RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 1 OF 73
ADNOC GAS
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY Contract No.
4700022871
JV TJN RUWAIS Contract No
215122C
Document Class
Class 2
Document Category (for Class 1)
NA
OPERATING CENTER Contract No.
OPERATING CENTER Doc Ref.
1
0
IFC - Issued for Construction
07-Oct-2024
E. Biedermann
ICR - Issued for Client Review
27-Jun-2024
E. Biedermann
K. Michineau M. Joshi R. Ikeya R. Biju
K. Michineau M. Joshi R. Ikeya R. Biju
S. Deilles F. Kiyoshi
S. Deilles F. Kiyoshi
Rev.
Revision Purpose
Date
Prepared by
Checked by Approved by
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 2 OF 73
Table of Contents
Contents
Page
1.0
INTRODUCTION … 3 1.1 Scope of the Document … 4 1.2 Holds List … 4 1.3 References … 4 1.4 Definitions and Abbreviations … 4 2.0 AMENDMENTS TO ADNOC GENERAL ENGINEERING SPECIFICATION AGES-SP-04-017 … 5 3.0 APPENDIX … 10 3.2 Appendix 1 – AGES-SP-04-017 … 10
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 3 OF 73
Table of Changes compared to previous revision (for Procedures and Job Specifications only)
Paragraph
Modification description
Remarks / Origin
INTRODUCTION
7.3.2.1 Cables installed Directly in the Ground
Word “LGN” is changed to LNG Wording “entry into buildings” cancelled in sentence “However, duct/pipe shall be used for road crossings,.
7.3.4.3 Cables transit
Wording “SIS / CCB “ is changed to “IES / CCB”
7.6 Instrument Electrical Junction Boxes
Deleted “painted with suitable corrosion resistant surface” in sentence With below : “Junction boxes shall be stainless steel ..”
Content of this section refers to Project document “ Installation Standard Typical Installation drawing “RLNG- 000-IC-DWG-0002
Content of this section refers to Project document “ Installation Standard Typical Installation drawing “RLNG- 000-IC-DWG-0002
APPENDIX A2
APPENDIX A3
1.0
INTRODUCTION
The ADNOC Ruwais LNG Project is a two train, near net-zero electrically driven LNG facility, targeting international markets. The feed gas for the project is supplied from the Habshan Gas Processing Plant via a new export gas pipeline. The plant will have two 4.8 MTPA (nominal capacity) electric driven LNG Trains with associated LNG storage/marine export facilities and utilities.
Figure 1 – Project Context
The ADNOC Ruwais LNG Project foresees the following main components at the facility:
• Onshore LNG Liquefaction facilities for 2 x 4.8 MTPA electrically driven LNG Trains (9.6MTPA total)
• Common facilities including inlet receiving facilities, LNG storage, BOG handling, flare, refrigerant
storage and support buildings.
• Utilities to support the facilities including import power from the national grid.
• Marine facilities for LNG export and bunkering.
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 4 OF 73
1.1
Scope of the Document
The purpose of this document is to provide a Project specific addendum to the ADNOC Group Engineering
Standard AGES-SP-04-006, Instrument and control cables Specification. This document provides
an overview of Instrument & Telecommunication cables specification to be applied for the Project.
1.2
Holds List
HOLD
DESCRIPTION
1.3
References
[1] RLNG-000-PM-PP-2002
Project Basis of Design
1.4
Definitions and Abbreviations
COMPANY
CONTRACTOR
EPC ADOC POC YOC
ABU DHABI NATIONAL OIL COMPANY (ADNOC) P.J.S.C. TJN Ruwais, Joint Venture of Technip Energies France-Abu Dhabi, JGC Corporation and National Marines Dredging Company (NMDC) Engineering Procurement Construction Abu Dhabi Operating center - National Marines Dredging Company Paris Operating Center - Technip Energies Yokohama Operating center - JGC Corporation
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 5 OF 73
2.0
AMENDMENTS TO ADNOC GENERAL ENGINEERING SPECIFICATION AGES-SP-04-017
The following specific amendments and additions shall apply to AGES-SP-04-017, Specification for Instrument Installation and Design.
Instructions contained below such as “Add”, “Substitute”, “Revised”, or “New” shall be interpreted as follows:
-
Add: Requirements shall be a continuation of the paragraph in the referenced specification.
-
Substitute: The requirement of the referenced specification shall be replaced in its entirety by the
requirements below.
- Revised: The requirement of the referenced specification shall be revised by the specific wording
below.
- New: A new requirement as described below.
GENERAL
- Scope – Add:
‘When reading this specification, Process Control System (PCS) shall be read as Distributed Control System (DCS).
ESD system shall be read as Safety Instrumented System (SIS).
This is to align with the terminology used on the Reference Project.’
- Abbreviations – Add below definitions:
DCS
SIS
Distributed Control System
Safety Instrumented System
SECTION A
2.2 ADNOC Specifications
The following AGES references are substituted with Project documents as detailed below:
AGES Reference
Project Document No.
Project Document Title
AGES-GL-02-001
RLNG-000-EL-BOD-0001 Electrical Design Basis
AGES-SP-04-006
RLNG-000-IC-SP-0741
Specification for Instrumentation Cables
AGES-SP-04-006
RLNG-000-TE-SP-0020
Specification for Telecommunication Cables
AGES-SP-04-009
RLNG-000-IC-SP-0601
Specification for Packaged Analysers
AGES-SP-04-015
RLNG-000-IC-SP-0802
Specification for Compressor Control System
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 6 OF 73
AGES Reference
Project Document No.
Project Document Title
AGES-SP-12-010
RLNG-000-TE-SP-0010
Telecommunications Systems Specification
AGES-SP-12-014
AGES-SP-09-001
RLNG-000-PI-SP-0001
Piping Design Basis
AGES-SP-02-011
RLNG-000-EL-SP-0006
Specification for Electrical Power, Control and Earthing Cables
AGES-PH-04-001
RLNG-000-IC-PP-0002
Philosophy for Automation & Instrumentation Design
AGES-SP-07-004
RLNG-000-MT-SP-0001
Specification for Protective Coating of Equipment, Piping & Structures
- TECHNICAL REQUIREMENTS FOR INSTRUMENT INSTALLATION
7.2. Installation Design Requirements
7.2.1 General
Substitute following sentence :
“Instruments that are installed in lethal services shall have its drain/vent hard piped to a closed system.”
With below :
“In principal, drains and vents in Hydrocarbon service are to be connected to a closed drain system. Exceptions, if required, shall be approved by COMPANY.
It is recommended that all hazardous services (including hydrocarbons) vent to flare and drain to a closed drain system, and that all non-hazardous services vent to atmosphere and drain to an open or closed drain system depending on the pressure rating. All online instruments where instruments contain large inventories of process fluid e.g. level transmitters floating type or where frequent blow down of instrument impulse lines is envisaged, vents and drain shall be minimum size 2” NPS.”
7.2.3 Level Instrument Installations
Substitute following sentence :
“Level instrument installation shall be such that the instrument can be removed for maintenance. Center-to- center length of magnetic level instrument shall not be more than 2.5m”
With below:
“Level instrument installation shall be such that the instrument can be removed for maintenance. Center-to- center length of magnetic level instrument shall not be more than 2m”
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 7 OF 73
7.2.11 Instrument Process ConnectionsSubstitute following sentence :
Substitute following sentence and table 7.1:
“Instrument Process Connections shall comply with the following, unless otherwise stated by COMPANY. Table 7.1 Instrument Process Connections”
With below:
“For instrument Process Connections, please refer to Philosophy for Automation & Instrumentation Design “RLNG-000-IC-PP-0002”.
Substitute following bullet points:
“7. Instrument impulse tubing shall be 12mm O.D., 0.89 mm minimum wall thickness, SS-316L. However, selection of materials shall be chosen based on the process condition.
- Instrument pneumatic signal air supply tubing minimum size 6mm O.D., 0.89 mm minimum wall thickness, SS-316L.”
With below:
“7. Instrument impulse tubing shall be 12mm O.D., 0.89 mm minimum wall thickness, 6Mo. However, selection of materials shall be chosen based on the process condition.
- Instrument pneumatic signal air supply tubing minimum size 6mm O.D., 0.89 mm minimum wall thickness, 6Mo.”
7.2.12 Instrument Hook-ups
Substitute below sentence :
“The distance between any two supports shall not exceed 1.5m for 15mm Outer Diameter (OD) tube. 6mm and 10mm tuning shall be continuously supported by cable tray and firmly fixed by the use of clips.”
Below :
“The distance between any two supports shall not exceed 1.5m for 12mm Outer Diameter (OD) tube. 6mm and 10mm tubing shall be continuously supported by cable tray and firmly fixed by the use of clips.”
7.3 Cable installation
7.3.1 General
Add the below sentence:
“All cable markers shall be tied to the cable using PVC coated stainless steel cable ties”
7.3.1 General
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 8 OF 73
Substitute following sentence :
“Cable trays/ladder shall be as per COMPANY Standards for GRP Cable Trays and Ladders for Onshore and Offshore Facilities.”
With below:
“Cable trays/ladder material shall be “GRP” or “SS316L (subject to COMPANY approval)”.
7.3.2. Underground Cable Installation
7.3.2.1 Cables installed Directly in the Ground
Substitute following sentence :
“However, duct/pipe shall be used for road crossings,. Refer to APPENDIX A3 for typical drawing. Refer to APPENDIX A3 for typical drawing.”
With below:
“However, duct banks with sleeves shall be used for road crossings, etc. Refer to APPENDIX A3 for typical drawing.”
7.3.4.3 Cables transit
Substitute following sentence :
Field Instrument cables and electrical interface cables entry into the SIS / CCB etc shall be through Multi Cable Transit.
With below:
Field Instrument cables and electrical interface cables entry into the IES / CCB etc shall be through Multi Cable Transit.
7.6 Instrument Electrical Junction Boxes
Substitute following sentence :
“Junction Boxes shall be stainless steel with suitable corrosion resistant surface. They will be built in accordance with safety requirements and will be fitted with cable glands (bottom mounted).
With below:
” Junction Boxes shall be stainless steel, as alternate, GRP material could be used. They will be built in accordance with safety requirements and will be fitted with cable glands (bottom mounted). Small termination box like used for limit switches boxes could have side entry.”
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 9 OF 73
- TECHNICAL REQUIREMENTS FOR INSTRUMENT PIPING CLASSES
8.2 Materials
8.2.3. General Specification for Instrument Impulse Lines
8.2.3.7 Corrosive Services
Substitute following sentence :
“For applications where 317L SS is not suitable with respect to general corrosion, other materials such as monel, hastelloy, tantalum, titanium, etc., can be applied for the various components of the impulse lines…”
With below:
“For applications where 6Mo is not suitable with respect to general corrosion, other materials such as hastelloy, tantalum, titanium, etc., can be applied for the various components of the impulse lines…”
APPENDIX A2 . LIST OF TYPICAL INSTRUMENTATION INSTALLATION DETAILS
Content of this section shall refer to Project document “ Installation Standard Typical Installation drawing “RLNG-000-IC-DWG-0002
APPENDIX A3 . TYPICAL DIRECT BURIED CABLE INSTALLATION DETAIL
Content of this section shall refer to Project document “ Installation Standard Typical Installation drawing “RLNG-000-IC-DWG-0002
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
SPECIFICATION FOR INSTRUMENT INSTALLATION & DESIGN
COMPANY DOCUMENT REF.
RLNG-000-IC-SP-0701
CONTRACTOR DOC. REF.
215122C-000-JSD-1570-0001
REVISION: 1
PAGE 10 OF 73
3.0
APPENDIX
3.2
Appendix 1 – AGES-SP-04-017
The ADNOC Group Engineering Standard AGES-SP-04-017, Specification for Instrument Instrument Installation & Design is attached below for reference
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.
ADNOC GROUP PROJECTS AND ENGINEERING
INSTRUMENT INSTALLATION DESIGN AND PIPING CLASSES
Specification
APPROVED BY:
10/02/2022
NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:
AGES- SP-04-017
All parties consent to this document being signed electronically -PT&CS/GP/INT/2022/1245
GROUP PROJECTS & ENGINEERING / PT&CS DIRECTORATE
CUSTODIAN ADNOC
Group Projects & Engineering / PT&CS Specification applicable to ADNOC & ADNOC Group Companies
REVISION HISTORY
DATE
REV.
NO
05 Jan 2022
1
PREPARED BY (Designation / Initial) Annamalai Kulandaivel Sr. Eng. I-C
REVIEWED BY (Designation / Initial) Mahmoud Abdel Hakim/ HOD Pipeline Eng. - GPE
ENDORSED BY (Designation / Initial) Najem Qambar/ VP Group Eng.- GPE
ENDORSED BY (Designation / Initial) Ebraheem AlRomaithi / SVP- GPE
26/01/2022
Reuben Yagambaram/ Manager Proj. Portfolio- GPE
Ali Al Breiki/ VP Upstream projects- GPE
09/02/2022
26/01/2022
Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance and periodic update.
In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this Specification and its version control.
This specification will be reviewed and updated in case of any changes affecting the activities described in this document.
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INTER-RELATIONSHIPS AND STAKEHOLDERS
The following are inter-relationships for implementation of this Specification:
i. ADNOC Upstream and ADNOC Downstream Industry, Marketing & Trading Directorate.
ii. ADNOC Onshore, ADNOC Offshore, ADNOC Sour Gas, ADNOC Gas Processing. ADNOC LNG,
ADNOC Refining, Fertil, Borouge, Al Dhafra Petroleum, Al Yasat
The following are stakeholders for the purpose of this Specification:
i. ADNOC PT&CS Directorate
This Specification has been approved by the ADNOC PT&CS is to be implemented by each ADNOC Group company included above subject to and in accordance with their Delegation of Authority and other governance-related processes in order to ensure compliance.
Each ADNOC Group company must establish/nominate a Technical Authority responsible for compliance
with this Specification.
DEFINITIONS
“ADNOC” means Abu Dhabi National Oil Company.
“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.
“Approving Authority” means the decision-making body or employee with the required authority to approve Policies & Procedures or any changes to it.
“Business Line Directorates” or “BLD” means a directorate of ADNOC which is responsible for one or more Group Companies reporting to, or operating within the same line of business as, such directorate.
“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.
“CEO” means chief executive officer.
“Group Company” means any company within the ADNOC Group other than ADNOC.
“Specification” means this Instrument Installation Design and Piping Classes Specification.
CONTROLLED INTRANET COPY The intranet copy of this document located in the section under Group Policies on One ADNOC is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest version.
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TABLE OF CONTENTS
GENERAL … 6
INTRODUCTION … 6
PURPOSE … 6
DEFINITIONS AND ABBREVIATIONS … 6
SECTION A – GENERAL … 9
REFERENCE DOCUMENTS … 9
INTERNATIONAL CODES AND STANDARDS … 9
ADNOC SPECIFICATIONS … 12
OTHER REFERENCES … 13
DOCUMENT PRECEDENCE … 13
SPECIFICATION DEVIATION / CONCESSION CONTROL … 13
PROCESS SAFETY REQUIREMENTS … 14
DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS … 14
OPERATION & DESIGN LIFE… 14
ENVIRONMENTAL REQUIREMENTS … 14
ELECTRIC UTILITY DATA … 14
SEISMIC REQUIREMENTS … 15
HAZARDOUS AREA PROTECTION … 15
INGRESS PROTECTION … 16
ENGINEERING UNITS … 16
SECTION B – TECHNICAL REQUIREMENTS … 17
TECHNICAL REQUIREMENTS FOR INSTRUMENT INSTALLATION … 17
GENERAL INSTALLATION REQUIREMENTS … 17
INSTALLATION DESIGN REQUIREMENTS … 18
CABLE INSTALLATION … 33
EARTHING AND BONDING … 41
SUPPORTS … 44
INSTRUMENT ELECTRICAL JUNCTION BOXES… 44
DRAWINGS … 45
CORROSION PROTECTION … 45
TECHNICAL REQUIREMENTS FOR INSTRUMENT PIPING CLASSES … 45
DESIGN SPECIFICATION … 45
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MATERIALS … 47
ADDITIONAL SPECIFIC REQUIREMENTS … 53
SECTION C – OTHER REQUIREMENTS … 54
DETAILS OF SCOPE … 54
QUALITY CONTROL AND ASSURANCE … 54
SUB-CONTRACTORS, SUB-SUPPLERS … 55
CERTIFICATION … 55
INSPECTION AND TESTING REQUIREMENTS … 56
SPARE PARTS, CONSUMABLES AND SPECIAL TOOLS … 56
PAINTING, PRESERVATION AND SHIPMENT … 56
INSTALLATION, COMMISSIONING AND MAINTENANCE SUPPORT … 56
TRAINING… 56
DOCUMENTATION / MANUFACTURER DATA RECORDS … 56
GUARANTEES AND WARRANTY … 57
PROJECT ADMINISTRATION … 57
PROJECT PERSONNEL … 57
PROJECT SCHEDULE … 58
PROGRESS REPORTING … 58
COORDINATION MEETINGS … 58
SECTION D – STANDARD DRAWINGS & DATASHEETS … 59
DATASHEET TEMPLATES … 59
STANDARD DRAWINGS … 59
SECTION E - APPENDICES … 60
LIST OF TYPICAL HOOK-UP DIAGRAMS … 60
LIST OF TYPICAL INSTRUMENTATION INSTALLATION DETAILS … 62
TYPICAL DIRECT BURIED CABLE INSTALLATION DETAIL … 63
LIST OF TABLES
TABLE 1.1 LIST OF ABBREVIATIONS … 7 TABLE 7.1 INSTRUMENT PROCESS CONNECTIONS … 28
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GENERAL
Introduction
This specification defines the minimum requirements for the following:
Instrument Installation Design
Instrument Piping Classes
Purpose
The purpose of this specification is to define the minimum mandatory execution, functional and technical requirements for design, materials, fabrication, assembly for instrument installation and instrument piping classes together with associated unpacking and installation requirements for application across ADNOC Business Units.
Unless otherwise stated in this specification, the supplied equipment shall comply fully with the requirements of relevant AGES, ADNOC Group standards / guidelines, industry, national and international standards.
