new lpg bottling plant at hazira

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

NEW LPG BOTTLING PLANT AT HAZIRA

GENERAL SPECIFICATION FOR INSTRUMENTATION

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New LPG Bottling Plant at Hazira


31-Dec-10

© Copyright 2010 WorleyParsons




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SYNOPSIS

Disclaimer

This specification has been prepared on behalf of and for the exclusive use of Hindustan

Petroleum Corporation Limited (HPCL), and is subject to and issued in accordance with the

agreement between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons.

WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or

reliance upon this report by any third party.

Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or

WorleyParsons is not permitted.




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TABLE OF CONTENTS

1.0 INTRODUCTION 6

1.1 Purpose

6

2.0 APPLICABLE CODES, STANDARDS, ABBREVIATIONS & DEFINITION

6

2.1 Precedence of Codes, Standards and Specifications

6

2.2 International Codes and Standards

7

2.3 Abbreviations

8

2.4 Definitions

8

3.0 GENERAL DESIGN INFORMATION 9

4.0 GENERAL DESIGN CRITERIA

9

4.1 Quality Assurance

9

4.2 Reliability and Maintenance

9

4.3 Ingress Protection

9

4.4 Electromagnetic Compatibility

9

4.5 Units of Measurement

10

4.6 Special Tools

11

4.7 Nameplates

11

4.8 Packaged Equipment 11

4.8.1 General 11

5.0 TECHNICAL DESIGN DOCUMENTS

12

5.1 Piping and Instrumentation Diagram (P&ID)

12

5.2 Instrument Data Sheets

12

5.3 Instrument Drawings 12

5.4 Calculations 12

6.0 DESIGN AND CONSTRUCTION 13

6.1 Hazardous Area Requirements 13

6.2 Instrument Cabling and Glands 13

6.2.1 Cables 13

6.2.2 Glands 13

6.3 Instrument Junction Boxes 14

6.4 Instrument Earthing 14

6.5 Process Installations

15

6.6 Materials

15




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6.7 Utilities 15

6.7.1 Electric Power 15

7.0 INSTRUMENTATION 16

7.1 General 16

7.2 Transmitters

16

7.3 Electrical Certification 16

7.4 Flow Measurement

16

7.5 Level Measurement

17

7.6 Pressure Measurement

18

7.7 Temperature Measurement 19

7.8 Vibration Monitoring

20

7.9 Control Valves

20

7.10 Relief Valves

21

7.11 On-Off Valves

21

7.11.1 General 21

7.11.2 Pipeline Valves 22

7.11.3 Actuator Operating Medium 22

8.0 GENERAL REQUIREMENTS FOR INSTRUMENTATION INSTALLATION 23

9.0 INSTRUMENT PROTECTION 23

9.1 Methods of Prevention 24

9.2 Mobility 24

9.3 Homogeneity 24

10.0 INSTRUMENT PIPING & TUBING 25

11.0 CABLE INSTALLATION 26

11.1 Cable Grouping 26

11.2 Segregation 26

11.3 Spacing 28

11.4 Location of Cable Routes 28

11.5 Entries and Sealing 28

11.6 Cable Ladders/Trays 29

11.7 Above Ground Conduits 30

11.8 Below Ground Cables and Conduits 31

12.0 TERMINATIONS 36

12.1 General 36




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13.0

FIELD INSTALLATION 42

14.0 INSTALLATION INSPECTION AND TESTING 44

15.0 QUALITY ASSURANCE AND QUALITY CONTROL 49

16.0 ELECTRICAL CERTIFICATES AND REPORTS 50

17.0 DOCUMENTATION 50




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1.0 INTRODUCTION

1.1 Purpose This document provides general information, process and engineering data, and guidance on selection and installation of field instruments. Instruments are the primary field devices that provide the process measurements to the facility control system, i.e. SCADA/PLC/ESD/FGS. Therefore, the reliability and accuracy of each instrument is an essential component in the availability of the overall system. The design intent is for instrumentation to be selected and installed with the latest technologies available in the market.

2.0 APPLICABLE CODES, STANDARDS, ABBREVIATIONS & DEFINITION

2.1 Precedence of Codes, Standards and Specifications It is the main responsibility of CONTRACTOR to inform the EPMC of any deviations from or exceptions to the listed specifications, codes, and standards. EPMC will take non- listing or non-specification of exception or deviation by CONTRACTOR in the bid proposal document, as being in full compliance with the specifications, codes, and standards listed. If there is a conflict between the various codes, standards, specifications and the attached drawings, the following shall govern: CONTRACTOR shall seek EPMC'S final interpretation of any conflicts prior to the execution of work. Rework of engineering and relevant scope arising out of underestimation shall be done at no additional cost to the EPMC. As a minimum, all equipment shall be designed, manufactured, and delivered in accordance with the relevant section of the national/international Codes, Standards, and Regulations as listed below. The latest editions of Codes, Standards including all addenda, supplements, or revisions current at time of order placement, as issued by the following authorities shall apply:

• International Electrotechnical Commission (IEC)

• The Institute of Petroleum (IP)

• Institute of Electrical Engineers (IEE)

• IP Codes of Practice

• American Petroleum Institute (API)

• Instrument Society of America (ISA)




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2.2 International Codes and Standards The design shall comply with the applicable sections of the latest editions of the engineering codes and standards listed below: Document Number Document Title AGA 3 Orifice Metering of Natural Gas AGA 8 Compressibility and Super-compressibility for Natural Gas API 6D Pipeline Valves API 14 C Manual of Petroleum Measurement Standards API MPMS Sizing, Selection and Installation of Pressure-Relieving Devices In Refineries, Sizing and Selection API RP 520, Part l Sizing, Selection and Installation of Pressure-Relieving Devices In Refineries, Installation API RP 520, Part ll Guide for Pressure-Relieving and De-Pressuring Systems API RP 521 Flanged Safety-Relief Valves API RP 526 Flanged Safety-Relief Valves API RP 527 Commercial Seat Tightness of Safety Relief Valves with Metal to Metal Seats API RP 551 Process Measurement Instrumentation API 607 Fire Test for Soft Seat Quarter Turn Valves ANSI B 16.5 Pipe Flanges and Flanged Fittings ANSI B16.10 Face to face dimensions for flanged globe style control valves ANSI / FCI 70.2 Control Valve Seat Leakage ANSI / ISA S5.1 Instrumentation Symbols and Identification ANSI / ISA 75.01 Flow Equations for Sizing Control Valves ATEX 94/9/EC Equipment Intended for use in Potentially Explosive Atmospheres BS 1904 Industrial Platinum Resistance Thermometer Sensors BS 5308 Instrumentation Cables – Specification for PVC Insulated Cables BS 5555 SI Units BS 6174 Differential Pressure Transmitters with Electrical Output BS-EN-60751 Industrial Platinum Resistance Thermometer Sensors BS-EN-837-1 Bourdon Tube Pressure and Vacuum Gauges IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres. IEC 60331 Fire Resisting Characteristics of Electrical Cables IEC 60332 Test on Electrical Cables under Fire Conditions IEC 60529 Degrees of Protection Provided by Enclosures (IP Code) IEC 60540 Test Method for Insulation and Sheaths of Electrical Cables and Cords I EC 61000 Electromagnetic Compatibility IEC 61508 Functional Safety: Safety Related Systems IEC 61511-1 Functional Safety: Safety Instrumented Systems for the Process ISA S75.01 Control Valve Sizing Equations ISO 5167 Part 1 – 4 Measurement of Fluid Flow by means of Pressure Differential 2003 Devices ISO 5168 Measurement of Fluid Flow: Estimation of Uncertainty of Flow- Rate Measurement. OISD - 118 Layouts for Oil and Gas Installations OISD - 149 Design Aspects for Electrical Systems




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2.3 Abbreviations AGA American Gas Association ANSI American National Standards Institute API American Petroleum Institute ASME American Society of Mechanical Engineers BS British Standards CCR Central Control Room CENELEC European Committee for Electrical Standardization DCS Distributed Control System DP Differential Pressure DPDT Double Pole Double Throw EEx Explosion rated EMC Electro Magnetic Compatibility ESD Emergency Shutdown System FGS Fire and Gas System HART Highway Addressable Remote Transducer IP Ingress Protection IEC International Electrotechnical Committee ISA Instrument Society of America ISO International Standards Organization NPT National Pipe Thread/Taper P&ID Piping and Instrumentation Diagram PLC Programmable Logic Controller RTD Resistance Thermometer Detector RTU Remote Terminal Unit SCADA Supervisory Control And Data Acquisition SEHMS Skin Effect Heat Management System SIL Safety Integrity Level UCP Unit Control Panel UPS Uninterruptible Power Supply

2.4 Definitions

COMPANY The party that initiates the projects and ultimately pays for its design and construction, Hindustan Petroleum Corporation Limited EPMC The party which carries out all or part of the design, engineering, procurements, construction, and commissioning. SUPPLIER/VENDOR The party which manufactures or supplies the equipments and services to perform the duties specified by the Contractor

CONTRACTOR Construction / Installation Contractor for other than Instrumentation activity.




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3. GENERAL DESIGN INFORMATION 3.1 Location of SITE and Climate

Please refer Specification for Turnkey Instrumentation System at Hazira and Icchapore document no. 0435-JH0911-00-IN-SPC-0002 for site conditions and environmental data.

4.0 GENERAL DESIGN CRITERIA

4 .1 Quality Assurance CONTRACTOR, SUPPLIER and VENDOR of equipment shall operate a Quality Assurance system. This system shall be based on the principles of ISO 9001 or equivalent. The quality system may be subject to auditing and monitoring by the EPMC or his representative.

4.2 Reliability and Maintenance High reliability of instrumentation is of paramount importance and therefore only existing field proven instrumentation, which is readily available and used widely in similar applications, shall be considered. Selection of instrumentation systems and equipment shall take account of the projects overall requirements for high availability. Importance shall be given to reducing the maintenance frequency and duration.

4.3 Ingress Protection

All field mounted equipment, junction boxes, etc. including entries and blanking plugs shall have an environmental protection rating of IP65 to BS EN 60529. Indoor located equipment shall be to IP42.

4.4 Electromagnetic Compatibility Individually supplied instruments should conform to the intent of IEC 61000 and carry a CE/UL/CSA conformity mark.




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4.5 Units of Measurement

PARAMETER/QUANTITY UNIT NAME NOTATION STANDARD

Pascal Pa

Bar bara, barg

Pounds per square inch

psi

Atmosphere atm

Torr torr

Kilogram/metre2 kg/m

2

PRESSURE

Kilogram/centimetre2 kg/cm

2

barrels/day BLPD, BOPD,

BWPD

meter3/hour m

3/h

k i logram/second kg/s

Foot3/hour ft

3/h

centimetre3/second cm

3/s

FLOW

l i ter /hour l/h

Celsius °C

Fahrenheit °F TEMPERATURE

Kelvin K

k ilogram/metre3 kg/m

3

Gram/metre3 g/m

3

gram/cent imetre3 g/cm

3

Mil l igram/centimetre3 mg/cm

3

DENSITY

pound/inch3 lb/in

3

k i lometre km

metre m

foot ft

yard yd

mile mi

LENGTH

inch in

Pascal second Pa.s

Metre2/second m

2/sec VISCOSITY

centipoise cP

SULPHUR CONCENTRATION

Parts per million ppm




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4.6 Special Tools

The SUPPLIER/VENDOR of the main equipment shall provide tools, and any other specialist items, required to operate and maintain any instrument or system.

