PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
SECTION-VI
INSTRUMENT ERECTION,
INSTALLATION & COMMISSIONING
SPECIFICATIONS
Page 1 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
INDEX
SR.
NO.
1
2
3
4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
7
8
8.1
8.2
8.3
8.4
8.5
9
10
11
12
13
TOPIC
SCOPE
RESPONSIBILITIES
REGULATIONS
GENERAL
INSTRUMENT MECHANICAL INSTALLATION
REQUIREMENT
INSTRUMENT MOUNTING
INSTRUMENT PROTECTION
INSTRUMENT CONNECTIONS TO PIPING AND VESSELS
INSTRUMENT PROCESS PIPING AND TUBING
INSTRUMENT AIR PIPING AND PNEUMATIC
TRANSMISSION
INSTRUMENT TAGGING
INSTRUMENT ELECTRICAL INSTALLATION
REQUIREMENT
INSTRUMENT WIRING SYSTEM INSTALLATION
CABLE ROUTES
INSTRUMENTATION E&C SPECIFICAITONS
INSTRUMENT
INSTALLATION,
COMMISSIONING
SCHEDULE
OBLIGATION OF IEC
GENERAL CONDITIONS
STANDARDS
WORKMENSHIP, TIDYNESS, SAFETY
SCOPE OF WORK OF BIDDER’S IEC
PAINTING
IDENTIFACTION OF INSTRUMENTS
TESTING OF INSTRUMENTS
LOOP CHECKING/COMMISSIONING
SUPPLY OF MATERIAL
PAGE
3
3
3
4
4
5
5
5
7
7
7
7
14
18
18
19
19
20
21
24
24
25
27
28
Page 2 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
1.
1.1
1.2
2.0
SCOPE
This specification gives directives for the design, selection
methods, instructions and examples of instrument installation,
and commissioning scope of work for the entire PAC project.
This specification shall be read in conjunction with the
specification specified and individual instruments specifications
other parts of this ITB document.
criteria,
erection
general
given in
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.
In cases of conflict between standards the most stringent requirements
shall apply.
3.1.2
3.2
CODES AND STANDARDS
-API
-API 551
- BS
-BS 729
-BS 3643
-BS 5308 Part II
-IEC 60331
-IEC 60332
-IEC 60391
-IEC 60423
-IEC 60757
-IEC 60584-3
:American Petroleum Institute
:Process Measurement Instrumentation.
:British Standards
:Hot-dip Galvanized Coating on Iron and Steel
Articles (1971).
:ISO Metric Screw Threads principles and data.
:Specifications for PVC insulated cables
:Test for electric cables under fire conditions – Fire
Resistance
:Test for electric cables under fire conditions –
Circuit integrity
:Marking of Insulated Conductors (1972).
:Conduits for Electrical Purposes: Outside
diameters of conduits for electrical installation and
threadsfor conduits and fittings.
: Code for Designation of Colors (1982).
:Thermocouples
Part
3:
Extension
and
Compensating
Cables
Tolerances
and
Identification System (1989).
Page 3 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
-IEC 61000
-IBR
:Electromagnetic Compatibility
:Indian Boiler Regulations
IS Indian Standard
-IS 1554 Part 1
-IS 2148
4.0
:PVC Insulated electric cables working up to 1100V
:Flameproof enclosures for Electrical Apparatus
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
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
IEC shall be responsible for issuing instruments, transportation from local
store to site, unpacking, inspection for any damage, assembly, etc. of all
the instruments.
IEC’s scope shall include plugging of all the unused (spare) cable
entries in the junction boxes
Each instrument, erection hardware, or accessory to be installed by
the IEC shall be inspected visually for any damage.
The IEC shall then take it from where it is stored, lift it into position
and ensure it is leveled, plumbed and firmly secured.
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.
Instruments shall not be bracketed directly off process lines except
where specified by engineer-in-charge.
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.
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.
Handrails shall not be used for supporting instruments.
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.