CONTRACTOR together with SUPPLIER(s) (Control System, Package Equipment, Field Instrumentation, etc.) shall be responsible for complying the installation design and materials as defined within this specification.
The requirements detailed within this specification shall apply to both offshore and onshore installations, unless specifically stated to apply for either one or the other, i.e., requirement starting with “for installations offshore” applies only to equipment to be located on an offshore installation.
This specification provides the structure to support standardisation and its associated savings in lifecycle costs, including total cost of ownership, and maintenance requirements.
Definitions and Abbreviations
1.3.1
Definitions
The following defined terms are used throughout this specification:
‘[PSR]’ indicates a mandatory Process Safety Requirement
“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or consultant authorised to act for, and on behalf of the COMPANY.
“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning or management for ADNOC projects. CONTRACTOR includes its approved MANUFACTURER(s), SUPPLIER(s), SUB-SUPPLIER(s), and SUB-CONTRACTOR(s).
“MANUFACTURER” means the Original Equipment Manufacturer (OEM) or MANUFACTURER of one or more of the component(s) which make up a sub-assembly or item of equipment assembled by the main SUPPLIER or his nominated SUB-SUPPLIER.
‘may’ means a permitted option
‘shall’ indicates mandatory requirements
‘should’ means a recommendation
“SUB-CONTRACTOR” means any party engaged by the CONTRACTOR to undertake any assigned work on their behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the
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CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and the SUB-CONTRACTOR.
“SUPPLIER” means the party entering into a Contract with CONTRACTOR to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally appointed successors and/or nominated representatives of the SUPPLIER.
“SUB-SUPPLIER” means the sub-contracted SUPPLIER of equipment sub-components, software and/or support services relating to the equipment / package, or part thereof, to be provided by the SUPPLIER. COMPANY maintains the right to review all proposed SUB-SUPPLIERS, but this right does not relieve the SUPPLIER of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and any individual SUB-SUPPLIER.
“CONCESSION REQUEST” - A deviation requested by the CONTRACTOR or SUPPLIER, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.
1.3.2
Abbreviations
The abbreviations used throughout this specification are shown in Table 1.1
Table 1.1 List of Abbreviations
Abbreviations
ADNOC
Abu Dhabi National Oil Company
C&I
CCB
ESD
F&G
FAT
FDS
FTS
GRP
HF
HSE
Control and Instrumentation
Central Control Building
Emergency Shutdown
Fire and Gas
Factory Acceptance Test
Functional Design Specification
Functional Test Sheet
Glass Reinforced Polyester
Hydrogen Fluoride
Health, Safety & Environment
HVAC
Heating, Ventilation and Air Conditioning
I/O
ICSS
IE
IES
IFAT
IP
IS
Input/Output
Integrated Control and Safety System
Instrument Earth (Clean Earth)
Instrument Equipment Shelter
Integrated Factory Acceptance Test
Ingress Protection
Intrinsically Safe
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ISE
ITP
LP
MC
MCR
MCT
MP
OD
OTP
P&ID
PE
PCS
QA
QC
RF
RFC
RFHO
RFO
RFSU
RTD
RTJ
SAT
SIS
SIT
UV
Abbreviations
Intrinsically Safe Earth
Inspection and Test Plan
Low Pressure
Mechanical Completion
Main Control Room
Multi-cable Transits
Medium Pressure
Outer Diameter
Operating Test Procedure
Piping & Instrument Diagram
Protective Earth (Safety/Dirty Earth/Plant Earth)
Process Control System
Quality Assurance
Quality Control
Radio Frequency
Ready for Commissioning
Ready for Handover
Ready for Operation
Ready for Start-up
Resistance Temperature Detector
Ring Type Joint
Site Acceptance Test
Satellite Instrument Shelter
Site Installation Test
Ultra-Violet
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SECTION A – GENERAL
REFERENCE DOCUMENTS
International Codes and Standards
The following Codes and Standards shall form a part of this specification. When an edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract award shall apply.
AMERICAN PETROLEUM INSTITUTE (API)
API RP 14C
API RP 14FZ
API RP 14G
API RP 540
API RP 551
API RP 552
API RP 553
API RP 554
API RP 555
API RP 941
Analysis, Design, Installation, and Testing of Basic Surface Safety Systems for Offshore Production Platforms
Design, Installation, and Maintenance of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class I, Zone 0, Zone 1, and Zone 2 Locations
Fire Prevention and Control on Fixed Open-type Offshore Production Platforms
Electrical Installation in Petroleum Processing Plants
Process Measurement
Transmission Systems
Refinery Valves and Accessories for Control and Safety Instrumented Systems
Process Instrumentation and Control
Process Analysers
Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants
API STD 520 Part II
Sizing, Selection, and Installation of Pressure-relieving Devices
API STD 527
Seat Tightness of Pressure Relief Valves
AMERICAN SOCIETY FOR MECHANICAL ENGINEERS (ASME)
ASME B16.5
ASME B16.11
ASME B16.21
ASME B16.34
ASME B31.1
ASME B31.3
ASME B46.1
Pipe Flanges and Flange Fittings (NPS ½” to NPS 24”)
Forged Fittings, Socket-Welding and Threaded
Non-metallic Flat Gaskets for Pipe Flanges
Valves - Flanged, Threaded, and Welding End
Power Piping
Process Piping
Surface Texture (Surface Roughness, Waviness, and Lay)
ASME BPVS Set
Boiler and Pressure Vessel Code
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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
ASTM A153/A153M
ASTM A182/A182M
Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High- Temperature Service
ASTM A269/A269M
Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service
ASTM B164
ASTM B165
ASTM B423
ASTM B425
ASTM B381
ASTM B668
ASTM B861
ASTM F1387
Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire
Standard Specification for Nickel-Copper Alloy Seamless Pipe and Tube
Standard Specification for Nickel-Iron-Chromium-Molybdenum- Copper Alloy (UNS N08825, N08221, and N06845) Seamless Pipe and Tub
Standard Specification for Nickel-Iron-Chromium-Molybdenum- Copper Alloys Rod and Bar
Standard Specification for Titanium and Titanium Alloy Forgings
Standard Specification for UNS N08028 and N08029 Seamless Pipe and Tube
Standard Specification for Titanium and Titanium Alloy Seamless Pipe
Standard Specification for Performance of Piping and Tubing Mechanically Attached Fittings
ASTM G93/G93M
Standard Guide for Cleanliness Levels and Cleaning Methods for Materials and Equipment Used in Oxygen-Enriched Environments
BRITISH STANDARDS INSTITUTE (BSI)
BS 6121
BS 6739
BS 7430
BS 50288
BS EN 10204
BS EN 13601
Metallic Cable Glands - All Parts
Code of Practice for Instrumentation in Process Control Systems: Installation, Design and Practice
Code of practice for protective earthing of electrical installations
Multi-element metallic cables used in analogue and digital communication and control - All Parts
Metallic products - Types of inspection documents
Copper and copper alloys — Copper rod, bar and wire for general electrical purposes
Institute of Electrical and Electronics Engineers (IEEE)
IEEE 1100
Recommended Practice for Powering and Grounding Electronic Equipment
INTERNATIONAL ELECTRO-TECHNICAL COMMISSION (IEC)
IEC 60028
International standard of resistance for copper
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IEC 60079
IEC 60228
IEC 60304
IEC 60331
IEC 60332
IEC 60529
IEC 60654
IEC 61144
IEC 61511
Electrical Apparatus for Explosive Gas Atmospheres
Conductors of Insulated Cables
Standard Colours for Insulation for Low-Frequency Cables and Wires
Tests for Electric Cables under Fire Conditions
Tests on Electric and Optical Fiber Cables under Fire Conditions
Degrees of Protection Provided by Enclosures (IP Code)
Operating conditions for industrial-process measurement and control equipment
Test Method for the Determination of Oxygen Index of Insulating Liquids
Functional Safety – Safety Instrumented Systems for the Process Industry Sector -Part 1, 2
INTERNATIONAL ORGANIZATION FOR STANDARDISATION (ISO)
ISO 4200
ISO 9000
ISO 9001
ISO 9004
ISO 15156
ISO 17945
ISO 21457
Plain End Steel Tubes, Welded and Seamless - General Tables of Dimensions and Masses per Unit Length
Quality Management Systems - Fundamentals and Vocabulary
Quality Management Systems - Requirements
Quality Management – Quality of an organization - Guidance to Achieve Sustained Success
Petroleum and natural gas industries Materials for use in H2S- containing Environments in oil and gas production - All Parts
Petroleum, petrochemical and natural gas industries - Metallic materials resistant to sulfide stress cracking in corrosive petroleum refining environment
Petroleum, petrochemical and natural gas industries — Materials selection and corrosion control for oil and gas production systems
ISO 80000
Quantities and Units
INTERNATIONAL SOCIETY OF AUTOMATION (ISA)
ISA 5.1
ISA RP 31.1
Instrumentation Symbols and Identification
Specification, Installation, and Calibration of Turbine Flowmeters
ISA TR 84.00.04 Part 2
Example Implementation of ANSI/ISA-84.00.01-2004(IEC 61511 Mod)
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MANUFACTURERS STANDARDISATION SOCIETY (MSS)
MSS SP 58
Pipe Hangers and Supports - Materials, Design, Manufacture, Selection, Application, and Installation
MSS SP 69
Pipe Hangers and Supports - Selection and Application
NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)
NACE MR0103
Petroleum, petrochemical and natural gas industries - Metallic materials resistant to sulfide stress cracking in corrosive petroleum refining environment
NATIONAL ELECTRICAL VENDORS ASSOCIATION (NEMA)
NEMA RN 1
NEMA TC 2
NEMA TC 3
Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit
Electrical Polyvinyl Chloride (PVC) Conduit
PVC Fittings for Use with Rigid PVC Conduit and Tubing
NEMA TC 6 & 8
PVC Plastic Utilities Duct for Underground Installations
NEMA TC 9
NEMA VE 1
NEMA VE 2
Fittings for PVC Plastic Utilities Duct for Underground Installation
Metal Cable Tray Systems
Cable Tray Installation Guidelines
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 72
National Fire Alarm and Signalling Code
TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)
TIA-568
Commercial Building Telecommunications Cabling Standard - All Parts
ADNOC Specifications
AGES-GL-02-001
Electrical Engineering Design Guide
AGES-GL-16-003
Basic Engineering Design Data (BEDD)
AGES-PH-04-001
Automation and Instrumentation Design Philosophy
AGES-SP-02-011
Electrical Power, Control and Earthing Cables
AGES-SP-04-006
Instrument and Control Cables
AGES-SP-04-009
Analyzer Package System Specification
AGES-SP-07-003
Requirements for Materials in Severe Service
AGES-SP-07-004
Painting & Coating Specification
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AGES-SP-09-001
Piping Design Basis
AGES-SP-12-014
Fibre Optic Cable Networks
Other References
Not applicable
DOCUMENT PRECEDENCE
The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved issue at the time of contract award.
It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.
The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.
Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.
In case of conflict, the order of document precedence shall be:
UAE Statutory requirements
ADNOC HSE Standards
Equipment datasheets and drawings
Project Specifications and standard drawings
Company Specifications
National / International Codes and Standards
SPECIFICATION DEVIATION / CONCESSION CONTROL
Deviations from this specification are only acceptable where the SUPPLIER has listed in his quotation the requirements he cannot, or does not wish to comply with, and the COMPANY / CONTRACTOR has accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the SUPPLIER complies fully with this specification.
Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Specifications shall be sought by the SUPPLIER only through Concession Request Format. Concession requests require CONTRACTOR’s and COMPANY’s review / approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.
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PROCESS SAFETY REQUIREMENTS
Sr. No. Description
1
2
3
4
5
Safety related instrumentation shall be installed meeting the associated requirements as per IEC 61511-1 section on “SIS installation and commissioning”, ISA TR84.00.04 Part 2 section on SIS Installation, Commissioning, Validation, BS 6739 (relevant sections), NFPA/ FM/ UL codes and the SUPPLIER recommendations.
Use of standpipe or bridle shall be avoided for Emergency Shutdown (ESD) applications.
Separate tappings and isolation valves to be provided for Control and ESD service.
In critical services, each ESD Valve shall be provided with a local device to permit (subject to permissive) the manual closing and opening of the valve (where specifically required and stated on the P&ID and data sheets).
All BDVs and critical ESDVs, XVs and deluge valves shall be provided with air volume tanks with the capacity for 3 full cycles (valve open to close and close to open shall be considered as 1 full cycle) to prevent the opening/closing on loss of instrument air.
DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS
Operation & Design Life
Instrument equipment, Control valves, Shutdown Valves, On/off valves including accessories, and cabling shall be designed, manufactured, tested, transported and installed to achieve a minimum design life duration of thirty (30) years. The Control systems shall have an active life of fifteen (15) years and will have repair capability / spare parts available for minimum period of fifteen (15) years from the withdrawal date.
Environmental Requirements
Instrument control components and cabling shall be installed within 19” network cabinets in a climate-controlled area and be suitable for an air-conditioned environment to ISA S71.04, G3 classification.
The selected electrical and electronics items shall be suitable for air-conditioned environment classification ISA S71.04, G3 and cards/circuit boards/PCBs shall be provided with suitable conformal coating accordingly for protection against environment corrosion.
Normal indoor operating conditions will be 22°C ± 2°C and 50% Relative Humidity.
Control equipment shall continue to operate in Heating, Ventilation and Air Conditioning (HVAC) upset conditions, for an extended period of up to 8 hours, during which the temperature in the indoor location of the installation can fall to 0ºC or rise to +60ºC, and the humidity can vary between 5% and 95% non-condensing.
Field instrumentation shall be designed and suitably rated for use, without the need for additional protection, in high temperatures up to +60ºC, surface temperatures in direct sunlight up to +85ºC and relative humidity up to 100%.
Field instrumentation shall be protected to safeguard against all adverse environments expected at the Facility, such as wind carried salts, dust and sand, and highly corrosive environments with traces of hydrogen sulphide. CONTRACTOR shall ensure equipment is suitably housed and fit for purpose.
Electric Utility Data
Two separate power feeders from dual redundant UPS and one feeder from Utility power supply shall be made available for use by the SUPPLIER for powering cabinets.
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The Electrical power supply details are as follows:
Nominal voltage – 110VAC to 240V AC; however, existing Facilities shall follow as per Facility standard.
i. 415V (Non-UPS for Remote MOV)
ii. 24V DC (solar power system)
Single Phase, 50 Hz, earthed
Steady state Voltage variation ± 10% nominal voltage
Steady state Frequency variation ± 5 %
110 VAC, 60 Hz utility supply operation should be possible, where required by Project.
Seismic Requirements
Hardware shall be designed to operate in the presence of a sinusoidal vibration of 2g at 10 - 500 Hz and withstand a shock of 15g for 11 milliseconds.
Hazardous Area Protection
Unless otherwise specified, control / marshalling cabinets shall be installed within a general purpose, non-classified electrical area, typically a, Equipment Room.
If equipment is located in a hazardous area, the hazardous area classification and method of protection shall comply to IEC 60079. Installation requirements for explosion proof equipment/instrumentation shall comply requirements specified in IEC 60079-14. Equipment located in certified Hazardous Area enclosures shall comply with maximum ambient conditions for continuous operation.
Sunshade or shelter for equipment/cabinet/panel in field shall be provided to avoid direct sunlight.
Instrumentation in hazardous area shall be certified by IECEx or equivalent recognised certifying body. The IECEx directive requires that a register is held of all IECEx certified equipment installed on the facilities and that the equipment is certified to the IECEx 02 scheme in conformance to IEC 60079.
For instrumentation installed in hazardous area, Ex ia or ib (Intrinsically Safe) design is the preferred method for hazardous area protection. The use of flameproof or increased safety instruments shall be avoided except for solenoid valves which should be certified Ex db (Flame Proof) or Ex mb eb (combined encapsulation and increased safety), operating on 24 V DC with maximum power consumption, of 12W. Ex ia or Ex ib solenoid valves shall not be permitted. Use of Ex ia or ib (Intrinsically Safe) solenoid valves is subject to COMPANY approval.
Instrument Junction Boxes/Local Panels shall be flameproof Ex db as per IEC 6007901, or Increased Safety Ex eb as per IEC 60079-7, for installation within a Zone 1 or Zone 2 hazardous area.
For further details refer to AGES-PH-04-001, Automation and Instrumentation Design Philosophy.
Unless stated otherwise by Project, Control and Instrumentation (C&I) equipment design, including related accessories (such as junction boxes, glands, etc.), shall align with the hazardous area classification philosophy. Where C&I cabling passes through a hazardous area, it shall be designed and protected for this duty.
In addition, for the UAE, Ex certified equipment requires an Emirates Conformity Assessment System (ECAS) Ex Certificate of Conformity (CoC) issued by the notified body. Requirement of the ECAS Ex programme utilises IEC standards, and qualification of conformity is met by meeting the requirements of the IEC Ex scheme in full, including mandatory factory site Quality Assessment Reports (QARs).
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Ingress Protection
The degree of Ingress Protection (IP) for equipment shall comply with IEC 60529 and equipment data sheets. The equipment minimum IP rating shall be as follows:
IP42 for equipment installed in indoor climate-controlled environments
IP52 for equipment installed in indoor dry environments
IP56 for equipment installed in indoor damp environments
IP65 for outdoor onshore field environments
IP66 for outdoor offshore field environments
All field equipment shall have non-metallic Glass Reinforced Polyester (GRP) enclosures to withstand harsh environmental conditions.
Engineering Units
Reference shall be made to Project Engineering Design basis for Units of Measure. For brownfield projects, units shall be followed as per existing plant’s design basis.
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SECTION B – TECHNICAL REQUIREMENTS
TECHNICAL REQUIREMENTS FOR INSTRUMENT INSTALLATION
General Installation Requirements
CONTRACTOR shall provide fully qualified and competent personnel skilled in the particular field of work in which they are engaged. CONTRACTOR shall be responsible to provide Engineer or Supervisor experienced in instrument installation and testing in accordance with the drawings, relevant standards and regulations. CONTRACTOR’s key personnel including Lead Engineers resumes will be reviewed and approved by COMPANY prior to mobilisation.