4.7 Nameplates All instruments, junction boxes, cabinets, panels and ancillary equipment should be provided with a manufacturer’s engraved corrosion resistant nameplate, permanently attached with stainless steel screws or rivets. In addition, instruments shall be provided with stainless steel tag number plates and junction boxes shall be provided with traffolyte service labels.

4.8 Packaged Equipment 4.8.1 General

In order to obtain commonality of instrument types, only instruments manufactured by approved SUPPLIER/VENDOR shall be adopted for packages. A Packaged Unit Specification shall be developed during detailed design to ensure uniformity of the instrument design with the entire project. All instruments shall be supplied, installed and cabled to skid edged junction boxes by the package SUPPLIER/VENDOR. Separate junction boxes and cables shall be used for:

• ESD circuits

• FGS circuits

• General instrumentation

• Communications




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5. TECHNICAL DESIGN DOCUMENTS 5.1 Piping and Instrumentation Diagram (P&ID)

The instrumentation symbol and presentation on the P&ID’s shall be in accordance with ISA S5.1, including tag numbering. The numbering system shall follow the project standard. A strategy of numbering, however, shall be developed during the detailed design, and approved by the EPMC. Instruments supplied by mechanical package equipment SUPPLIER/VENDOR shall bear tag numbers provided by the CONTRACTOR and will be part of the Instrument Index prepared by the CONTRACTOR.

5.2 Instrument Data Sheets

Instrument data sheets shall be provided for all instrument types. Data sheets shall be subdivided for each process parameter, i.e. Flow, Level, Pressure, Temperature, Control Valves, Relief Valves, Analyzers, and Miscellaneous etc. Instrument Data Sheets shall completely identify the instrument by type and model number and shall indicate operating data such as range, capacity, action, and set-point. The package SUPPLIER/VENDOR shall supply data sheets for package equipment.

5.3 Instrument Drawings

The design shall include all detailed drawings to enable purchased equipment to be installed correctly. The following design drawings are typical requirements as minimum:

• Instrument location drawings

• Process hook ups

• Hook ups

• Cable Block Diagrams

• Cable routing diagrams

• Cable schedule

• Loop diagrams

• Instrument Index

• Junction box terminations 5.4 Calculations

Calculations shall include, but not be limited to, the sizing of orifice plates, control valves, relief valves etc. All calculations shall be performed in accordance with the international standards and codes. Control valve calculations shall be completed to the selected supplier’s formulae, including noise calculations. Noise level during day time shall not exceed 85dBA. Where excessive noise occurs, i.e. greater than 85 dBA, a suitable low noise valve shall be provided as the primary method of noise reduction. If this fails to meet the noise criteria, then noise attenuation shall be utilized.




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6. DESIGN AND CONSTRUCTION

6 .1 Hazardous Area Requirements In general, all field mounted instrument electrical components shall be preferably certified as EEx’ia’ or EEx’d’ suitable for Zone-1, 2. Gr. IIA/IIB, T3 area. It is a requirement that a full certification dossier is produced during detail design to ensure that all hazardous area components are correctly certified. The certification dossier is to cover all construction components, e.g. glands, junction boxes etc. in addition to instrument items. All electrical and instrumentations Items shall be Certified for use in Hazardous areas wherever applicable including CCOE approval.

6.2 Instrument Cabling and Glands

6.2.1 Cables In general, cables shall conform to the standards defined in the Power, Control and Instrument Cable Specification and BS 5308 Part I Type 2. The standard outer sheath colors for BS5308 are blue or black. For large quantities, however, the cable can be manufactured in an outer sheath color of choice. Hence grey outer sheath color is recommended for instrument cables, thus avoiding the clash with electrical cables, which have black outer sheath. Solenoid and Power cables shall be standardized as 6, 12, 24, 30, 50 cored cables. All instrument cables for control and indication shall be flame retardant, and tested in accordance with IEC 60332 Part 3. ESD and FGS cables shall be Fire resistance as per IEC 60331. Telecom cables for communications, public address and general alarm shall be low smoke zero halogen (LSZH), in accordance with the revised version of OISD RP 149. The cable racking system shall be installed to common electrical standards and shall be made from hot dip galvanized steel. Separate cable racks and trays shall be used for:

• Instrument and Communication Cables

• Power supply cables Instrument cables shall be segregated from power cables by a minimum distance of 500mm. Cable design shall ensure that at least 20% spare pairs or cores are included within each multi-core.

6.2.2 Glands Field installed cable glands shall be double compression type made of brass, certified EExd, and have an ingress protection of IP65. The glands are to seal on the inner and outer sheaths, clamp on the metal armouring and come complete with a gland fixing kit containing earth tag, serrated washer, shroud etc. Generally, field instrument cable glands shall be threaded M20. Cable glands for indoor use shall be made of brass, non-certified industrial type and have an ingress protection of IP42.




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6.3 Instrument Junction Boxes

In view of the 35 year design life, aluminum alloy junction boxes shall be used throughout. Junction boxes and associated terminals shall be certified EEx’e’ or EEx’d’ based on signals to be connected. Weather protection shall be to IP 65 minimum and all junction boxes shall be capable of being locked in the closed position. Cable entry shall be through the bottom (preferred) or side. All entries shall be supplied with certified blanking plugs. Each junction box shall be provided with sufficient terminals for the individual termination of all spare cores within the interconnecting cabling. As minimum, additional 20% wired terminals shall be provided for future use. Junction boxes shall be clearly identified with the junction box number and service. Labels shall be white / black / white traffolyte labels. Junction boxes shall be supported using frames that will be constructed in the field. Separate junction boxes and cables shall be used for:

• ESD circuits

• FGS circuits

• IS Signals

• Non-IS Signals

• General instrumentation

• Communications

6.4 Instrument Earthing Two separate instrument-grounding systems shall be provided, namely Protective/Dirty Earth and Instrument/Clean Earth. Protective/Dirty Earth – Connections to earth for all electrical equipment, for personnel safety. Each electrical cabinet, marshalling unit, local panel or junction box shall have a separate earth bar or 10mm earthing stud. Instrument/Clean Earth - Cable screens shall be run continuously from each instrument through the junction box to the instrument earth bar in the centrally mounted instrument equipment room. The screen shall be earthed at the equipment room only and tied back and insulated at the instrument device. Each instrument earth bar must be insulated from steel or any other earth system. All field instruments / junction boxes shall be bonded to earth using 2.5mm2 minimum conductor size earth cable. The cable shall be terminated to an external earth stud on the field device and terminated to the nearest structural steel member with a suitable nut and bolt arrangement. Earth cable insulation shall be colored green / yellow.




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6.5 Process Installations Pressure instruments shall have block and bleed isolation at the instrument located at easy access for calibration and maintenance. These shall be in the form of 2 valve, 3 valve or 5 valve manifolds. Process connections shall be 1/2” NPT (F). The manifold material shall be standardized on type AISI 316 stainless steel as a minimum. All process tubing shall be 1/2” OD, in AISI 316L stainless steel. Sensing lines shall be kept as short as possible and correctly inclined (minimum slope of 1 in 10). Fittings shall be double ferrule compression type, with one selected compression-fitting manufacturer used throughout the whole installation, including packaged plant. Where instruments require stainless steel flanges to be fitted, the ratings are to follow the project piping specification.

6.6 Materials The CONTRACTOR is responsible for ensuring that all equipment, instrumentation, fittings and installation materials supplied shall be suitable for and unaffected by prolonged operation in the environmental conditions described in section 3.0. All external parts that are not corrosion resistant by choice of material shall be prepared and finished by an approved plating or paint finish. In all cases, material and paint shall be proven to be suitable for the environment. The materials for in-line instruments shall be selected in accordance with the project piping specification. Due consideration shall be given to dissimilar materials and corrosion by galvanic effects. Where dissimilar materials are unavoidable, the contact between the two materials should be insulated to prevent accelerated corrosion.

6.7 Utilities

6.7.1 Electrical Power Power to the field instrumentation within the terminals shall be derived from the respective control system equipment room. For the pipeline routes, electrical instrumentation shall be powered from the Electrical Switch rooms, located at each remote station. For all cases, instrumentation, control and telecommunications systems shall be power by uninterruptible power supply (UPS) systems. This shall include local panels.




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7. INSTRUMENTATION 7 .1 General

Separate transmitters shall be provided for (a) process control/monitoring and (b) shutdown functions, with each having separate process line tapping points and isolation valves. All electronic transmitters shall be fitted with an integral local indicator, with a read-out in engineering units. All instrument ranges shall be selected such that the normal operating point is between 35% and 75% of the instruments total range. The use of transmitters rather than switches is preferred.

7.2 Transmitters

Electronic instruments shall be the “smart” type with 2 wire 24VDC loop power and HART protocol included. This allows efficient preventative maintenance with the use of a HART communicator. The maintenance shall be able to investigate parameters such as range, calibration, temperature, pressure etc. Transmission of measurement control signals will be 4-20mA. All transmitters shall have local digital readouts in engineering units. Materials for all wetted parts shall be stainless steel and the transmitters shall be able to withstand differential pressures equal to full line pressure without zero or calibration changes.

7.3 Electrical Certification

Instruments shall be certified EEx’ia’ (Intrinsic Safety), EEx’e’ (Increased Safety) or EExd (Explosion Proof) to suit the area classification Zone 1, Temperature Class T3, Gas Group IIB.

7.4 Flow Measurement

As a minimum following specifications shall be followed by EPC contractor for selection of Flow Meters where indicated on P&IDs : Turbine Meters The turbine meters shall be flanged and rated in accordance with the relevant piping specification.

The turbine meters shall comply with the following requirements: ANSI/API MPMS Manual of Petroleum Measurement Standards API 2534 Turbine meters

• Linearity: ± 0.25% over a 10:1 flow range at the operating viscosity. The meters shall be calibrated initially on water by an independent authority contracted by the Vendor.

• Repeatability: ± 0.02% of the mean pulse count under stable conditions.