Page 4 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.1.11
5.1.12
5.1.13
5.1.14
5.1.15
5.1.16
5.1.17
5.1.18
5.1.19
5.1.20
5.1.21
5.1.22
5.1.23
Instrument shall be installed in accordance with the appropriate hookup 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.
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.
The instrument already mounted on the equipment shall be removed
by the IEC for the calibration check and re-fix back.
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.
All instruments shall be accessible either from ground or from a
permanent finished floor and/or permanent platforms.
Instruments shall be mounted on a vibration free place. Special care shall
be taken for heat expansion.
Local converters, amplifiers, switches, etc., shall be installed near the
corresponding instrument.
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.
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.
Instruments shall not be direct mounted on handrails. No support of
instrument stanchions, cable tray, etc. shall be taken from any type of
handrails.
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.
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.
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.
Page 5 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.1.24
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.3
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.
INSTRUMENT PROTECTION
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.
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.
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.
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.
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).
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.
It is an engineering design criterion to protect electronic instruments
against direct solar radiation by way of instrument Sunshades.
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.
Page 6 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4
5.4.1
5.4.2
5.4.3
5.4.4
INSTRUMENT PROCESS PIPING AND TUBING
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.
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.
Pressure gauges will be hooked-up by means of “pancake” flanges.
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
Liquid
Gas
Vapor
Steam
5.4.5
Under / Above tapping
Under
Above
Under
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.
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
Page 7 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
5.4.12
5.4.13
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.
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.
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.
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.
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.
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.
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.
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.
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
Page 8 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4.14
5.4.15
5.4.16
5.4.17
5.5
of up to one week, adhesive tape may be used, for a longer period caps
or plugs shall be used.
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.
Threaded fittings will have their threads specified in the purchaser’s
documentation. All threaded joints shall have Teflon tap as sealing
medium.
Where compression fittings are used, the fittings shall be installed in strict
accordance with the manufacturer’s recommendation.
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.
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
¾" Pipe according to ANSI
1" Pipe according to ANSI
1½" Pipe according to ANSI
1-5 users *
6-12 users *
13-20 users *
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.
Page 9 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.5.10
5.5.11
5.5.12
5.5.13
5.6
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.
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.
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.
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.
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.
All pneumatic signal tubing shall be cleaned by blowing through with
instrument air prior to installation.
Single tubing shall be run in such a manner as to give the maximum
protection against mechanical damage.
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.
Instrument air and signal tubing shall be adequately supported
wherever possible to prevent any mechanical damage.
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.
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
Page 10 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
6.1.1.2
6.1.1.3
6.1.1.4
done in such a way that after successful implementation of complete
project, there shall be 20% spare space shall be available for future use.
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.
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.
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.
Page 11 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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.
6.1.1.6
6.1.1.7
6.1.1.8
6.1.1.9
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.
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.
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.
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.
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
Page 12 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
6.1.1.10
6.1.1.11
6.1.1.12
6.1.1.13
6.1.1.14
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.
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.
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.
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.
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.
Cables shall not be bent to radius less than the manufacturer’s
recommendations (i.e 10 times the cable O.D).
Page 13 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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
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.
6.1.1.18
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.
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
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.
6.1.3.2
6.1.3.3
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.
Page 14 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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
6.2.1.3
6.2.1.4
6.2.1.5
6.2.1.6
6.2.1.7
6.2.1.8
6.2.1.9
6.2.1.10
6.2.1.11
6.2.1.12
6.2.1.13
6.2.1.14
Electric/electronic single cables in the field shall be suitably supported
and protected by means of cable ducts/trays, conduits, etc.
The cable trays shall be safely and easily accessible for maintenance
purposes.
Proper alignment and fixing/ clamping (with SS clamps and SS
nut/bolts/washers) shall be carried out for all duct/trays.
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.
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 prefabricated 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.
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.
The sub trays shall be properly finished and laid to give neat appearance.
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.
Welding of cable trays joints is strictly not permitted.
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.
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.
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.
The instrument cables shall be grouped according to the signal types.
The main groups are:
Page 15 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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.