Where applicable and at the discretion of COMPANY, CONTRACTOR shall engage the services of a Specialist Sub-Contractor, Sub-vendor, System Integrator to ensure the equipment is correctly installed, commissioned and guarantees maintained. All system related modifications shall be performed by MANUFACTURER.
Locations of instrument stands, marshalling boxes, etc., shown on drawings are approximate. It shall be the responsibility of CONTRACTOR to obtain exact location information and ensure that cables are laid to the required position with sufficient termination length. Cables, which are re-routed, shall not be disconnected without written permission of from COMPANY.
Field installed instruments mounting arrangement shall be suitable for the UAE desert environment, which is hot, arid, with sandstorms, high condensing humidity. As a minimum field installed instruments shall be provided with UV, chemical resistant GRP protective full enclosures and sunshade to protect against direct sun-light impingement with anti-static electricity coating treatment and considerations shall also be given to project specific requirements. Protective enclosures for safety related devices, specifically, fire and gas detection/ suppression related items shall meet the requirements of the associated codes/ standards/ certification.
CONTRACTOR shall comply with COMPANY regulations regarding safety to work. No excavation shall be commenced without a duly authorized and valid ‘Excavation Permit’. All new buried cable routes shall be pegged out prior to excavation. Trial pits shall be made at strategic locations, to ensure underground facilities are exposed or known prior to excavation. Only hand excavation is permitted while excavating existing cable routes.
Particular attention shall be paid to the installation and testing of instrumentation and equipment associated with Ex/hazardous locations inclusive of Intrinsic Safety (IS) circuits. Work shall be done in strict accordance with the particular construction specification and relevant certificates of approval where applicable. Testing shall include the necessary initial inspection of IS systems prior to commissioning.
CONTRACTOR shall be responsible to perform calibration verification of all the field instruments supplied by them, including of Vendor packages and any instruments free issued by COMPANY, prior to installation at site. This calibration verification requirement is in addition to the calibration certificate received from MANUFACTURER as a part of shipment.
Inspection and acceptance of the completed installation shall be based upon compliance with all relevant drawings, Standards and Codes of Practice and Procedure mentioned herein. In the instances where conflict or ambiguity arises, CONTRACTOR shall seek the advice of COMPANY whose decision shall be final.
Control systems and instrumentation shall be properly stored as per MANUFACTURER’s recommended procedure and protected from damage at all times.
CONTRACTOR shall be responsible to check other discipline drawings for coordination to eliminate conflicts prior to the installations.
Working areas shall be kept clean and free of debris to the maximum extent.
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CONTRACTOR shall be responsible for coordinating with ongoing Projects as and when required.
Special attention shall be paid to the installation of instruments and ancillaries, considering weight and space concerns and material selection, as the same are installed in marine services and/or in coastal or offshore aggressive corrosive environments.
Installation Design Requirements
In general, installation requirements for instrumentation shall follow API 551.
7.2.1
General
No instrument shall be installed so that it depends for support upon:
The impulse piping (except for direct mount self-supported pressure gauges on impulse lines)
The electrical connection to it
For typical instrument mounting details refer to APPENDIX A2.
Instruments shall be located in accordance with Piping and Instrument Diagrams, Hook-ups, Design Specification, Instrument Location Plans, Piping Layout/Isometric Drawings, etc. Due consideration shall be to maintenance and operation activities, vents, drains and filling points to minimise the impingement of process fluids on instrument and cables.
If the adjustment of one locally mounted device affects the operation of another (such as local controller or control valve), the devices should, where practical, be mounted so that both devices can be seen at the same time.
Instruments shall be accessible from floor levels, walkways, permanent ladders or platforms for adjustment or maintenance. instruments shall be oriented to permit viewing from grade, platform or deck, and be oriented in a way such that the scale faces the direct access approach.
Instruments shall be mounted such that they can easily be removed for maintenance. Instruments shall be mounted with minimum clearance of 50mm from each other.
Instruments shall be located so that they will not interface with aisle, space on platforms or catwalks or tube bundle removal area etc.
Instruments shall be mounted with a recommended clearance of at least 600mm.
Care shall be taken to ensure that no passageways or access to plant equipment, panels, other instruments etc., are obstructed. Where instruments are accessed from an adjacent walkway, an additional 600mm access space should be provided where possible to allow for maintenance and calibration without comprising the walkway. Additional clearance shall be provided in front of field panels for component removal or door opening.
Field instrumentation shall be mounted on instrument stands or firm steelwork or masonry with suitable bracketry. Handrails or process pipe work shall not be used for support unless prior approval in writing has been received from COMPANY. Field instruments shall be mounted 1.4m above grade, platform or deck level.
Instruments shall be located away from potential fire risks, spillage areas, hot environments and sources of radiation. Instruments shall be mounted and supported such that it is free from vibration and misalignment.
Instrument removal and reconnection shall be possible without the need to remove or disconnect other fixtures/accessories, in particular, shutdown valve mounting plate, lagged/heat traced instruments shall be maintainable without removing the lagging or heat insulation. On-Off valves (inclusive of SDV/ BDV) local position indication shall be visible from outside all the times even when the related valves actuation sub-system is provided with passive fire protection cover/ enclosure.
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Instruments shall be provided with an engraved identification label and engraved scannable QR code. CONTRACTOR shall be responsible for supplying tags and labels, type to be approved by COMPANY, for all field instruments and marshalling boxes. The tags and labels shall be in accordance with an applicable dedicated ADNOC standard and not approved during the projects.
Open ends of Pneumatic/Impulse lines shall be provided with bug screen to prevent the entry of foreign substances.
It is recommended that where close-coupled instrument mounting is a preferred solution, some form of direct mounting isolation should be adopted and Mono-block valve can be considered, subject to COMPANY approval. All transmitters shall be provided with integral manifolds with isolation facilities for process connections, vent/drain. Instrument tubing, fitting & valves shall be in accordance with COMPANY specifications.
All outdoor installed electronic instruments, panels, etc., that are exposed to direct sun radiation, shall be provided with a protective shade. Where instruments require shades, which are not available as a standard accessory and require specially made supports and brackets (such as in-line flow meters, displacer level instruments, tank gauges), these shall be as shown on detailed construction drawings. The shade shall be fixed in such a way to allow quick installation and removal, and unimpeded access to the instrument/panel.
Instruments pipe stands shall be galvanised Carbon Steel pipe NPS 2 and a minimum of schedule 40 wall thicknesses, refer to APPENDIX A1 and painted as per COMPANY specification.
To avoid corrosion traps an approved inhibitor, such as silicone grease, shall be used when bolting through drilled holes.
Instruments that are installed in lethal services shall have its drain/vent hard piped to a closed system.
Transmitter manifolds shall be provided with ½” FNPT connections for impulse tubing; however, if hard pipe connections are used, then a suitable welding stub shall be provided on the flange adapter/kidney flange. This shall be reflected accordingly on the instrument datasheet and installation detail. Where welding studs are required for instrument manifolds, they shall be provided by MANUFACTURER to ensure that later welding is avoided which may generate heat impacting the seals/o-rings/non-metallic components.
When instruments are installed with diaphragm seals, Flushing rings shall also be installed with the diaphragm seals. The flushing rings shall have two ½” connections for flushing and draining/venting. Flushing rings, when provided, shall be designed/selected ensuring that the related diaphragm seals functioning is not impacted.
7.2.2
Pressure Instrument Installations
Gauges and indicators shall be positioned in such a way that they can be easily read, typically in a vertical direction.
Where pressure instruments are installed on a condensable service, a condensate pot shall be used. For pressure gauges installed in hot condensable vapours, the use of a siphon/pigtail shall be considered.
Pressure gauges shall be installed so that their blowout protectors are not obstructed. Protectors shall face away from the operator.
Low range equipment shall be installed such that gravitational effects on the sensing element do not cause calibration errors or induce noise due to vibration.
Where pulsation dampers are used, they shall be installed close to the measuring element. The use of partially closed isolating valves is not permitted.
The capillary tubing of filled and sealed instruments shall be adequately supported and protected from damage. MANUFACTURER recommended minimum being radius shall be maintained while coiling. With the exception of direct connected pressure gauges and switches, pressure instruments should be independently supported.
Vapor traps on liquid services and vice versa should be avoided.
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Irrespective of fluids the preferrable tapping location shall be vertical on pipes. Further considerations of API 551 for ‘above the taps’, ‘below the taps’ mounting shall also be taken into account for locating the taps.
For sour and lethal service, instrument drain valves and vent valves shall be connected to closed drain and vent systems.
7.2.3
Level Instrument Installations
The following requirements shall be specified for instrument connections in the design of tanks, columns, vessels, spheres and separators:
Nozzle diameter and their location
Nozzle orientations
Nozzle end connection type and face finish
Level instrument’s measuring ranges relating to the equipment and to each other
Alarm and trip setpoints (as applicable)
Instrument connections shall be positioned as follows:
Positioned horizontally in the liquid phase and on the same side of the equipment
May be positioned vertically upwards as well as horizontally in the gas phase
Instrument connections shall not branch off from the following:
Normal flow lines entering or leaving the equipment
From bottom of the equipment
Where more than one instrument shares the same connection, a dedicated primary isolation valve shall be provided for each connection such that it can be removed independently without interfering with neighbouring instruments. Also, the following shall be evaluated:
Evaluation of load on the nozzles
Potential for common mode failures (e.g., loss of fill fluid or plugging)
On steam duties, condensation chambers may require lagging for personnel protection and shall be installed in a vertical direction.
Level gauges shall be installed such that the indicator is visible from grade, platform or deck.
General area lighting shall allow any level within the range of the gauge to be seen at all times. Integral illuminators shall be provided for through vision level gauges.
When level instruments are mounted directly on the vessel, an isolation valve shall be considered to facilitate removal of direct mounted level instruments for maintenance without process shutdown. Installation shall endure the availability of adequate overhead lifting clearance. Use of direct top mounted instruments where it cannot be removed for maintenance without vessel depressurisation shall be avoided.
Use of standpipe or bridle shall be avoided for Emergency Shutdown (ESD) applications unless otherwise approved by COMPANY. In all applications, if the blockage risk is significant, standpipe methods shall not be used. When level instruments are installed on standpipe or bridle, size of the standpipe/bridle shall be minimum a nominal 75mm (3”). The vessel and bridal construction to level instruments shall be aligned with ±1 mm to ensure the external chamber is mounted vertically without exerting any stress on the instrument, float or displacer within the chamber. Vessel connections shall be minimum 2”, suitably gussetted or with integral body valves.
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For level instrument installation, the nozzle orientation and location shall be perpendicular or tangential to the vessel wall and in a zone of least disturbance. Contractor shall obtain approval for the location of nozzles from the instrument manufacturer and update with vessel manufacturer’s prior vessel manufacturing. Differential pressure instrument should be typically located at bottom of nozzle elevation.
For interface level measurements, top level connection shall be submersed in the lower density liquid under all operating conditions. The use of bridles in liquid-liquid interface shall be avoided, but may be considered where multiple level devices are required, and the temperature differences between the vessel contents and the bridle contents will not cause measurement error.
Critical and ESD service instruments shall be connected to separate nozzle connections.
On internal installations, displacers and floats shall be restricted by cages or alternative protection to retain the displacer in case of detachment. Level instruments that are provided for critical or shutdown applications shall use a separate connection from those used for level control and alarm devices.
Each instrument connected to the vessel or standpipe shall be installed on the full bore piping isolation valve. Additional valves shall be provided to facilitate in-situ calibration. Refer to APPENDIX A1.
Level instrument installation shall be such that the instrument can be removed for maintenance. Center-to-center length of magnetic level instrument shall not be more than 2.5m. The installation shall permit maintenance from grade, platform or deck. Isolation, vent, drain and calibration valves should be accessible. A minimum overlap of 50mm shall be provided when level gauges are split due to length restrictions.
For the removal of instruments used in lethal services, an inert gas purging connection shall be considered. Gas or liquid purge/flush shall be considered for the l(cid:72)(cid:89)(cid:72)(cid:79)(cid:3)(cid:76)(cid:81)(cid:86)(cid:87)(cid:85)(cid:88)(cid:80)(cid:72)(cid:81)(cid:87)(cid:86)(cid:3)(cid:76)(cid:81)(cid:86)(cid:87)(cid:68)(cid:79)(cid:79)(cid:72)(cid:71)(cid:3)(cid:76)(cid:81)(cid:3)(cid:87)(cid:75)(cid:72)(cid:3)(cid:89)(cid:72)(cid:86)(cid:86)(cid:72)(cid:79)(cid:3)(cid:90)(cid:76)(cid:87)(cid:75)(cid:3)(cid:75)(cid:76)(cid:74)(cid:75)(cid:3)(cid:89)(cid:76)(cid:86)(cid:70)(cid:82)(cid:88)(cid:86)(cid:3)(cid:11)(cid:149)(cid:3)(cid:21)(cid:19)(cid:70)(cid:51)(cid:12)(cid:3) or slurry service.
CONTRACTOR shall be Instrument MANUFACTURER to finalise the appropriate nozzle orientation and locations to ensure that the Instrument functional/performance requirements are not compromised.
to coordinate with vessel MANUFACTURER and
responsible
7.2.4
Temperature Instrument Installations
Sensing elements shall be in good thermal contact with thermowells.
Where capillary systems are used, they shall be continuously supported and protected, and any excess length neatly coiled, clipped and supported. The installation shall not introduce standing errors.
Clearance and sufficient cable or capillary slack shall be provided to allow element removal from pockets without disconnecting terminations or unclipping cables/capillaries from supports.
Where it is impractical to mount a temperature sensing device in a thermowell, each application shall be subject to individual approval by COMPANY. Such installations shall be clearly labelled for identification by maintenance personnel that no thermowell has been installed.
The most common application of sensors fitted without thermowells are skin thermocouples on heater-tubes, bearing temperatures and fast response measurements on gas turbines etc. Apart from such accepted applications, temperature devices shall be installed without thermowells only in exceptional circumstances, usually for reasons relating to speed of response or severe space limitations. The utmost care shall be taken in the design to prevent accidental removal. Clear, permanently affixed labels shall warn of the need to depressurise the line or vessel before removal.
Multipoint thermocouple installations for catalyst bed reactor temperature monitoring is a unique application and it requires a seal chamber with pressure monitoring to identify any leak.
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Specific attention shall be given to ensure motor and generator winding temperatures are segregated from other instrument sensing applications via galvanic isolators. The integrity of the hazardous area shall be protected against insulation failure or induced voltages.
Duplex temperature element terminals shall be clearly identified and marked. Both elements shall have a separate tag with in accordance with tagging philosophy. For remote mounted applications, both elements shall be terminated up to the main junction box/transmitter where multi-pair cable is connected to Marshalling cabinet.
Thermowells shall be mounted into a pipe, rather than a process vessel, unless the measurement would be adversely affected. Orientation is to be such that thermowells, thermocouples, etc., are accessible from a ladder or platform.
Temperature taps shall not be installed directly downstream of flashing and cavitation valves or directly upstream of flow meters requiring straight length. Pipe diameter for thermowell installations should be at least NPS 3.
Thermowell length, size and type shall be in confirmation with Acceptable wake frequency PTC 19.3 2016.
Thermowell installation shall allow immersion between (cid:1151) (cid:68)(cid:81)(cid:71)(cid:3)(cid:1152) the internal diameter of pipe, elbow or tee.
In vessels, the thermowell should have an immersion length of 400mm unless specific process requirement requires different length.
Test Wells shall be standard thermowells. Each well to have ½ inch 316 SS plug and chain connected to well.
In columns, thermowells shall normally be installed in the liquid unless noted otherwise on the P&ID. The preferred location for thermowells in columns is in the downcomer from the tray on which the temperature is required. The thermowell locations should be about three to six inches above the tray on which the downcomer feeds. This places the thermowell in the liquid at a point where there is good mixing. If it is impossible to locate the well in the downcomer, then the well shall be located in the liquid immediately ahead of the downcomer weir on the tray on which the temperature is desired. For Thermowell details refer to APPENDIX A1.
7.2.5
Flow Instrument Installations
Orifice and Differential Pressure Flow Meter
Spare tapings on orifice flanges shall be plugged with suitable pressure rated plugs. Tapings at 45 degrees may be used on orifice flanges to permit closer spacing of adjacent pipe work. The two impulse lines for a differential pressure instrument shall be run together to maintain both at the same temperature and to facilitate heating and lagging. Separate tappings and isolation valves to be provided if same Orifice plate is used for Control and ESD service.
Orifice plates shall be installed such that ‘sharp’ side of the orifice shall face incoming flow.
For measurement accuracy upstream and downstream straight runs are important and based on ISO 5167 with column A used for Class 2 type metering and column B used for Class 3 type metering. Any deviations from these minimum straight runs shall be approved by COMPANY.
For flange tap installations the line size should not be less than DN 50 (NPS 2). Use of the flow straightening vanes to reduce the straight run requirements shall be justified on the basis of economics and/or piping layout.
Orientation of taps of metering orifice shall be checked prior to installation. The location of remote differential pressure measurements as follow:
Dry and non-condensate gas:
Above taps
Condensable gas and liquid:
Below taps
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Steam:
Below taps, with condensate pot
Except for wet gas or steam flows, all metering runs should be arranged horizontally. Vertical runs should be used with downward flow for steam and condensable, and with upward flow for liquids nearing their boiling point.
Orifice flanges shall have “jack bolts” that allows flanges to be forced apart for insertion of the metering orifice plate and new gaskets. Flange bolting shall not obstruct the vertical orientation of the tab on the orifice plate. The orientation shall be checked prior to welding in place.
Where Ring Type Joint (RTJ) flange are used, alternate tapping arrangements or measurements technique should be considered.
Annubars with retractable probe shall be installed with adequate clearances and space for retracting, cleaning and performing maintenance. It is to be inserted truly across the central axis, in a vertical upward direction. For saturated steam applications, MANUFACTURER recommendation shall be followed.
For ESD/Trip applications a separate transmitter including manifold, isolation valves and impulse lines shall be installed and connected to the second pair of tappings on orifice flanges. Tappings of the primary impulse lines are not acceptable.
For certain gases and steam flow application, temperature and pressure transmitters shall be required to install in conjunction with the flow transmitter to make the compensation calculation in the DCS. Flow compensation shall be limited to critical flow applications which is to be identified by the CONTRACTOR & approved by COMPANY. For material balance and sales meters, flow shall be compensated.