• Accuracy: ± 0.15% of the measured value

• Body material: as per piping class

• Internal trim material: as per piping class (stainless steel 316 preferred)

• Bearings material: Tungsten Carbide sleeve

• Two pick-up heads shall be provided for the checking of pulse integrity




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Orifice Fitting with Meter Tube : The design, construction, installation and calibration of orifice plates / fittings shall compile to ISO 5167 / AGA report No.3, latest Edition. The units positively seal against both outer faces of the plate and against both seats of the orifice fitting to prevent leakage. The orifice plate measurement method is generally preferred for steam/gas services. Wherever possible, prefabricated metering runs shall be used for below 2” (50 mm) line size. The minimum size orifice flange shall be 50 mm (2") and the minimum flange rating shall be 300# ANSI. Standard orifice differential pressure ranges shall be adopted with the normal range being 250 mbar. Weep holes shall be provided in steam and gas flow installations where liquid entrainment is possible. Material shall be ANSI Type 316 stainless steel as a minimum. Concentric, square edged orifice plates with flange taps shall be used. The bore calculations and the straight upstream / downstream length requirements shall be in accordance with the applicable code. Beta ratio shall be between 0.3 and 0.7. The minimum and maximum flow rates shall fall between 20% and 90% of the transmitter range. - Meter tubes to be designed in accordance with ANSI/ASME B31.8 or B31.3. All fittings must be of higher yield strength. Orifice fitting tolerances per AGA report no.3 part 2. - The meter tube internal roughness of inside walls shall be as smooth as possible and must be within the tolerances specified in AGA 3 report No.3, April 2000 Edition to achieve maximum smoothness of 250 micro inch. The inside pipe walls to be bored honed.

Other Flow Meters: For normal applications, standard multivariable differential pressure flow transmitters are preferred, allowing the configuration of the output value in volumetric units or mass flow units. For all other services at the terminals, Ultrasonic Flow Meters, Vortex meters, Coriollis meters, Magnetic meters, Variable area meters shall be considered, depending upon the service and the process conditions.

7.5 Level Measurement

The major level measurements apply to the white oils storage tanks. A non intrusive level measurement device is necessary and top mounted radar gauges are proposed throughout for tank gauging. The tank gauge shall require the following as minimum:

• Data acquisition transfer for inventory management and alarms

• No moving parts, i.e. Non float device to avoid sticking and wear and this eliminates Servo operated tank gauges

• Local digital readouts




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Capacitance, ultrasonic, tuning fork or other type level monitoring devices shall be considered where displacement / float type or differential pressure type of devices are impractical. For critical control duties, alternative level control sensing, with deviation alarm between the two measurements shall be provided. For measurement of level in sump etc where the specific gravity of the fluid is variable, Radar type level transmitters shall be used. The instrument shall be top-inserted into an internal standpipe, and shall be configured for on-line withdrawal. External displacer cages shall be supplied with side / side connections. Where this is not possible, top/bottom or side/bottom connections may be provided. External displacer level transmitters shall be used to activate level alarm and shutdown devices. Top-mounted internal displacer level transmitters may be considered if process or application requires. Measurement of levels in floating roof/ fixed roof storage tank shall be by means of either Radar type or Servo operated tank level gauge. These tank gauges shall be provided with local digital read out and shall be provided with transmitters for transmission of level signal to the control system (i.e. PLC). Magnetic Follower or glass / reflex type Level Gauges shall be used for local level indication. The use of DP cells should be considered for large vessel ranges (greater than 1219mm) applications. Level switches shall be avoided in preference to level transmitters. Where necessary to be used, float operated type with an external cage shall be utilized. Level gauges shall be the magnetic type in preference to reflex or transparent types. The exception is steam service where the level gauge shall be transparent type. Switch contacts shall be DPDT, 1 amp, 24VDC rating.

7.6 Pressure Measurement

For the white oil service, direct mounted pressure transmitters shall be utilized. If the location does not allow this, then pressure transmitters with remote seals shall be adopted. Similarly, pressure gauges for the white service shall be direct mounted type or remote seals type. Pressure switches shall be avoided in preference to pressure transmitters. Local pressure and differential pressure indication shall be by means of pressure gauges and differential pressure gauges respectively. Pressure gauge measuring element shall generally be the Bourdon tube type. Pressure gauges shall have 150mm dial with glycerin filling, 316SS casing, internal micrometer pointer and blow out disc. Pressure gauges for high-pressure applications shall be solid front type. Differential pressure gauges and transmitters shall be capable of withstanding full line static pressure on either side of the element without damaging or affecting calibration and accuracy. Electronic transmitters for remote signal transmission shall be "SMART" type with 2-wire, 24 V DC, loop powered output. The transmitters shall be locally mounted and may be either diaphragm type or bellows type. All transmitters shall have local output meter of LCD type.The pressure and DP transmitters shall be capacitance/inductance/piezo-resistance types. Process connection size shall be generally 1/2" NPTF threaded process connection and electrical cable entry size M20 x ISO.




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Capillaries if used shall be in 316L stainless steel, fully armoured, and run in supporting channel for protection. Such diaphragm seal connections shall be provided with bleed rings with vent and drain connections between the process isolation valve and the diaphragm connection for flushing and calibrating purpose. Pressure transmitters to be used in place of pressure switches, however if pressure switch is used in some applications (e.g. inside vendor packages), it shall have a DPDT type gold plated contact with a contact rating of 2A at 24 VDC. The dead band shall not exceed +12% of range, the switch shall have its own integral terminal housing (flying leads are not acceptable). Where pressure pulsations are present, then restrictor screws and glycerine fill shall be applied to pressure gauges. For pressure transmitters, restrictor screws or “reduced vibration” type shall be used. Over-range protection shall be provided for a maximum operating pressure plus 30 percent Over-range. Siphons or "pig tail" condensate seals shall be provided in impulse lines for steam service.

7.7 Temperature Measurement

Temperature transmitters shall be electronic "SMART" type with 2-wire, 24 VDC loop powered output. Surface mounted RTD’s are proposed for signals to the control system. Each RTD shall be fixed to a pipe clamp and the wiring tails connected to local temperature transmitter. Surface mounted bi-metal temperature gauges shall be used for local indications along the white and gas pipelines. All process temperature elements such as at the terminal, station, SEHMS stations, etc shall be furnished with proper flanged thermo wells. Thermowell shall as a minimum be machined 316 SS drilled from solid bar stock. Thermo wells shall be capable of withstanding the maximum design temperature and pressure of the system. The thermo well flange material shall be selected based on the associated piping class, and shall withstand the associated pressure or temperature rating. For 4" pipe and smaller, the thermo well shall be installed in an elbow or tee branch. When this is not feasible, the line shall be swaged to larger size, minimum of 4". For 4" pipe and smaller, the insertion length shall be selected such that the tip of the temperature elements is located in approximately the centre of the pipe. For pipe sizes larger than 4" or for the vessels, the insertion length specified shall be such that the temperature elements are in the main flow of the pipe or vessel. Thermo wells shall be checked for the possibility of wake frequency induced damage, based on ASME PTC 19.3 wake frequency calculations. Local temperature indication shall use bi-metallic type, weatherproof hermetically sealed, every angle adjustable, with 150 mm (6") diameter dial thermometers. Dial of 75 mm (3") diameter may be used in equipment of auxiliary services.




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7.8 Vibration Monitoring

Vibration monitoring system shall be part of the rotating equipment package such as motor, generator etc. This system shall be supplied by the respective CONTRACTOR. Signals from vibration monitoring systems shall be interfaced and made available to the control system, i.e. DCS/SCADA for monitoring purpose. Based on periodic analysis of the available data, maintenance personnel can arrange necessary service required for the equipment.

7.9 Control Valves

Control valves shall generally be globe style single or double seated with top guided trim which can be removed from the top of the valve. Control valves shall be single/ multi cage type with complete stelliting of all the wetted parts. Butterfly valves shall be used for very low pressure drop application. Control valves shall be flanged in accordance with the pipe specification. Valve body material shall be equal to or better than the piping specification. Equivalent manufacture standards may be considered. Valve trim shall be 316 SS minimum. Stellite hardened trims shall be specified for flashing services and for critical, high pressure drops or erosive conditions. Valves shall be class 300 minimum, and sized in accordance with ISA 75.01. Control valve shall have a minimum seat leakage class of IV as defined by ANSI FCI 70-2 valve leakage classifications. Actuators for control valves shall be electro-hydraulic with position feedback potentiometers. Where possible, all valves operating at service conditions shall travel over their full range with an actuator loading. Diaphragm actuators with spring return and electro-hydraulic positioners are preferred but piston actuators with spring return may be used if a diaphragm does not provide sufficient force. SMART positioners shall be provided for control valves. They shall be supplied complete with air set with input & output gauges. Control valves shall be sized to pass normal flow at about 70% valve opening. At Maximum flow valve opening shall not exceed 95% and at minimum flow the valve shall have more than 15% ~ 20% opening so as to have good controllability over the entire flow range from minimum to maximum. Pressure reduction valves for non-critical gas or steam service, where control within 10% of set point is acceptable, may be self-acting. Bypass valves shall be located so that they are readily accessible for maintenance purposes. The valve shall be selected such that its capacity is 120-140% of design for linear trim or 130- 160% for equal percentage trims. Trim characteristics shall be chosen to suit the particular process conditions but as a general guideline, a linear trim shall be selected for Level control and equal percentage trim shall be selected for Flow, Pressure and Temperature control. Generally, contoured type plugs with top and bottom guiding shall be used. On severe process




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conditions, e.g. cavitations, flashing, high pressure drops and excessive noise, then cage type trims shall be selected. Where high wear situations occur on continuous duty valves, dual valves in parallel shall be considered to maintain production. Valve noise shall be restricted to 75dBA maximum at 1 metre distance away from the valve. For all control valves installed at the terminals and pipeline facilities shall be equipped with SMART positioners.

7.10 Relief Valves

Relief valves shall be of the conventional type or balanced bellows type, depending on the process conditions. Sizing shall be in accordance with API RP 520. Pilot operated relief valves shall only be used if no alternative is available, but in any case these shall not be used on waxy white duty.

Relief valves on continuous duty shall be installed as 2off x 100% duty / standby, with key interlocked isolation valves to enable relief system integrity, routine testing and when a faulty valve has to be isolated / replaced. The isolation valves shall be installed both upstream and downstream of the relief valve.

7.11 On-Off Valves 7.11.1 General

On-off valves shall generally be flanged ball type, automatically operated by a dedicated solenoid valve. Full ported ball valves shall be used only as required such as on pigging lines. Floating ball design shall be used for 3" and smaller valves and in low pressure applications. Trunnion style valves shall be used for 4" and larger valves. All shutdown and blowdown valves in hydrocarbon service shall be "fire safe" design. Floating ball valves shall meet the requirements of API STD 607/BS 6755 part 2 and trunnion ball valves shall meet the requirements of API-RP 6F or API-STD 607. Alternative valve types shall be considered in accordance with the project piping valve specification. Materials shall generally be carbon steel bodies with 316 stainless steel trims but all selections shall be in accordance with the project piping specification Shutdown and blow-down valves shall be furnished with limit switches and Solenoid Valves. Limit switches for shutdown and blow-down valves shall be proximity type NAMUR switches certified intrinsically safe. Solenoid valves shall be supplied complete with reverse polarity protection diodes. Solenoid valves shall be certified EExd. Intrinsically safe solenoids shall not be used. Each solenoid valve shall be activated from the operator console in the CCR. For the white pipeline and the gas pipeline, all valves are to be full bore to allow pigging operations, be “fire safe” and comply with API 6D. Services at the terminals can be reduced bore. Valve body connections can be either flanged in accordance with the applicable piping specification. The valve opening and closing times shall be reviewed and for critical applications where quick closing is required, quick exhaust valves shall be provided. All accessories shall be neatly tube and mounted in a control box adjacent to valve actuator. For critical service and large size shutdown valves, a "Partial Stroke Test" facility shall be provided to test the stroking of valves frequently without shutting down the valve. Hand-wheel shall be provided for all pipeline valves.




