section-vi instrument erection, installation & commissioning specifications...

PAC PROJECT INSTRUMENTATION SPECIFICATION

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SECTION-VI

INSTRUMENT ERECTION, INSTALLATION & COMMISSIONING

SPECIFICATIONS


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INDEX

SR. NO. TOPIC PAGE

1 SCOPE 3 2 RESPONSIBILITIES 3 3 REGULATIONS 3 4 GENERAL 4

5 INSTRUMENT MECHANICAL INSTALLATION REQUIREMENT

5.1 INSTRUMENT MOUNTING 4 5.2 INSTRUMENT PROTECTION 5 5.3 INSTRUMENT CONNECTIONS TO PIPING AND VESSELS 5 5.4 INSTRUMENT PROCESS PIPING AND TUBING 5

5.5 INSTRUMENT AIR PIPING AND PNEUMATIC TRANSMISSION 7

5.6 INSTRUMENT TAGGING 7

6 INSTRUMENT ELECTRICAL INSTALLATION REQUIREMENT 7

6.1 INSTRUMENT WIRING SYSTEM INSTALLATION 7 6.2 CABLE ROUTES 14 7 INSTRUMENTATION E&C SPECIFICAITONS

8 INSTRUMENT INSTALLATION, COMMISSIONING SCHEDULE 18

8.1 OBLIGATION OF IEC 18 8.2 GENERAL CONDITIONS 19 8.3 STANDARDS 19 8.4 WORKMENSHIP, TIDYNESS, SAFETY 20 8.5 SCOPE OF WORK OF BIDDER’S IEC 21 9 PAINTING 24 10 IDENTIFACTION OF INSTRUMENTS 24 11 TESTING OF INSTRUMENTS 25 12 LOOP CHECKING/COMMISSIONING 27 13 SUPPLY OF MATERIAL 28


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1. SCOPE 1.1 This specification gives directives for the design, selection criteria,

methods, instructions and examples of instrument installation, erection and commissioning scope of work for the entire PAC project.

1.2 This specification shall be read in conjunction with the general specification specified and individual instruments specifications given in other parts of this ITB document.

2.0 RESPONSIBILITIES

Any conflict between the requirements of this specification and related codes, standards, data sheets, drawings, requisition, etc., shall be referred to the OWNER for clarification and most stringent method shall be followed by BIDDER

3.0 REGULATIONS 3.1 GENERAL 3.1.1 The instrument design scope of work covered by this specification shall

be designed and constructed in accordance with the requirements of this specification and the edition of the applicable National and/or International Codes and Standards.

3.1.2 In cases of conflict between standards the most stringent requirements shall apply.

3.2 CODES AND STANDARDS

-API :American Petroleum Institute -API 551 :Process Measurement Instrumentation. - BS :British Standards -BS 729 :Hot-dip Galvanized Coating on Iron and Steel

Articles (1971). -BS 3643 :ISO Metric Screw Threads principles and data. -BS 5308 Part II :Specifications for PVC insulated cables -IEC 60331 :Test for electric cables under fire conditions – Fire

Resistance -IEC 60332 :Test for electric cables under fire conditions –

Circuit integrity -IEC 60391 :Marking of Insulated Conductors (1972). -IEC 60423 :Conduits for Electrical Purposes: Outside

diameters of conduits for electrical installation and threadsfor conduits and fittings.

-IEC 60757 : Code for Designation of Colors (1982). -IEC 60584-3 :Thermocouples Part 3: Extension and

Compensating Cables - Tolerances and Identification System (1989).


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-IEC 61000 :Electromagnetic Compatibility -IBR :Indian Boiler Regulations IS Indian Standard -IS 1554 Part 1 :PVC Insulated electric cables working up to 1100V -IS 2148 :Flameproof enclosures for Electrical Apparatus

4.0 GENERAL

This instrument design specification provides the basis of design for instrument drawings and documents, instrument subcontracts and instrument installation material requisitions along with erection and installation specifications. Project requirements that differ from this specification will be submitted as exceptions with requisitions and subcontracts by BIDDER.

5.0 INSTRUMENT MECHANICAL INSTALLATION REQUIREMENTS 5.1 INSTRUMENT MOUNTING 5.1.1 IEC shall be responsible for issuing instruments, transportation from local

store to site, unpacking, inspection for any damage, assembly, etc. of all the instruments.

5.1.2 IEC’s scope shall include plugging of all the unused (spare) cable entries in the junction boxes

5.1.3 Each instrument, erection hardware, or accessory to be installed by the IEC shall be inspected visually for any damage.

5.1.4 The IEC shall then take it from where it is stored, lift it into position and ensure it is leveled, plumbed and firmly secured.

5.1.5 Throughout the construction period, instrument shall be adequately protected wherever necessary, by covering with suitable plastic bags. The IEC shall supply and fit these bags as required.

5.1.6 Instruments shall not be bracketed directly off process lines except where specified by engineer-in-charge.

5.1.7 Local mounted instruments shall be bracketed, mounted in sub-panels or placed on a suitable pedestal. They shall, wherever necessary, be secured to the nearest suitable firm steelwork in a manner prescribed by OWNER. Wherever possible, instruments shall be located so that they are protected from damage by passing or falling objects.

5.1.8 Local instruments with the exception of those on lines and vessels shall be mounted with the centerline at approximately 1.2 meters above the platform or floor in a position accessible for operation and maintenance.

5.1.9 Handrails shall not be used for supporting instruments. 5.1.10 All electronic instruments or instruments with electrical components

shall be electrically earthed in strict accordance with drawings. Steel panel board shall not be used for earthling.


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5.1.11 Instrument shall be installed in accordance with the appropriate hook-up diagrams or as per the manufacturer’s recommendations, wherever hook diagrams are not available. The IEC is not permitted to deviate from these diagrams with prior written approval from engineer-in-charge. Instruments, JBs, analyzer panels shall be installed strictly as per the installation drawings provided for the projects.

5.1.12 All cable entries to instruments shall be preferably from bottom. If bottom entry is not possible due to any reason, the cable entry shall be from side.

5.1.13 The instrument already mounted on the equipment shall be removed by the IEC for the calibration check and re-fix back.

5.1.14 All instruments shall be mounted as close as possible to the process connection provided. Maintenance and accessibility requirements are to be taken into account. The length of the impulse line shall be minimal. The location of instruments shall be such that direct drainage of condensate, water or process fluids from adjacent equipment has no adverse effect on surrounding equipments, instruments or human beings.

5.1.15 All instruments shall be accessible either from ground or from a permanent finished floor and/or permanent platforms.

5.1.16 Instruments shall be mounted on a vibration free place. Special care shall be taken for heat expansion.

5.1.17 Local converters, amplifiers, switches, etc., shall be installed near the corresponding instrument.

5.1.18 Local indicating instruments shall be readable from where the related equipment is operated or from where the primary instruments are to be tested or calibrated.

5.1.19 Pressure gauges shall be preferably installed direct mounted. Offline installation shall be preferred when the direct readout is not possible or instrument is subjected to high vibrations. In all such cases, all PG shall be mounted with 2” pipe stanchion and required tubing/supports.

5.1.20 Instruments shall not be direct mounted on handrails. No support of instrument stanchions, cable tray, etc. shall be taken from any type of handrails.