Variable Area Flow Meter
Variable area flow meters shall be installed vertically with sufficient clearance to permit tube and float removal, in a true vertical position (plumb) to prevent the plummet from touching the sides of the tube. The piping installation shall not put undue stress on flow meter bodies.
Variable area flow meters shall be usually mounted vertically with flow upward. The meter shall be oriented to allow easy reading of the scale. Sufficient clearance shall be provided over and under the meters for dismantling, cleaning or maintenance.
Turbine Flow Meter
For turbine flow meters, ISA RP31.1 and MANUFACTURER recommendation shall be consulted regarding installation and calibration requirements. Provisions shall be made for checking the calibration of the turbine meter using a meter prover.
The minimum back pressure requirement on turbine meter should not be less than 2P + 1.25pv. Where ‘P’ is pressure drop across meter and ‘pv’ is the absolute vapour pressure of fluid at maximum meter operating temperature.
Upstream and downstream flow conditioning straight lengths without straightening vanes shall be to MANUFACTURER’s standard, but no case less than 10D upstream and 5D downstream of the meter. Temperature tap shall be located after the meter downstream straight length.
A facility shall be available, with a bypass manifold or a replacement spool piece or any alternate arrangement agreeable to COMPANY, for turbine removal and flow meter maintenance.
To avoid hydraulic shock, a valve bypass shall be provided for the upstream block valve.
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Coriolis Flow Meter
Typically, coriolis meter installations shall have rigid mountings that are isolated from plant vibrations. The piping/equipment around the meter should not have same natural vibration to that of the meter. In such case suitable mechanical decoupling isolation methods shall be used to avoid vibrations affecting measurements. MANUFACTURER’s advice on decoupling shall be followed.
Imposed pipe stress across meter flanges should be eliminated by pipe work design, such as by keeping pipe stress off the flanges of coriolis meters. Varying pipe stress across meter can cause significant shifts in meter zero and span calibration with some models.
Coriolis flow meters on liquid service installed in horizontal pipe runs shall be orientated such that the flow tube “loop” (if applicable) is below the pipe, to avoid gas built up within the tube. In horizontal runs, meter shall be installed with the tubes down. In vertical pipes, tubes shall be mounted in the “flag” position with liquid flowing upward through the tubes. In all the cases, MANUFACTURER’s recommendation shall be considered for the installation based on the service and size of the meters.
Adequate backpressure shall be maintained to avoid flashing and cavitation.
For gas flow meters, the sensing tubes/flow meter must be mounted such that any liquids can freely drain from the meter.
There shall be upstream and downstream isolation valves to facilitate setting at zero flow. Valve closure and impact on the instrument installation shall be considered.
Vortex Flow Meter
Vortex flow meters in vertical installation for Gas and Steam service flow can be up or down, for Liquid measurement flow shall be upward to ensure piping is full of fluid.
Straight length requirement shall be as per MANUFACTURER’s standard or same as the orifice, when information from MANUFACTURER is not available, with minimum of 10D upstream and 5D downstream.
The pressure and temperature tapping installed for density corrections shall be installed 5D downstream as minimum.
Positive Displacement Flow Meter
Positive displacement meters shall be normally installed in a horizontal position. Positive displacement meters do not require upstream and downstream straight length prerequisites.
In view of their considerable mass, especially for large sizes, positive displacement meters and their ancillary equipment, such as filters and vapor eliminators shall be installed such that they are well supported and can easily be reached by hoisting equipment. Adjacent piping shall not exert any stress on the meter body.
Electromagnetic Flow Meter
Electromagnetic flow meter straight length requirement shall be as per MANUFACTURER’s recommendation.
Installation of magnetic flow meters shall be such that the meter tube runs liquid full and there is no entrainment of gas or vapour. If installed in a vertical line, flow should be upward to ensure meter is liquid full.
Grounding shall be installed per the MANUFACTURER requirements. Continuous electrical contact to the same ground potential is required for the liquid, piping and meter.
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Ultrasonic Flow Meter
Ultrasonic flow meters shall be installed horizontally when the meter is installed as a part of horizontal pipe work.
Sensors should be located at least 3m (10ft) and preferably as far as possible from pumps or compressors which can generate spurious ultrasonic signals that can ride through the band pass filters in the receiver.
Installation of this type of meter is critical, particularly alignment of the probes and accurate measurement of interprobe distances. MANUFACTURER recommendations should be closely followed including straight run requirements.
Installation of Ultrasonic flow meters in the vicinity of control valves, regulators, or near a potential noise is anticipated, the design shall comply requirements in API 551, BS 6739, AGA-9 etc. and MANUFACTURER’s recommendations to avoid adverse impact on meter performance.
Flow Computers
Post mounted flow computers shall be protected either by individually mounting in a GRP enclosure with suitable access or in groups located in a shelter. Generally, flow computers connected to and incorporating telemetry systems, standby streams, printers, recorders etc., shall be mounted in an air-conditioned room.
7.2.6
Analyser
All analysers shall be protected against adverse ambient conditions and be installed in a temperature controlled environment (other than the in-situ probe and sensors).
Analysers fitted with sample systems that require gas bottles shall be installed at grade level in a designated analyser house. All bottles shall be secured in an upright position.
Transportation of gas cylinders shall be via purpose built trolleys. Rolling of gas cylinders along the ground is potentially hazardous and not acceptable.
To minimise the quantities of hazardous materials inside the analyser house, gas bottles and sample systems shall be located outside. Chemical storage shall not be part of analyser house.
Adequate access shall be provided for bottle or chemical replenishment.
Analyser houses shall be provided with Fire and Gas (F&G) detectors, audible and visual alarms, manual call points and HSE devices for personnel protection.
Analyser houses with sample transport of flammable fluids or non-inert carrier gas such as Hydrogen, shall be reviewed in regard to hazardous area classification, and assigned accordingly.
For further details related to analyser installation, refer to AGES-SP-009, Analyser Package System Specification.
7.2.7
Control Valve
Installation design requirements for control valves shall comply with API RP 553.
Control valve body connections will be flanged, integrally cast, with the exception of butterfly valves which may be lugged if approved by COMPANY.
Clearance shall be provided above and below the valve so that its internals and actuator can be removed.
Control valves shall be installed such that they and their associated accessories are accessible for maintenance and manual operation. Access shall be from grade, platform or deck.
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The valve shall be capable of being maintained and operated from these access areas, within comfortable arms reach set by the physical constraints of the hand railing, etc.
To facilitate maintenance, required lifting equipment shall be provided.
Sufficient access shall be provided for welding and heat treatment of valves if welded into the process line.
Control valves for volatile liquids shall not be installed adjacent to hot equipment.
Diaphragm and piston actuated valves shall be installed with their stems vertical.
Butterfly valves shall be installed with their shafts horizontal unless a different orientation is approved by the MANUFACTURER.
To facilitate local manual operation, the local indication of a process variable associated with a control valve shall be clearly visible from that valve.
Control valve pipe support at end shall be sliding type to allow for stress movements due to differential temperatures.
Block and bypass piping around control valves should be installed on the basis of operational requirement. Bypass valves should be manually operated with identical characteristics of the control valve and procured from same MANUFACTURER. It shall be suitable for applications to manually control the fluid flow. Bypass piping and bypass valves shall be at least the same maximum capacity as the control valve body.
All enclosures and instrument cases shall be painted to COMPANY Specifications.
7.2.8
Shutdown Valves
Installation design requirements for shutdown valves shall comply with API RP 553.
The actuator assembly shall be assembled to the valve at the valve MANUFACTURER’s premises and be fully tested with the local shutdown box.
The local shutdown box shall not be integral to the valve and shall be mounted separately in the field.
The pneumatic supply shall be fed from Instrument air headers. A supply line shall be connected to the actuator assembly.
Shutdown boxes shall be installed locally, near the shutdown/blow down valves on offshore Platforms.
Cables shall enter the shutdown box through appropriately sized and rated cable glands with shrouds.
Passive fire protection shall be box type and easily removable to enable inspection and testing of valve and actuator. All accessories shall be accessible for maintenance in case of passive fire protection.
Valves shall require partial stroke operation on a periodic basis to ensure reliability.
In critical services, each ESD Valve shall be provided with a local device to permit (subject to permissive) the manual closing and opening of the valve (where specifically required and stated on the P&ID and data sheets).
7.2.9
Relief Valves
Installation design requirements for relief valves and rupture disks shall comply with API STD 520 Part II.
Relief valves shall be installed with the spindle in a vertical upward position. Pressure testing and setting of safety shall comply with COMPANY procedures.
The discharge piping arrangement shall be such that it will prevent any hazard to personnel and equipment.
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Bonnet for conventional type relief valves shall be of closed type with isolated spring chamber and sealable caps. Tapped and plugged vents shall be provided on the bonnet. Balanced bellow relief valves shall have a vented bonnet.
In sour service applications, the balanced bellow type bonnet vent shall be piped to a safe location without causing back pressure to valve and considering the spill of process liquid in case of damage to the bellows. The bonnet vent connection shall be ½” 150#RF flanged. The bonnet vent for balanced bellow valve installed on non-lethal service shall be open to atmosphere with bug screen.
Balanced bellows valves, with a bonnet vent open to atmosphere, shall not be used on streams which cause the valve to freeze up when it leaks. If this happens, the bonnet and balancing bellows will fill up with ice due to condensation and subsequent freezing of the moisture in the air, making the valve inoperative. Spring-loaded, non-balanced valves and pilot-operated valves, the pilot of which stays relatively warm, are less sensitive in this respect.
Balanced bellows with supplementary piston shall be considered as this functions as a backup device in the event of bellows damage due to high backpressure.
7.2.10 Fire and Gas Installation
F&G device type, quantity and installation location shall be as per F&G Mapping in accordance with COMPANY’s HSE requirements.
F&G Detection Systems shall be installed to facilitate in-service testing, maintenance, calibration and repair, considering F&G mapping. Due regard shall be made for safety of personnel and access of equipment. F&G Detection Systems shall be in accordance with Company specifications and international standards IEC 60079-2, ISA 92.00.02, API RP14C, API RP 14G, FM 3260 and NFPA 72.
All F&G detectors shall be protected from the effects of corrosion, dust, vibration and hosing-down operations.
The location of gas detectors shall consider the type of gas or gas mixtures being detected (heavier or lighter than air), natural and mechanical ventilation, possibility of gas accumulating to a level which could become hazardous, and the most likely source of leakage. All gas detectors mounted above 2m from grade shall be fitted with remote gassing facilities for calibration. Such facilities shall preferably not be used in ventilation ducts, as calibration accuracy can be impaired due to the high air velocities normally experienced in these ducts. All gas detectors fitted outside air-conditioned enclosures shall be fitted with wind/rain/hosing type weather protectors.
Correct installation and orientation of detection equipment is critical to reliable performance and shall be installed in accordance with MANUFACTURER’s installation manual and F&G mapping recommendations. Verification of safety critical equipment and systems shall comply with COMPANY procedures.
F&G installation elevations shall be subject to HSE review and approval.
F&G device layouts shall be prepared based on performance targets fixed as part of an engineering study. At site, only minor modification shall be allowed with respect to this layout. Any modifications shall be validated. After installation, all detectors shall be checked for correct elevation, cone vision, etc., to ensure coverage of entire area as designed.
Any special method, such as computerised technique, set forth by MANUFACTURER for verification of the installation against the design shall be followed. The F&G performance target study, F&G mapping study, and verification of installation/validation shall be performed by a COMPANY approved 3rd party consultant engaged by CONTRACTOR.
UV/IR type flame detectors shall typically be placed between 3m and 4m above local deck or access platform and MANUFACTURER recommendation.
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Open path gas detectors shall be installed in locations where their paths shall not be interrupted by routine operations.
Special attention shall be paid to the protection of detectors detecting gases “heavier than air” and installed close to the ground. Low-level gas detectors aimed at detecting heavy gas hazards shall be located no higher than 300mm above local deck or grade. Detectors shall be oriented downward.
Detectors shall be installed on surfaces free from vibration. Detectors shall be fitted with guards to protect them from mechanical damage and the effects of rain, water wash, strong wind, dust and sand. Detectors shall be protected from greases or silicone oils to prevent contamination and shall be located away from direct sprays of oils and other liquids.
Detectors shall be readily accessible for calibration and easy maintenance. If such access is not available suitable access in terms of permanent/mobile platforms shall be provided.
Beacons shall be positioned so that they are visible in the area for which they are to provide a warning, but they shall be accessible for maintenance.
Manual call points shall be positioned so that they stand out against the background and are clearly recognisable from a distance. If necessary, they shall be provided with signs to enhance their visibility from access roads. Flame detector installation shall ensure that the installed flame detector does not create any spurious alarm to light, sight of flare and reflections from sea etc.
7.2.11
Instrument Process Connections
Instrument Process Connections shall comply with the following, unless otherwise stated by COMPANY.
Table 7.1 Instrument Process Connections
Instrument Device
Connection on Equipment
Pressure Vessel
Piping
Storage Tank
Instrument Connection
Vent and Drain
Pressure Gauge
1 ½” RF Flg
*½” NPT
2” RF Flg
Press Transmitter / Press. Switch (Note 6)
1 ½” RF Flg
*½” NPT
2” RF Flg
Differential Transmitter
Pressure
1 ½” RF Flg
*½” NPT
2” RF Flg
Level Displacer (Note 1)
4” RF Flg
Level switch (Notes 1 & 6)
4” RF Flg
Gauge Glass (Note 3)
2” RF Flg
Diff Pressure Transmitter
2” RF Flg
4” Flg
4” Flg
2” Flg
2” Flg
4” RF Flg
4” RF Flg
2” RF Flg
2” RF Flg
½”
½”
½”
4”
4”
¾”
½”
Thermowell
Local Indicator
Thermocouple
RTD
Filled Bulb
1 ½” RF Flg
1 ½” Flg
2” RF Flg
2” RF Flg
1 ½” RF Flg
1 ½” Flg
2” RF Flg
To suit installation
1 ½” RF Flg
1 ½” Flg
2” RF Flg
To suit installation
1 ½” RF Flg
1 ½” Flg
2” RF Flg
To suit installation
1 ½” RF Flg
1 ½” Flg
2” RF Flg
To suit installation
In-Line Indicator
Rotameter (Note 2)
N/A
N/A
Line size
Line size
N/A
N/A
N/A
Line size
½”
½”
½”
2” Flg
2” Flg
½”
½”
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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Instrument Device
Connection on Equipment
Pressure Vessel
Piping
Storage Tank
Instrument Connection
Vent and Drain
Annubar
Analyzer
N/A
3” RF Flg
N/A
MANUFACTURER
2” RF Flg
2” RF Flg
2” RF Flg
MANUFACTURER
Guided Wave Radar
2” RF Flg
2” RF Flg
2” RF Flg
To suit installation
Non-Contact Radar
4” RF Flg
4” RF Flg
4” RF Flg
To suit installation
Magnetic Level Gauge
2” RF Flg
2” RF Flg
2” RF Flg
To suit installation
N/A
N/A
N/A
N/A
¾”
Notes:
- An external chamber with 4” RF top flange, 2” RF side flange, and 2” RF vent and drain flanges shall
be provided.
-
Confirm sizing with meter capacity and measurement requirements.
-
Gauge valve process connection is ¾“MNPT. Gauge glass chamber connection is ½” FNPT. Flanged
gauge valves shall be used where required per vessel trim class.
In general instruments and valves should follow the project piping specification. Process flange connections shall be ASME Class150 minimum rating on pipes, and ASME Class 300 minimum on vessels and tanks. All control valves shall be ASME Class 300 minimum.
- Minimum flange top entry connection on Vessels, Tanks and external chamber bridles shall be 4”
NB. External bridle chambers shall have 2” NB side entry process connections.
-
Switches shall be avoided and require COMPANY approval. All switch device functions shall be implemented using electronic analogue transmitters with the switching functions incorporated within the ICSS or UCP.
Instrument impulse tubing shall be 12mm O.D., 0.89 mm minimum wall thickness, SS-316L. However, selection of materials shall be chosen based on the process condition.
Instrument pneumatic signal air supply tubing minimum size 6mm O.D., 0.89 mm minimum wall thickness, SS-316L.
-
Where listed above NPT connections shall be used when permitted by the project specifications.
-
Where piping supplies a flange, a lap joint style tubing adapter or flanged style gauge mount shall
be used.
In the event that it is impractical or unreasonable to apply the above process connection sizes due to application or access constraints, the CONTRACTOR/SUPPLIER shall request COMPANY approval to deviate from these requirements stating his alternative connection method.
7.2.12
Instrument Hook-ups
Impulse Line Hook-up
For Impulse line hook-up details refer to APPENDIX A1. Material for sour service shall comply with applicable COMPANY and NACE standards MR0175/ISO 15156 and MR0103/ISO 17945.
For lethal service and pipe class rating of 1500# and above, hard pipe shall be used for hook-up of the transmitters. MANUFACTURER shall provide a 2 valve manifold for instrument isolation for pressure transmitters and 5 valve
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manifold for instrument isolation for differential pressure level, differential pressure flow and differential pressure instruments (d/P type). All the manifolds shall have a port for in-situ calibration. Manifolds shall be integral to the transmitter. For hard pipe hook-up, the manifolds shall be provided with flange adapter/kidney flange with the nipple welded for process and vent connection. Refer to APPENDIX A1, for a list of typical hook-ups.
The 5 valve manifold shall be with process isolation valves, test port isolation valve, vent/drain port isolation valve along with a process equalizing valve. The test port shall be plugged and vent/drain port shall be plug or connected to closed drain/vent, as per the Projects Process Isolation Philosophy.
Instrument impulse lines shall not be supported from process pipe work except where other means would be impractical and COMPANY has given his approval.
Piping and tubing shall run with the minimum number of direction changes. Where unions are used, joints shall be offset neatly and shall be systematically staggered when two or more lines run together.
Precaution shall be taken to prevent foreign material entering pipelines before or during installation. All lines shall be blown with oil free dry air before being connected to instruments.
Impulse lines shall be constructed using only the material approved by COMPANY.
The impulse lines shall be bent where necessary using only approved tube benders. There shall be no reworking of tubing and no tight bends. Where a tight bend is unavoidable an elbow compression fitting shall be used.