PAGE NO: 22 OF 50

7.11.2 Pipeline Valves

The valves shall be specified for maximum differential pressure such that no seat damage occurs during normal operations. A “partial stoke test” facility shall be included for the large white valves to test the stroking of the valves at frequent intervals, without having to shutdown.

7.11.3 Actuator Operating Medium

Limit Switches All block valves shall be supplied with limit switches for valve position indications. Two separate limit switches are required, one for “closed” position and one for “open” position. Each limit switch is to have DPDT type contacts. Limit switches for block valves and isolation valves shall be certified EEx’d’. Actuator Sizing The actuators shall be sized for maximum differential pressure across the valve body at the minimum medium supply pressure. The breakaway, run and end torque values of each actuator shall be carefully designed to ensure no damage to the valve stem will occur. Electric Actuators Electrical actuators shall be considered for the motorized valves (MOV) in the terminal and pipeline. The motor power supply shall be 415V AC, 3ph, 50Hz. The motor power supply at Sectionalizing Valve Station shall be 48V DC. MOVs shall have wire wound position feedback potentiometers. Electric actuators shall be designed for On-Off and inching operation.




PAGE NO: 23 OF 50

8. GENERAL REQUIREMENTS FOR INSTRUMENTATION INSTALLATION

• All instrument installation work, the protection and handling of all associated materials and equipment shall be conducted in a safe manner. Particular care shall be exercised in the protection and handling of delicate instruments to prevent ingress of moisture, dust and/or other foreign material.

• Equipment shall be installed in accordance with the manufacturer’s instructions paying particular attention to functional requirements of the instrumentation so as to ensure installation permits convenient and efficient operation and maintenance.

• The installation of instruments shall be scheduled and coordinated so as to minimize conflict with other work in progress and in so far as possible, protect the installed instruments from abuse and mechanical damage. Instruments shall be protected from such activities as sandblasting, welding, painting, and direct exposure to water deluge. All instruments and junction boxes shall be closed when not being worked on.

• Competent tradesmen working under appropriately experienced supervisors shall install all instrumentation to a high standard of workmanship. All work shall be finished to a neat appearance and shall be performed with tools that will not damage the instruments and materials being installed.

• All materials used shall be suitable for the service, pressure and temperature range for which they are to be applied.

• All brackets and supports shall be protected against corrosion.

• Particular care should be taken with flameproof, intrinsically safe and other types of equipment to ensure that the metal joints are clean and that safe gaps are not exceeded.

• Provide adequate labor and facilities to meet the completion target of the project.

• Instrument installations include all instrument process and utility and piping components, except the valve connections used to connect instruments to other piping or equipment.

9. INSTRUMENT PROTECTION

• The purpose of this section is to assist in the design to ensure that all installations will function with the best reliability and minimum maintenance.

• An installation requiring monthly or more frequent attention is considered unsatisfactory. To achieve this, it shall be ensured that fluids within instruments and impulse lines are mobile, homogenous and non-corrosive at all foreseeable conditions and have no effect or at least a constant effect on the measurement. Foreseeable conditions means within the Specification of the particular instrument and climatic extremes of the location

• The process liquid/ gas can react with the sealing fluid, thus blocking the impulse lines, and these effects shall be taken into consideration:

• All electronic instruments in field shall be protected with sunshade. Displacer type level instruments shall be protected with supplied sunshade. The shade shall be fixed to the mounting plate in such a way that quick installation and removal is guaranteed.




PAGE NO: 24 OF 50

9.1 Methods of Prevention

Methods by which, process liquids can be prevented from entering instruments and impulse lines are as follows:

• Alternative measurements

• Application of diaphragm seals

• Liquid seals

• Purges

Where diaphragm type seals are most applicable, they shall be given first consideration. Seals or purge shall be used in place of heat tracing.

9.2 Mobility

• Liquids within instruments and impulse lines shall be maintained in a sufficiently fluid state to maintain instrument performance by preventing high viscosity, fouling, freezing and solidification.

• When liquids have a pour point below -80C, no mobility problems are foreseen.

• When liquids have a pour point above -80C, protection by insulation shall be applied.

• Liquids that have a pour point above 50C shall be prevented from entering instrument

piping where possible. If this is not possible, trace heating shall be applied.

9.3 Homogeneity

The following requirements do not apply to locally mounted pressure gauges.

Phase Separation

Protection by tracing shall be applied when instruments and impulse lines carry solutions which undergo a separation of liquid phases upon cooling down to -8

0C, to maintain homogeneity.

Non-Volatile Liquids

When liquids are not vaporized at 650C at the minimum operating pressure, no provision need be

made for the purpose of maintaining homogeneity.

Fully Volatile Liquids

Diaphragm seals or vapor purging shall be applied when liquids are fully vaporized at -80C at the

minimum operating pressure.

Partially Volatile Liquids

When liquids are either non-volatile or fully volatile, diaphragm or liquid seals shall be applied. The seal shall be arranged to minimize the extent of the unsealed portion of the system and piping between the seals and the process shall be as such as to maintain a constant liquid head formed by the liquid seals.

Non-Condensable

When no portion of a vapor or gas is condensed at -80C at the maximum operating pressure, no

provision need be made for the maintenance of homogeneity.




PAGE NO: 25 OF 50

Partially Condensable

When vapor or gases are neither (non-condensable or fully condensable, diaphragm seals shall be applied. If this is not possible then liquid seal shall be applied.

The seals shall be arranged to minimize the extent of the unsealed portion of the hydrostatic system, and the piping between the seal and the process shall be such as to maintain constant liquid heads formed by the liquid seals.

10. INSTRUMENT PIPING & TUBING

• The instrument piping installation shall be neat and consistent with good engineering practice to avoid measurement errors.

• All instrument piping shall contain a minimum number of joints, which shall be staggered and neatly offset.

• All piping and tubing shall be provided with sufficient supports such that forces applied to the piping/tubing are not transmitted to the fittings, valves or instruments.

• Pipes or tubes installed, but not connected, shall have their ends closed with approved blanking-off plugs.

• Tubing shall be installed in neat orderly runs, plumb and parallel. Formed bends shall be used in preference to elbow fittings. Tubing shall be installed in a manner to provide maximum mechanical protection using cable tray or ladder if necessary.

• Tubing shall be fixed to the supports using proprietary clamps or approved equivalent.

• Hand force applied to piping/tubing shall not produce deflections exceeding 25mm.

• Tubes and fittings shall be installed so as to allow for removal of instruments and replacement of fittings without kinking of the tubing.

• Vents and drains shall be sited correctly to ensure they are at the highest and lowest points respectively of the piping run.

• Vents and drains shall be piped away from the body of a plant operator in the vicinity.

• Prior to connecting pipes and tubing to instruments, all pipes and tubes shall be cleaned by blowing through with filtered and dried instrument air or nitrogen. The inside of all tubes, instrument piping, valves and fittings shall be free from blisters, mill scale, sand, dirt etc.

• Stainless steel tubing shall be insulated from any non-stainless steel supports to prevent galvanic corrosion, using Stauff pipe clamps or approved equivalent.

• Instrument piping/tubing shall not be run in common cable ladder/tray with electrical cables.

• Fittings and ferrules for all 316 stainless steel tubing shall be 316 grades, stainless steel NPT threaded (where appropriate) double compression fittings, Swagelok or approved equivalent.

• Tube fittings shall be installed strictly in accordance with the manufacturer’s directions.




PAGE NO: 26 OF 50

• All supplied impulse tubing and fittings shall be complete with material and test certification. All materials purchased shall be made available for inspection before installation. Fittings and tubing without certification will be rejected.

• Instrument process connections shall be made in strict accordance with the hook–up drawings.

• All impulse tubing shall be run with a slope of not less than 1 in 12. The slope of the impulse pipe work shall be down from the tapping point for liquids and up from the tapping point for gas service.

• Impulse lines shall be kept as short as possible consistent with good practice and accessibility.

• Installation and fabrication of instrument process piping and pneumatic tubing, wherever applicable, shall comply with the requirements of ANSI B31.1.

• Pipes shall be bent using pipe benders only. Pipes shall be cut using pipe cutting devices. Hot cutting and bending is not allowed.

• All threaded joints except those, which need welding, shall be joined with suitable sealant viz. Teflon. The threads shall be free from tears, shoulders, cuts or any defects, which may break the continuity of the threads. The threads shall have NPT threads.

• Use of tube unions shall be avoided and shall only be used where necessary on long runs.

• Differential pressure instrument leads shall be run together as much as possible.

11 CABLE INSTALLATION

11.1 Cable Grouping

• Grouping of cables shall be used for different signals as below: - -

- Electronic signals. 4 - 20 mA, RTD, TC

- Control signals (24 VDC).

- Digital signals (24 VDC).

- Shutdown signals.

11.2 Segregation

• Cables shall not be run in common ladders/trays with pneumatic or instrumentation piping/tubing.

• The cable layout shall be designed to provide segregation/separation between certain electrical services grouped together as follows:

Power cables (Low Voltage) and Lighting Cables.

Control, Instrumentation and Communication Cables.

Intrinsically Safe cables.

Non-Intrinsically Safe cables.

Fire and Gas Protection Cables




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• Generally each group is allocated to a separate cable ladder, or duct but where indicated on the design drawings:

• Instrumentation cables including IS cables shall be installed separately from LV or lighting cables.

• LV cables and control cables including IS cables installed on the same cable ladder shall be installed on opposite sides of the cable ladder and separated by metallic barriers or installed separately in conduit.

• Segregation shall not be less than the distances (mm) shown below in Table 1:

Table1: Segregation of Cables

Distance unit is in millimeter DESCRIPTIONS/

CATEGORY INSTRUMENTS

COMMUNICATION

FIRE

&

GAS

LOW

TENSION

HIGH

TENSION

INSTRUMENTS 0 0 150 300 900

COMMUNICATION 0 0 150 600 1200

Low Voltage

FIRE & GAS 150 150 0 600 900

LOW TENSION & CONTROL 300 600 600 0 600

HIGH TENSION 900 1200 900 600 0

Note: The above segregation is applicable for parallel runs of cables. For cross over a minimum of 500mm separation distances to be permitted on all applications.

• In areas where low level computer signal wire is installed, special additional segregation may be required as detailed on the design specification and drawings or as specified by the EPMC.

• Cables shall be segregated from communication cables as detailed in accordance with the Indian Telecommunication Standards.

11.2.1 Intrinsically Safe Cables

• Cables carrying intrinsically safe circuits shall not be installed adjacent to or parallel with

single core cables carrying currents in excess of 100 A.