Page 16 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
Note 1:
No.
Category
Susceptibility Signals
Measurement Signal Very sensitive Video and communication cables Fire
warning cable
Cable
I
II
III
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
relay
Medium
Susceptibility
relay control
Susceptibility
low voltage power
Power
Cables with analogue signals greater than
50 V AC, 30 V DC, All cables that
involve operation of relays ( switching
circuits)
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
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
voltage power
Power
AC and DC cables >1000 V with
currents of =-800 A
IV
V
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
Page 17 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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
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
8.1.1
8.1.2
8.1.3
OBLIGATIONS OF THE IEC
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).
Instrument Installation work as per OWNER’s specifications, drawings
and good engineering and construction practice.
Erection, checking, tests.
Page 18 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.3
Preparation of testing/loop checking reports/records in specified
formats.
Co-ordination (as and when required with OWNER/other contractors/
agencies working in the same area)
Providing guarantees for the work carried out/ materials supplied.
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.
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.
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.
Keeping proper record of all free issue material received, used and
balance and submitting the material reconciliation statement at the
end of the job.
Visual inspection of all free issue material and in case of any defect or
shortage, bringing it to the notice of BIDDER immediately.
GENERAL CONDITIONS
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.
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.
Any instruction given by the OWNER’s Engineer to the person shall
be deemed to have been given to the BIDDER.
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.
STANDARDS :
Page 19 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
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
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
8.4
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.
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.
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.
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.
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.
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.
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.
WORKMANSHIP, TIDINESS AND SAFETY
Page 20 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
8.4.9
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
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.
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.
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.
The IEC shall take adequate precautions during use and storage of
gas cylinders.
The IEC shall use, ELCB, with each power supply board required for
the installation work.
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.
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.
The IEC shall prepare a comprehensive schedule for carrying out the
installation before commencement of actual work.
The IEC shall arrange for the necessary staff as and when required
for keeping to the schedule in consultation with OWNER.
SCOPE OF WORK AND RESPONSIBILITY
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.
Fabrication of pipe nipples, including threading wherever required.
Fabrication of seal pot/siphon/drain pot as per standards. Filling of
seal pots with filling liquids as per instructions from engineer-incharge.
Back/seal welding of screwed fittings as required.
Laying of cable underground wherever required including excavation,
sand filling, brick laying and back filling.
Page 21 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.6
8.5.7
8.5.8
8.5.9
8.5.10
8.5.11
8.5.12
8.5.13
8.5.14
8.5.15
8.5.16
8.5.17
8.5.18
8.5.19
8.5.20
8.5.21
8.5.22
Connection of purging devices for instrument as per drawings.
Minor civil works like chipping of pavements & grouting on the
pavements the instrument panels/supports/stanchions, & chipping,
refilling & finishing of the pavement for conduits.
Sealing of cables/tube entries into the control room after laying and
testing of all tubes, cables etc.
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.
Reversing the action of control valve either by replacement of springs,
accessories or in positioner wherever required.
Painting of all structural supports for trays, pipes, junction boxes,
instruments, ducts, etc. as per painting specifications.
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-incharge.
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.
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.
Grounding of shield of all shielded cables to respective instrument
earth bus provided in the control room/ local panel/ thermocouple
head/ junction boxes.
Laying and termination at both ends between instrument earth buses
provided in the control room/ local panel to instrument earth pit
provided by others.
Completion of ALL drawings / documents, as per the execution of
work at site.
Preparation and submission of “As Built” drawings (marked up copies)
as required in two sets.
Start-up and commissioning assistance.
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
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.
Sealing of switches with standard lead seals after final setting in the
presence of engineer-in-charge.
Page 22 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.23
8.5.24
8.5.25
8.5.26
8.5.27
8.5.28
8.5.29
8.5.30
8.5.31
8.5.32
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.
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.
Fork lifts, jumbo etc. if required by IEC to carry out work, shall be
arranged by them at his cost.
The IEC shall be responsible for the supply of installation materials as
detailed elsewhere in this document.