5.1.21 Plates welded to structures, yokes and similar support arrangements shall be used for mounting of off-line instruments/stanchions. Instrument supports attached to process piping or vessels shall not be allowed. Apart from mandatory in-line instruments, no direct mount instruments are acceptable, except RADAR type Level transmitters installed from tank top nozzles, level switches installed from top of the thanks.

5.1.22 On prefabricated skids, modules or packages, instrument cabling and/or tubing leaving or entering the unit, as well junction boxes, bulkheads or panel plates, shall terminate at a central location near the edge. All cables shall be protected in closed tray of FRP MOC tray/cover. The closed cable trays are minimum requirement of all cables within any skid.

5.1.23 All instrument supports, cable ladders/trays, conduits and other iron supporting materials shall be hot dip galvanized and painted as per specifications given in this chapter.


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5.1.24 Fasteners such as bolts, nuts and washers shall at least be made of SS as a minimum. No copper/brass alloys are allowed in the whole plant.

5.2 INSTRUMENT PROTECTION 5.2.1 All electronic instruments and junction boxes in the field shall be

protected by the use of individual enclosures, i.e. canopies. This shall be fabricated from 2 mm thick FRP sheet to suite site condition. In case of clubbing of more than one instrument under one large canopy like 3 or more JB or instruments, the thickness of FRP shall be selected such that it will prevent sag in canopy and with proper angle supports in between. However, the min. thickness of these type of bigger canopies covering more than 2 instruments shall be min. 4 mm. The design of canopy for various instruments, group of instruments, JB, etc. shall be approved by OWNER. The provision of canopy on each instrument is applicable for all those instruments also which are under close sheds/shelters or within machine house also.

5.2.2 In-line instruments (e.g. control valves, flow meters), and closely connected instruments (e.g. pressure gauges), which require tracing, shall be traced using an extension of the process pipeline tracing.

5.2.3 Off-line instruments requiring tracing shall protect the process tubing. The valve manifold block and process part of the instrument shall be insulated by means of a protective housing.

5.2.4 Off-line instruments requiring process tracing, tracing shall protect the process tubing and the valve manifold block shall be protected by means of a direct mounted heating block with thermostat if required. Valve manifold block and process part of the instrument shall be insulated by means of a protective housing.

5.2.5 Heat tracing may be executed by applying electrical tracing and/or steam tracing (if available and indicated on the process instrument diagrams, P&I D).

5.2.6 Steam-tracing systems shall be executed by copper tubing for steam temperatures up to 200”C. The tubing shall be seamless copper tubing, solid drawn soft annealed.

5.2.7 It is an engineering design criterion to protect electronic instruments against direct solar radiation by way of instrument Sunshades.

5.3 INSTRUMENT CONNECTION TO PIPING AND VESSELS

The interface connection between piping and instruments shall be always after the first mechanical isolation valve provided by piping group. No instrument needle valves shall be used as first isolation valve. The various piping / instrument connections details are given in this ITB document at Volume-3, Section-9, Chapter-II. This type of mechanical isolation valve shall not be part of instruments, even if provided by instrument vendor.


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5.4 INSTRUMENT PROCESS PIPING AND TUBING 5.4.1 At the instrument side of the first block valve, using tubing with double

compression-type fittings shall make instrument connections. Piping shall provide reducing flanges with a ½” O.D. tube connector to accommodate the instrument connection requirements. All SS316 tubing shall be either ½” or ¼” OD, Seamless SS316 tube only and all instrument fittings shall be double compression, Swagelok type. These thickness shall be followed as standard as a minimum, except special case requirements for vary high pressure and temperature services. For steam, BFW and high pressure gas (working pressure > 100 barg) services, it shall be ½” CS/SS/IBR pipes (Min. SCH80, higher based on requirement) with all welded joints in place of SS impulse tubing.

5.4.2 For pipe classes above 600 # up to and including 2500 # piping shall provide a flange connector with a ½” compression-type fitting to accommodate the instrument tubing.

5.4.3 Pressure gauges will be hooked-up by means of “pancake” flanges. 5.4.4 Manifold shall be mounted closed coupled to the transmitter.

Service Type Manifold Type Flow / Differential pressure -Block/Equalizing/Drain/Vent(3-valve

manifold) Pressure Block/Drain/Vent -2-valve manifold Differential pressure Block/Drain/Vent -(3-valve manifold) Position of transmitters (based on API RP 551): Phase Under / Above tapping Liquid Under Gas Above Vapor Under Steam Under

Final orientation of tapping to be determined in conjunction with process conditions on the project. However, BIDDER shall take enough care while designing the pipe lines with liquid services in such a way that the line carrying pressure and flow sensors/instruments shall be run well above ground /finished floor level (min. 3 meter) so that the transmitters of all liquid services shall be installed at min. 1.5 meter height on stanchion below the sensor tapings with downward tapping orientations. No instruments installed below 1.5 meter height from ground or finished floor / gratings level shall be acceptable.

5.4.5 All pressure instruments, except for those fitted with diaphragm seals, shall have a block valve and a drain/vent facility, to provide the capability of depressurizing the impulse line. Diaphragm seal Pressure instrument shall have mechanical isolation/drain valve and flushing ring with


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drain/vent. All the diaphragm seal type instruments installation shall be such that removal of first mechanical isolation valve shall not require removal of instruments/sensors/diaphragm.

5.4.6 Differential pressure instruments shall be located above the taps for gas and non-condensable fluids, and below the taps for liquids and condensable liquids. For steam service, pressure instruments shall be mounted with a steam siphon with sufficient impulse pipe length and steam service flow instrument shall be mounted with condensate pots. The preferred orientation for steam service orifice/flow nozzle assembly is horizontal. Hence BIDDER shall take enough care while designing steam line in such a way that it will facilitate installation of transmitters at minimum 1.5 meter from ground/finished floor level with tapings orientation below the sensors. Also the parallel running pipe line shall have enough margins for horizontal run of taping for steam service flow instruments. The minimum elevation of all such pipe lines from ground or finished floor level/gratings shall be min. 3 meters.

5.4.7 All process impulse pipe/instrument tubes shall be supported on MS angles of suitable size welded on structures. When instrument supports have to be fixed to fireproofed plant structures, these supports shall be welded to the steel structure before the fireproofing is applied.

5.4.8 Instrument process impulse lines shall generally be ½” OD. Seamless, annealed, stainless steel Grade AISI-316, wall thickness of 0.065” as a minimum. Care shall be taken that selected fittings are compatible with the tubing size and its specifications.

5.4.9 Where the above tubing and fittings are not suitable for the process fluid or the process conditions and/or specific project requirements, other materials/higher thickness conforming to the piping specification shall be used.

5.4.10 Instrument and capillaries shall be plumb and level. Impulse lines which run at a slope shall be continuously sloped in not less than one (1) in ten (10) except where otherwise specified. Preferred direction of slope is downward from the process for liquid service and upward from the process for gas service. Tubing shall be supported and protected from vibration and physical damage. All type of instrumentation tubing, including process impulse tubes, instrument air tubing, etc. shall be individually supported on MS angles and/or perforated FRP trays with SS304 MOC U clamps with SS nut/bolts at every 500 mm distance in a staggered fashion.

5.4.11 No mechanical stress shall be induced upon an instrument that will cause a malfunction or error in the readout. Tubing shall not be secured directly to machinery or pipes. Tubing clamps and miscellaneous hardware shall be SS304 stainless steel.