• They shall not be run in the same conduit, ducting or tray as other cables unless either:

The intrinsically safe cable or the other cables are armoured or metal sheathed

The location of the cables is such that the risk of mechanical damage is slight and

the cables are insulated and sheathed.

The number of cables is only one or two, and in this case a metallic divider shall be provided.




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11.3 Spacing

• The spacing between cables is a specified requirement of the installation design. The

CONTRACTOR shall ensure that the spacing between individual cables is as follows:

Cables on ladder

• 3 and 4 core cables 35mm2 and above shall be single layer touching

• 16mm2 cables and smaller may be installed to a maximum of 2 layers

• Control and instrument cables may be installed to a maximum of 2 layers

Control and instrumentation cables shall be separated by a minimum distance equal to the diameter of the largest adjacent cable unless otherwise noted on the drawings.

Note: Extra low voltage cables including IS cables shall be segregated from LV cables by 100mm minimum when laid in cable ladders and 200mm in trenches.

11.4 Location of Cable Routes

• Prior to commencing the pulling or laying of cables, the actual route length shall be checked by the CONTRACTOR to ensure sufficient cable is available to meet the requirements without recourse to jointing of cable.

• It shall be the responsibility of the CONTRACTOR to ascertain prior to work commencing that adequate space exists on the cable tray and clearance for conduit installations, along the routes indicated on the drawings.

• The routing of above ground cables to general power outlets and light fittings is dependent on structural conditions and final equipment locations. Exact final routing shall be subject to the EPMC approval.

11.5 Entries and Sealing

• The CONTRACTOR shall be responsible for providing all necessary openings in walls, roofs and floors and those entries shall be made so as to prevent the ingress and accumulation of fluids, debris, dust and vermin and to provide mechanical protection.

• All such openings shall be effectively sealed and weatherproofed using purpose built hardware such as glands or cable transits and including the installation of flashing or rain boards.

• In hazardous areas, such openings shall in addition be filled with a fireproof compound.

• Silastic and similar compounds shall not be used for weatherproofing in lieu of glands and purpose built hardware.

• For cable entry into buildings, MCT (Multi-Core transit blocks) shall be used.

• All cable entries into equipment shall be effectively sealed using cable glands or cable transits.

• All conduits and ducts shall be sealed at cable entry and exit points using epoxy cement grouting mix such as "Escoweld" or equivalent (to be approved by EPMC)

Note: Where conduit is used only for mechanical protection, i.e. on walkways etc., there is no need for sealant to be used, provided that the conduit does not leave or enter a hazardous area.




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• Flameproof metal conduit systems, installed in hazardous areas shall be terminated via compound filled, flameproof sealing end fittings installed at each end of conduit runs and within 600 mm of terminations to an arcing device.

• To prevent the accidental transmission of hazardous areas through openings, conduits or ducts:-

Openings in walls shall be sealed using cable transits.

Compound filled sealing fittings or glanded junction boxes shall be installed at both ends of all continuous conduit runs.

• Cables entering equipment which may be pressurized by flammable gas/liquid in normal operation or by seal failure or other equipment failure shall be glanded using EPMC approved Barrier glands to prevent transmission of flammable gas/liquid through the cable interstices.

11.6 Cable Ladders/Trays

• The CONTRACTOR shall be responsible for the installation of all cable ladders/trays, which are required for the installation of cables on the major cable routes and up to the positions of individual items of electrical equipment unless otherwise specified.

• The top layer of horizontal and vertical cable ladders located outside shall be fitted with covers fixed at 600mm centre and which allow adequate ventilation and provide shielding against solar radiation.

• All cable ladder joints shall be made with standard fittings and provided by the CONTRACTOR.

• Ladder/tray sections shall be bolted together using two coupler plates and connections locked so that the ladder is electrically continuous and no bolts protrude into the sections, which may damage cables during installation. Cable ladders/trays shall be internally smooth, round headed bolts shall be installed with head inside and nut outside.

• All cable ladder/tray runs shall be bonded to earth bars by connecting 10mm2 PVC

covered earth cable at the end of each cable ladder run or any intermediate point requiring earth continuity.

• Cable ladders shall be installed at the levels and the horizontal dimensions as per Drawings. However the position of the ladders shall be determined also in relation to pipes and other services. Any alterations required shall be made only with the written approval of the EPMC.

• Where it is necessary to cut or weld cable ladders, the exposed metal shall be cleaned and painted with a zinc-enriched paint, which shall be to the approval of the EPMC.

• Cable ladder support clamps shall permit tray movement along the route to allow for expansion and/or expansion joints shall be f it ted according to the ladder SUPPLIER / VENDOR's recommendations.

• Cable ladders shall be supported at intervals not exceeding 2.0 meters and shall be indicated on the design drawings.

• Cable ladder supports and brackets shall be installed by the CONTRACTOR, and shall be to the approval of the EPMC.




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• The installation of cable ladders shall not interfere with access to equipment or passage ways nor subject the cables to excess heat or the possibility of mechanical damage resulting from adjacent services of equipment.

• Fibre optic cables and other communication cables above ground at co-located terminals shall be installed in closed cable ducts, hot dipped galvanized steel of 100 mm x 100 mm, to protect the cables.

11.7 Above Ground Conduits

• Conduits shall be provided at any location where additional mechanical protection and/or support of cable are required.

• All conduit material shall be EPMC approved and comply with the following:

Above ground conduits shall be heavy duty, seamless, galvanized steel, screwed type.

All flexible conduits shall be heavy duty PVC sheathed metallic type.

• Unless otherwise agreed with the EPMC, conduit elbows and tees shall not be used. Changes in directions shall be by bends, large radius sets in the conduits or by using junction boxes, or pull in boxes.

• The minimum nominal size of conduits shall be as follows:

• 25mm for lighting circuits, general purpose power and instruments.

• 32mm for all other circuits.

11.7.1 Conduit Installation

• The installation of conduits shall comply with the following requirements:

Conduits shall be installed in neat orderly runs, plumb, level, parallel, and properly supported. Conduit runs shall be continuous from points of origin to destination. All joints and fittings shall be made off to provide a mechanically strong weatherproof system. Adequate supports shall be provided such that forces applied to conduit runs are not transmitted to the associated equipment and fittings.

Steel conduits shall be properly cut, reamed and deburred.

Fixing of surface mounted conduits shall be by means of galvanized steel, double sided saddles. The saddles shall be installed at intervals not exceeding 2m and at a distance not exceeding 1 .5m from any electrical equipment or conduit fitting.




PAGE NO: 31 OF 50

Saddles shall be fastened as follows:

• To steel by means of machine screws and nuts, or by bolts, and in all cases anti vibration washers shall be fitted.

• To brick and concrete by means of threaded metal plugs.

• Hand force applied to conduit shall not produce deflection exceeding 5mm.

Conduits shall be swabbed clean and free of foreign matter prior to pulling cables. Bushes shall be provided at conduit ends to prevent cable damage during pulling and blanking-off plugs shall be fitted to all free ends of conduits.

Bending of conduits shall only be carried out using approved bending tools

• Draw wires for future use shall be installed in all spare above ground conduits.

• Multiple conduit runs shall be supported from mild steel brackets fixed to walls or structures.

• Conduit runs shall be provided with drainage at the lowest point of the run to prevent condensation build up.

11.8 Below Ground Cables and Conduits

• Underground cables shall be either laid direct in the ground or run in heavy duty PVC pipe.

• The CONTRACTOR, prior to commencing trench excavations, shall be responsible for ascertaining final ground levels, i.e. whether the ground level in which the trench is to be excavated is to remain at that level. Also, he shall be responsible for obtaining any necessary permits and authorizations and shall establish the location of all other services e.g. cables, pipes, and ducts etc., which cross the route of the proposed trench. All LV cables shall be installed in accordance with the Indian Electrical Act.

• Unless otherwise shown on the drawings, all underground cables shall be run at a minimum cover depth of 600mm.

11.8.1 Direct Buried Cables

• Trenches shall have parallel sides with side and bottom surfaces free from projection.

• The radius for a change in direction of a trench shall not be less than the minimum permissible bending radius of any cable to be laid along the inside radius of the trench. For this purpose, the minimum bending radius, in any case, shall not be less than one meter.

• The CONTRACTOR shall supply clean bedding sand uncontaminated and sieved through a 3mm screen to the satisfaction of the EPMC. No rock shall be included in the backfill.

• The cables shall be installed in reasonably straight runs within the trench and close to the centre of the trench. The distance between cables laid in the same trench shall be as specified by the EPMC.

• Armoured Fibre optic cable shall be buried without additional protection apart from crossing areas. HDPE casing shall be used for fibre optic installation at all crossings along the pipeline.




PAGE NO: 32 OF 50

• Approved PVC cable covers shall be laid on top of the packed bedding sand prior to backfilling.

• The CONTRACTOR shall be responsible for the packing of the sand and the laying of the cable covers as required by the EPMC. The CONTRACTOR shall supply the necessary cable covers and the sand.

• Immediately after laying of cables has been completed and prior to backfilling, the cable route shown on the layout drawings shall be marked to the "as built" stage. Actual measurements from fixed structures or other permanent points shall be marked on the drawing and shall clearly locate the cable route and all changes of direction.

• Cables laid direct in ground shall be inspected and tested and the 'as built' markups verified by the EPMC, before backfilling commences.

• After cable covers have been placed in position, the trench is to be backfilled and compacted. At a level 300mm from ground level, the CONTRACTOR shall supply and install a continuous strip of 150mm wide orange PVC marker tape marked in legible black or yellow lettering in two or three languages to be defined by the EPMC,

"ATTENTION CABLE DANGER"

or similar over the position of the cables. The finished surface shall be left proud of natural country by approximately 50mm to allow for subsidence. The finished surface of lawns, paths and roadways shall be finished to match the original surface.

• Trenches shall be backfilled in 150mm layers, each layer being compacted with an approved mechanical tamper or rubber tyred compaction vehicle.

• Sufficient backfill material shall be used so that the trench is slightly overfilled.

• The CONTRACTOR shall spread and compact the backfill as required by the EPMC.

• A minimum of 150 mm gap shall be maintained between IS and non-IS buried cables inside the cable trench.

11.8.2 Below Ground Conduits and Ducts

• Where cables are to pass beneath roads, foundations or where shown on the design drawings, they shall be installed in PVC ducts to allow installation, removal or additions with minimum disturbances.

• Underground ducts and conduits shall be heavy duty, PVC type bedded in sand.

• Each duct system shall either stub up directly into or below the equipment to be connected or shall finish at the concrete cable trench. All stub-ups subject to weather or UV damage shall be protected by means of painting or other appropriate means approved by the EPMC.

• The CONTRACTOR shall be responsible to ensure that the positioning of the stub ups is correct before pouring of concrete. The stub ups shall project 100mm above floor level.

• The CONTRACTOR shall ascertain at an early stage in the construction the underground duct requirements and shall co-ordinate with the civil construction work.




PAGE NO: 33 OF 50

• The conduit laying, backfilling, compaction and associated civil work shall be in accordance with the project requirements.