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.
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.
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.
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.
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.
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.
Page 23 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.33
9.0
However this shall be supervised by IEC in consultation with site
instrument engineer.
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.
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
10.2
10.3
10.4
10.5
10.6
The surface to be painted shall be thoroughly cleaned with wire brush/
sand paper to remove all scales.
After cleaning, one coat of red oxide zinc chromate primer shall be
given conforming to IS-2074 and allowed to dry.
One coat of final red oxide shall be applied prior to first coat of paint.
Final coat of color shall be given before handing over the plant /
commissioning.
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).
The primer & final paint shall be of first class quality & shall confirm to
the following.
Primer
Type
DFT
Finish coat
Type
DFT
:Red oxide Zinc Chromate Primer
:Single pack Composition
Modified phenolic
alkyd pigmented with red oxide & zinc
chromate.
:25 microns / coat (min)
:Epoxy Paint (Chemical Resistant)
:Single pack Composition Phenolic medium
pigmented with superior quality pigments.
: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
Page 24 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
10.1
10.2
10.3
10.4
11.0
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.
The engineer-in-charge will provide a table of label and other details
for labels within IEC supply.
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.
Air stations and local instruments shall have their reference numbers
neatly marked on them.
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
11.2
11.3
11.4
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.
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.
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.
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 /
Page 25 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.19
11.20
or equipment enclosures are to be checked for compliance with the
appropriate clause of IS-3043.
Transmitter connection to the correct receivers and polarity shall be
checked.
Correct connection of pneumatic and electric switches shall be
checked. All type of cable/wire terminations shall be subject to pull
test by OWNER.
The written results of the test in duplicate for retention by OWNER/
Engineer in charge shall be approved by the engineer in charge.
The IEC responsible for supplying the necessary test equipment and
reasonable evidence of the satisfactory condition of this shall be
provided, if required.
All errors all faulty workmanship discovered during this testing or
during subsequent testing and commissioning shall be corrected by
the IEC at his cost.
All test results shall be recorded in the approved formats.
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.
All cables shall be checked for proper clamping / support and shall be
neatly dressed.
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.
All control valves prior to stroke checking shall be externally cleaned
thoroughly.
The stroke of the valve shall be checked for opening & closing with
25% steps.
Any adjustments required for obtaining full stroke & reducing
hysteresis shall be carried out.
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.
The limit switch (if any) shall be adjusted if necessary.
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.
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.
Page 26 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
11.21
11.22
12.0
12.1
12.2
12.3
12.4
12.5
12.6
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.
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.
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.
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 coordination with DCS/PLC supplier and BIDDER in presence of
OWNER Engineers / Technicians.
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.
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.
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.
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.
In case of loop, in which certain instruments of the loops are
calibrated by other agency, the loop testing shall be performed in
Page 27 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
12.7
13.0
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.
Final certified loop sheet should be submitted in two copies to
OWNER and two copies to consultant.
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
13.2
13.3
13.4
13.5
13.6
13.7
Materials to be supplied by the IEC at his own cost, as part of these
specifications.
The supply of consumables like Teflon tape, insulation tape, welding
rods, gas cutting sets, piping compound, nitrogen in cylinders etc.
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.
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.
Paints (in various colors as required), primers, rustoline, TCE and
other solvents.
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.
All materials for minor civil work like grouting etc.
Page 28 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
13.8
13.9
13.10
13.11
13.12
13.13
13.14
13.15
13.16
13.17
13.18
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.
Spool pieces and blinds for testing wherever required.
Lubricating oil, silicon oil, grease, soap solution.
Silicon carbide paper, painting brushes, yellow cloth, waste cotton for
cleaning, wire brushes, paint brushes, etc.
Neoprene rubber sheets, asbestos sheets,
Nozzle cleaning wires
Araldite, M-seal, locktite, quick fix, rubber compound, silicon rubber
tube.
GE make HRC fuses, glass fuses (ISI approved).
Any other items not specified, but required for completion of the job.
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.
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.
Page 29 of 29