5.4.12 All instrumentation Pipes/ Tubes shall be bent using pipe / tube bender; any hot bending will be totally rejected. These shall be cut using pipe / tube cutting devices. Hot cutting will not be allowed. Cutting of the tubes/tubing by hacksaw shall not be acceptable.

5.4.13 Pipes or tubes installed, but not connected, shall have the ends closed in an approved fashion to, prevent the entry of foreign material. For a period


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of up to one week, adhesive tape may be used, for a longer period caps or plugs shall be used.

5.4.14 Where instrument tubing is run parallel to each other, joints should be systematically staggered and neatly offset. There must be at least two pipes / tubes diameter space between adjacent joints.

5.4.15 Threaded fittings will have their threads specified in the purchaser’s documentation. All threaded joints shall have Teflon tap as sealing medium.

5.4.16 Where compression fittings are used, the fittings shall be installed in strict accordance with the manufacturer’s recommendation.

5.4.17 The number of joints in the tubing shall be kept to a minimum consistent with good practice and also to keep the wastage to the minimum.

5.5 INSTRUMENT AIR PIPING AND PNEUMATIC TRANSMISSION 5.5.1 Instrument sub-headers shall be executed in accordance with the piping

specification. 5.5.2 The sizing of instrument air supply sub header shall be in general as

follows:

SIZE NUMBER OF USERS ½" Pipe according to ANSI 1-5 users * ¾" Pipe according to ANSI 6-12 users * 1" Pipe according to ANSI 13-20 users * 1½" Pipe according to ANSI 21-50 users * * In case off large air consumers (on/off valves etc.) air consumption must be calculated and number of users shall be adjusted.

5.5.3 Individual instrument air supply and pneumatic transmission lines to and

from instruments shall be SS 316 tubing, distributed via instrument air manifold. All such instrument air manifold shall have first mechanical isolation valve well before instrument air manifold and not part of manifold.

a.Tubing shall be ¼” OD x 0.039” wall thickness soft annealed, seamless. b. High-volume pneumatic actuators may require ½” OD x 0.065” tubing. c. Fittings shall be SS double compression, Swagelok only. Care shall be

taken that selected fittings are compatible with the tubing size and its specifications.

d. Instrument tubing and fitting/ferrule hardness shall be selected such that proper crimping / sealing is ensured.


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5.5.4 Individual tube runs shall be supported by existing structures and steelwork with SS304 MOC U clamps and SS nut/bolts at every 500 mm distance.

5.5.5 The thickness of instrument air impulse tube shall be 1.6 mm for ½” OD SS tubes and 1.0 mm for ¼” OD SS tubes, unless otherwise specified.

5.5.6 The scope shall include the installation of tubes using compression fittings, laying of separate trays for instrument tubes, clamping (SS clamps), supporting, pressure testing, leak checking and leak arresting.

5.5.7 Instrument air tubes shall be laid in separate perforated FRP cable trays in a group with parallel run with sufficient gapes in between to facilitate mounting of U clamp in staggered manner for individual tube.

5.5.8 Horizontal runs of pipes and tubes shall have pipes / tubes laid vertically in parallel and shall be run with the minimum number of changes of direction consistent with good practice and neat appearance.

5.5.9 All pneumatic signal tubing shall be cleaned by blowing through with instrument air prior to installation.

5.5.10 Single tubing shall be run in such a manner as to give the maximum protection against mechanical damage.

5.5.11 Where permanent enclosure trunking or conduit, etc., are left, space for tubes to be pulled at some future date, a galvanized draw wire of adequate size shall be left in the enclosure.

5.5.12 Instrument air and signal tubing shall be adequately supported wherever possible to prevent any mechanical damage.

5.5.13 Angle iron or suitable size of perforated trays shall be used for continuously supporting four or more SS tubes and the tubes shall be secured to the tray at 0.5 meter intervals by suitable U-clamps(SS). The tray must be provided with suitable supports to prevent sagging.

5.6 INSTRUMENT TAGGING

SS304 MOC Nameplates of a permanent type, firmly fastened with screws, showing tag number shall be used on each of the instruments in the entire project.

6.0 INSTRUMENT ELECTRICAL INSTALLATION REQUIREMENTS 6.1 INSTRUMENT WIRING SYSTEM INSTALLATION 6.1.1 Cabling 6.1.1.1 In general, field mounted electric instrumentation shall be wired and

connected to identified junction boxes by means of single cables as specified in section Volume-3, Section-9, Chapter-II. Each junction box shall be of FRP MOC and with all type of entries shall be from bottom only. All junction boxes shall have 12 nos. of branch cable entries and 1 no. of multi pair entry at bottom only. The junction box loading shall be


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done in such a way that after successful implementation of complete project, there shall be 20% spare space shall be available for future use.

6.1.1.2 In general, Instrument wiring between the field junction boxes and control room shall be by means of multi-pair cables as specified in Voume-3, Section-9, Chapter-II. Use of 6 pair or 12 core cable is not allowed.

6.1.1.3 In case of special requirements for field mounted instrumentation, direct run (single) cables shall be used. (e.g. frequency signals, governor signal, etc.) with OWNER’s approval.

6.1.1.4 The instrument signal cables shall comply with the following minimum requirements: a. Cables shall be properly protected where required, e.g. on

hydrocarbons, hot oil, other liquid solutions’ ingress and/or mechanical damage with closed FRP cover on cable trays/ducts. As a minimum, all cables within skid shall be protected in closed cover trays. Trays shall be FRP MOC and cover shall be of FRP MOC.

b. All cables shall be water, oil and sunlight resistant, gas and vapor tight and Flame Retardant according to IEC 60332.

Note : Cables used for Telecommunication System shall be Fire Resistant

according to IEC 60331. c. Insulation materials shall be XLPE (cross-linked polyethylene). d. Mineral insulated cables may be considered for high temperature

services (e.g. furnaces, reactors, etc.). 6.1.1.5 All instrument signal cables shall be installed and terminated observing

the following details:

a. Special signals cables (such as coaxial cables, fiber optic etc.) shall be installed in Accordance with the Seller's instructions.

b. All instrument cables shall be individually marked at both ends with markers of SS tags tied with SS wire.

c. Special attention shall be paid to the interconnection of cable screens, such that the screening is earthed at the intended location only so that multiple earthing does not occur. Generally all shields shall be earthed at DCS/ESD marshalling panel side only. EMC guidelines to be followed, if applicable.

e. Cable glands on equipment in the plant shall be mounted at the bottom to prevent ingress of water. Where cable glands are installed in the sidewall of the equipment, the cables shall enter from below. Cables coming from above shall first drop to below the elevation of the gland.

f. All cables used for intrinsically safe signals shall be identified as such. g. All field signal cabling shall be coded with the applicable instrument

tag number at both ends close to the instrument and to the junction box with SS tag tied with SS wire.


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h. Junction Boxes shall be preferably installed at ground level. Material shall be FRP. Junction box segregation philosophy shall be used for various category of I/O as under - Analog Input/ Analog Output ( 4-20 ma) - Digital Input (0-24 V DC) - Digital Output ( 0-24 V DC, lamps) - Digital Output ( 110 V AC for Solenoid valves) - Power distribution ( 110 V AC)

Separate junction boxes shall be provided for control and interlock category of signals, which are destined for ESD or DCS marshalling cabinets. Intrinsic safe and flameproof instrument signals shall be mounted in separate junction boxes. All junction boxes shall have WAGO make, screw less, side entry, DIN rail mounted terminals with 0.5 to 4.0 sqmm size.

