Intrinsically safe protection using
external barriers shall be provided for all process transmitter loops (closed as
well as open). Isolating barriers shall be of the plug-in type, mounted on modular
back plane termination units. Each input and output in a loop shall have a
separate barrier. No barrier shall be shared between two loops in input / output.
All other instrument loops shall be provided with explosion proof / flame proof
protection. Solenoid valves, electric hand switches, signaling lamps and Intercom
/ Paging system shall be Explosion proof / flame proof to Ex d or NEMA 7. If
specialist instrumentation cannot be provided with the above methods of
protection, then alternative methods suitable for the classified area and certified
by an acceptable Authority may be proposed. The Contractor shall submit a
technical report justifying the instrument selection for the Company’s
consideration.
5.6 R F INTERFERENCE
All equipment shall remain unaffected by radio transmissions (Levels of
permissible RFI shall be as per IEC 801). Band-pass and / or band stop filers
shall be fitted, as necessary.
5.7 SEALING
Seal systems shall be used to isolate instrument from the process fluid
encountered in the following services:
a. Wet gas, which may condense in the instrument lines.
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b. Process fluids that vaporize condense or solidify under operating pressure and
ambient temperature.
c. Process fluids that will subject the element to high temperature.
d. Process fluids that will subject the element to high temperature.
e. Viscous liquids.
Sealing may be accomplished with diaphragm seals. All venting
instrument and pilot valves shall have bug screens fitted to atmospheric vents.
6.0 EARTHING SYSTEM
Safety of the system as well as its people is the two most important aspects to be
considered. Earthing system is provided to protect a system from sudden mishap or
short circuit that can harm lives of inhabitants.
6.1 ELECTRICAL SAFETY EARTH
Bonded to the site structure and utilized for electrical safety of metal
enclosures and chassis on all instrument and electrical components.
6.2 INSTRUMENT CLEAN EARTH
Instrument clean earth will serve as basis for the earthing of DC instruments that
are usually located near or inside the control rooms. Data and communication busses
are earthed due to vulnerability of low level CMOS and microprocessor circuits and to
prevent noise interference or risk of data/communication loss.
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6.3 INTRINSICALLY SAFE EARTH
Process equipment such as motors, lightings, and power distribution
system which runs at 120VAC, 220VAC and 480 VAC are power earthed due to
high current level switching and to prevent radio frequency or electromagnetic
interference.
.
7.0 CABLE REQUIREMENTS
A well-designed and applicable system cable is necessary to achieve the
required performance of the system.
7.1 CABLE TYPES
There are several cable types for each area to be used for. Certain
standards must be followed in choosing the right cable for each function. The
inner and outer jacket of the cables shall be made of extruded flame retardant
194 °F PVC to IS 5831 type ST2. The O2 index of PVC shall be over 30. The
temperature index shall be over 482 °F.The following products shall be within the
jurisdiction of this Group: NEC, NEMA and, IEC.
7.1.1 INSTRUMENT CABLE
Cables with soft annealed bare or tinned copper conductors and
PVC flame retardant insulations and jackets are the standard offering for
300V Power-limited tray instrumentation installation. The specified cable
to be use is #18 AWG, 8 pair tinned copper conductor with PO (Polyofelin)
insulation.
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7.1.2 SYSTEM CABLE
The core of a single-mode fiber is smaller (<10 micrometers) and
requires more expensive components and interconnection methods, but
allows much longer, higher-performance links. Installed cable shall be
8.3/125micron core/cladding, single mode, and graded index glass fiber.
All materials in the cable are to be dielectric. A multipair shielded #20
AWG type of cable is used in the system. It is made up of copper with
PVC jacket material.
7.1.3 SIGNAL CABLE
Typical cable shall be #18 AWG twisted pair, PVC insulation, braid
or foil shield, with drain wire, PVC jacket with rated voltage of 220-
600VAC. The drain wire shall be connected at one end of the cable
choosing the end with the lowest impedance ground source.
Multi-pair cables shall have the following additional features:
Color coding or tagging of the wires.
Individual pair shielding apart from overall shielding.
Maximum of 12 pairs per cable
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7.1.4 POWER CABLE
Power Cables shall be PVC sheathed 3 core, minimum of 2.5mm2
conductor area (Max. conductor resistance of 7.41Ω/km), 0.9 mm nominal
thickness of insulation, and minimum thickness of inner sheath of 0.3mm.
7.1.5 JUNCTION BOX CABLE
Instrument cable and signal cable are terminated inside the junction
box. Typical cable shall be #18 AWG shielded twisted pair. The specified
home run cable used is a traditional MC Cable with interlocking metal-tape
armor. This MC Cable carries no limit of current-carrying conductors as
per NEC® Table 310.15(B)(3)(a). Several cable types are used for
different junction boxes.