• 300mm below ground level, the CONTRACTOR shall supply and install a continuous strip of 150mm wide orange PVC marker tape marked in legible black or yellow lettering in two or three languages to be defined by the EPMC, "ATTENTION CABLE DANGER" or similar over the position of the cable ducts.

• Each duct system shall be complete with manholes and pull pits as is necessary to facilitate installation and possible future replacement of cables.

• Bending of ducts/ Hume pipes should be avoided as far as possible.

• Spare ducts should be installed with draw wires.

11.9 Minor Cable Routes

• Cables not run in cable ducts or on cable ladders shall be protected by enclosing in adequately supported steel conduit, PVC jacketed flexible steel conduit or galvanized water pipe or steel ducting whichever is applicable and approved by the EPMC.

• All conduit and water pipes shall have smoothed or bushed ends prior to installation of cables.

• All cables rising from below decking shall be mechanically protected by galvanized steel water pipe and/or mechanical guards.

• Where underground cables leave the ground such as for equipment stub-ups, they shall be installed in PVC conduits, extending a minimum of 500mm below the surface encased in concrete and be provided up to a minimum height of 300mm above finished level.

• The grouping of cables shall comply with the following installation requirements:

Single, double and triple cable runs may be fixed directly to structural members and run in conduit in accordance with this document.

Groups of four or more cables shall be run on cable ladders/trays.

• Cables shall not be installed in positions where they are susceptible to mechanical damage.

• Cable clamps and associated mounting channels shall be installed where required to ensure that no strain is imposed on terminations.

11.10 Cable Laying

• Cables shall be run with all due care, which shall include the following precautions to prevent cable damage:

• Cables shall not be subjected to twisting, crushing, kinking or contact with sharp edges, as this could result in sheath or core damage.

Cable drums shall be rolled only in the direction indicated on the side of the drum. The drum shall be stoppable to avoid overrunning.

The bending radius of cables shall not be less than the minimum recommended by the SUPPLIER/VENDOR.

• Maximum stresses stated by the cable SUPPLIER/VENDOR shall not be exceeded when laying or pulling any cables.




PAGE NO: 34 OF 50

• Pulling of cables shall only be carried out by one of the following methods:

By stocking pulling grip, for which the stress applied shall not exceed 10 MPa.

By cable SUPPLIER/VENDOR approved pulling eye attached to the conductors, for which the stress applied shall not exceed 70 MPa.

• Unless otherwise approved by the EPMC, any cable being drawn into position shall be run on sufficient rollers to ensure that it is kept clear of the ground or other obstructions. Vertical rollers shall be used at all points of change in direction.

• Cable runs shall be dressed and clamped back before terminating.

• At least 0.5 meter slack shall be provided at all field connections to allow adjustment and/or removal of equipment, motors etc.

• For final cables terminating at individual field devices such as instruments, position switches, solenoids etc., a length of slack cable shall be arranged in two coils of approximately 200mm diameter, immediately preceding the cable gland.

• Cables installed on cable ladders/trays shall comply with the following requirements:

Cables shall be neatly laid in parallel runs with a minimum of crossovers.

Cables run on flat horizontal ladder/tray shall be fixed with nylon cable ties at a

maximum separation distance of 1.2m.

Cables run on, on-edge ladder/tray, shall be fixed every 300mm with nylon cable ties.

Cables run vertically shall be fixed with nylon cable ties every 300mm.

• All Nylon cable ties shall be heavy duty colored black and UV resistant.

• Maximum number of cables tied together shall be not greater than four and in no case shall cable ties span a distance exceeding 100mm.

• Single core cables carrying alternating current shall be run strapped to tray in close trefoil formation using non magnetic trefoil cable clamps of a proven mechanical strength for the circuit fault rating. The maximum spacing of strapping for such cables shall be 600mm.

• Any damage sustained by a cable (including the outer serving) shall be reported to the EPMC and EPMC approved remedial action taken before work upon the particular cable proceeds.

• The CONTRACTOR shall be responsible for determining the final cable run length before cutting and also record the 'as built' length on the cable schedules.

• Through joints shall not be performed on any cable run.

• During installation, all cables shall be cut from drums in such a manner that off-cuts are a minimum. All cables shall be recapped immediately after cutting.




PAGE NO: 35 OF 50

11.11 Cable Marking

• All cables shall be identified using engraved aluminium plates fixed to the cable with stainless steel cable ties as follows:

At each end of the cable

Where cables enter and leave ducts and pits

Both sides of wall and floor penetrations

Both sides of gland plates of floor mounted cubicles.

Where cables change direction or trench.

11.12 Cable Route Marking

Above ground cable route markers shall be installed at each end and change in direction of cable route in accordance with the installation detail drawings.

11.13 Cable Glands

• Before installation all cable gland threads shall be coated with a EPMC approved anti seize compound.

• Any gland fitted to any explosion-protected enclosure shall in addition be of the flameproof type.

• The CONTRACTOR, in accordance with the SUPPLIER/VENDOR’s recommendation, shall correctly size glands for each cable.

• The CONTRACTOR shall be responsible for drilling any undrilled gland plates prior to fitting cable glands.

• The installation of cable glands shall not rely on a lock-nut type fitting. All cable glands shall be installed into a threaded entry. Appropriate threaded reducers shall be used, if necessary.

• Cable glands for armored cable shall be of the correct construction for the type of cable and shall be fitted with brass earthing tags where required.

• PVC shrouds are not to be fitted to indoor equipment, but should be fitted to outdoor equipment to prevent water ingress.

• Cable glands for Junction boxes shall be installed in the bottom. Each Junction box shall be provided with a breather plug in the bottom gland plate to prevent condensate build up in side the Junction Box. A water seal ring shall be provided to prevent water ingress.

11.14 Cable Testing

The CONTRACTOR shall test all cables for insulation and continuity. The results of these tests shall be recorded on appropriate tests sheets. When insulation tests are carried out great care must be taken to ensure all equipment is disconnected to prevent damage.




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12.0 TERMINATIONS

12 .1 General

• The CONTRACTOR shall supply all cable terminating kits, lugs, tapes, compounds, resins and cable core markers required to terminate all cables.

• If it is not intended to terminate the cables immediately after cutting, cable ends shall be sealed immediately after cutting to prevent ingress of moisture.

• Except as described below, all cables shall be terminated using approved glands or cable transit frames to seal and support cables.

• Cables entering open bottom cubicles do not require glands. The cable shall be clamped for physical restraint and the armour earthed as follows:

Clamping: this shall be over the outer sheath on to clamping rails located at the bottom of the cubicle.

Earthing: where specified, the cable armour shall be earthed by fitting a suitably sized hose clamp over the exposed armour and connecting the clamp to the cubicle

earth bar via an individual earth wire.

• The CONTRACTOR shall be responsible for ensuring the correct entry point for cables into equipment. Where multiple cable entry occurs the CONTRACTOR shall plan each cable gland location near its associated terminals to minimize cable and cable core interweaving.

• Each cable core shall have sufficient spare length to allow for replacement of terminating lug. In addition the tails of installed multicore control cables shall be of sufficient length to allow connection of each core to any terminal on the associated terminal blocks.

12.2 Cable Core and Wiring Preparation for Termination

All cable cores and wiring shall be terminated in compliance with the following requirements:

• All wires and cables shall be terminated with solder less crimp-type cable pins or lugs of the size and material recommended by the lug SUPPLIER/VENDOR for that cable.

• Automotive type quick connect insulated crimp connectors shall not be used.

• Lugs for cables up to 4mm2 shall be of the pre-insulated type. All control cables shall be

terminated using lugs of the pre-insulated type.

• Lugs not of the pre-insulated type shall be insulated by means of an approved heat-shrink sleeve or be neatly stepped and taped up to the lug with tape having a di-electric strength for the particular application as recommended by the tape manufacturer.

• All lugs shall be crimped using compression tools of the correct size and type. Such tools shall be approved by the EPMC.

• The correct size and type of lugs shall be used in all terminations.

• Tinned copper lugs shall be used for connection of copper cables to copper terminals or lugs.

• Where the cable conductor and terminal are dissimilar materials then bi-metal lugs shall be used, as recommended by the lug SUPPLIER/VENDOR for those materials.




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12.3 Cable Shields/Drain wires Preparation for Termination or Isolation

• Where cable shields shall be terminated or earthed, the shields and drain wires shall be prepared as follows:

For individually shielded single pairs or triples and overall shields of multi pair cables where continuous shielding up to the final equipment terminals is required

The Aluminum polyester shield shall be cut back by 100mm and the drain wire sleeved with green PVC sleeving from this point to its termination or earthing point.

For overall shields of single and multipairs and triples and where continuous shielding to the final terminations is not required

The Aluminum polyester screen shall be cut back to within 100mm of the cable crotch and the drain wire sleeved and the junction covered with heat shrink as detailed above.

• Where cable shields shall not be terminated but shall be isolated from earth and from each other, the shields and drain wires shall be prepared as follows:

The individual and overall shields and drain wires shall be cut back to within 100mm of the cable crotch and each individual and the overall shield and drain wire shall be covered with 100mm of clear heat shrink tubing to ensure electrical isolation.

12.4 Cable Core and Wiring Terminations

• Terminals shall be rail-mounted.

• No more than one wire shall be connected to each terminal tunnel connection.

• Bridging shall only be by means of the terminal manufacturer's standard bridging strips, barrels and screws.

• Terminal identification shall be by means of the terminal manufacturer's standard labels.

Terminals shall be consecutively numbered from top to bottom, or from left to right of each terminal strip, unless noted otherwise. Terminal rails shall be identified, as shown on the drawing, by a label with lettering of at least 20mm height at the top of each row.

• 20% spare terminals shall be provided for future termination requirements.

• Where control devices, i.e. pressure switches, contain insufficient wiring space, a junction box shall be installed alongside the device and the cable terminated in terminal strips in the junction box.

• Spare cores of cables terminating in hazardous areas shall be earthed at the non-hazardous area end only.

• Barriers shall be provided between terminals carrying wiring of different voltages.

• Hazardous area side terminations for intrinsically safe circuits shall be totally separated from non-intrinsically safe terminations.

• Control and instrumentation cables shall be terminated with core numbers/colors consecutive, starting from the top, when practical.

• All spare cores shall be terminated to individual terminals and ferruled "SP".




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• Individual shield drain wires shall be terminated with, and below, their respective conductor pairs or triples.

• Overall shield drain wires shall be terminated as the last or second last core of a cable as applicable.

• Communication wires of multipairs cables shall be terminated as the last core of each cable and labeled “SP” if not used.

• Connections in cubicles between cable cores of different cables shall preferably be via ferruled jumper wires. Direct cable core to cable core terminations shall not be used unless specifically required.

12.5 Cable Core and Wiring Identification

• All conductors shall be uniquely identified at each termination as shown on the relevant design drawings by means of numbered ferrules. Ferrules shall be of the full circle type self interlocking

• Ferrules shall be the correct size for the wire to be ferruled and shall have black letters/numerals on a white background. Ferrules shall read left to right or bottom to top.