Color of terminals shall be grey for non-Exi signals, color blue for Exi signals. Each junction box shall be tagged by means of a screwed SS tag plates with tag number engraved on it.

6.1.1.6 The scope shall include the IR test before and after laying the cables, for all multi pair cables, IR test for single pair cable before laying, installation, glanding and termination of cables using cable glands at both the ends for all single and multi pair cables, grounding of junction boxes & cable –glands, supply of bootlace lugs, continuous ferrule sleeves, insulation tapes, Teflon tapes, etc., laying of cables on trays, dressing, clamping, supporting, continuity checking, meager testing and all related activities.

6.1.1.7 IEC will supply all the consumable items & accessories for the grounding of junction boxes & cable glands and other items shall also be included in the scope of supply of IEC like insulation tape, Teflon tape, Teflon paste, silicon rubber paste, bootlace ferrules, lugs, earthing/shielding cable sleeves, of all types/size, etc.

6.1.1.8 The IEC must ensure that whenever an electrical specification is issued the appropriate sections shall be read in conjunction with these specifications and any omission or ambiguities should be resolved with the OWNER’s engineer-in-charge.

6.1.1.9 The cable installation drawings and documentations provided by the engineer will normally specify or incorporate regulations for the electrical noise pick up. However following general rules apply, a. Parallel runs of the instrument cables and power cables

should be avoided where parallel runs must be made cable spacing specified in this ITB documentation must be maintained.

b. Where instrument and power cable cross in close proximity the cross shall be made at right angle.

c. Multi core / multi pair cables shall be cut after the exact site measurements are taken between ends the cable drum schedule shall be followed before cutting the length to avoid


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any wastage and damage to complete length of cable from drum. Drum schedule shall be provided by BIDDER during execution.

d. Joints shall only be made at terminals in instruments or approved equipments like JB and marshalling panels. No intermediate joints in any cable shall be made on cable tray or in conduit. Cables must be run in accordance with the purchaser’s documentation.

e. All cables shall be terminated at junction boxes and instruments by proper glanding, using proper size crimping lugs of approved design and with appropriate crimping tools.

f. Qualified electrician who is well experienced in this type of work shall do the junction box or instrument wiring connections in an approved manner.

g. Where conduit terminates at cabinets, terminal box trunking or ducting, it shall be secured with a lock nut, brushed and ferruled in an approved manner. Sharp edges shall be removed and conduit not otherwise connected shall be terminated in smooth brushes.

h. Cables shall properly be laid in perforated trays of suitable size FRP MOC. There shall be no multi tier laying in any cable trays. All cables shall be laid in parallel in side-by-side in single layer/tier only.

6.1.1.10 All cable shall be tagged with permanently punched strip of SS and identified as given in cable schedule. The cable tag shall be on instrument side, junction box side, & control room panel. The SS strips shall be securely fastened to cables using SS wires. Cable identification tags shall be provided at an interval of 10 mtrs.

6.1.1.11 Shield, drain wire, terminated in junction boxes or earthling strips shall be provided with green color PVC sleeve cover. This shall be supplied by IEC. Inside JB, all multi pair signal cable’s each pair’s individual shield cable shall be connected to respective branch cables’ shield via dedicated shield terminals in these green sleeves. All spare pair’s shield cable of multi pair shall be terminated on insulated system earth bus bar of JB.

6.1.1.12 Yellow color continuous Ferrules sleeve (with black font) of proper size shall be provided for each terminated wire as per termination drawing. Double cross ferruling philosophy shall be used at all locations, which indicates source/destination side detail at each end.

6.1.1.13 Spare wires shall also be ferruled / tagged and neatly dressed and terminated inside JB and marshalling panels in the same group of terminals as those of main cable. All multi pair cable’s shield /drain wires shall be individually connected to marshalling panels’ system earth bus-bar with green sleeves.

6.1.1.14 Cables shall not be bent to radius less than the manufacturer’s

recommendations (i.e 10 times the cable O.D).


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6.1.1.15 Clips and saddles securing to steelwork or tray shall be of SS. These clips shall be spaced at 0.5-meter intervals.

6.1.1.16 The cable laid on the cable tray shall be properly dressed in such a

manner that the crossing of cables shall be minimized and only one tier/layer of cables in one tray is permitted (of any size). The cable on the cable tray shall be clamped with THICK PVC straps at every 0.5 mtrs in vertical trays/ducts & 1 mtrs in the horizontal cable tray.

6.1.1.17 No cable laying cables in the cable trench or to be buried in concrete

trench 6.1.1.18 All the cable exchange between the central cabinet room and field

instrumentations shall be from any one side of the cabinet room through MCT blocks of Roxtec - Sweden make only with 50% spare MCT blocks of each category/size of cables.

6.1.2 Types of Cable

The number of types of cable shall be restricted to a minimum. The broad, general specifications shall be as per Volume-3, Section-9, Chapter-II.

6.1.3 Cable Glands 6.1.3.1 Cable glands shall suit the selected instrument cable and shall be suitable

for the area classification concerned, standard Ex-d IIC/T6 and weatherproof to IP65 as a minimum with PVC hood for all flameproof instruments and weatherproof to IP65 for all intrinsically safe instruments.

6.1.3.2 The thread of cable gland shall be ISO metric in accordance with BS 3643/IEC 60423 and with the applicable classified area concerned. The size shall be in general ½” NPT for various branch cables on JB and instrument side and 1 ¼” or 1 ½” NPT for various multi pair cables, unless otherwise specified

6.1.3.3 All the field Cable glands shall be made of Stainless Steel (SS304) and double compression type only. The cable glands to be used inside central cabinet room and various panels shall be anodized aluminum MOC and shall be with check nuts. Other specifications shall remain same for indoor cable glands.

6.2 CABLE ROUTES 6.2.1 General 6.2.1.1 Cables may be routed:

- On cable ducts, trays, conduits or on special constructions. - Trenches (underground). or concrete ducts are not allowed.


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Inside the cabinet room, engineering room and control room, cables shall be laid in perforated FRP cable trays below the false flooring. The depth of false flooring shall be minimum 800 mm. The cable entry for all panels shall be from bottom only.

6.2.1.2 Electric/electronic single cables in the field shall be suitably supported

and protected by means of cable ducts/trays, conduits, etc. 6.2.1.3 The cable trays shall be safely and easily accessible for maintenance

purposes. 6.2.1.4 Proper alignment and fixing/ clamping (with SS clamps and SS

nut/bolts/washers) shall be carried out for all duct/trays. 6.2.1.5 The cable duct/trays shall be of GI/ perforated FRP as specified in the

detail in Section-II, General Instrument Specifications part of this ITB document. The cable trays shall be supplied in standard straight lengths of approx. 2500 mm.

6.2.1.6 Any bends, elbows, risers, tees etc. as required for FRP ladder as per site conditions and cable tray lay out shall be procured pre-fabricated by the BIDDER and IEC shall not fabricate at site unless it is straight run only. For all type of perforated FRP trays, the same shall be arranged pre-fabricated at site based on site condition requirement as per cable tray lay out drawings. The coupler plates shall be used to join the two trays with SS304 nut/bolts and washers.

6.2.1.7 Cable trays / ducts for multi pair cables from control room to JB is considered as main trays. Rest all trays shall be considered as sub trays. Perforated FRP sub trays/ branch trays shall be used to run individual pneumatic signal / sample tubing/ electrical (signals not to be mixed up) and shall be mounted on steel structure. All sub trays shall be bolted to the steel supports.