Piping and tubing shall be supported to provide adequate mechanical security and installed so that no section or run is left under strain.
The distance between any two supports shall not exceed 1.5m for 15mm Outer Diameter (OD) tube. 6mm and 10mm tuning shall be continuously supported by cable tray and firmly fixed by the use of clips.
15mm tubing may be installed by suitable supports with a minimum of 0.75m spacing. Mounting to the supports shall be by poly-tube spacers or similar to ensure tubing separation and elevation, with prior approval of COMPANY. The type of clips shall be resistant to the corrosive offshore environment and are subject to COMPANY approval.
It shall be incumbent on CONTRACTOR to satisfy COMPANY that the above has been complied with.
All impulse lines shall be installed with a slope of not less than 1:12 except where otherwise stated. The slope shall be downward from the tapping point for liquid, steam and condensable and upward from the tapping point for gases in accordance with drawings.
Impulse lines shall be kept as short as possible consistent with good practice, accessibility and neat appearance. However, it shall be installed such that the process fluid operating temperature at instrument is well within the MANUFACTURER specified limits and subject to an overall maximum limit of about 80°C.
Impulse tube work shall be lagged, or heat traced and lagged, where the process liquid would otherwise condense, solidify or be otherwise adversely affected by low or high ambient temperatures. Lagging shall also be provided to protect personnel from high or low temperature impulse lines.
Tube shall be carefully stored and handled to avoid scratches on tube OD and never be dragged across cement, asphalt gravel steel work or other hard surfaces.
fittings shall be
recommendations. Where a The MANUFACTURER recommends that a special number of turns from hand tight are required, the nut and body shall be marked in order that the correct pull up can be verified or a gap gauge used when recommended or supplied. Care shall be taken to ensure the tube is correctly aligned and inserted into the fitting body.
in accordance with MANUFACTURER
installed
Compression fittings shall only be used on the range of tube wall thickness specified.
The following errors shall be avoided:
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Fittings are not under or over-tightened
The use of a mixture of different MANUFACTURER parts or incompatible tube/fitting materials
The use of out of specification tubing. Prior to fitting, the tube surface condition shall be checked. The
outside diameter and wall thickness shall be checked by physical measurement
The reverse fitting of ferrules in twin-ferrule designs (e.g. fitting ferrules the wrong way round)
Poor tube cutting and de-burring. Correct cutting, ensuring a square tube end, with no reduction or swaging
of the tube OD, is essential to avoid any leakage
The use of incorrect size spanners (pipe wrenches shall not be used)
Bending of tube inserted in a fitting or the installation of a coupling on a tube bend
Interfering with the ferrule after it has been made up
Bleeding a system by loosening a fitting nut or retightening fittings when a system is pressurised. Depending on the hardness of the ferrule and tube, and the system pressure, loosening a joint under pressure may cause the tube to blow out of the fitting
Where practical, compression fittings shall not be fitted within five diameters of a pulled bend to avoid crimping ferrule on a hardened or thinned pipe section. Sufficient straight length shall be provided to allow the tube to bottom in the fitting
Attention shall be given to tube runs, to protect couplings from the effects of strain and vibration. Tube runs shall be securely clipped (but not directly to couplings) and shall be flexible enough to absorb equipment and pipe movements, thermal expansion and contraction. Couplings shall not be used to pull tubing and equipment together
Where a compression fitting on an existing system is disassembled it shall be remade using all the original parts, by following the MANUFACTURER’s re-assembly instructions or re-made with a complete new compression fitting. Any elastomeric ‘O’ rings ferrules shall be replaced.
During installation 100% of joints shall be visually inspected by the installer. Hook-ups shall be as per approved hook-up drawings. The same shall be updated after installation.
Pneumatic Hook-up
The minimum Instrument air design pressure required for actuators is 4.0 barg and the dew point temperature at operating pressure is -40°C.
The piping group shall install 316L SS 2” instrument air header with 1” branches for instrument air distribution. Piping group shall provide a sufficient amount of 1” take-off points from the main instrument air header in the proper areas for present and future air users. Refer to AGES-PH-04-001, Automation and Instrumentation Design Philosophy for recommended number of users and spares based on air distribution line sizes.
Details of Instrument air manifolds and downstream tubing shall be covered in pneumatic hook-up drawings by Instrument group. Where a number of instruments are grouped together, then standardised instrument air manifolds (e.g., 10-way) shall be used for instrument air distribution. Considering simultaneous opening of all the valves, air manifolds shall be stainless steel (316L SS) with individual ball valves for feeders clearly identified with valve tag numbers to prevent inadvertent shut off of the supply to the wrong user.
The design shall facilitate isolation of air supply to individual manifolds for maintenance. Some large instrument air consumers shall require direct connection to the instrument air header (e.g., large pneumatic on/off valve
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actuators). The piping group shall design for a 1” pipe with a ball valve branch to a location adjacent to these valves. The final tie-in shall utilise tubing as required.
Instruments operated by instrument air shall be installed with a filter regulator that shall regulate the specified output pressure to within 5% over the range of the specified instrument air design pressure. Ball valve shall be installed upstream of the regulator at each instrument. Instrument air systems must be clearly identified and labelled to prevent non instrument usage.
All pneumatic supply for the valves shall be specified to operate on dry instrument air, at the pressures specified in section 8.2.2.1.
Mechanical design pressure of valves and accessories shall be designed to withstand the instrument air header design pressure.
Note: Pneumatic supply pressure to valves installed in existing Facilities shall be as per respective existing Facility.
All BDVs and critical ESDVs, XVs and deluge valves shall be provided with air volume tanks with the capacity for 3 full cycles (valve open to close and close to open shall be considered as 1 full cycle) to prevent the opening/closing on loss of instrument air.
Unless otherwise specified in the requisition, the capacity of the instrument air buffer vessel shall be sized for a minimum instrument air supply pressure of 4.0 barg.
Hydraulic Hook-up
Hydraulic supply shall be distributed from the Hydraulic Safety Shutdown System, isolation valves near individual user on supply and return line shall be provided.
The size and thickness of the hydraulic tubing shall be chosen based on the hydraulic system design pressure and the various consumers.
Teflon tapes and jointing compound on screwed fitting is not permitted.
For tubing support details refer to clause 7.2.12.1 Impulse Line Hook-up.
7.2.13 Control Panels and Cabinets
Panels and cabinets shall be installed in true vertical orientation.
Locally mounted panels shall be located as far as practicable from sources of harmful matter (such as pressure, heat, water splash etc.,) and vibration. If the area requires hosing down, the panels shall be mounted on a plinth approximately 100mm high.
Readability of instrument displays, panel mount display and HMIs shall not be impeded by reflections caused by natural or artificial light. In such cases, CONTRACTOR shall provide suitable shade to ensure the display can be read at all times. Panel mounted annunciators shall be clearly visible under all lighting conditions.
Outdoor control cabinets shall have cable entry from the bottom. A removable gland plate shall be provided in the bottom of the panel.
All unused cable entry ports shall be fitted with approved plugs.
Panels and cabinets shall be installed as per the layout drawings. Access for maintenance operations and removal of equipment shall be provided. Where panels or racks have doors, there shall be access past them when they are open. MANUFACTURER documentation giving advice on layout and space requirements shall be followed. Particular attention shall be given to handling existing or new equipment modules during removal and installation
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operations. This shall include the size and layout of passages and doorways. Where panels are installed in rows adjutant to each other, cabinets shall be provided with double door to occupy less space when the door is opened.
The Instrument Equipment Shelter and Control Room shall have a false floor, for the easy cable installation. The false floor height depends on the number of cable tray layers installed but shall not be more than 1000mm depth.
Outdoor control cabinets shall be provided with suitable sunshades made of non-corrosive material.
Each item of equipment shall be identified by a permanent stainless steel nameplate attached to the panel or to the panel frame by stainless steel screws.
Cable Installation
7.3.1
General
Installation of wiring and cable systems shall be in accordance with this Specification, other COMPANY Specifications for Instrument Cables and international standards API RP 552, BS 6739, and IEC 60079-14.
Prior to commencement of the work, cable routes shall be identified and approved by COMPANY. CONTRACTOR shall obtain written agreement from the COMPANY establishing the condition of existing cable ducts where it is agreed existing infrastructure can be used. Any subsequent damages prior to re-installation shall be at CONTRACTOR’s cost. All duct covers are to be properly stacked in the locations agreed by the COMPANY.
While deciding on the cable route, appropriate care shall be taken in terms of voltage/signal segregation requirements. Trial pits shall be used to assess the cable installation whenever works are carried out in existing Facilities.
All cables shall be laid by hand unless otherwise agreed by COMPANY. In the event of pulling by mechanical means being permitted, CONTRACTOR shall provide the necessary dynamometer and all equipment necessary to ensure that the maximum stress permitted by the cable MANUFACTURER is not exceeded.
Cables shall be run in continuous, unbroken lengths. Joints shall not be permitted unless the route length exceeds the maximum manufactured drum length or jointing of the cable is otherwise specifically authorised by COMPANY. Cable joining is not accepted for instrument cables. New cables to be laid for upgrade projects wherever applicable.
All cables shall be neatly laid and crossovers reduced to a minimum to permit the removal and replacement of single cables with a minimum of disturbance to others.
Where existing earthing cables are being re-routed or cut, CONTRACTOR shall be responsible for obtaining the necessary permit for the work to proceed and also to ensure that all associated electrical equipment is properly earthed before any work commences. CONTRACTOR shall follow permit to work system for offshore and onshore as applicable in accordance with COMPANY procedures.
For onshore applications where the contract specification or drawings indicate cables laid as “direct buried”, or run in an existing concrete cable trench, CONTRACTOR is responsible for all cable route excavation and restoration. New clean sand, free of debris and pebbles, shall be used for back filling of cable trenches.
CONTRACTOR shall take into consideration that cable lengths stated in schedules are approximate. CONTRACTOR shall be responsible for ascertaining the actual cable lengths required for installation prior to cutting and laying.
When it is required to expose cables run in concrete duct sections, CONTRACTOR shall not use tools, which may cause damage to the cable outer sheath.
The minimum cable spacing requirements shall be in accordance with the following:
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AGES-SP-12-014 Fibre Optic Cable Network Specification (Details covered in section 7.11) and
AGES-GL-02-001 Electrical Engineering Design Guide (Details covered in section 14.3)
For installations, particularly offshore, where cable segregation as shown above either cannot physically be achieved or causes unacceptable penalties due to space and weight constraints, alternative arrangements should be considered, such as:
Parallel runs of power and instrument cables kept as short as possible
Ensuring all instrument cables are screened and earthed correctly
Running instrument cables least susceptible to ‘pick-up’ interference (for example 4-20mA and contact alarm signals) closer to the power cables, whilst keeping low level and data transmission cables as far away as practical
In cases where a spacing of only 50% or less of the recommended distance is achievable, instrument and power cables shall be separately routed. The cable spacing listed above may be relaxed at entries to instruments and associated housings, or where parallel cable runs are less than 30m in length and where, due to physical constraints, these spacing cannot practically be achieved. All such instances where relaxations of these requirements are proposed shall be highlighted to COMPANY and subject to approval.
Instrument power supplies above 10 A shall be treated as power cables and segregated.
Special cables (such as data highways) shall be installed in accordance with MANUFACTURER recommendations.
Where multi-core cables pass through floors, or rise through covered trenches, they shall be provided with adequate mechanical protection in the form of metallic sleeves or kick plates projecting not less than 75mm (3”) above floor level. Kick plates shall not constitute a trip hazard.
Where cables pass from one area to another the transit shall be sealed. This is of particular importance where the dividing wall or bulkhead separates a hazardous area from a non-hazardous area, between different rated hazardous areas, or where the bulkhead is of a specified fire rating. In these cases, Multi-cable Transits (MCT) appropriately rated shall be used.
Removable gland plates shall be furnished for cable access into panels and equipment enclosures.
Power and instrument cables shall be run on separate trays or ladders or in separate trenches or troughs. In a multi-purpose cable trench a division wall up to the full depth of the trench shall be provided. When power cables intersect instrument signal cables, the crossing shall be at right angles, with a minimum separation distance of 300mm. Where this is not practical, physical segregation shall be agreed with COMPANY.
Where conflicting segregation distances are stipulated in Project specifications and associated drawings, the most stringent shall be applied. In general control and power cables (up to and including 240 V, 20 A) may be run in the same tray if adequate mechanical segregation is provided such as barrier plates in the cable tray. The distance between the control and power cable shall however always be maximised.
The minimum distance between parallel instrument and power cable trench shall be in accordance with the following:
AGES-SP-12-014 Fibre Optic Cable Network Specification (Details covered in section 7.11) and
AGES-GL-02-001 Electrical Engineering Design Guide (Details covered in section 14.3)
Cable trench width shall be based on the type of cables, quantity of cables and the segregation philosophy.
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Wherever possible, cables installed above ground shall be routed to avoid areas of special fire risk or areas where leakage or spillage of contaminants could occur. All cables on trays which are located in potentially flammable areas shall be fireproofed as per COMPANY specification.
The routing of all cables shall be planned concurrently with main pipe racks, vehicle access ways, etc., to provide unimpeded direct routes wherever possible and to make maximum use of overhead pipe racks and other structures to support cable trays or ladders.
When planning cable routes, care shall be taken not to obstruct access to or movement.
Cables shall be securely fastened to trays or ladders. All cable ties used in the field shall be ‘nylon coated 316 stainless steel’.
Underground cable routes shall be identified by concrete cable markers. Markers are to be positioned at 30m intervals on straight runs and at all points where the route changes direction. Cable trenches less than 1 m wide shall be provided with single markers on the centreline of the run. Trenches wider than 1m shall be indicated by markers mounted on each side of the trench at specified intervals. Similar markers suitably inscribed shall be used to indicate the position of underground joints.
Cable trays/ladder shall be as per COMPANY Standards for GRP Cable Trays and Ladders for Onshore and Offshore Facilities. The installation shall be as per approved design and installed with the breadth of the tray in the vertical plane. Where COMPANY agrees that a vertical run is not possible, a short horizontal section may be used, but the run shall revert to the vertical plane at the nearest point. Cable trays/ladders shall have covers. Covers shall be secured with nylon coated stainless steel banding or with appropriate clamps duly painted to COMPANY Specification, one band/clamp per 1 m of cover length, with a minimum of three bands per cover. Cable trays run vertically in outdoor areas shall have covers on both sides. Tray/ladder cover shall be easily removable and steel band/clamp provided for the covers shall be reusable.
All cables shall be secured with correct glands and shall be in accordance with international standard BS 6121. Cable glands on outdoor service shall be shrouded. In outside locations, cables shall enter and exit junction boxes via the bottom or side. Where side entry is used, the cable shall be installed in a manner minimise the possibility of water ingress.
Sufficient cable slack shall be left at junction boxes, at instruments and at individual core terminals to allow for remaking connections. To avoid congestion at junction boxes, cable slack can be left on the cable tray/ladder below the junction box, to facilitate future re-termination if required.
Cables shall be identified at each gland end by identification tags with the allocated number indicated on the cable schedule. The identification tag shall be of non-corrosive K-type markers, or equivalent subject to COMPANY approval, with 5mm high embossed lettering and attached with nylon coated 316L SS cable ties.
For underground installations, the identification tag shall be of non-corrosive (such as nylon/PVC coated 316 SS type with numbers printed /punch legibly) identification tags. Similar tags shall be attached to cables at either side of a transit unit or cable duct and at specified intervals (40m) for the entire length of cable.
All back of panel wiring shall be run in trunking.
After completion of work, circuits shall be tested without disturbing the wiring.
All cores within a cable shall be identified with ferrules using thermal heat shrinkable type sleeves. Tinned lugs and no exposed copper cable which shall be covered by heat shrink cable sieves to avoid corrosion in harsh environment. The sleeve shall be appropriately sized suitable to the wire size to ensure the letters are visible after heat shrinking from distance. Cross-ferruling method shall be adopted with source and destination identification.
All multi-strand cable cores shall be terminated using insulated crimp connectors compatible with the terminal block used, such as flat pin and eyelet. Spade type connectors are not acceptable.
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Crimp connections shall be made using an approved crimping tool all to the satisfaction of COMPANY.
The screen shall be grounded at one point only, typically at the marshalling cabinet in the Equipment Room. The screen for thermocouple shall be ground in the field, at the thermocouple end. The screen drain wire on the ungrounded end of the cable shall be cut and insulated with a heat shrink sleeve to prevent unintentional grounding.
Generally, multi-pair cable shall have both individual screen and overall screen. The individual screen shall be sleeved using ‘green’ colour sleeve and the overall screen shall be sleeved using ‘green-yellow’ sleeve. For single pair cables, the screen shall be sleeved using green sleeve.
Terminations and entries of hazardous area installed equipment shall be in accordance with hazardous area certified equipment.
Signal wiring shall be installed in a manner that shall minimise unwanted and unnecessary distortion of the signal.
IS and non-IS signals shall be segregated as required by IEC 60079. Wiring for IS/NIS systems shall be segregated and installed in dedicated cable trays and terminated in dedicated junction boxes.
Data links, including fibre optic cables, shall be specified and installed as per MANUFACTURER recommendations. Minimum separation requirements between various instrumentation cables and data link cables (copper or fibre optic) shall be per MANUFACTURER recommendations. Data link cables shall not be routed in the same conduit, duct, or tray with other instrument cables.
Instrument power cable size and colour code shall be in accordance with AGES-SP-02-011, Electrical Power, Control and Earthing Cables specification.
Instrument signal cable size and colour code shall be in accordance with AGES-SP-04-006, Instrument and Control Cables Specification.
A minimum of 20% spare pairs/triads of a multi-pair/triad cable shall be terminated at both the field junction box and the marshalling cabinet and to be available until Project completion. Drain wires for spare shielded pairs/triads shall be individually terminated at these locations. Spare wires at the instrument side shall be neatly coiled and taped if there is no spare terminal block available.