JB No. Cable Type
DJB-A-001 1 pair
DJB-C-003 2 pair
DJB-A-001 8 pair
DJB-A-003 5 pair
DJB-B-001 6 pair
DJB-C-003 2 pair
AJB-A-002, AJB-C-004, 2 core
AJB-A-002 18 core
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AJB-A-004 25 core
AJB-B-002 12 core
AJB-C-004 28 core
7.2 CABLE IDENTIFICATION
All wiring, cables, tubes, multi-tube bundles, junction boxes and auxiliary
equipment shall be suitably identified clearly as per tag or addresses. Plastic
adhesive tapes shall not be used for instrument identification. All wiring shall be
tagged with slip on or clip-on wire marker at both ends with the wire number
specified on the drawings.
Terminals for power cables, polarity, ground connection, shall be identified
according to the specified tag.
Cable cores shall be colored as follows:
24VDC Digital Circuits: Positive: Red, Negative: Black, Ground: Yellow green
Analog Circuits: Positive: White, Negative: Black
Cable outer sheaths shall be colored as follows:
Intrinsically Safe: Blue
Non-IS Cables: Black
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7.3 CABLE SHIELDING
All instrument signal cables shall be braid/foil shielded/shield grounded at
the same point as the signal circuit.
7.4 CABLE MARKING
All cables shall be identified with stainless steel cable markers securely
fixed to the cable with cable tie wraps at the following locations:
All cable glands
Entering and leaving cable ladders, ducts, and supports
Both sides of walls or bulkheads
Cable markers shall be fitted during or immediately after cable termination.
7.5 CABLE RUNS
All cables going to and from control panels shall be supported with the
cable manager or tray. Power cables shall not be combined along with the
control cables in one cable manager. Cables in intrinsically safe circuits shall
preferably be not run in the cable manager for cables in non-intrinsically safe
circuits. If run in the same cable manager, a metallic earthed separator shall be
provided. Conduits carrying intrinsically safe cables shall be painted with the blue
color bands at each end.
The entry and exit of the conduit shall be smooth and free from burrs.
Cables shall be put inside the conduit to prevent damage. Splices shall be made
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only at the end of each terminal of the instrument cables going to the junction
boxes.
7.6 CABLE INSTALLATION
All cables including serial link and data highway cables going to or from
the equipment rooms shall be armored and continuously screened with screen
grounded at the equipment room end only.
For ease of instrument disconnection, an adjustable elbow or union shall
be provided between the terminating gland and the instrument.
A neat loop of 250mm diameter shall be left immediately adjacent to all
instrument devices in the field.
Cabling for locally mounted instruments carrying sensitive signals and
normal/emergency walkways or other installation that can interfere with the
equipment shall be separated.
Cable transits shall be used to provide gas-tight cable penetrations
through decks or firewalls.
7.7 CABLE TERMINATION
All cable glands shall be double compression type and explosion proof.
Cable glands subjected to salt water spray shall be weather proof. All
terminations shall be screw type terminals for 2.5mm2 conductors (minimum)
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Insulated crimp lugs shall be used for all cable core connections, with only one
conductor per terminal side.
Cables shall be terminated in 316 SS glands. The inner sheath shall be left
on the cable after the gland, and removed at the point of entry into wiring duct.
Cable cores shall not be “pig-tail” finish. Electrical tapes or other safety
accessories shall be provided for safety.
Cable screens and drain wires shall be securely insulated at the final field
termination.
The communications conductor of a cable shall be terminated in the bottom
terminal of a row of terminals.
Printed sleeve-type ferrules shall be used in both terminals of control wires
or any other cables depending on the size of the wire being used.
Only one conductor shall be used per terminal side.
Cable entry to control room/ other rooms shall be through listed multicable
transits.
Terminal blocks shall be vibration proof, din rail mounted, stack on type and
shall use screws for terminals. Fused terminal blocks shall also be used for
safety purposes. Termination of shall be through the use of wire lugs / ferrules.
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Cable termination of skid items: Manufacturer supplying skid mounted
equipment or vessels with instrumentation (alarms, shutdowns, control functions)
shall be accessible and terminated on a central junction box near skid boundary,
available for hook up by contractor.
B. CONTROL
1. INTRODUCTION
Geothermal powerplant separator, scrubber and brine disposal system
process control shall be according to DCS and PLC control system. User
interface and remote control capability of the said types of control are the basis
for control for the processes involved. Less human intervention shall be adopted
using the advanced control system.