6.2.1.8 The sub trays shall be properly finished and laid to give neat appearance. 6.2.1.9 All supports, clamps and other fixtures shall be painted with min. two

coats of Redoxice and two paint coats of expoxy paints as per OWNER’s standard color codes.

6.2.1.10 Welding of cable trays joints is strictly not permitted. 6.2.1.11 All the main duct on main pipe rack shall be preferable run/liad on straight

horizontal plane, preferable on top most tier on any structure. In specific cases, straight vertical runs are also allowed. However, no inclined duct shall be acceptable. All support trays/sub-trays shall be run with the breadth of the tray in a vertical plane. Where the engineer agrees that the breadth horizontal the tray must be provided with additional support prevent sagging.

6.2.1.12 The cable trays shall be routed away from hot environments and places with potential fire risks, such as hydrocarbon process pumps, burner fronts of furnaces and boilers, etc.

6.2.1.13 The cable ducts/trays shall be located away from where they are subject to mechanical damage, spilt liquids, escaping vapors and corrosive gases. Where cable trays are liable to damage by traffic, they shall be protected by freestanding and sturdy mechanical structures.

6.2.1.14 The instrument cables shall be grouped according to the signal types. The main groups are:


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Grouping of various Low Voltage Instrument cables: - Electronic signals (4-20mA), including various field bus trunk and spur cables, Low Voltage switching (24V DC) for Proximity Switches (EEx-i), Proximitor (Vibration, Key-phasor, etc.) (EEx-i), Bearing Temp.(EEx-i), 24 V DC Solenoid signals and 24Vdc power supply cables, fire and gas signals. Grouping of various High Voltage Instrument cables: - Other cables like 110 V AC Solenoid valves, PA system signal and power cables, Telephone - intercom communication cable, Fiber Optic Cables, 110 V AC supply cables, 230 V AC Utility cable, any other cable carrying 50 V AC or higher voltage and 30 V DC or higher voltage, etc.

6.2.1.15 Maximum filling of Cable ladders/trays shall be 70%. A distance of at

least 0.60 m shall be provided between instruments cables as mentioned in section 6.2.1.6 (both the groups) and electrical power and/or lighting cables in case of parallel runs. However, in general trenches are not allowed. Ladder / Tray routing: for distances between instrument cables as mentioned in section and electrical power and/or lighting cables see table 6.2.2 and 6.2.3 given below. - Electrical power and/or lighting cables shall not be laid in the same cable ladder/tray as those of instrument cables. - When power and/or lighting cables intersect instrument signal cables, the crossing shall be at right angles, with a minimum separation distance of 0.30 m. - Instrument air tubing shall not be laid in the instrument cable trays. These shall be in a separate cable trays. For single or dual instrument tubing in scattered location, MS angle can also be used.

6.2.1.16 All the cable exchange between the central cabinet room and field

instrumentations shall be from any one side of the cabinet room through MCT blocks of Roxtec - Sweden make only with 50% spare MCT blocks of each category/size of cables.


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Note 1:

When separate trays are Impractical, Category number I and II may be combined, provided the category and groups are separated by a separation shield. When category numbers I and II run side by side in tray for more than 1500 mm a minimum distance of 150 mm is recommended. Note 2: Category No. III & IV may run in same cable tray provided categories are separated by a separation shield or the distance between two categories has a minimum of 150mm

No.

Category

Susceptibility

Signals

I

Measurement Signal Cable

Very sensitive

Video and communication cables Fire warning cable

Instrumentation signal cable

Sensitive

Cables with analogue signals of less than 50 V

Instrumentation signal cable

Sensitive

Digital signals of less than 24 V DC

II relay

Medium Susceptibility

Cables with analogue signals greater than 50 V AC, 30 V DC, All cables that involve operation of relays ( switching circuits)

III relay control

Susceptibility

Cables with switching signals greater than 50 V AC/30 V DC, analogue signals greater than 50 V AC/30 V DC, regulating signals of 50 V AC/30 V DC with currents less than 20 A and AC feeders less than 20 A

IV

low voltage power

Power

AC and DC cables of 0-1000 V with currents of 20-1 00 A

low voltage power

Power

AC and DC cables of 0-1000 V with currents of 100-800 A

V

voltage power

Power

AC and DC cables >1000 V with currents of =-800 A


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7.0 INSTRUMENTATION E&C SPECIFICAITONS

This specification and all additional documentation as listed under the appendices covers the materials and methods to be followed by the Instrument Erection Contractor (hereinafter referred to as IEC) when installing and testing instruments and associated cabling, tubing, tray work etc. in the entire project hired by BIDDER. However, the final responsibility lies with BIDDER only. Hence wherever IEC is specified in this entire document, it is BIDDER.

8.0 INSTRUMENT INSTALLATION, COMMISSIONING SCHEDULE

BIDDER shall mobilize the site within 15 days from the date on which they have been issued mobilization notice. This includes time required to set up facilities at site. IEC shall start work within 15 days from the date of notice.

Commissioning schedule shall be followed as agreed upon between OWNER and BIDDER and it shall be strictly followed. Various types of weekly, monthly progress and schedule review shall be submitted by BIDDER as and when required by OWNER.

8.1 OBLIGATIONS OF THE IEC 8.1.1 The obligations of IEC in fulfillment of the requirements of this

specification are briefly stated below (elaborated further in various annexure, appendices, and technical documents).

8.1.2 Instrument Installation work as per OWNER’s specifications, drawings and good engineering and construction practice.

8.1.3 Erection, checking, tests.

Category No

I

II

III

IV

V

I

0

Note 1

150

700

700

II

Note 1

0

150

450

700

III

150

150

0

Note 2

300

IV

700

450

Note 2

0

0

V

700

700

300

0

0


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8.1.4 Preparation of testing/loop checking reports/records in specified formats.

8.1.5 Co-ordination (as and when required with OWNER/other contractors/ agencies working in the same area)

8.1.6 Providing guarantees for the work carried out/ materials supplied. 8.1.7 Submitting the bar chart, progress report on weekly basis for the work

done during the period, Tag wise status for all tags of instruments list of all complete section, manpower and construction equipments, deployment details and such other activities as per requirements of OWNER. Submission of monthly material appropriation statement for cables, tubing, piping materials fittings, indicating the quantity issued and expended in standard Performa.

8.1.8 Providing proper tools and tackles, manpower (fully conversant with their job), consumables required for carrying out and completing the job correctly and within the scheduled time.

8.1.9 Receiving the material from BIDDER stores and transporting the same to IEC’s stores/ work place. Returning balance material to the place as advised by BIDDER.

8.1.10 Keeping proper record of all free issue material received, used and balance and submitting the material reconciliation statement at the end of the job.

8.1.11 Visual inspection of all free issue material and in case of any defect or shortage, bringing it to the notice of BIDDER immediately.

8.2 GENERAL CONDITIONS 8.2.1 The IEC shall be provided with open space for the site office by

BIDDER and shall be provided with electrical supply from construction power feeder at one point within 100 m from IEC’s office only. Further distribution, as required, shall be done by IEC’s as per the rules/regulations given by OWNER. It shall be IEC’s responsibility to protect the area allocated to him.