Cross-connect jumpers and cables used for patch cords as well as equipment access shall meet the performance requirements described in TIA-568. Connector and cable components shall be installed in such a manner as not to degrade the performance of the system and any network. Therefore, consideration is to be taken for the installation of:
Connector termination
Cable management
Use of cross-connect jumpers/patch cords
Multiple connections in close proximity
Following wire and cable management practices shall be followed:
Eliminating cable stress caused by tension in suspended cable runs and tightly clinched cable bundles
Reducing untwisting of wire pairs by stripping back only as much cable jacket as is required to perform
termination (with allowance for excess length that may be removed during termination)
Maintaining minimum bend radius in accordance with MANUFACTURER recommendations
Installation requirements specified in TIA-568 shall be observed for all categories of connecting hardware.
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Redundant communication signals shall be diversely routed using separate above ground/underground routes to maintain minimum segregation and to avoid single points of failure.
For Fibre Optic cable installation requirements, refer to AGES-SP-12-014, FO Cable Networks.
7.3.2
Underground Cable Installation
Cables Installed Directly in the Ground
Cables installed directly in the ground for the whole or part of the route in hydrocarbon spillage areas shall provide the barrier to avoid ingress of hydrocarbon. CONTRACTOR to refer to the COMPANY Specification for Instrument Cables for suitable cable selection.
Cables shall be surrounded by not less than 200mm of washed sand and protected by suitably sized concrete tiles. Warning tapes shall be placed 100mm above buried cables.
Backfilling of cable trenches shall be well compacted and the ground reinstated to its original grade and finish. Backfill materials shall be free of large stones or other injurious objects to a level at least 150mm above the protective tiles. Backfilling of the cables trenches shall be done only after the cables are tested.
Cables shall be installed with the aid of purpose constructed rollers and guides. Cables up to 38mm diameter shall be installed by hand, but larger cables may be installed with the assistance of a suitable winch, having an adjustable tensioning device and indicator, and operated by a qualified operator. The maximum pulling force shall be in accordance with MANUFACTURER recommendations. Cable socks shall be sized to the cable and fitted correctly. Where recommended by the MANUFACTURER, pulling eyes shall be fitted to the cable at the time of manufacturing. Cable shall not be installed directly from a drum mounted on a moving vehicle. The maximum permitted pulling tension for the type and size of cable shall not be exceeded.
Drum jacks, cable rollers and other installation equipment shall be the correct type and size for each drum and cable laid. Equipment shall be kept in good condition and be used in the approved manner.
Distance between the direct buried cables and top finish in accordance with surrounding area shall be minimum 750mm or in accordance with the Project specifications and associated drawings. Normally, direct buried cables are not required to be installed through duct/pipe. However, duct/pipe shall be used for road crossings, entry into buildings, etc. Refer to APPENDIX A3 for typical drawing.
Installation of direct buried cables shall not start until the entire route has been excavated and prepared ready to receive the cable. Where such procedure is impracticable, a detailed program of laying shall be agreed with COMPANY.
When cable is left exposed above ground (with approval from COMPANY) it shall be coiled, suitably protected against damage and include temporary fence/barriers around the coil. Alternatively, such cable may be left on the drum, which shall be lowered from its jacks, firmly anchored and fenced.
Cables duct shall be of heavy-duty PVC or high-pressure polyethylene and a minimum diameter of 150mm unless approved otherwise. For road crossing they shall be embedded in concrete, with the top of the concrete at least 600mm below finished ground level.
Ducts shall be filled to a maximum of 30% and a spare draw wire (draw rope) left in each conduit.
PVC protection pipe ends shall be smoothed or bent to avoid possible cable damage. Steel pipes, where used, shall be fitted with bushings and grounded. Once cables are installed, PVC pipe ends shall be fitted with a sealant such as polyurethane foam.
CONTRACTOR shall prepare accurate and detailed records of buried cables, as each section of cable is installed. Recorded information shall include dimensioned trench positions, duct and trench sections indicating circuits
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installed and the location of underground joints taken by measurement from fixed and permanent landmarks. CONTRACTOR shall subsequently transfer this information to permanent “As Built” drawings.
7.3.3
Cables Installed in Ducts
Overall length of ducts and pipe crossings shall extend at least 300mm beyond the limits of the area requiring ducts. Draw wires (draw ropes) shall be installed in each duct.
Ducting shall be temporarily sealed when not required for immediate use.
Before cables are installed, the duct run shall be cleared of obstructions by compressed air, use of a wooden mandrel or by rodding.
Relevant procedures detailed in Section 7.3.2 shall be followed for the underground cable installations.
Ducts allocated to specific circuits on Project drawings shall be followed, otherwise duct banks shall be filled from the bottom upwards and spare conduit left unobstructed at the top of the bank. Instrument and control cables shall not be installed together with a power cable in the same duct. Cable segregation philosophy shall be maintained.
Ducts shall be sealed at both ends immediately after cable installation and spare ducts shall be sealed with suitable sealant such as polyurethane foam.
All cables shall be identified with suitable cable tags. Cable tags shall be provided at the entry and exit of the ducts.
7.3.4
Cable Installed Above Ground (Onshore) or Above Deck (Offshore)
General
Material used for cable trays and ladder racks shall comply with COMPANY Standards.
Cables shall be allocated to racks in the grouping arrangement detailed on Project drawings.
On minor cable routes involving both power and instrumentation cables where it is impractical to route more than one rack level, instrumentation cables shall be installed on one side and power cables on the other subject to COMPANY approval.
Care shall be taken to maintain the segregation distances between power and instrumentation cables as indicated in Section 7.3.1.
Cable cores shall be identified at each terminal with individual number/letter combinations using non-split cylindrical ferrules.
Cable ties for indoor installation shall be used with nylon 12 and outdoor installation shall be using Nylon coated 316L SS cable ties.
Cables shall be securely fastened to trays and ladders at spacing.
Cables, which leave main tray or ladder routes for connection to individual items of equipment, shall be installed on tray, between the main cable tray/ladder and the equipment.
A minimum of 30% spare capacity in each cable ladder/tray shall be provided at the time of handover for future use.
Cable ladder/tray shall be bolted or clamped to support.
To avoid corrosion, insulation pads shall be installed wherever dissimilar metals come into contact.
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Support Steel Work and Fixings
Contractor shall provide supports necessary for mounting cable trays and cable ladders. These shall be pre- fabricated construction supplied by tray/ladder MANUFACTURER or by CONTRACTOR, to minimise onsite fabrication.
Site fabricated steel supports and brackets shall be fabricated and installed with sharp edges de-burred.
Supports shall be made from steel coated with hot dipped galvanized in accordance with ASTM A153/A153M and painted in accordance with COMPANY Specifications. Bolts, nuts and washers shall be in accordance with COMPANY Specifications. Vibration proof spring washers shall be installed at all bolted connections.
Structural steel on pre-cast concrete members shall not be drilled unless specifically approved by COMPANY. Fixing shall be by means of clamping brackets.
Under no circumstances shall welding or fixing operations be carried out on any process Facility equipment, vessels, pipelines or structures unless specifically approved by COMPANY.
Cable Transits
Transits shall be used where cables pass through walls, roofs and floors considering the following:
From a safe area to a hazardous area
Through blast walls
Through fire walls
On offshore installations, bulkhead and deck penetrations by cables shall be done using agreed MCT. Transit frames shall be carbon steel and all other metallic accessories shall be 316L SS. The transit frame shall be painted after welding as per COMPANY painting specifications.
CONTRACTOR shall provide the number of transit frames and tiers for each penetration position by reference to the schedule of cable transits. CONTRACTOR shall determine the quantity (including spares) and provide and install the transit insert blocks and frame accessories. The size of the transit block shall be dimensionally suitable for the cables to be installed.
Field Instrument cables and electrical interface cables entry into the SIS / MCR / CCB etc shall be through Multi Cable Transit.
Transits shall be located in positions indicated on the drawings. CONTRACTOR is responsible for cutting bulkhead, welding plates and the welding of transit frames into position and painting.
Care shall be taken when cable passing through transits.
Spare ways in transit frames shall be filled with blank filling blocks. A minimum of 25% spare ways shall be allowed in each penetration location. The size of the spare ways shall be suitable for the similar type of cables that are already passing through transit frames. Cables passing through transits shall be perpendicular to the transit for a minimum distance of 100mm on each side of the transit. Spare ways shall be accessible for future use.
CONTRACTOR shall prepare drawings for transits, to co-ordinate cable positions passing through and indicating cable number, insert block and spare block sizes. Ways allocated for cabling, as determined from the drawings and cable schedule, shall also be indicated.
Transits shall be identified by installing weatherproof labels on either side of the penetration. Durable labels with letters of at least 50mm height shall be permanently fixed to adjacent racking and shall be easily readable. All cables passing through transits shall be identified with a cable tag on either side.
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Conduit Installations
Conduits are not preferred by COMPANY. In unavoidable cases, conduit installations shall be as described in this section and are subject to COMPANY approval.
Conduits may be used as mechanical protection for unarmoured cables, such cables shall be in accordance with COMPANY Standards. Where COMPANY approval to use conduits has been granted, conduit installations shall, as a minimum, be as follows:
Conduit systems shall be designed and installed in accordance with MANUFACTURER instructions and
safety procedures for hazardous area applications
Conduit systems shall be coordinated with installations for other services
Conduit fittings shall be manufactured from malleable cast iron and, for outdoor installations, hot dipped galvanized and of weatherproof design. Conduits installed in non-climate controlled area shall be painted as per COMPANY specification.
Heavy gauge, hot dipped galvanized screwed steel conduit shall be used for Facility installations. Conduits shall be sized to accommodate the total number of circuits involved without exceeding conduit fill limitation specified in the wiring regulation
Conduit for installations in hazardous areas shall be solid drawn, fitted with stopper boxes as required and
shall be suitable for the specified hazardous area and duly certified
Conduit systems shall be electrically and mechanically continuous throughout and rigidly secured before wiring is commenced. An adequate number of pull boxes shall be installed to facilitate wiring without strain or damage to cable. In outdoor locations, and other areas where the formation of condensate may occur, conduit systems shall be provided with drain points. Conduit shall be installed in a manner, which provides an adequate slope to ensure that the system drains to drain points. All spaces around the cables and the conduit pipes at entry points shall be properly sealed
Conduit shall not be installed in the ground or in sand filled trenches
Conduit threads shall be cleanly cut to a finished length that leaves the minimum exposed length of thread when installed. Threads shall be checked for correct size using an appropriate gauge. Leading edge and bore shall be made smooth. Exposed bare metal shall be cleaned and protected against corrosion using materials that are compatible with the original protective coating
Locknuts shall be used at all entries and be fully tight. The use of running couplers in installations in Zone
1 (Class 1, Division I and II) areas is prohibited and conduit unions shall be used instead
Bends and offsets formed in conduit shall be made in an approved manner and without indentation or alteration of the conduit section. Bend radius shall be not less than that shown under appropriate regulations and shall consider the bend radius of cabling to be installed in the conduit
Wiring in conduits shall be looped from point to point and where joints are unavoidable, they shall be made in junction boxes. Junction boxes shall be adequately sized and fitted with fixed connector blocks rated for the circuit requirement. In hazardous areas, junction boxes (and associated fixings, glands, etc.) shall be certified for use in the relevant area
Flexible non-corrosive metallic conduits can be reviewed and used for the mechanical protection for the
unarmoured cables
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Cable Records
CONTRACTOR shall prepare, and keep up-to-date, a cable drum schedule. The cable drum schedule shall be prepared to minimise cable wastage.
Entire cables indicated in the cable schedule shall be marked with respective cable drum details.
Records of all cable requests shall be kept.
CONTRACTOR shall institute a recording system to record actual lengths of cable removed from the drum, drum reference and purpose for which each length is used.
The cable schedule shall be updated regularly with actual length of the cable laid.
Earthing And Bonding
7.4.1
General
Electrical/electronic systems shall be connected to ground for the protection of personnel and equipment from fault currents (AC safety ground) and to minimise electrical interference in signal transmission circuits (instrument circuit ground).
Earthing and bonding requirements shall comply with API RP 552, BS 6739, and IEC 60079-14.
Grounding systems considered for instrumentation systems are:
Safety Earth (ELE) – also called as Plant Earth or Protective Earth or Electrical Earth
Instrument Earth (INE) – also called Clean Earth or System Earth
Intrinsically Safe Earth (ISE) – also called Barrier Earth or Zener Barrier Earth
Earthing and bonding shall ensure signal integrity against Radio Frequency (RF) or any form of electromagnetic induction is reduced to a practicable minimum.
The arrangement for earthing of IS equipment shall comply with the requirements of IEC 60079.
Where existing instrumentation is to be incorporated as a whole or in part into a new or revised control system (such as re-instrumentation projects or Facility revamps) CONTRACTOR shall ensure that signal transmission, earthing practice and electrical safety of new and existing equipment is compatible. Particular attention shall be given where IS equipment is involved on either an existing or new Facility:
Existing field instrumentation and associated cabling supplied and installed as IS many years ago may not
meet the system certification requirements of the new equipment
Existing earthing policy for signals and signal cable screens may differ from the new equipment
MANUFACTURER recommendations
Interconnections between instrument earth bars and power system earth shall be provided with insulated conductors of not less than 35mm2 in cross sectional area.
Where single conductors are used for interconnection between earth bars, they shall be doubled.
Where an earth bond cannot be assured by the mounting arrangement, a separate earth conductor shall be run from the equipment case to the ELE bar.
Screens shall be insulated from one another and earthed only at one point as indicated below:
For IS circuits at the ISE bar
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For non-IS circuits at the INE bar
On offshore installations where earth rings do not exist, the earthing shall be by minimum 35mm2 green/yellow cross-linked polyethylene (XLPE) covered, flexible copper earth cable to a suitable earth bar or structure earth point.
Through joints with using ‘C’ type crimping connectors are acceptable.
Continuity of earth on cable armouring shall be provided. Particular attention shall be paid when plastic cases or glands are used.
Earthing positions shall be selected to avoid earth loops which could result in common or series mode signal interference.
Where surge protect device/terminals are used, earthing of surge output shall follow MANUFACTURER recommendations.
Earthing conductors shall be stranded and insulated 750 V grade with the following colour code:
ELE: Green/Yellow
INE: Green
ISE: Green with blue sleeve (50mm) at both end/termination point
7.4.2
Field Devices and Marshalling/Junction Boxes
The instrument earthing installation shall be carried out in accordance with the relevant Standards, Codes of Practice and Procedure given herein, with particular reference to IEC 60079, BS 7430 and IEEE 1100.
Field instrument cables between a marshalling/junction box and the control cabinet shall have the armour earthed at both ends of the cable via the gland.
All metallic instrument elements in the field shall be bonded to the Facility/Platform steelwork at bolted connections. These shall be provided with serrated spring washers to give earth continuity. Where the earth bond cannot be assured, a 4mm² single core, insulated conductor shall be provided between the enclosures as an effective local earth point.
7.4.3
Marshalling Panel/Cabinets/Control Room
Cabinet earthing requirements shall comply AGES-PH-04-001, Automation and Instrument Design Philosophy.
Panel earth bars shall be hard copper to BS EN 13601 or equivalent and a minimum of 75mm2 in cross sectional area. They shall be mounted on insulators with a minimum spacing of 25mm from the panel frame. All earth bars shall be appropriately labelled according to their functions, e.g., ELE, INE or ISE. Only tinned copper bar is acceptable. Bus bars shall be tinned after making holes.
Flexible earth straps shall be fitted between panel doors and frame.
Where galvanically isolated barriers are to be provided, cable screens shall be taken to an ISE bar.
If the cable has only an overall screen, the same shall be connected to INE bar. The screen shall be sleeved using ‘green’ colour sleeve. The screen shall be earthed at one end (typically the marshalling cabinet end to the respective earth bar). If the cable is with overall and individual screen, both the screen shall be connected as above using green sleeve.
Dedicated terminals in junction boxes shall connect the screens of single and multi-core cables. These terminals shall be insulated from safety earth. In installations where there is a transition from multi-pair or multi-triad cables
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to individual pairs/triads for field device connection in a junction box, the respective screen drain wires shall be joined via terminal strip and shall not make electrical contact with the junction box or any other circuit.
Earth leads between the control cabinet ISE bar and the control outstation earth bar, shall be provided with identification labels at both ends indicating an IS circuit.
Process data communication cables may be co-axial or twisted pair as required by the system. The system MANUFACTURER’s specific screening and earthing philosophy shall be complied with, provided it does not prejudice the conditions specified elsewhere in this specification.
Three sets of earth bars shall be provided for connections as follows:
ELE to which equipment cabinets are earthed
INE to which drain wires from screens from non-IS cables are connected
ISE to which drain wires from screens from IS cables are connected
For the Details of earthing connectivity, cable and connectivity refer to APPENDIX A2.
Earthing for analogue and digital IS loops are as follows:
Metallic instrumentation enclosures shall be bonded to the Facility/Platform steelwork at bolted or process
connections
Armour/braiding of the field cables are connected through the respective glands to the instrument housing
on the field side and the ELE bar within the marshalling cabinet on the other side
The screens of the field cables are isolated at the field instrument side and connected to the reference ISE
bar. This enables single earthing at the one end of the loop
Earthing for analogue and digital non-IS loops are as follows:
The metallic instrument enclosure and cable braiding is connected in the same way as IS loops
The screens of field cables are isolated at the field instrument side and connected to the reference IE bar
in the panel. This enables single earthing at one end of the loop
Earth bars are connected to earth pits/structure (offshore) using insulated cables. The ELE bar is connected with green/yellow sheathed cable. The INE bar shall be connected with green sheathed cable
In the case of offshore applications, the overall steel super structure has an adequately low earth resistance. This allows local earthing at the instrument to be implemented directly to the structure by means of adequately sized earth bosses without the need to apply a central earthing system. Where instruments are mounted on package units or stands, the package unit or stand shall only be regarded as having an adequately low earth resistance if it is fully welded to the super structure. Bolted structural connections are not permissible for this purpose.
INE and ELE shall always be segregated and never combined into one earth boss. The minimum distance between INE bosses and ELE bosses shall be 1m.
Lighting strikes on process piping may cause damage to electronic components and sensors. Lighting protection is necessary to prevent the high voltage surges that can create line voltages that are above the operating tolerances of the measuring equipment. The protection can be provided by galvanic separation, or by surge protectors. When surge protectors are used, the protectors are installed at both ends of the signal to a good earth ground, with 1 ohm ground resistance.