2. OPERATION SYSTEM
Central DCS located at control room shall monitor and control all process
units for the entire project. Control room shall provide adequate space and
guarantee a safe, effective and efficient control and monitoring of the plant. Every
major and minor unit of the plant shall operate independently from its dedicated
console, providing machine edition HMI and VDU-based DCS Monitor Interfaces.
Each of these consoles shall have 32” LED monitor.
The DCS operator interface (VDU based) shall be the primary integrated
window for operation of the control and safeguarding systems and shall provide
access to:
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1. Process Control
2. Sequence Control
3. Equipment Status
4. Alarm Overview
5. Trip Status Overview
6. Real-time Trending
7. Fire and Gas Detection Status
2. SAFEGUARDING SYSTEM
The main objective of the plant and its control system is to, safely, reliably, and
continuously produce on-specification product. Without compromising these objectives,
the control systems shall also be designed to maximize plant availability, minimize plant
energy consumption, adverse environmental impact and requirements for operator
interventions. The principle objective of the safeguarding systems is the protection of
personnel, environment, plant and equipment and the maintenance of safe operating
conditions compatible with production requirements.
This shall result in control and safeguarding design that is:
1. Safe
2. Simple to maintain and operate
3. Reliable and flexible to accommodate changes in technology and
operating requirements.
4. Low cost
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3. EQUIPMENT LOCATIONS
The location plan for equipment installation shall be based on methods where
instruments are accessible for maintenance. Instrument installation shall be based on
the manufacturer’s specifications.
3.1 METHODS
Two general methods are used to position equipment:
Group Pattern where vessels, exchangers, columns, pumps and
etc., are group in separate areas. This method shall be applied in
the project.
Flowline Pattern where equipments are laid out as arranged in the
process flowsheet.
For the process, a compromise between the two shall be used for ease of
operation and maintenance.
3.2 ELEVATION
Heavy and bulky units such as columns, tanks, and etc. shall be
placed on the ground with proper support to avoid high expense of
elevating equipments.
Therefore, pumps or other equipments shall be used to force the
fluids to flow unnaturally.
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3.3 OPERATING CONVENIENCE
Equipments requiring frequent attention shall be grouped together
to facilitate operation and maintenance. However, the safety
clearance between the units has to be observed to ensure safest
possible arrangement and the most hazard prone equipment shall
be placed at the location most convenient for it to be removed.
Equipments that provide local indication shall be mounted within
eye level for ease access of operator.
A rectangular setup with a central overhead pipe rack permits
equipment to be installed along both sides of the pipe way with
ease of access.
3.4 PLANT EQUIPMENT LAYOUT
Pumps shall be located in line along each side of an access way
with the motors aligned outwards for easy access and
maintenance.
Equipments requiring large cranes for services shall be located at
the perimeter of the rectangular set up, adjacent to the main road.
Compressors shall be installed to allow for rapid dismantling and
reassembly thus avoiding from the needs to have a standby unit.
Compressors with bottom suctions and discharge connections shall
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be used, supporting it on a platform above ground level
(approximately 2.5 m or so).
4. BASIC CONTROL AND MONITORIING
This level comprises basic control and monitoring of process, utility,
equipment and auxiliary systems and is implemented in DCS. These
functions can be categorized as follows:
4.1 UNIT MONITORING
Unit monitoring comprises all Human Machine Interface (HMI)
function provided to those responsible for monitoring and control of the
process and its environment. These includes alarm and monitoring
display, group and detail displays, custom graphic displays, data historian
and retrieval, reporting, etc.
4.2 REGULATORY CONTROL
Basic regulatory control provides closed loop control functions for
stable and safe operation around steady points of operation. The basic
control functions comprise mainly of flow, level and pressure control loops
required as a minimum to operate and control the process. These loops
may include extended regulatory control functions such as: split range
control, override control, ratio control, and cascade control. They may also
include control based on calculated variables, such as heat duty control,
pressure compensated temperature control, etc. all of these shall be
realized on the central DCS system only.
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5. BASIC SEQUENCE, CONTROL, LOGIC, INTERLOCKS
All Sequence control, interlocks and logic shall be realized in the central DCS to
provide automatic performing of task in a defined sequence.
5.1 SEQUENCES
Sequences shall be used where appropriate for frequently repeated
series of control actions. All sequences shall include feedback for the
operator of the current step and status of the sequence. All transitions
must be configured with an alternative path in the event of the failure of an
action that drives the process to a safe state. If possible, large sequences
should be broken into smaller components that can be activated from a
supervisory sequence. For example, if a pump with inlet and outlet valves
is part of a sequence, the pump start/stop can be made into a smaller
sequence called from the main process sequence.