8.2.2 The IEC shall keep on site during all working hours a site in charge thoroughly familiar with the class and nature of the work to be performed under the terms of the contract. This responsible person will be deemed to have full authority to receive and to pass on to the IEC’s other employees all instructions relating to the work under the terms of the contract.

8.2.3 Any instruction given by the OWNER’s Engineer to the person shall be deemed to have been given to the BIDDER.

8.2.4 The IEC shall in the execution of his work use exclusively new material to the standards laid down in this or any supplementary document given thereafter, any inconsistency or ambiguity in the purchasers documentation shall be brought to the notice of OWNER’s engineer –in- charge and shall be resolved before work commences.

8.3 STANDARDS :


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8.3.1 The instrumentation installation and calibrations works shall be carried out generally in accordance with various international and Indian standards listed below but not limited to the following.

b. API-RP-550 Manual on installation of refinery instruments and control system.

c. ISA standards and practices for instrumentation. d. All engineering documents enclosed with this enquiry and those

issued subsequent to awarding of ITBand during execution of contract.

e. Manufacturers’ standards and practices.

8.3.2 The IEC shall carry out the work in accordance with the documents /standards /drawings listed herein, and in accordance with any local ‘Statutory Regulations’, OWNER’s safety and environment policy, client’s requirements and supplementary documentation.

8.3.3 The IEC shall instruct his staff. Skilled and semi-skilled, in the standards required by the purchaser and shall ensure that only competent persons are allowed to handle or work on instruments or instrument systems.

8.3.4 All tools and tackles including welding sets, gas-cutting sets required for carrying out the work uninterrupted shall be provided by the IEC. Tools and tackles shall be as per Appendix VII(as a minimum) of an approved type. IEC shall furnish details of all calibration equipment, their makes, model, calibration certificate etc. to OWNER before commencement of work. Any instrument without proper and valid calibration certificate from a recognized/ certifying agency like ISO9001, NABL accreditation / approval, etc. will not be allowed to be used.

8.3.5 The IEC shall arrange for the necessary staff, tools and tackles as and when required for meeting the project schedule in consultation with engineer-in-charge.

8.3.6 The working hours, holidays, weekly off etc., shall be followed as per OWNER’s rules/ regulations. However, if required IEC shall arrange their personnel to work extra after office hours and / or in shifts and on holidays to meet project completion schedule with the prior permission of OWNER / BIDDER site In charge.

8.3.7 The IEC shall be responsible for all arrangements with respect to workmen’s compensation, insurance, food, travel, accommodation and any other local regulations covering the labor employed by him.

8.3.8 All rules & regulations pertaining to the ISO 14001 certification shall be followed by IEC skilled/ semiskilled workman. IEC shall follow the guidelines given by G.N.F.C. site in charge regarding ISO 14001 and safety rules observed by OWNER.

8.4 WORKMANSHIP, TIDINESS AND SAFETY


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8.4.1 The IEC shall not allow rubbish and scrap material from his operation to lay above the site. Such rubbish and scrap shall be collected daily and be deposited at a place approved by the engineer in charge.

8.4.2 The IEC shall be responsible for protecting installed equipment from damage and pilferage, and shall ensure that all covers, caps, screws and weather protections etc. are replaced at the end of each working day.

8.4.3 Only the best construction and engineering practices are to be used, and all work must be done to the satisfaction of OWNER engineer who should be consulted on any point requiring clarification. The IEC is free to suggest to OWNER engineer alternative methods for the execution of the work where this would result in improvement.

8.4.4 The IEC shall take adequate precautions during use and storage of gas cylinders.

8.4.5 The IEC shall use, ELCB, with each power supply board required for the installation work.

8.4.6 Upon completion of the work, the IEC shall promptly remove his equipment and return to the relevant places and shall return any unused material supplied by the engineer-in-charge. Finally the IEC must clear the site of all rubbish and scrap deposited by him to the satisfaction of the engineer-in-charge.

8.4.7 The engineer-in-charge will with due reference to the relevant section of the conditions of the ITB lay down the safety regulations for the site and IEC shall ensure all his personals understand and comply with this regulations. IEC shall make sure that manpower deployed at OWNER site for this job shall be issued Safety Helmet , Safety shoes , safety goggles and any other PPE as instructed by OWNER. For working at height IEC shall provide safety belts , ledders , proper approach , scaffolding etc at its own cost.

8.4.8 The IEC shall prepare a comprehensive schedule for carrying out the installation before commencement of actual work.

8.4.9 The IEC shall arrange for the necessary staff as and when required for keeping to the schedule in consultation with OWNER.

8.5 SCOPE OF WORK AND RESPONSIBILITY 8.5.1 The instrumentation erection work covers various jobs listed under the

various schedules. However to ensure proper execution and completeness of the instrumentation work any or all of the following shall also form the part of the scope and shall be covered in the quoted rates.

8.5.2 Fabrication of pipe nipples, including threading wherever required. 8.5.3 Fabrication of seal pot/siphon/drain pot as per standards. Filling of

seal pots with filling liquids as per instructions from engineer-in-charge.

8.5.4 Back/seal welding of screwed fittings as required. 8.5.5 Laying of cable underground wherever required including excavation,

sand filling, brick laying and back filling.


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8.5.6 Connection of purging devices for instrument as per drawings. 8.5.7 Minor civil works like chipping of pavements & grouting on the

pavements the instrument panels/supports/stanchions, & chipping, refilling & finishing of the pavement for conduits.

8.5.8 Sealing of cables/tube entries into the control room after laying and testing of all tubes, cables etc.

8.5.9 Rotation of control valve bonnet wherever required/instructed by OWNER in case the valve positioners and other accessories are facing opposite to ground/finished floor level outside hand rails on platforms.

8.5.10 Reversing the action of control valve either by replacement of springs, accessories or in positioner wherever required.

8.5.11 Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts, etc. as per painting specifications.

8.5.12 Identification with approved color of paint the instrument/impulse line/manifolds connected with alarm / trips circuits. Also, punching of tag no on items shall be carried out as per instructions of engineer-in-charge.

8.5.13 Coordination with BIDDER mechanical and other BIDDER sub contractors for proper installation of lines/vessels/ equipments mounted instruments like control valves, orifice assemblies, mass flow meter, level transmitter, level gauges, level switches, other type of flow meter, flame arresters, breather valves etc., which involves removal of instruments, disconnection of tubes / cables, reconnection for alignment and proper installation etc. These instruments will be required to be uninstalled and reinstall before final installation for flushing.

8.5.14 Drilling holes and making cut outs as required on panels, shutdown cabinets, power supply cabinets, control panel pneumatic enclosures, junction box etc, for cables/ multi tubes/glands/ grommets.

8.5.15 Grounding of shield of all shielded cables to respective instrument earth bus provided in the control room/ local panel/ thermocouple head/ junction boxes.

8.5.16 Laying and termination at both ends between instrument earth buses provided in the control room/ local panel to instrument earth pit provided by others.

8.5.17 Completion of ALL drawings / documents, as per the execution of work at site.

8.5.18 Preparation and submission of “As Built” drawings (marked up copies) as required in two sets.

8.5.19 Start-up and commissioning assistance. 8.5.20 Any other work not mentioned above, but required for the proper

execution of the work like working at height and scaffolding/proper approach provision shall be in the scope of IEC

8.5.21 All or any of the works detailed above and works as per various schedule shall also be performed on package units, local panels, cabinets, gauge board installed by owner or by others.