Floating power supply for field instruments is recommended, if power supply is earthed, galvanic isolators shall be used in the circuit.
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Supports
Close coupled instruments should be mechanically supported from the associated process piping, and occasionally from adjacent structural members. The use of welded-on line-mounted supports may be considered, subject to COMPANY approval. Instruments shall not be line mounted when temperature or vibration from hydraulics or operating equipment will affect the operation of the instrument, or cause damage to instrument piping.
The manifold block, which forms part of the impulse line arrangement, shall be bolted to a mounting plate. Selection of the type of mounting plate depends upon the various components required:
L-shape Mounting Plate:
i. When a sunshade is required
ii. When a junction box is required (in combination with a requirement for a protective housing for
transmitter)
Rectangular Mounting Plate: for All others.
Instrument piping shall be supported from pipe supports, pipe and any other permanent structure, except as follows:
Instrument piping shall not be supported from uninsulated pipes 51 °C and above or 4 °C and below, pipe or pipe supports, handrails etc., that would be subjected to above normal vibration.
Instrument piping supports shall not be welded to stress relieved equipment or internally line equipment. Instrument piping supports shall be sufficient to maintain the instrument piping in a neat manner.
All applicable details for each installation shall be examined before work on mounting or piping is started. This is particularly important when sealing or purging is shown on the detail, and when heat tracing or special insulation is indicated.
Sufficient clearance shall be provided for the removal of the instrument cover or the instrument enclosure and for access to external adjustments.
All packaged equipment shall be piped and instrumented so that on-stream performance verification can be made.
Instrument Electrical Junction Boxes
Junction boxes for instrument cables shall be installed at the locations indicated on the layout drawings in such a way that they are permanently accessible.
The ideal location for junction boxes is against the supports of main pipe rack. For open areas such as tank farms, etc. they should be supported on substantial frames. Junction boxes located in the units shall be distributed in order to place them as near as possible to the center of their associated instruments.
The junction boxes shall be marked externally with suitable nameplates. All junction boxes shall be kept closed when not being worked upon. Junction boxes should be installed before the start of cable laying.
Junction Boxes shall be stainless steel with suitable corrosion resistant surface. They will be built in accordance with safety requirements and will be fitted with cable glands (bottom mounted). Only metallic cable glands are acceptable.
Cable glands shall be of the correct size to match the appropriate cable. Cable glands should preferable be in the bottom and never in the top, to prevent ingress of water.
All spare cores shall be labelled and connected to terminals. There shall be only one core/wire on each side of the terminal. Junction boxes will be fitted with an extension earth terminal.
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Drawings
The minimum drawings/documents required prior to Instrument/Cable installation are:
Piping and Instrument Diagrams
Instrument Location Plans
General Layout Drawings
Instrument Mounting/piping Details
Hook-up/Installation Drawings
Cable Schedules
Interconnection Diagrams
MANUFACTURER’s Installation Manual
Corrosion Protection
CONTRACTOR shall ensure that all instrumentation equipment or materials free issued by COMPANY or CONTRACTOR supply are protected in accordance with COMPANY Preservation of New Materials and Equipment specification.
CONTRACTOR shall replace at his expense any items of equipment that have suffered damage or deterioration as the result of improper attention to corrosion protection.
TECHNICAL REQUIREMENTS FOR INSTRUMENT PIPING CLASSES
Design Specification
8.1.1
General
This section describes specific requirements for the materials, design, fabrication and construction of instrument piping systems.
Instrument installations between the process block valve and the instrument typically use instrument tubing. Use of pipe (as opposed to tubing) is encountered in applications with high pressure/temperature ratings, toxic/lethal services where no tubing fittings are allowed or where corrosion resistivity requires a tubing material that is essentially non-bendable.
8.1.2
Design Conditions
Unless otherwise specified, pressures and temperatures refer to Project design conditions.
8.1.3
Pressure-Temperature Ratings
Pressure-temperature ratings for 2” and smaller carbon steel, ferritic alloy steel, and austenitic stainless steel piping, flanges, and valves are based on the latest edition of ASME B16.5 and ASME B16.34.
Allowable internal pressures for pipe shall be verified in accordance with ASME B31.3, in order to meet the design limits of piping classes. In some cases, these allowable internal pressures are decisive for the design limits of a piping class. In each material class a note indicates on which code the design limits are based.
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8.1.4
Fabrication
The requirements for protective heating of pipe and instruments shall be indicated on the Project P&IDs and on the equipment data sheets.
Heating is required when temperatures drop below a certain minimum value would give rise to:
Coagulation, crystallisation, paraffin separation, congealing, hydrate formation
Condensation of gaseous process fluids
Viscous process fluids, such as no-flow situations, shutdown, isolating lines
The heating medium for tracing and jacketing should be saturated Low Pressure (LP) steam. However, Medium Pressure (MP) steam may be used.
A steam trace heating system may be:
A closed system, in which the condensate is collected for re-use
An open system, in which the condensate is discharged into a drain or soakaway
Tracing steam and condensate headers should be separate from the normal steam distribution and condensate collecting system.
Pipe supports shall be designed, manufactured, fabricated, inspected and installed in accordance with ASME B31.3 Typical sketches and dimensions of pipe supports are given in MSS SP 58 and MSS SP 69. Hanger supports shall be clamped around the pipes and bolted. Insulating strips of glass fibre or similar material shall be applied between pipe and support.
8.1.5
Vacuum Service
For vacuum service down to a pressure of 375 mmHg, Class 150 piping should be applied for all sizes.
For vacuum service in the range of 375 to 150 mmHg, Class 300 piping should be used for sizes ½” to 1-½” and Class 150 piping used for other sizes.
For vacuum service below 150 mmHg, special vacuum classes are used.
8.1.6
Hydrogen Service
Hydrogen Service shall have 7.1 kg/cm2 (g), or greater partial pressure of hydrogen. Selection of steels shall be in accordance with API RP 941.
8.1.7
Sour Service
Materials for Sour Service shall be in accordance with NACE MR0103 for refinery/petrochemical applications and NACE MR0175 (ISO 15156) for Upstream applications.
8.1.8
Caustic Soda Service
Design
Caustic soda corrosion cracking is strongly influenced by temperature. The temperature the pipe may reach in service shall therefore be established to determine the required preventive measures.
The application of cold-formed parts or cold forming shall be restricted as far as possible.
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Hot spots due to direct wall-to-wall contact with steam or electrical tracing shall be avoided by applying spacers (ceramic, glass fibre or filled phenolic resin).
Materials
8.2.1
General
Purchase Specifications
Valves, pipe, fittings, and flanges shall conform to specifications as it is referenced in specific purchase descriptions.
8.2.2
Fabrication Requirements
Instrument Air Lines
Instrument air supply lines and pneumatic instrument signal lines to the instrument and/or final control element shall be made up from tubing and double ferrule compression fittings. The minimum material requirements of air tubing, fittings, and isolation valves shall be in accordance with Appendix A1 Table A1.1 provided in AGES-PH- 04-001, Automation and Instrumentation Design Philosophy.
COMPANY shall be consulted for special applications such as ‘Fire Safe’ design requirements. The optimal arrangement shall be determined for each instrument and final control element and shown in detail on a drawing.
Specification of Field Mounted Components
For general applications, the instrument air supply lines from the header up to the isolating valve close to the air consumer shall consist of piping, terminating in a ball valve.
The instrument air supply lines from the isolating valves (close to the Air consumer) to the air consumer and pneumatic signal lines shall Consist of 10 or 6 mm OD with 1 mm wall thickness tubing and compression fittings. All components, the tubing and compression fittings, shall be suitable for use at10.2 kg/cm2 (g) at 38ºC.
The minimum material requirements for air tubing, fittings, and isolation valves shall be in accordance with Appendix A1 Table A1.1 provided in AGES-PH-04-001, Automation and Instrumentation Design Philosophy.
The instrument air lines shall be pressure tested after installation.
Each instrument and final control element requiring an air supply shall be provided with an individual air filter reducer. The types of air filter reducers shall be kept to an absolute minimum.
The maximum number of consumers that may be connected to the same ½” NPT take-off point shall be calculated, considering the minimum allowable inlet pressure of each air filter reducer and the total length of supply tubing, assuming maximum air consumption of all connected instruments. Refer to AGES-PH-04-001, Automation and Instrumentation Design Philosophy for recommended number of users and spares based on line sizes.
Air consumers, which must stay in operation after a total air supply failure shall be provided with a backup vessel and a lock-up device.
Mounting of Field Components
All components such as air filter reducers, lock-up devices, solenoid valves shall be bolted to a stainless steel mounting plate which is fixed to a support with stainless steel bolts. The mounting plates shall have facilities for installing nameplates. The nameplates shall be fixed to the plates with screws.
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Mounting plates shall not be supported from vibrating process pipes or on piping other than carbon steel. For such applications they shall be installed on separate supports and the reduced air supply lines and pneumatic signal line tubing shall then be sufficiently flexible to take the vibration.
Tubing is considered to be self-supporting up to lengths of 0.5 m. For longer lengths, the tubing shall be supported over the full length and fixed to the support at approximately 1 m intervals with cable ties.
Specification of Control Room Mounted Components
When specified by COMPANY, one or more filter/reducing station(s) shall be installed in the basement under the Control Room, or in the ancillary room when no basement is provided, for reducing the incoming air to the required pressure.
Separate filter/reducer station and air headers shall be installed for:
Processing units connected to the Instrument Air Supply which may not stay in operation during a failure
of the instrument air supply plant. Downstream pressure is 1.5 kg/cm2 (g)
Consumers requiring higher supply pressures, such as. for direct operation of depressurizing valves. With
a downstream pressure according to specification
Each filter/reducing station shall consist of at least two filters in parallel followed by two high-quality pressure reducers in parallel, one acting as standby for the other.
Each pressure reducer shall be fitted with a gauge indicating its downstream pressure. The capacity of each pressure reducer shall be such that at maximum capacity with an upstream pressure of 4.3 kg/cm2 (g) and only one reducer in operation, the specified downstream pressure is maintained.
A safety-relief valve shall be installed in the reduced air header between each reducer and the related downstream isolating valve to protect the consumers. The relief pressure setting, shall be 0.2 kg/cm2 (g) lower than the maximum allowable working pressure of the instruments supplied by the header concerned. The following shall apply:
Oversizing of pressure reducers by more than 10% of the maximum air consumption shall be avoided to
prevent instability during normal operation and to limit the size of the safety-relief valve
The exhaust port of the relief valve shall be provided with a pipe of which the outlet is located more than
2 m above floor level in a vertical direction
The air piping upstream of the reducers shall be provided with a ½” NPT female threaded connection for a pressure indicator. A ½” NPT female threaded connection shall also be provided for a low pressure alarm in the reduced air piping, downstream of the isolating valves. The low pressure alarm setting shall be 0.3 kg/cm2 (g) lower than the required reduced air pressure.
The main header shall be welded stainless steel construction with carbon steel tapped joint flanges and with stainless steel (ball type) isolating valves, installed in each branch-off to cabinets, racks or operating consoles.
The size of the air piping downstream of the reducer stations shall be based on:
Maximum air consumption of all consumers
Spare capacity of 30% for future extensions
Flexible hoses shall be applied to connect the isolating valve on the main air header to the air manifolds.
Mounting of Control Room Component
Prefabricated filter/reducer station(s) shall be mounted on a freestanding rack.
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The main reduced air header shall be installed in such a way that cable trays, exhaust and returns of air conditioning systems are not obstructed. Special attention hall be given to the supporting arrangement to prevent stresses on the flanged connections.
Protection of Components
Electronic instruments/components, such as Internet Protocol convertors, installed in the open air should be provided with a protective shade. The shade shall be installed in such a way that instruments/components can be serviced without its removal. COMPANY shall be consulted concerning the provision of such protection.
Arrangement
The air supply systems shall provide the required quantity of:
Instrument air of a quality as specified in 8.2.2.8
Service air
The system shall comprise an air supply plant, a main air supply piping system and an air supply.
Instrument Air Quality
The instrument air shall be free from oil and other liquids, and free from toxic, corrosive, flammable and obnoxious gases or vapours.
The quantity of solids shall be less than 0.1 g/m3, and the diameter of the particles shall not be more than 3 μm.
To prevent condensation in the supply piping or in the instruments, the dew point of the air at operating pressure shall always be at least 10°C lower than the lowest expected ambient temperature for the air system at any location.
Unless otherwise specified, the instrument air pressure in the air supply piping shall be as follows.
Normal pressure 7 bar (g)
Minimum pressure 5.5 bar (g)
Design pressure 10 bar (g)
Water dew point -20°C at 7.5 bar (g)
Service Air Supply
Service air is a segregated air supply system that can be applied for industrial consumers.
Instrument Air Quantity
The quantity of instrument air shall be estimated as accurately as possible, considering the requirements for:
Pneumatically operated instrumentation, based on the data stated by the MANUFACTURER of such
equipment
Pressurising electrical instruments in order to prevent an explosive gas atmosphere inside the enclosure, by maintaining an over-pressure above the surrounding atmosphere and where necessary by continuous dilution
Purging/cooling of essential instruments
The consumption thus obtained shall be multiplied by 1.3 to account for uncertainties in the data used for the estimate and to allow the installation of additional instruments during the first years of plant operation.
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8.2.3
General Specification for Instrument Impulse Lines
General
The minimum material requirements for impulse line tubing, fittings, and isolation valves shall be in accordance with Appendix A1 Table A1.1 provided in AGES-PH-04-001, Automation and Instrumentation Design Philosophy.
The instrument impulse lines shall consist of tubing and fittings, i.e., 10 mm or 12 mm OD x 1.5 mm wall thickness tubing and double compression fittings. For other applications such as drain may use 10 mm OD x 1 mm wall thickness and double ferrule compression fittings.
COMPANY approval for the materials selected shall be obtained.
Metric tubing and compression fittings (10 or 12 mm OD) shall be used. The application of imperial sized tubing and related compression fittings (3/8 inch OD) requires the approval of the COMPANY and should be restricted to locations which have standardized on imperial sizes. It shall be ensured that (cid:490)” OD tubing is not used in combination with 10 mm compression fittings because this will result in unreliable joints.
For special applications, such as corrosive or toxic duties, other materials and/or additional provisions are required.
For protection of instruments from abrasive, corrosive, solidifying mediums the following should be considered and in the following order of precedence:
Special materials
Diaphragm seals with/without purge
Seal pots with/without purge
Heat tracing
The application of sealing and purging shall be kept to a minimum.
Steam Service
Steam entering impulse lines will condense before reaching the instrument. To establish a firm reference point for the condensate level, the impulse line shall slope downwards from the instrument process connection to the instrument. Seal pot(s) with venting facilities should be provided to establish the condensate reference points.
For differential-pressure flow instruments these condensate reference points shall be at the same elevation.
Fluids with High Pour Points
Liquids which solidify at ambient temperature shall be prevented from entering the instruments and their impulse lines in order to prevent malfunctioning and/or damage.
Special attention shall also be given to those gas services where hydrates may form at low temperatures.
In such cases, a liquid seal, a diaphragm seal or heating should be applied where necessary. Those parts of impulse lines which are filled with the process fluid shall be heated.
Fluids Containing Suspended Solids
When process fluids contain suspended solids, the danger exists that these solids will settle in the impulse lines and ultimately cause a complete blockage.
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When the concentration of the suspended solids is relatively low, blockage may be prevented by having the process connection and (short) impulse lines sloping downwards to the process at an angle of approximately 45(cid:113). When the concentration of suspended solids is high, a liquid seal or purging should be applied.
Oxygen Services
All material for gaseous oxygen applications shall be kept separate from other materials and carefully degreased and inspected, per ASTM G93/G93M.
Low-Temperature Services
Process liquids in plants operating at temperatures below ambient and which are close to their vapor pressure, will evaporate on entering the impulse lines which are normally at ambient temperature, before reaching the instruments. The vapours so formed will push the liquid back towards the process until an equilibrium is established.
This self-purging normally occurs in all cryogenic processes operating at -100°C to -170°C. In other processes operating below ambient temperature, such as Liquefied Petroleum Gases, heating shall be considered to assist self-purging.
Corrosive Services
For applications where 317L SS is not suitable with respect to general corrosion, other materials such as monel, hastelloy, tantalum, titanium, etc., can be applied for the various components of the impulse lines, selected to suit the application in the same way as the process piping, using the piping classes. These components may be very costly and at a later stage may inadvertently be interchanged with unsuitable stainless steel components. Therefore, for these applications, alternative installations (purging or a liquid seal) or the use of alternative (in-line) instruments shall be considered.
Approval from COMPANY shall be obtained for the selected option.
Toxic Services
A toxic fluid service in which exposure to very small quantities of the fluid in the environment can produce serious irreversible harm to persons upon breathing or bodily contact, even when prompt restorative measures are taken. For such services, the manifold valves (isolate/equalise and isolate/vent) shall be provided with an interlocking system.
All vents from manifolds for toxic/noxious services shall be connected to the (low-pressure) flare, and all drains to a drain vessel or covered pit which is allocated for toxic products and for which adequate disposal should be arranged.
The required length of tubing for the vent and drain lines, shall be added on the relevant Instrument Installation Detail drawing.
Where flushing and neutralising the instrument and the manifold block is necessary before the instrument is disconnected, the instrument or the pressure manifold shall be provided with filling/flushing connectors, such as a non-return valve with a compression fitting end.
A compatible material based compression-type plug, secured by a bead-type chain to the non-return valve, shall be fitted to plug-off the compression fitting end when not in use.
A flexible metal hose provided with a compression fitting should be used to flush the instrument body and manifold.
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Sour Environment
When the service is sour (as defined in NACE MR0103) all impulse line components shall comply with the requirement of NACE MR0103.
When impulse line components and/or parts thereof cannot be obtained in accordance with NACE MR0103 (such as the rolled thread of some male compression fittings) COMPANY shall be consulted.
The male and female threads shall be provided with a sealing material which will withstand a temperature of 538° C.
The front ferrules of compression fittings are the second or third sealing in the fitting and, since they need to have higher hardness in order to function properly, they may be exempted from the hardness limitations of NACE MR0103.