5.2 INTERLOCK
Interlocks refer to logic that would be used to control the operation
of devices. In general all interlocks must default to a state that would drive
the process to a safe state. Any interlocks that are uncertain or have bad
signals transmission would be assumed to be in the fault state. The
system will be configured to include bypass interlocking operation
whenever presence of inconvenient process occurs.
Hardwired Interlock
A signal wired directly to the motor control relay. Hardwired
interlocks may be required by construction codes or for fundamental
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safety. These interlocks could only be bypassed by inserting jumpers in
the field which should never be required.
Safety Interlock
A logic required for the safe operation of a device and
equipment protection. These interlocks cannot be bypassed except by
changing the control logic.
Process Interlock
A logic required for the normal operation of a device in the
process. In local mode process interlocks could be bypassed. In the
transition to remote mode, all process interlocks would be activated.
Permissive
A condition that must be true for a device to change state but
when the state has changed it would be ignored.
All interlocks, except permissive, would be latched in the control
system and require acknowledgement by the operator. Motor controls
would only start on a direct start command and would not be set to trigger
when an interlock clears or is acknowledged.
6. DCS DESIGN REQUIREMENTS
The process shall have workstations, for control, for monitoring, for
maintenance, and for data archiving. Control shall be centralized in
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one control room. Each workstation must compose of one engineer
to monitor the plant operation. EXIDA will be used to provide
functional safety and security software feature in the system.
Redundancy of smart switch must be provided for 100% reliable
communication.
The DCS shall be using Delta-V S series controller for economical
and reliable control of the plant. Also SIS (Safety instrumented
System) as supported by S-series, will be used for safe and
maintainable control of ESD devices and MCC (Motor Control
Cabinet) devices. Stand-by controller or a redundant controller
must be used as a backup control for emergency situation.
Redundancy of controllers, power supply, network switch, I/O
modules and other significant devices must be provided as a
backup during emergency situation, e.g. emergency shutdown.
The controllers must have enough number of AI, AO, DI, and DO
modules to support digital and analog devices. Also it shall support
HART devices, thus it must contain HART module.
Complete software, hardware, and communication load shall not
exceed 50% system load even after the complete implementation
of project and running pick load. This also includes redundant
processor.
The system shall have 50% margin in software memory load for
future spare addition without replacing or upgrading existing system
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hardware or software at all levels. Also it shall be capable of
loading up to 100% without overrun or degradation of performance.
It also must report all type of load limit alarm, diagnostic alarms up
to channel level, communication alarm system, hardware failure
alarm and other global information with alarm facility on engineering
or operator station in real time with 1 second resolution.
System shall support various types of control, interlock, sequence
algorithm and shall also support various types of high level
programming language like function block and sequential function
chart in real time control application in addition to standard control
algorithms available in DCS.
The system shall also support several of hourly shifts, daily and
monthly, report logs, totalizes reports, snap shots reports, etc in
Microsoft excel format only. The layout and type of reports or data,
number of tags per report, etc shall be as per owner’s requirement.
All operator stations and engineering stations shall be equipped
with MS Office license copy. And system shall support minimum of
1000 tag historian software at 1 second interval.
Purchaser shall provide 230Vac +/- 10% at 50Hz -3/+1 Hz, UPS
grade, floating/grounded power supply for complete DCS system at
cabinet room. All digital inputs shall have 24Vdc interrogation
voltage level. All digital outputs shall drive 24Vdc, 2 NONC, socket
mounted, interposing relays with 230D AC/5Amp contact ratings.
All field loads from digital output, including solenoid valves, MCC
switch gear signals, etc. shall be interfaced via these interposing
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relays only to avoid interference problems in low voltage instrument
signal cables.
There shall not be any interposing relays for field Digital inputs but
all MCC digital inputs shall be wired to DCS via interposing relays.
While preparing the DCS database, all configurations like graphic
symbols, color codes, control or logic schematics, etc. shall be
based on ISA standards.
7. SYSTEM ARCHITECTURE
7.1 NARRATIVE
The proposed DCS System Architecture for Geothermal Power Plant
Separator, Scrubber and Brine Disposal System is composed of five workstations. It
includes Delta-V Pro-plus for Engineering Workstation, Operator workstation, AMS
Suite for Maintenance workstation, OPC server and Historian workstation for alarm
logging. These workstations gather the data from field devices to execute commands
and to monitor the status of field devices for maintenance purposes.