• Wire number ferrules shall consist of Tag Number, Terminal Block Number and Terminal Number, this is also applicable to junction boxes. For marshalling panel side, the ferrule number shall become same.

• The position of the ferrule on the conductor shall be such that each identifier is clearly visible without manipulation of the ferrule. (Ferrules for small conductors may need to be "staggered" to achieve clarity).

• Only when specifically stated on drawings approved by the EPMC, multicore or multipair control and instrumentation cables installed with core numbers/colour consecutive, starting from the top and terminating on to terminal strips where ferruled wires are terminated on the opposite side of the terminal, shall not be ferruled.

12.6 Panel Wiring Panel wiring shall be colour coded for voltage identification/segregation purposes as detailed below:-

Phases : Red, Yellow, Blue

Neutral : Black

Earthing (power) : Green & Yellow

230 V AC (Live) : Brown

230 V AC (Neutral) : Blue

IS Earth : Yellow

Instrument Earth : Green

Signal Cable : Black, White

Control Cable : Black, Blue

24 V DC Positive : Red

24 V DC Negative : Black




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12.7 Wiring Details and Installation

• Wiring shall be installed in a neat manner by qualified personnel.

• Wiring shall be restrained from disturbance using plastic ducting or a similar system approved by the EPMC. All wiring leaving the ducts shall be neatly grouped and bound with ties and shall be supported to prevent pull out. Cable ducts shall be filled to a maximum of 60%.

• Wiring looms shall be neat with parallel wires tied at all wire exit points and every 100mm.

• When the wiring is completed, it shall be possible to access and reconnect any single cable core or wiring termination without disturbing or disconnecting other terminations, or associated equipment.

• Wiring to Equipment mounted on movable panel sections shall be loomed and protected from physical damage by spiral sleeving over the loom (Spiro-flex or EPMC approved equivalent). The loom shall be routed to avoid fouling equipment movement or being damaged by the movement.

• All wiring shall be completed without any splices or joints between terminals.

• All wire cores shall be insulated with PVC compound in accordance with IEC 60189.

• All control wiring shall be carried out in flexible, copper cables, 0.6/1 kV, V105 grade PVC insulated of minimum size 1 .5mm2 (30/0.25mm) and terminated with insulated crimped pins or lugs.

• All power wiring inside cubicles shall be carried out in stranded copper cables, 0.6/1 kV, V105, grade PVC insulated and of minimum size 2.5mm2 (7/0.67mm) and terminated with compression lugs.

• Intrinsically safe wiring shall be clearly identified and completely separated from all other wiring by means of segregation barriers or conduit. Conduit within cubicles used for segregation of IS wiring shall not be less than 50mm diameter.

• IS wires shall have a minimum cross-section of 0.5mm2 (7 strands, each 0.3mm) and be

installed to IEC 60079.0 and IEC 60079.11.

12.8 Earthing Requirements

12.8.1 Earthing

• The following earthing points for connection by others shall be provided:-

• Panel metalwork

• Electrical AC mains supply earth

• 2 off M20 brass studs per panel section. These brass studs shall be fitted with vibration roof nuts and washers.

• Instrument 'clean' earth

• Electrically insulated copper bus-bar 75mm2 minimum separated from the panel

metalwork by 25mm minimum. 2 off M20 brass earth studs to be provided at each end of the bars with associated shake proof nuts and washers.

• An intrinsically safe earth bar similar in construction to the instrument clean bar shall be installed. This bar shall comply entirely with the requirements of IEC 60079.14. The bar shall incorporate a removable section to facilitate earth continuity testing.




PAGE NO: 40 OF 50

• On intrinsically safe circuits the following shall be adhered to:-

Unused cores of multicore cables nominated as spares shall be terminated to earth via dummy barriers. All other unused cores shall be taken direct to the I.S. earth bar.

The earth connection shall be via dual shake proof screws or clamps.

Brass studs shall be incorporated on the I.S earth bar for connection of dual I.S earth cables.

The I.S earthing system shall be labeled "Safety earth - Do not disconnect".

• Similarly unused cores of non-I.S. field cables and system cables shall be terminated and connected to the instrument 'clean' earth. A minimum of 20% spare capacity shall be provided within system cables and ELCO connectors.

• All panels, internal fabrication and racks shall be earth-bonded together and finally to position determined for field earth cable connections.

• Each earthing stud and bus bar shall be permanently and durably labeled as to its service.

• All earthing cables shall be green/yellow, multi stranded PVC insulated copper conductor and of minimum size 6 mm

2.

• All Equipment panels and cubicles shall be connected to earth and be supplied with a suitable earthing bar or boss or stud.

• Unless noted otherwise, all structures and vessels shall be connected to earth, and be supplied with two suitable earthing bosses, located on diagonally opposite corners of the structure or vessel.

• All cable ladders shall be connected to earth and bonded across joins.

• All exposed earth connections shall be painted using EPMC approved water based inhib it ing pr imer beneath industr ia l c lass acryl ic top coat according to SUPPLIER/VENDOR's instructions.

• All earth bars shall be constructed from high conductivity electrical copper and have a minimum cross sectional area of 38mm2 (based on a maximum fault current of 5 kA for 1 sec and a 100

0C temperature rise above a 50

0C ambient).

• Contact surfaces of earth connections shall be cleaned, and then inhibited from corrosion immediately prior to making the connection with a compound approved by the EPMC.

• The complete earth system shall have a resistance to earth of not greater than one ohm, with 0.5 ohm being a desirable resistance.




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12.8.2 Cable Earthing

• Cables terminating in hazardous areas shall have the armoring earthed at the field end only. The armoring at the control room gland shall be insulated from earth, and from the armoring of other cables terminating at that gland plate.

• Armored cable glands shall be fitted with an earth tag for bonding to the equipment earth.

• Where armored power cables terminate into polycarbonate equipment the armoring and gland shall be earthed to the incoming cable power supply earth. This earth shall be removable for test purposes.

• All earth wires, including cable earth wires shall be labeled at their earth point. This is required to facilitate removal for testing of the site earthing and cathodic protection systems.

• Shielded cables shall have their shields and drain wires connected.

• Where specified on the drawings, cable earth wires in junction boxes or panels shall be terminated onto rail mounted, green/yellow tunnel type terminals and each terminal rail shall be connected to the safety earth bar or stud by means of a green yellow PVC insulated conductor.

12.8.3 Panel and Junction Box Earthing

• All panels and junction boxes shall be constructed with a solid safety earth connection (either earth bar or stud) bonded to the metalwork. All exterior surfaces of the cubicle shall be equipotentally bonded to this earth connection point.

• All doors, panels and equipment pans, which have live equipment mounted upon them, shall have a solid earth connection point (minimum: bolt, two flat washers, star washer and two nuts). This earth point shall be connected to the metalwork safety bar or stud by means of green-yellow PVC insulated conductor having a minimum cross section of 4mm

2.

• Gland plates shall be earthed as specified above. Separate gland plates shall be used for intrinsically safe and non-intrinsically safe cables.

Junction boxes shall be equipped with a stud for metalwork earthing. The stud shall be electrically connected to adjacent earthed metalwork or to an adjacent main earth connection point on an individual basis.

• All earth bars shall be clearly labeled, have a minimum cross-sectional area of 75mm2

and 150mm of unused but utilizable extra length for future use and the attachment of main earthing or power supply connections.

• In addition, enclosures housing "Zener" type Intrinsically Safe (I.S) barriers shall have the barrier manufacturer's proprietary earthing bars for equipment mounting and for termination of IS cable shields.




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12.8.4 Shielding

• A shielded cable shall have its shield insulated from earth metallic conductors and other cable shields at all points except the single earthing point.

• Shields in a system to and within the control room will be connected to a common earthing point for that system in the control room.

• All shielded cables shall have their shields/drain wires earthed at the respective cubicles designated signal shield earth bar only. Shields shall be continuous from this earth bar throughout any intermediate enclosures up to the final instrument.

• In intermediate enclosures the shields shall be terminated into insulated tunnel type terminals and the respective terminals connected as required.

• In hazardous areas the shield shall be insulated.

13 FIELD INSTALLATION

13.1 Layout

Location

• Instruments in vapour or gas service shall be mounted above the sensing point. Instruments in liquid service shall be mounted below the sensing point. If accessibility, visibility or clearance requirements preclude either of these situations, provision shall be made in the instrument piping configuration to ensure proper continual operation of the instrument.

• Instrument block valves at mechanical piping or equipment shall be accessible from grade, platform, stairway, permanent or portable ladder. Instrument block valves in pipe ways shall be considered accessible by portable ladder although the height may vary.

• A pipe class primary block valve shall be provided at process connection. Piping take-off shall always include Isolation valves at piping taps. (Instrument manifold shall not be used as piping Isolation.)

• Indicating instruments that shall be visible for automatic control adjustment or manual operation shall be visible from the adjustment or operating point. Indicating instruments that are not to be observed during adjustment shall be visible from operating aisles or passageways.

Clearances

• Instruments shall be located so as to maintain clearances required for walkways, access ways, operation and maintenance of valves and equipment.

Supports

• Pedestals, as well as all instrument and supporting brackets welded to structures shall conform to the Specification for structural steel works and general welding requirements of AWS D1.1.

• Instruments (except flange mounted instruments) shall be remotely mounted with the centre line at 1.4 m from grade level or outside of platform handrails, and shall be supported as shown on the relevant drawing.




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• When practical, remote mounted instruments shall be grouped and have common supports as shown on the relevant drawing.

• The manifold block, which forms part of the impulse line arrangement, shall be bolted to amounting plate.

13.2 Installation Materials

Routing and Support

• The minimum slope on impulse lines shall be 1:12.

• Impulse lines shall be routed in order to minimize the length of the lines. They shall be routed so as not to obstruct access ways and to protect them from damage and malfunctioning during plant operation and maintenance.

• Impulse lines shall be supported from pipe supports, and any other permanent structure except where:

Pipe temperatures have an influence on the operation of the impulse lines

Pipe or pipe supports are subject to vibration

Note: Instrument supports shall not be welded to stress relieved pipe and equipment or internally lined pipe and equipment.

• Supports shall maintain the installation in a neat manner.

• Instrument cable and tubing racks shall not be routed above pumps/ compressors handling flammable liquid /gas having a flash point below 38

0C and having a vapor

pressure not exceeding 2.76 kg/cm2 at 38

0C. Nor shall instrument cable and tubing racks

be routed above pumps handling liquids whose operating temperature falls into a range whose upper point is defined as the ignition point of the liquid/ gas and whose lower point is at maximum 15

0C below the ignition point. Cable racks, under these circumstances,

shall be located remotely from those pumps or on the top of pipe bridges, but below fin- fans.

13.3 Control Building Instruments

13.3.1 Control Room

• For accessibility of control panels, horizontal clearances between the control panel structure and any permanent part of the control house shall be 1250 mm minimum. Instruments, installation materials, electrical wiring and structural members that form part of the control panel shall be considered as part of the control panel structure.