The impulse line tubing thickness for required pressure and temperature rating shall be determined based on material grade and wall thickness calculated as per ASME B31.3 standard.
Based on the specifications given and the additional requirements for sealing, purging and instrument protection given, the best arrangement for each instrument shall be determined and shown in detail on a drawing.
8.2.4
Mounting of Instruments
Mounting of instruments shall be in accordance with Instrument Installation Design Specification.
8.2.5
Thread Compound
Thread compound requirements shall be in accordance with AGES-SP-09-001, Piping Design Basis.
8.2.6 Weld-Neck Flanges
Weld-neck flanges shall be in accordance with AGES-SP-09-001, Piping Design Basis.
8.2.7
Lap Joint Stub Ends
Lap joint stub ends shall be in accordance with AGES-SP-09-001, Piping Design Basis.
8.2.8
Bolting
For bolting refer to Bolt Torquing/Tensioning Procedure for flanged connections in AGES-SP-09-001, Piping Design Basis.
8.2.9
Flange Finish
Flange finish shall be in accordance with AGES-SP-09-001, Piping Design Basis.
8.2.10
Item Descriptions
The item descriptions shown in the individual Material Classes are abbreviated and shall not be used for purchase.
8.2.11 Purchase Description
Purchase descriptions shall be developed by the CONTRACTOR to fully identify the item type, size, material, pressure rating or any other unique features.
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8.2.12 Materials not in Specification
Components not listed in the individual line classes of this specification shall be considered out-of-specification components and shall, in general, be identified as specialty in the purchase description.
8.2.13 Pipe Bends
Where applicable bends may be used in place of fittings, refer to Piping Flexibility Analysis Specification.
8.2.14 Tube Bends
Use minimum tube bend radius in place of fittings wherever possible. Bends shall be made with a hand or production type bender. Minimum tube bend radius is as follows:
6 mm OD tubing, 14 mm radius
10 mm OD tubing, 24 mm radius
12 mm OD tubing, 38 mm radius
20 mm OD tubing, 45 mm radius
Where Imperial tube size is specified and approved by COMPANY for the purpose of standardization with existing facilities, the following bend radius shall be used.
¼” OD tubing, 9/16” radius
½” OD tubing, 1-1/2” radius
3/8” OD tubing, 15/16” radius
¾” OD tubing, 1-3/4” radius
8.2.15 Seal Welding
Seal welding is not applicable due to the restriction of threaded connections in process piping. Threaded instrument connections are allowed only downstream of a piping root valve and shall not be seal welded.
ADDITIONAL SPECIFIC REQUIREMENTS
Not applicable
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SECTION C – OTHER REQUIREMENTS
DETAILS OF SCOPE
Detailed engineering and design of instrumentation installation and piping classes in accordance with this specification and all specifications, standards, datasheets, and other statements of requirement included with or referenced in the CONTRACTOR’s scope of work.
The CONTRACTOR shall have single point responsibility for all aspects of the works, inclusive of all components sub-contracted or purchased from other parties. These shall include, but not be limited to:
Prepare installation design drawings, hook-up drawings, etc. for installation of the system equipment and instrumentation.
Supply all types of bulk installation materials, storage facility (air-conditioned where required), temporary construction materials, special tools, supports, accessories, consumables, paint, etc. and other items not exclusively identified in this specification but required for completing the installation. All supplied materials shall be submitted for COMPANY review and approval.
Provide storage and protection requirements for system equipment and instrumentation in accordance with manufacturer’s recommendation for the duration from receipt till its installed.
Unpack, inspect, transport, and install the system equipment and instrumentation supplied including free issued items as part of others scope in accordance with COMPANY approved drawings and specifications.
Supply fully qualified and competent tradesmen skilled in the field of work engaged to perform activities required for installation.
Engage the services of a specialist sub-CONTRACTOR, sub-SUPPLIER, System Integrator / System SUPPLIER to ensure system equipment/instrumentation is correctly installed and guarantees maintained.
Engage SUPPLIER specialists for performing any modifications related to system equipment / instrumentation.
Coordinate with COMPANY regarding Work safety, Permit to Work, Work method statement approval, seek clarification / response to technical & interface queries, obtain information related to existing facilities, inspection of existing facilities, identification of cable routes, etc.
Follow manufacturer’s recommendation for control systems and instrumentation with regards to storage and protection, unpacking, transportation, and installation supervision.
Coordinate with inter-disciplines, other CONTRACTORS, SUPPLIERs, MANUFACTURERs, etc. to check, and verify their documentation to eliminate conflicts prior to installation.
Prepare as-built documentation and submission to COMPANY.
Replace any damaged items that have suffered damage or deterioration as the result of improper protection and handling without any additional cost.
CONTRACTOR shall be fully responsible to provide all resources and materials that are not explicitly identified but required for the installation under their scope.
QUALITY CONTROL AND ASSURANCE
CONTRACTOR’s quality management systems shall comply with all the requirements of ISO 9001 - Quality Management Systems – Requirements and ISO 9004 - Quality Management — Quality of an Organization —
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Guidance to Achieve Sustained Success. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design.
The quality management system shall be implemented in accordance with the CONTRACTOR’s Quality Manual and the Project Quality Plan, which shall both together with all related / referenced procedures, be submitted to COMPANY for review, comment, and approval.
CONTRACTOR shall have in effect at all times, a QA/QC program, which clearly establishes the authority and responsibility of those responsible for the quality management system. Persons performing quality functions shall have sufficient and well-defined authority to enforce quality requirements that initiate, identify, recommend, and provide solutions to quality problems and verify the effectiveness of the corrective action.
CONTRACTOR shall identify in purchase documents to its SUB-CONTRACTORs / SUPPLIERs all applicable QA/QC requirements imposed by the COMPANY and shall ensure compliance. On request, CONTRACTOR shall provide objective evidence of its QA/QC surveillance of its SUB-CONTRACTORs / SUPPLIERs activities. If selected SUB-CONTRACTORs / SUPPLIERs have ISO 9001 certification, as required for contracted scope, then copies of these certifications are to be provided for COMPANY review. The COMPANY may elect to waive their audits in favour of ISO 9001 registrar audits. Any contracted services without ISO 9001 certification will be subject to COMPANY audit requirements.
SUPPLIER’s specialist Engineer/Representative shall be engaged by CONTRACTOR for System Equipment and special instrumentation at site during site installation to ensure QA/QC of the installation.
COMPANY reserves the right to inspect materials and workmanship standards at all stages of installation.
Installation materials shall only be purchased from SUPPLIERs approved by COMPANY Category Management. This approval indicates that the SUPPLIER has an approved Quality management system and a proven track record in supply of materials.
SUB-CONTRACTORS, SUB-SUPPLERS
All subcontracted services and hardware materials shall be approved in writing by COMPANY. The term services include all installation design, fabrication, assembly and installation.
CONTRACTOR shall assume responsibility and overall guarantee for all supply and services provided by SUB- CONTRACTOR/SUB-SUPPLIER.
The CONTRACTOR shall transmit all relevant Purchase Order documents including specifications to his SUB- CONTRACTORS.
It is the CONTRACTOR’s responsibility to enforce all Purchase Order and Specification requirements on his SUB- CONTRACTORS / SUB-SUPPLIERs.
CONTRACTOR shall submit all relevant SUB-CONTRACTOR’s / SUB-SUPPLIER’s drawings and engineering data to the COMPANY.
CONTRACTOR shall obtain necessary warranties from SUB-CONTRACTORS/ SUB-SUPPLIERS.
CERTIFICATION
Certification requirements shall be in accordance with AGES-PH-04-001, Automation and Instrumentation Design Philosophy.
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INSPECTION AND TESTING REQUIREMENTS
Inspection and testing requirements shall be in accordance with AGES-PH-04-001, Automation and Instrumentation Design Philosophy.
SPARE PARTS, CONSUMABLES AND SPECIAL TOOLS
Not applicable.
PAINTING, PRESERVATION AND SHIPMENT
Painting and Coating Specification AGES-SP-07-004 to be complied for instrument supports and applicable requirements.
INSTALLATION, COMMISSIONING AND MAINTENANCE SUPPORT
Not applicable.
TRAINING
Not applicable.
DOCUMENTATION / MANUFACTURER DATA RECORDS
CONTRACTOR shall submit all drawings and documentation required for the instrument installation design for COMPANY review and approval.
Comments made by COMPANY on drawing / document submittal shall not relieve CONTRACTOR of any responsibility in meeting the requirements of this specification and referenced specifications. Such comments shall not be construed as permission to deviate from requirements of the Project Specifications unless specific and mutual agreement is reached and confirmed in writing.
All drawings, documents, information, correspondence and like items shall be in the English language and metric Units.
All documents and drawings issued by the CONTRACTOR shall be produced in an electronic format compatible with Microsoft Office computer software. Documentation shall also be provided in Native format, in order to allow COMPANY to update during operational upgrade and future projects. CONTRACTOR shall provide final documentation on DVD-ROM with search and retrieval capabilities.
All drawings shall be prepared and submitted in accordance with recognised standards. Every effort shall be made to minimise the total number of drawings prepared by use of common drawings, where practicable without loss of clarity.
Before Site Acceptance Test, CONTRACTOR shall issue As-Built drawings incorporating all changes that have taken place during installation, testing and commissioning at site. Each drawing shall be clearly marked ‘As-Built’ and dated.
The below list of documents required is intended to define the minimum technical documents to be provided by the CONTRACTOR. This list is not exhaustive and additional documentation necessary for the work execution shall be provided by the CONTRACTOR. Documentation to be supplied by CONTRACTOR shall include, but not be limited to:
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Piping Layout/Isometric Drawings
Hook-up Drawings
Instrument Location Plans
General Layout Drawings
Instrument Mounting/Piping Details
Cable Schedules
Interconnection Diagrams
Instrument Loop Diagrams
Quality Manuals
Manufacturing Data Records (MDR) Book
All drawings, lists, datasheets etc. shall be submitted in native format.
GUARANTEES AND WARRANTY
CONTRACTOR shall provide warranty support for a period of two (2) years, commencing on the date of the PAC following the site acceptance test. Warranty shall apply to defective material workmanship and installation design, and/or materials. Warranty work shall be done at COMPANY local facilities. The cost of diagnostics and/or correction of any warranty items shall be borne by the CONTRACTOR. Software programming shall be in English and program shall not be KNOW-HOW protected.
CONTRACTOR will not be required to provide resident maintenance personnel during the warranty period but shall have competent skilled/technical personnel available from their local facility within 24 hours, if so, required by COMPANY.
PROJECT ADMINISTRATION
Project Personnel
CONTRACTOR shall insure that sufficient qualified personnel are at all times allocated to the project. The CONTRACTOR shall utilise a project team structure to achieve continuity and accuracy of installation. The CONTRACTOR shall submit for COMPANY approval the résumés of all lead / key personnel engaged in the project.
The CONTRACTOR, their staff including SUB-CONTRACTOR personnel shall sign and agree to Acceptable usage and confidentiality agreements and follow applicable COMPANY policies, procedures and standards.
The CONTRACTOR shall conduct security-related background checks on all personnel before they are assigned to the project.
It is anticipated that the project team shall comprise at least the following disciplines:
Project Manager (Commercial/Technical) (shall be nominated representative of the CONTRACTOR with responsibility and authority to fully implement the project with technical correctness, on schedule and within the budget).
Site Engineer
Site Supervisor
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Skilled Workmen
Project Schedule
The CONTRACTOR shall include with his quotation, a detailed Project Schedule showing the best estimate of the achievable major schedule milestones.
The Project schedule shall be used as the main progress control document during the installation phase of the project. The Project Schedule shall clearly show any ‘float’ or ‘slack’ time available together with any freeze dates required by the CONTRACTOR and major milestones for system equipment delivery and installation.
Progress Reporting
The Project Schedule shall be used as the basis for monthly progress reporting, schedule controlling and schedule forecasting. At regular intervals, the CONTRACTOR shall revise the Project Schedule to include the effect of changes and to reflect actual Project Progress.
Coordination Meetings
Coordination meetings shall be held as required between COMPANY, CONTRACTOR(s) and SUB- CONTRACTOR(s).
The agenda for each coordination meeting will be prepared by the CONTRACTOR prior to each meeting. Detailed meeting minutes will be taken by the CONTRACTOR and submitted to COMPANY for approval. An ‘action item’ log shall be prepared and continuously updated by the CONTRACTOR.
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SECTION D – STANDARD DRAWINGS & DATASHEETS
DATASHEET TEMPLATES
Not Applicable
STANDARD DRAWINGS
Not Applicable
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SECTION E - APPENDICES
LIST OF TYPICAL HOOK-UP DIAGRAMS
NOTE: This is a preliminary list which be shall developed by CONTRACTOR based on instruments selected and approved by COMPANY for each project. Each operating entity shall utilise their own hook-up drawings till this is developed, without any conflicts to project specifications and standards.
S. No.
Description
GENERAL
001
002
003
Cover Sheet
Revision Index
General Notes
PROCESS HOOK-UP DRAWINGS
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
Flow Transmitter - Liquid Service
Flow Transmitter - Gas Service
Flow Transmitter - Steam Service
Flow Orifice Plate
Pitot Tube - Retrieval Type
Level Transmitter - DP
Level Transmitter - Remote Seal
Level Transmitter - Displacer
Level Gauge – Magnetic
Level Transmitter - Radar Type - Top Mounted
Pressure Gauge - Liquid Service
Pressure Gauge - Gas Service
Pressure Gauge - Steam Service
Pressure Transmitter - Liquid Service
Pressure Transmitter - Gas Service
Pressure Transmitter - Steam Service
Differential Pressure Gauge - Liquid Service
Differential Pressure Gauge - Gas Service
Differential Pressure Gauge - Steam Service
Differential Pressure Transmitter - Liquid Service
Differential Pressure Transmitter - Liquid Service - Lethal Service
Differential Pressure Transmitter - Gas Service
Differential Pressure Transmitter - Gas Service - Lethal Service
Differential Pressure Transmitter - Steam Service
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S. No.
Description
028
029
030
031
032
033
034
035
036
037
038
039
Steam Tracing - Single Line
Steam Tracing - Double Line
Thermowell
Temperature Elements
Temperature Gauge
V-CONE Meter – DP Type Flow Meter (Liquid Service)
V-CONE Meter – DP Type Flow Meter (Gas Service)
Venturi Meter – DP Type Flow Meter (Liquid Service)
Venturi Meter – DP Type Flow Meter (Gas Service)
DP Type (Orifice) Flow Meter – Pipe Taps (Liquid Service)
Automatic Grab Sampler
Analyzer Fast Loop Hook-up
PNEUMATIC / HYDRAULIC HOOK-UP DRAWINGS
040
041
042
043
044
045
046
047
048
049
050
Control Valve - Pneumatic Connection
Shutdown Valve - Pneumatic Connection
Pressure Pilot
Shut Down Valve - Hydraulic Connection
Choke Valve
Wing Valve
Surface Safety Valve
Down Hole Safety Valve
MSAS Valve for GL Wells – Hydraulic Hook-up
Fusible Plug
Panic Push Button
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LIST OF TYPICAL INSTRUMENTATION INSTALLATION DETAILS
NOTE: This is a preliminary list which be shall developed by CONTRACTOR. Each operating entity shall utilise their own installation drawings till this is developed, without any conflicts to project specifications and standards.
S. No.
Description
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
Cover Sheet
Revision Index
General Notes
Mounting Support-Single Instrument (For Grating and Steel Platforms)
Mounting Support-Single Instrument (For Concrete Floor/Paved Area)
Mounting Support-Double Instrument (For Concrete Floor/Paved Area)
Mounting Support-Single Instrument (For Unpaved Area)
Mounting Support-Double Instrument (For Unpaved Area)
Mounting Support-Double Instrument (On Existing Structure)
Mac Mounted on Steelwork
UV-Heat-Gas & Smoke Detectors and Audible Alarm (Mounted On Steel Work)
Smoke Detector or LED mounted in False Ceiling
UV/Smoke/Heat and Gas Detector mounted on Wall or Ceiling
Gas Detector mounted in Duct
Single Instrument Support with Sunshade
Junction Box Mounting-Frame Detail
Mounting Detail for Instrument JB (Column/Structure)
Mounting Detail for Instrument JB Skid Mounted/Package Interface
Cable Tray mounting Support
Typical Cable Installation Detail (Paved Area
Typical Cable Installation Detail (Unpaved Area)
Vertical Cable Ducting Arrangement
Typical Fire Stopping and Sealing For Instrument Cable Through Wall
Trench & Cable Route Marker
Cable Route Marker Post
Trench Details in Paved Areas
Concrete Trench Installation Details
Trench Details-Road Crossing Duct Bank
Instrument Earthing (IS)
Instrument Earthing (Non-IS)
Typical Instrument Earthing (IS/Non-IS) Onshore/Offshore Application
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TYPICAL DIRECT BURIED CABLE INSTALLATION DETAIL
Below is a typical installation detail which shall be further developed in accordance with project requirements.
600mm
min.
750mm
min.
Notes:
For buried cables, detectable warning marker tape of Green or Blue coloured PVC as approved by COMPANY, 150 mm wide, with black letters shall be supplied and installed above tiles. The warning label such as ‘SIGNAL CABLE BELOW’ or “INSTRUMENT CABLE BELOW”, etc) shall be indicated in English and Arabic language. Warning Label shall be agreed with COMPANY based on type of instrument & telecom cables buried. RED and YELLOW colours are reserved for the warning tapes of buried HV, LV electrical cables and hence these colours shall not be used for the warning tapes of instrumentation and telecom cables.
Cable protection tiles made of pre-cast, red coloured concrete, 150mm wide, 300mm long, 50mm thick (min.) on top of the buried cables shall also be supplied and installed. Sand used for backfilling shall be clean and free of stones.
The Instrument “signal cables” are allowed to be installed in 3 rows (3 layers). When approved by COMPANY for reasons, instrument “signal cables” can be laid in maximum of 5 rows (that is., up to 5 layers). For Power cables (30V and above for DC and 50V and above for AC) installation, Electrical System Design requirement shall be followed considering cable derating factor. Please refer to AGES-GL-02- 001 -Electrical Engineering Design Guide and its referred guidelines and international standards for more details.
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Project: Q-32859 - NMDC - Ruwais Folder: RFQ Files