Delta-V Pro-plus is used in engineering workstation, where the operator or
an engineer has an access in making changes in the control system program. Since
Operator workstation is for monitoring and manually operating the system, it does not
need any Delta-V Pro-plus. AMS Suite for maintenance workstation is used to monitor
field devices status, whether they should be calibrated or replaced with other devices,
this intelligent device manager avoid further damage of the field devices and secure that
plant operation is efficient. Historian workstation archived all the alarms and log errors
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to trace them and monitor that the process is in its normal state and is efficiently
running.
These workstations communicate with two smart switches via Industrial
Ethernet to avoid error in delivering the signals from the controllers to the workstation.
Redundant S-series controllers and SIS (Safety Instrumented System) are useused as
a back-up if the active controllers fail to work. SIS or Safety Instrumented System
controller is used for those ESD field instrument. HART module is used for HART
(Highly Addressable Remote Transducer) devices. All digital devices will only be in a
conventional type of wiring. A motor control cabinet (MCC) is provided for centralized
control of motor. All MCC devices are controlled by active S-series controller and SIS
controller for safety control via interposing relay cabinet to avoid interference problem in
low voltage instrument signal cables and communicate via HART protocol.
7.2 DRAWING
(See Document No. PIC-E-SYS-396-001)
C. SAFETY
1. INTRODUCTION
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The production of steam can acquire can cause several types of hazards which
are being pre-determined to evaluate the appropriate safety standards to be followed.
These standards are guidelines for the purchase of materials that are applicable for
the area that is classified according to the hazards that are most likely to occur and for
personnel safety considerations. Potential hazards include process hazards, presence
of flammable fluids and combustible gas or vapors, and toxic gases.
Area classifications are based on the presence of possible cause of hazards that
are pre-determined and assumed in a specific location. The most commonly used
codes are from IEC/NEC standards which defines the level of hazard present that may
affect process equipment and personnel’s health.
Geothermal process hazards are due to the critical temperature and pressure by
which the control system is operating. Another hazard that must be put into
consideration is the emission of hydrogen sulfide and CO2. Hydrogen sulfide is a
highly flammable, explosive gas, and can cause possible life-threatening situations if
not properly addressed. In addition, hydrogen sulfide gas burns and produces other
toxic vapors and gases, such as sulfur dioxide. Excessive amount of carbon dioxide
released to the surface is health threatening and creates environmental issues. At this
stage government involvement is felt.
Basis of Safety and Layers of Protection
Plant safety integrity can be measured by the level of protection it applies. Safety
starts with the basic control system. The BPCS or the basic process control system
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provides significant safety through proper design. This automatic sequence has
already considered safety procedures but is not reliable enough to sustain external
sources of hazards. Sometimes the equipment itself can be the source of unsafe
process control. Process equipment exposed to high temperature and pressure and
corrosive environment application are prone to deterioration.
The next layer is still based on the control system wherein automated shutdown
routine is enforced as long as it is within the scope of the configured cause and effect
matrix.
The next layer for protection is the intervention of the operators. In this situation
the accurate decision making determines whether alarming condition can be put into
stabilized state. Operators shall follow enacted protocols as a guide to proper response
to emergencies whenever it occurs.
Another high degree of protection uses automatic SIS. The safety instrumented
system is based on ANSI/ISA 84 functionality safety standards which state the
requirement under IEC/NEC 61511. Automatic SIS does not only include the process
level safety but also for the safety of the personnel. By integration of fire and gas and
basic process control system emergency detection the automatic, SIS is able to
determine the action to take. These actions are configured in the engineering
workstation. Safety instrumented system is also capable of diagnosing the process
equipment reliability.
The next active layer is by means of rupture disks, valves, etc.to mechanically
release process variable at an uncontrolled stage and prevent explosion or fire.
The final layer is the emergency response which includes evacuation plans,
firefighting, etc. and means to minimize ongoing damage, injury or loss of life. Plant
safety regulating body shall impose protocol whenever an emergency occurs. They
shall also assigned areas for evacuation which shall be designed to be accessible all
the time. These areas must be safe all the time even during presence of hazards in
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other plant areas. Medical teams and means of transport for evacuation shall also be
considered due to critical process environment.
2. Safety System (Fail Safe Action)
Geothermal power plant process control system safety and efficiency shall not
only be based on the configured final control element response to configured sequence.
Programmed sequences are dependent on system supplies such as pneumatic and
electrical supplies. When these supplies fail, process sequence are interrupted which
will make process control unstable. Fail safe actions must not be dependent on the
program which the final control elements follows but must beare mechanically capable
of giving the safest possible position in case power interruptions occur. The required
predetermined control element’s fail-safe actions of final control elements areis shown
in Table 1. Also, provided at Table 2 is the action taken at a specific process alarm
condition..