8.5.22 Sealing of switches with standard lead seals after final setting in the presence of engineer-in-charge.


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8.5.23 Installation and terminations of tubing, cables etc. For analyzers (from field to analyzers house and within analyzer house) and its accessories like sample cooler etc.

8.5.24 IEC shall be responsible to draw free issue items from BIDDER’s store. Transportation required to shift to site shall be arranged by IEC. IEC shall check all material before it is shifted from store, any discrepancies or damage shall be reported to engineer-in-charge immediately. IEC shall be responsible for the safe custody and protection of this material until OWNER representative accepts the installation and plant is successfully handed over to OWNER by BIDDER. Any loss or damage incurred during this period shall be chargeable to the IEC/BIDDER.

8.5.25 Fork lifts, jumbo etc. if required by IEC to carry out work, shall be arranged by them at his cost.

8.5.26 The IEC shall be responsible for the supply of installation materials as detailed elsewhere in this document.

8.5.27 The installation will be tested in accordance with the instrument installation testing procedures given elsewhere in this specification. If, however, others carry out the testing, the IEC shall ensure that instruments are adequately protected during flushing and pressure testing.

8.5.28 The IEC shall be responsible for the supply and cost of all replacement material and labor necessary to rectify faults which show up during instrument installation/ testing / commissioning, provided such faults are due to faulty workmanship of faulty materials in the IEC’s scope of supply.

8.5.29 The IEC shall be responsible for the expediting and inspection of all materials in his scope of supply. However, the OWNER reserves the right to expedite and inspect such materials. OWNER reserves the right to reject any material supplied by the IEC if not found technically acceptable or of specified/ required quality.

8.5.30 The IEC is expected to hand over a fully operable system and any defects of design omission or discrepancies found which would impede this achievement must be brought to the attention of OWNER representative without undue delay.

8.5.31 The main instrument air header will (unless otherwise specified) be installed by others as a part of piping upto and including the take off point (including the isolation valve) on air header. Generally the IEC shall be responsible for the installation of instrument air manifold, tubing downstream of a given isolation valve from each branch of instrument air manifold and this valve and testing.

8.5.32 The installation of orifice plate assemblies, safety valves, breather valve, flame arrestor, rupture disc, control / switching valves, sensors of mass/magnetic/vortex flow meters, Rota meters, sample connection points up to and including the first isolation valve for flow, pressure, analysis, provision of flanged connection for temperature and any other in-line equipment will be carried out as a part of piping work by a contractor or agency responsible for piping by BIDDER.


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However this shall be supervised by IEC in consultation with site instrument engineer.

8.5.33 All welders deployed on the job by the IEC shall be approved by OWNER. Any expenses to be incurred for welders’ qualification as per requirement of OWNER shall be borne by IEC.

9.0 PAINTING

All ferrous materials for brackets and supports supplied by the IEC and other material not already protected in an approved way shall be cleaned and primed before erection with primer as per painting specification given by OWNER. Painting of instrument supports, cable tray supports, all structural, all structural supports shall be as under

10.1 The surface to be painted shall be thoroughly cleaned with wire brush/

sand paper to remove all scales. 10.2 After cleaning, one coat of red oxide zinc chromate primer shall be

given conforming to IS-2074 and allowed to dry. 10.3 One coat of final red oxide shall be applied prior to first coat of paint. 10.4 Final coat of color shall be given before handing over the plant /

commissioning. 10.5 The two coats of primer & two coats of final paint shall show DFT ad

25 microns (min) respectively. The painting shall have total DFT as 100 microns (min).

10.6 The primer & final paint shall be of first class quality & shall confirm to the following.

Primer :Red oxide Zinc Chromate Primer Type :Single pack Composition Modified phenolic

alkyd pigmented with red oxide & zinc chromate.

DFT :25 microns / coat (min) Finish coat :Epoxy Paint (Chemical Resistant) Type :Single pack Composition Phenolic medium

pigmented with superior quality pigments. DFT :25 microns / coat (min)

The paints shall be confirm to the specifications given above & first class quality in

their products range of any of the following manufactures 1) Asian Paints 2) Bombay Paints 3) British Paints 4) Johnson & Nicholson 5) Shalimar Paints 10.0 IDENTIFICATION OF LINES AND INSTRUMENTS


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10.1 All site mounted instruments, cables, junction boxes, air header isolation valves, tubing’s and wiring termination, shall be labeled or tagged in a manner approved by OWNER. Material for tag plate and tie wire shall be SS.

10.2 The engineer-in-charge will provide a table of label and other details for labels within IEC supply.

10.3 All cable termination shall be identified by double cross ferrules. The ferrules shall be continuous sleeve type, white or yellow PVC with black lettering. IEC shall supply ferrules of different sizes based on the cable sizes.

10.4 Air stations and local instruments shall have their reference numbers neatly marked on them.

11.0 TESTING

All the necessary test equipments for performing the following tests shall be provided by the BIDDER in multiple sets. BIDDER shall furnish a list of test and calibration equipments with make / model no that will be provided by him. This list should include instrument listed at annexure as a minimum. However, other types of test equipment shall be provided by BIDDER, if required in order to carry out work as per specifications. OWNER shall check the calibration of the test equipments of BIDDER. All the test equipment being used in the project shall be as a minimum with ISO9001 and/or NALB accreditation instrumentations with valid calibration certification.

11.1 All pneumatic signal lines shall be disconnected and blown through

with instrument air for 15 minutes to remove traces of oil, dust and moisture. Air manifolds shall also be blown with instrument air after installation.

11.2 All instrument air mains shall be isolated from the instrument and pressurized pneumatically, 1.5 times the design pressure and isolated from the source of pressure. The pressure shall not fall by more than 0.1kg/cm2 in ten minutes. Also leak test by soap solution shall be performed in presence of OWNER on each joint, which are to be leak tested.

11.3 All impulse lines shall be isolated from the instrument and hydraulically tested to 1.5 times the design pressure and isolated from the source of pressure. The pressure shall not fall by more than 0.1 kg/ cm2 in ten minutes.

11.4 All thermocouple, electric, power, and electronics instrument wiring shall be tested for resistance between conductor and earth and for insulation between conductors with a potential of 500V /1.1KV DC. This test shall be carried out with all conductors disconnected except from the test instruments. The resistance shall not be less than 10 M ohm. The IR test shall be carried out for all multi pair cables before and after laying, while for single pair cables, the same shall be carried out before laying. Electrical continuity of cable armoring or braiding, conduits and any associated flexible tubing, earthing conductor and /


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or equipment enclosures are to be checked for compliance with the appropriate clause of IS-3043.

11.5 Transmitter connection to the correct receivers and polarity shall be checked.

11.6 Correct connection of pneumatic and electric switches shall be checked. All type of cable/wire terminations shall be subject to pull test by OWNER.

11.7 The written results of the test in duplicate for retention by OWNER/ Engineer in charge shall be approved by the engineer in charge.

11.8 The IEC responsible for supplying the necessary test equipment and reasonable evidence of the satisfactory condition of this shall be provided, if required.

11.9 All errors all faulty workmanship discovered during this testing or during subsequent testing and commissioning shall be corrected by the IEC at his cost.

11.10 All test results shall be recorded in the approved formats. 11.11 All cable connections at field instruments and control rack terminals

shall be checked for : Correct polarity Correct Numbering Proper jointing / termination using copper lugs and PVC sleeves Cable continuity check: This check shall be done from junction box to individual instrument under supervision and as per the instruction of OWNER.