PAGE NO: 44 OF 50

13.3.2 Marshalling Cabinet Room

• The requirements of the previous paragraph shall be applied for instrument racks, instruments and electrical equipment.

• Rack rows shall be separated with a horizontal clearance of 600 mm. Instrument racks that do not require rear access can be located against the building structure.

14 INSTALLATION INSPECTION AND TESTING

14.1 Definition

Testing shall be defined as including the following:

• Pre-installation checks

• V isual checks

• Static tests

• Loop tests

General

• Equipment received on site shall be immediately inspected for signs of damage during transit. Each item shall be checked against its data sheet to ensure that it has been correctly supplied and has the correct range of operation.

• CONTRACTOR shall provide a list of all calibration and testing equipment.

• Testing and checking shall be performed on the installation and instrumentation equipment in accordance with the following requirements.

• All necessary skilled labour and test equipment shall be supplied to undertake testing of the equipment or complete installation.

• All tests shall be carried out by the CONTRACTOR. The EPMC’s representative reserves the right to witness testing at any point.

• Test report sheets shall be completed by the CONTRACTOR and accepted by the EPMC’s representative.




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• Test report sheets shall include as a minimum at least the following general information:

• Test report sheet name and number

• SUPPLIER/VENDOR's name

• Contract number and title

• Site reference

• Plant/area details

• Equipment details

• Tag numbers

• Ambient conditions

• Remarks

• Signature and dates for:

Person performing test.

CONTRACTOR’s quality inspector

EPMC’s representative

Al l test results

• Test report sheets shall be provided for all equipment and for all wiring and cabling. These reports shall also be bound in the CONTRACTOR’s data report and summarized by the instrument index.

• Calibration equipment shall have a test certificate to show the equipment has been laboratory calibrated at a registered Test Laboratory or subject of a mutual recognition agreement within the previous 6 months from date of intended use. Copies of all certificates shall be provided for approval prior to testing, who may demand additional certification if the equipment accuracy is suspect.

• Calibration equipment shall have accuracy of between 3 to 5 times better than the specified accuracy of the instrument under test.

• All calibrations shall be to the maximum accuracy obtainable for the instrument under tests, and include adjustment to eliminate where possible instrument inaccuracies.

• The instrument system (whole or parts of) shall not be energized until authorized by the EPMC’s representative.

• All instruments shall be disconnected from process piping when hydrostatic testing is being performed.

• Only calibrations that cannot be accomplished with the instruments in situ shall be performed prior to installation.

• All cables shall be disconnected from instruments and Intrinsically Safe Barriers if Megger tests are being performed.

• All wiring and cabling shall be checked for correct connection.




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• The equipment shall be checked against data sheets on receipt and shall be carefully examined for damaged glassware and other easily breakable components.

• Any defects shall be reported to the Engineer-in-charge.

• An Instrument Supervisor shall not attempt any testing without the permission from the Engineer-in-charge.

• Details for site modifications and approval procedure:

• Any modifications, exceptions or additions to the documentation to be confirmed in writing by the Engineer-in-charge.

14.2 Pre-Installation Checks

All instruments shall be checked to confirm the following:

• Correct tagging and manufacturer's type number

• All parts are present

• Freedom from damage or physical defect

• All instruments shall be subjected to a full functional test and calibration check before installation.

• Instruments shall only be tested over normal operating ranges.

• Instruments shall be tested and calibrated in accordance with the SUPPLIER/VENDOR’s instructions. If an item is pre-calibrated at the factory and supplied together with a SUPPLIER/VENDOR’s calibration certificate, (e.g. Turbine meters) on site calibration will not be required.

• Calibration checks on transmitters, indicators and actuators shall be made at 0, 25, 50, 75 and 100% of range with both rising and falling signals.

• If an instrument is found to be out of calibration it shall be recalibrated to specification.

• Switch set point calibration checks shall be made with the signal rising or falling as specified.

• Both the rising and falling settings shall be recorded on the certificate. Switch operation shall be monitored with a continuity detector.

• Solenoid valves and instrument valves shall be checked for correct operation, port configuration and tightness of shut-off with “snoop” test solution (a soapy liquid to determine presence of leaks) or equivalent.

• After calibration, instruments shall be returned to the store complete with shipping stops and plugs, until required for installation.

14.3 Visual Checks

Visual inspection shall be made to show that:

• Approval/certification requirements for hazardous area installation have been carried into effect for each item of instrumentation equipment.

• Items of equipment and their mechanical supports have been securely mounted, are plumb and that no rusting of metal parts is evident.




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• Wiring, earth conductors and cable shields are correctly installed, terminated in accordance with the specified method, identified with the correct ferrule, and firmly secured to terminals

• Cables have been installed and terminated in accordance with the relevant technical standards.

• Cables have been fitted with identification tags at the specified locations and intervals and that the tags are secure and bear the correct identification reference

• Tubing, equipment and enclosures are correctly identified and labeled

• Painting and protection against corrosion is complete

• Correct materials have been used

• Piping, tubing and equipment are adequately supported, clean and suitable for instrument installation.

• Accessibility to equipment is adequate • Equipment located in hazardous areas has been properly installed. Particular attention

shall be paid to ensure that the enclosures are sound, free from mechanical damage and complete with all screws, bolts and locks.

14.4 Static Tests

• All adjustments and tests shall be made in accordance with SUPPLIER/VENDOR's instructions.

• Notification shall be provided in writing of any defects, which cannot be rectified of any instrument, which fails the testing.

• Approval shall be obtained in writing before any non-standard modifications or adjustments are made.

• Such approvals shall not release any responsibilities with regard to the equipment being tested.

14.5 Instrument Tubing, Piping and Connections

• Each pipe/tube shall be traced to ensure correct connection to process pipe or specified interface point and instrument and checked for correct labeling.

• Supply piping between the header connection point and the individual filter regulators shall be tested as one separate entity.

• Each pipe/tube shall be cleaned out, isolated from the instrument then charged with air or nitrogen at 1.5 times specified operating pressure then isolated from the supply and pressure tested for leak tightness using “snoop” solution or equal.

• Any instruments, which can be damaged by hydraulic pressure testing or flushing of process lines, shall be completely isolated or removed from the line until flushing and pressure testing is finished.




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14.5.1 Electrical Wiring

• Circuit equipment and components shall be protected against damage during testing by disconnection, removal or other suitable means.

• Where applicable, the insulation resistance between conductors and earth shall be tested with a 500V DC insulation tester.

• Acceptable resistance values are 1 Mega ohm. Lower values obtained shall be reported.

• Every earthing conductor connection, circuit system and loop for which a maximum resistance is nominated shall be tested with a low-resistance-testing equipment to ensure compliance.

• Using a continuity tester or bell set, a point-to-point check of all instrumentation cable connections shall be carried out by CONTRACTOR to determine that the wiring is correct and that each conductor is attached to the correct terminal. Particular care shall be taken in circuits, which may contain semi-conductors to ensure that they are not damaged in such tests.

• Verification in the form of checked, marked-up and signed prints of the drawing(s) concerned is required to ensure that all connections are in accordance with the relevant diagrams.

14.5.2 Field Instruments

Testing of indicators, transmitters, converters, valve positioners and controllers shall include:

• Simulation of the process variable or input signal and measurement of the electronic, pneumatic or mechanical output.

• Calibration at 0 or 5, 25, 50, 75 and 100 percent of range to achieve the specified accuracy.

• Repetition of the above, for a rising and falling signal and checking of Hysteresis.

• Water bath test for temperature gauges or dry temperature test.

14.5.3 Process Switches

Testing of process switches shall include:

• Simulation of the process variable and measurement of contact continuity

• Calibration of the switch point and checking of the dead band for rising and falling signals.

14.5.4 Controllers

Testing of Controllers shall include:-

• All open and closed loop functions as applicable.

• Simulation of the input signal and measurement of the output signal.

• Check for zero output drift with integral action at maximum, and zero error signal

• Separate check of integral, derivative and proportional action in response to a step change




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• Check for correct action of mode selector switch including bump-less transfer

• Check set point alignment on pneumatic controllers.

14.5.5 Loop Tests

• Each instrument loop shall be tested to prove that the installed instrumentation system functions correctly and is correctly calibrated.

• The gas/air supply and electrical supply shall be within specified tolerances during loop testing.

• Loop tests shall be conducted only after the associated cabling, wiring, piping and tubing has been tested.

• The field transmitter shall be manually or otherwise operated to cause a change in input signal and the receiving instrumentation shall be observed for the appropriate response and the correct direction of the latter. As a minimum, each loop shall be checked at 0, 50 and 100% input.

• Changes shall be made to set-points, manual adjustments and like elements of controllers and similar devices and the final operators observed for the appropriate response and the correct direction of the latter. As a minimum, each loop shall be checked at 0, 50 and 100% positions.

• Specific testing procedures shall be provided by the CONTRACTOR and approved by the EPMC.

14.5.6 Alarms and Trips

• Alarms and trips shall be tested by simulating the alarm or trip conditions at the switching device and observing that the relevant receiving devices respond appropriately

• Alarms and trips originating in electronic and electric circuitry shall be tested for correct operation at the same time that the electronic circuitry is tested

• If no other information is available, then alarm and trip settings shall be made at 20% (for low) and 80% (for high) of the specified range

• Vibration switches, proximity switches and similar devices may not be supplied pre- calibrated and where this is so, settings required for operation shall be made in accordance with the manufacturer's information.

15 QUALITY ASSURANCE AND QUALITY CONTROL

The CONTRACTOR shall operate a Quality System meeting the requirements of the relevant part of ISO 9002. CONTRACTOR shall provide documents such as plans, procedures, instructions, etc. for the accomplishment of all works covered in this document to provide the required quality. Specific adherence to the guidelines set down in ISO 9002 series documentation shall be detailed out by the CONTRACTOR and shall be subject to review and approval by the EPMC and also reserves the right to undertake such audit as deemed necessary to assess the effectiveness of the CONTRACTOR’s quality system.




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16.0 ELECTRICAL CERTIFICATES AND REPORTS

CONTRACTOR shall submit the following reports: -

• Electrical and electronic equipment hazardous area certification schedule and associated and other certificates.

• Insulation test report

• Electrical performance test report

• Electrical functional test report

• Other - Electrical test reports

17.0 DOCUMENTATION

The CONTRACTOR shall provide installation drawings of each instrument and its associated tubing, cabling etc. as below: -

• Instrument installation drawings shall be diagrammatic isometric drawings with a bill of materials attached.

• Instrument installation drawings shall show the instrument location, orientation, supporting piping component arrangement and materials.

• Field instrument location and orientation shall be shown on the general arrangement drawings. All instruments, except minor components of a control system, shall be shown.

• Instrument installation drawings shall be prepared for process piping of this document. The instrument index shall be used to correlate these drawings with the proper instrument tag.

• For new installations, control panel or rack location, installation and layout drawings shall show the location of the rack or panel and all the installation details for mounting the panel or rack.

For modifications to control panel or rack location, installation and layout drawings shall show the layout of the existing rack or panel and all the installation details for mounting the new equipment in the panel or rack.

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