Table 1. Control Element Fail Actions
Tag No.Loop
No.Description Service Fail action
LCV-103B L-103B Level control valve Discharge saturate to D-1200 Fail-to-open
LCV-103B L-103A Level control valve Discharge saturate to D-1100 Fail-to-open
LCV-104 L-104 Level control valve
-Brine disposal to wells 33,77,
31A, 50 & binary
-To hot brine injection
Fail-to-Close
LCV-504 L-504 Level Control Valve-Condensate discharged to
sump S-1100Fail-to-Open
PCV-505A P-505A Pressure Control Valve -Reduce outgoing steam Fail-to-Open
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pressure to secondary rock
muffler (M-700)
PCV-505B P-505B Pressure Control Valve
-Reduce outgoing steam
pressure to secondary rock
muffler (M-700)
Fail-to-Open
Table 2. Alarm Summary and Actions
ALARMS
Loop
No. Description Actions
LAH-102 L-102 Level alarm high Start P-300B, opens LCV-103A
LAHH-102 L-102 Level alarm very high Start P-300C, opens LCV-103B
LAL-104 L-104 Level Alarm very low Disables AVS-102
LALL-104 L-104 Level alarm very low Trips P-300A and Closes LCV-104
PAH-306A P-306 Pressure Alarm High Trips P-300A
PAH-306B P-306 Pressure Alarm High Trips P-300B
PAH-306C P-306 Pressure Alarm High Trips P-300C
PAH-105 P-105 Pressure Alarm High Trips all active brine pumps
LAH-203 L-203 Level Alarm High Start P-200
LAL-203 L-203 Level Alarm Low Stop P-200
dPAHH-301A P-300
Differential Pressure Alarm
Very High Trip P-300A
dPAHH-301B P-300
Differential Pressure Alarm
Very High Trip P-300B
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dPAHH-301C P-300
Differential Pressure Alarm
Very High Trip P-300C
VAH-302A/B/C
V-300A/
B/C Vibration Alarm High Operator action/SIS
PAH-306A P-306 Pressure Alarm High Trip P-300A
PAH-306B P-306 Pressure Alarm High Trip P-300B
PAH-306C P-306 Pressure Alarm High Trip P-300C
PAH/PAHH-
305A/B/C P-305
High and Very High
Pressure Alarm
Close LCV-104 on condition that all Brine
Pumps are tripped
LAH-401 L-401 Level Alarm High Start P-400A/B
LAL-401 L-401 Level Alarm Low Operator Action
LALL-401 L-401 Level Alarm Very Low Trip P-400A/B
FAL-308A F-308 Flow Alarm Low Trip P-300A
FAL-308B F-308 Flow Alarm Low Trip P-300B
FAL-308C F-308 Flow Alarm Low Trip P-300C
LAHH-502/
LAHH-503
L-502/L-
503Level Alarm Very High
Disable AVS-502B, Open LCV-504 and
closed solenoid valve for PCV-505A and
PCV-505B air supply.
LAH-502B/
LAH-503
L-502/L-
503 Level Alarm High Disable AVS-502B, Open LCV-504
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2.1 System Architecture (Delta V SIS)
The integrated Delta V SIS in the system architecture shall have a
separate controller from the basic process controllers to achieve a higher degree of
plant and personnel protection and in compliance with IEC 61508 and IEC 61511
standards. The geothermal process control system shall have a redundant safety
instrumented system to maximize safety and efficiency within process control.
Safety instrumented system is composed of any combination of sensors, logic
solvers, and final elements which is separated from the process control system.
This can include safety instrumented control functions, safety instrumented
protection functions, or both.
The role of the workstations for safety purposes in the system architecture is as
follows: 1.) Proplus Station for cause and effect matrix configuration; 2.) Operator
workstation for process monitoring and remote intervention to process controls
specially during occurrence of process emergencies; 3.) Application workstations
(Historian) for alarm data archiving coming from process control transmitters and
fire and gas detectors; 4.) Application workstations configured as OPC is
responsible for open communication between devices with different protocols and
5) Application workstations for maintenance which diagnose process equipment
problems before they occur. The communication between controller and
supervisory level will be made possible using Ethernet.
The Delta V SIS controller will act as back-up system for which the main purpose
is to monitor continuously the ability of sensors, logic solvers, and final elements to
perform on demand, with faults diagnosed before they cause spurious trips and
implement response to alarms in case the basic process control system fails.
Unstable process control results to alarming conditions that affects plant integrity in
operating at stable and safe conditions.
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3. Emergency Shutdown System
The imposed safety system will include an emergency shutdown that is not
dependent on loop action as it independently shutdown control elements. The ESD
system is integrated in to the fire and gas system where both prevent and provide safety
from incidents and unnecessary shutdowns. All plant areas will be provided with safety
fire and gas detecting instruments in compliance with the standards imposed by the
regulating bodies for safety.