11.12 All cables shall be checked for proper clamping / support and shall be neatly dressed.

11.13 Solenoid Valves shall be checked for operation by energizing them and checking their operation. Suitable power source (as per the voltage value and type of voltage specified on the nameplate of the solenoid valve.) and suitable voltmeter shall be arranged by IEC fot this purpose.

11.14 All control valves prior to stroke checking shall be externally cleaned thoroughly.

11.15 The stroke of the valve shall be checked for opening & closing with 25% steps.

11.16 Any adjustments required for obtaining full stroke & reducing hysteresis shall be carried out.

11.17 Each on / off valve shall be checked by closing/ opening the valve a few times (through respective solenoid valves) and noting the time of travel.

11.18 The limit switch (if any) shall be adjusted if necessary. 11.19 Temperature Elements shall be checked for continuity and

resistance/milli volt value (at 0%, 25%, 50%, 75%, 100% of the range and vice versa) using a suitable temperature bath. Temperature transmitters (if any) shall be checked for operation.

11.20 The level switches (external cage type) shall be set by filling the cage with water to the desired alarm / trip level, while setting the switch, it shall be ensured that the micro switches do not reset for full rate travel of the float.


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11.21 All other transmitters shall be calibrated on test bench before installation and during installation, mounting zero will be checked and adjusted, if required. All calibration records shall be made available to OWENR for each tag.

11.22 The IEC shall be responsible to keep proper record of all the tests performed and these shall be approved by OWNER. These records shall be finally submitted to OWNER.

12.0 LOOP CHECKING

All the loops of entire instrumentation shall be subjected to 100% hot loop checking from field to DCS/ESD/systems in the control room and simulation. The logic check will be also done 100% for all interlock/logic on each and every trip parameter, start permissive and results shall be recorded in Sequence of Event recorder of ESD. However, 100% logic simulation shall be carried out by OWNER only after completion of 100% loop checking of all open and closed loops by OWNER.

12.1 Loop test shall be performed after calibration of all instruments and leak test of signal lines. Loop test are conducted to check the functional performance of all element comprising the loop, thereby ensuring proper conditions and operations. All the control room equipment namely DCS, PLC, and other peripherals are supplied, installed and commissioned by DCS supplier/BIDDER. IEC should bring all the field cable and terminate in the termination cabinet in the rack room. The loop testing shall be done by IEC with complete co-ordination with DCS/PLC supplier and BIDDER in presence of OWNER Engineers / Technicians.

12.2 Loop testing from field to system for all open/closed loops shall be generally by simulation of process condition from field sensor/transmitters and shall fix points namely 0%, 25%, 50%, 75%, 100% of full scale inputs. Detailed procedure shall be submitted to Engineer in charge for approval before proceeding with the loop testing.

12.3 In case of shutdown system field switches/transmitters are stimulated for abnormality by disconnecting the wires/feeding the trip values at field devices terminal and function of all associated system are checked.

12.4 After the loop testing is completed, the IEC shall connect back any terminations and connections removed for loop test./ marking shall be done on “loop checked” instruments.

12.5 A loop shall be considered as handed over only after all the tests are over in that particular loop and are completed and certified by Engineer in charge of OWNER, in addition to loop sheets being duly filled in all respects and approved and accepted by Engineer in charge of OWNER. Proposed loop test format shall be as per OWNER requirement.

12.6 In case of loop, in which certain instruments of the loops are calibrated by other agency, the loop testing shall be performed in


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coordination with agency involved. If any defect in the calibration of the instruments in IEC’s scope is observed, it shall be rectified to the satisfaction of the engineer in charge. However, defect in calibration in the instruments in the scope of other agency; it shall be rectified by other agency involved. After the calibration has been rechecked by other agency, the loop checking would be performed to the satisfaction of Engineer in charge, and this part is covered under the scope of the contract.

12.7 Final certified loop sheet should be submitted in two copies to OWNER and two copies to consultant.

13.0 SUPPLY OF MATERIALS

The responsibility of IEC for the supply of all materials will unless otherwise specified be as follows, but not limited to the

13.1 Materials to be supplied by the IEC at his own cost, as part of these

specifications. 13.2 The supply of consumables like Teflon tape, insulation tape, welding

rods, gas cutting sets, piping compound, nitrogen in cylinders etc. 13.3 SS Bolts and nuts for supports for fixing of Junction boxes and cable

trays on structural support fabricated at site, SS MOC U clamps/bolts with nuts, SS clamps for tubes and pipes, anchor bolts for panels, expansion bolts of various sizes( all nut/bolts, washers, etc. shall be of SS304 MOC) for fixing to concert structure.

13.4 All industrial gases like oxygen, acetylene or inert, and all types of electrodes, brazing rods, flux etc for welding purposes, with necessary facilities for testing the welded joints.

13.5 Paints (in various colors as required), primers, rustoline, TCE and other solvents.

13.6 All structural supports (size and quality of all MS channels, angels, flats, etc. shall be as per I.S.) for instruments (including 2” pipe with SCH40 as a min.), JB’s, Trays etc. Including their supply and fabrication including painting shall be in scope of IEC. For JB installation, min. size of wall/column mounted frame shall be ISMC channel of 75 mm, for panel installation base frame, it shall be C channels of size ISMC 100 mm. For 300 mm perforated cable tray support size shall be ISA 65 x 65 x 6. The stanchion base plate for 2” pipe stanchion for transmitters shall be min. 5 mm thick MS plates. Max. 1 or 2 transmitters can be installed on I/Y/L type 2” pipe stanchions with single pedestal support type. For multiple transmitters, C channel shall be fabricated out of ISMC 100 channels with min. two or three supporting legs and required base plates grouted/anchored and shall be used with pieces of 2” pipes on top tier. For analyser primary and secondary SHS installation, the field stanchion frames shall be fabricated from ISMC 100 C channels with min. two or three supporting legs and required base plates grouted/anchored.

13.7 All materials for minor civil work like grouting etc.


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13.8 Installation materials such as number ferrules, continuous ferrule sleeves, tag no. plates of SS MOC, SS clamp for securing the cables/tubes and all other clamps, SS MOC Nut/bolts/fasteners etc. required for installation of instruments/JB as specified/approved by OWNER. IEC shall use gold plated lugs for RTD loop terminations.

13.9 Spool pieces and blinds for testing wherever required. 13.10 Lubricating oil, silicon oil, grease, soap solution. 13.11 Silicon carbide paper, painting brushes, yellow cloth, waste cotton for

cleaning, wire brushes, paint brushes, etc. 13.12 Neoprene rubber sheets, asbestos sheets, 13.13 Nozzle cleaning wires 13.14 Araldite, M-seal, locktite, quick fix, rubber compound, silicon rubber

tube. 13.15 GE make HRC fuses, glass fuses (ISI approved). 13.16 Any other items not specified, but required for completion of the job. 13.17 Materials approved by OWNER‘s representative shall always be used.

The IEC shall submit in sealed pockets of all consumables like bolts, nuts, lubricants, ferrules lugs, Teflon taps, Teflon paste, insulation taps, etc for approval from engineer-in-charge which form the standards for erection works within the one week of placement of LOI.

13.18 The IEC shall procure the various installation materials from reputed vendors and such materials shall be of good quality. OWNER reserves the right to inspect and approve/reject such materials.

section-vi instrument erection, installation & commissioning specifications...

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