ESD system shall be hierarchal. Minor alarm action will trip an instrument so that
technicians can troubleshoot the area affected. Hierarchal ESD minimize dead time
costs or losses due to production loss.
An overall shutdown will be located at the central control room. The officers-in-
charge or authorized personnel are responsible in tripping this centralized ESD push
button except for extreme and critical situations. Safety board will assign level of
alarming condition where crews nearby can use this emergency button.
Strategic location for ESD stations with panels for system conditions, alarm
monitoring and location of affected area will be provided. Response is predetermined for
officer in charge to choose the corresponding action to a specific alarm condition. Push
buttons installed for a specific emergency response are hard-wire and normally de-
energized to prevent short circuit, line breaks, or ground fault. ESD can also be initiated
using the safety console integrated into the control system. Only authorized personnel
can activate the ESD.
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ESD initiation will be based on the following:
ESD TYPE RESPONSE
ESD #1 Unit shutdown
ESD #2 Process Shutdown
ESD #3 Over All shutdown
ESD Summary
Process Emergency Status - Initiate fail safe actions
Fire Emergency Status - ESD initiation is based on fire alarm status
Gas Emergency Status - ESD initiation is based on gas alarm status
3. Leak Detection System
Process equipments which areis responsible for process variable such as steam,
brine and fresh water supply transmission shall be monitored to keep thesethese
equipments reliable in transmitting the expected process output.
A level transmitter is integrated in all non-submersible pumps to detect fluids that
comesfluids that come out from these pumps. The transmitter will link its
measurement to the SIS controller to give the corresponding action to take. The
action usually taken at this condition is tripping the working pump and gives its work
to a back-up pump.
4. Fire Detection System
The fire detection system is integrated into the design to minimize risk of
equipment destruction and personnel safety. Smoke detectors and other fire
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detecting instruments are looped separately from process design but are integrated
into the delta V SIS for to provide interlocks to process equipment and provide safety
action in case fire occurs. Multiple installation of fire detecting instruments in an area
will increase the accuracy in terms of locating the defective area. Fire detecting
instruments are hard wired to delta V SIS controllers therefore special modules will
not be required.
Operator interfaces and indicators shall be installed to determine level of risk and
location of fire. Stations for manual fire alarm trigger will also be installed in different
plant areas. When these alarms are triggered by officers in charge, it usually intends
to imply a heightened level alert and response would be overall emergency
shutdown and evacuation. Personnel are obliged to report emergency status and
provide appropriate response to these alarms.
Fire detector output such as audible and visual consoles will be based on how
critical the present situation is. This is to provide accurate response in case fire
occurs.
Below are areas within geothermal power plant that are prone to fire and explosion.
Location # of Detectors ESD InitiationActive Alarm Consoles
HMI Audible Visual Workstations
Separator Multiple detection ESD #1-2
Scrubber Multiple detection ESD #1-2
Flash tanks Single detection ESD #1
Pipelines Multiple detection ESD #1-3
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Level Drums Single detection ESD #1-2
Control Room Multiple detection ESD #3
Other control
system loopsSingle detection ESD #1
5. Gas Detection System
Gas detection system comprise of instruments that measures level of risk once
an unstable amount of toxic gases or combustible gases reaches the surface or
exposed to an area. These gases are usually in the form of carbon dioxide and
hydrogen sulfide. Gas detectors are either installed at multiple points in an area or
single gas detectors.
Alarms will only read normal gas condition, toxic or combustible gas level rising
and alarming level of gas detected.
Gas detection system does not require special module in a controller. Its 4-20
mA signal to controller can support interfacing with the controller level and into the
supervisory level for complete safety compliance with IEC 61511.
Plant areas that usually exposed to this combustible and toxic gas are usually
found in venting areas. These areas include the well-field and the plant-site vent
mufflers. Pipelines will also be provided with gas detectors for cases where leaks occur.
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Graphical and tabulated data will be recorded in the in the historian workstation
for periodically evaluation of plant safety status. Location, alarm status and options for
alarm action will be displayed in HMI’s and workstations.
Below are the details for gas detection locations, console and ESD response
Location # of Detectors ESD InitiationActive Alarm Consoles
HMI Audible Visual Workstations
Separator Multiple detection ESD #1-3
Scrubber Multiple detection ESD #1-3
Flash tanks Single detection ESD #1-3
Rock mufflers Single detection ESD #1
Pipelines Multiple detection ESD #1
Level Drums Single detection ESD #1
Well Field Multiple Detection ESD #3
6. Audible and Visual Alarms
OSHA standards and guidelines which focus on the personnel safety shall be
implemented as well as the general industry standards. Installation of audible and visual
alarms especially for remote plants comply the requirements stated by the said
standards. To alert the personnel in case of emergency is the main objectives of these
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alarm hardware. Indication of these consoles shall only mean occurrence of
emergencies involving life threatening events.
The design for geothermal plant alarms shall indicate the following events:
Visual alarms (in the form of emergency lamps)
Indications:
Green – plant operating in normal condition
Yellow – presence of unstable process/environmental issue
Red- ESD 3 response or evacuation
Audible alarms (usually Beacons/ Alarm Bells)
Indications:
No sound - Plant operating in normal conditions
Non-continuous sound - presence of unstable process/environmental issue
Continuous sound - ESD 3 response or evacuation
D. NAMING CONVENTION
1. SCOPE
This document contains the naming convention of different deliverables, and
used as a reference for easy identification of each part.
1. NAMING CONVENTION
The naming convention of each deliverable can be determined by the following:
“X” symbolizes alphabet letters (e.g. A, B, C, D…)
“0” symbolizes numbers (e.g. 0, 1, 2, 3..)
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CLASSIFICATION
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1. DOCUMENT/DRAWING
XXX – X – XXX – 000 - 000
Example: PIC-E-PID-396-001
Company Name – PIC (Process Instrumentation Company) is the company
name used in this document.
Classification – To determine either Engineering (E) or Design (D) is
involved in the deliverables.
Deliverable - The list of requirements provided by the company.
No. Code - This is used for determining the main deliverables.
Sheet No. - This is used for determining the subtopics of main deliverables.
Abbrv. Description
PID Process and Instrument Diagram
NTV Narrative
SARC System Architecture
SPC Specification
SHT Data Sheet
INDX Index
SHEET NO.
NO. CODE
DELIVERABLE
COMPANY NAME
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IOL I/O List
JBL Junction Box List/Schedule
CBL Cable List/Schedule
IAM Instrument Air Manifold
WRG Wiring Diagram
LPD Loop Diagram
LOC Location (JB/IAM)
INS Installation
DELIVERABLES NO.CODE
Abbrv. DescriptionNo.
Code
DWG Drawing 396
NAR Narrative 627
IDX Index 439
SPC Specifications and Datasheets 773
LST List 578
SCD Schedule 723
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2.2 JUNCTION BOX
XXX – X - 000
Example: DJB-A-001
JUNCTION BOX NO.
AREATYPE OF SIGNAL
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Type of Signal - The instrument’s signal type can either be Analog (A) or
Digital (D). After determining its signal type, “JB” initials is followed which
stands for Junction Box.
Area- It represents “A” which stands for Area.
Junction Box No. - It identifies the number of junction box within the area.
2. DEVICE CABLE
XX – XXX - 000
Example: DC-LSH-102
Device Cable- It represents “DC” which stands for Device Cable.
Instrument Tag No. – The instrument tag number is based on its function
and loop in the process.
3. SYSTEM CABLE
XX – XXX - 000
Example: DC-LSH-102
System Cable- It represents “SC” which stands for System Cable.
INSTRUMENT TAG NO.
DEVICE CABLE
INSTRUMENT TAG NO.
SYSTEM CABLE
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Instrument Tag No. – The instrument tag number is based on its function
and loop in the process.
4. LINE
0 – XX – X/X000 - X/X000 - 00
Example: 24”-CS-D1100-T100-01
Size- It indicates the pipe size in the process line, and usually measured in
inches.
Material- The pipe in the process is made of carbon steel (CS).
From and To Equipment – These specify the connection of pipe between
equipment. In this case, “-“ is removed in the tag name of equipment.
5. MARSHALLING CABINET
XX –000
Example: MC-LIT-104
Marshalling Cabinet - It represents “MC” which stands for Marshalling
Cabinet.
NUMBER
TO EQUIPMENT
FROM EQUIPMENT
MATERIALSIZE
MARSHALLING CABINET NO.
MARSHALLING CABINET
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Marshalling Cabinet No. - It identifies the number of junction box within the
area.
6. MAIN CABLE
XX – XXX – X – 000: 0 - 0
Example: MC-DJB-A-001:1-1
Main Cable - It represents “MC” which stands for Main Cable.
Junction Box – The place where the main cable is located.
Terminal Block No. – The main cable is terminated in a certain terminal
block no.
Terminal Strip No. - The numerator value of the terminal strip is used.
JUNCTION BOX
MAIN CABLE
TERMINAL BLOCK NO.
TERMINAL STRIP NO.
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