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INSTRUMENTATION SPECIFICATION
SECTION-VI
SECTION-VI
INSTRUMENT ERECTION,
INSTALLATION & COMMISSIONING
SPECIFICATIONS
Page 1 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
INDEX
SR.
NO.
1
2
3
4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
7
8
8.1
8.2
8.3
8.4
8.5
9
10
11
12
13
TOPIC
SCOPE
RESPONSIBILITIES
REGULATIONS
GENERAL
INSTRUMENT MECHANICAL INSTALLATION
REQUIREMENT
INSTRUMENT MOUNTING
INSTRUMENT PROTECTION
INSTRUMENT CONNECTIONS TO PIPING AND VESSELS
INSTRUMENT PROCESS PIPING AND TUBING
INSTRUMENT AIR PIPING AND PNEUMATIC
TRANSMISSION
INSTRUMENT TAGGING
INSTRUMENT ELECTRICAL INSTALLATION
REQUIREMENT
INSTRUMENT WIRING SYSTEM INSTALLATION
CABLE ROUTES
INSTRUMENTATION E&C SPECIFICAITONS
INSTRUMENT
INSTALLATION,
COMMISSIONING
SCHEDULE
OBLIGATION OF IEC
GENERAL CONDITIONS
STANDARDS
WORKMENSHIP, TIDYNESS, SAFETY
SCOPE OF WORK OF BIDDERS IEC
PAINTING
IDENTIFACTION OF INSTRUMENTS
TESTING OF INSTRUMENTS
LOOP CHECKING/COMMISSIONING
SUPPLY OF MATERIAL
PAGE
3
3
3
4
4
5
5
5
7
7
7
7
14
18
18
19
19
20
21
24
24
25
27
28
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
1.
1.1
1.2
2.0
SCOPE
This specification gives directives for the design, selection
methods, instructions and examples of instrument installation,
and commissioning scope of work for the entire PAC project.
This specification shall be read in conjunction with the
specification specified and individual instruments specifications
other parts of this ITB document.
criteria,
erection
general
given in
RESPONSIBILITIES
Any conflict between the requirements of this specification and related
codes, standards, data sheets, drawings, requisition, etc., shall be
referred to the OWNER for clarification and most stringent method shall
be followed by BIDDER
3.0
REGULATIONS
3.1
GENERAL
3.1.1
3.1.2
3.2
-IEC 60757
-IEC 60584-3
Page 3 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
-IEC 61000
-IBR
:Electromagnetic Compatibility
:Indian Boiler Regulations
IS Indian Standard
-IS 1554 Part 1
-IS 2148
4.0
GENERAL
This instrument design specification provides the basis of design for
instrument drawings and documents, instrument subcontracts and
instrument installation material requisitions along with erection and
installation specifications. Project requirements that differ from this
specification will be submitted as exceptions with requisitions and
subcontracts by BIDDER.
5.0
5.1
INSTRUMENT MOUNTING
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.1.11
5.1.12
5.1.13
5.1.14
5.1.15
5.1.16
5.1.17
5.1.18
5.1.19
5.1.20
5.1.21
5.1.22
5.1.23
Instrument shall be installed in accordance with the appropriate hookup diagrams or as per the manufacturers recommendations,
wherever hook diagrams are not available. The IEC is not permitted
to deviate from these diagrams with prior written approval from
engineer-in-charge. Instruments, JBs, analyzer panels shall be
installed strictly as per the installation drawings provided for the
projects.
All cable entries to instruments shall be preferably from bottom. If
bottom entry is not possible due to any reason, the cable entry shall
be from side.
The instrument already mounted on the equipment shall be removed
by the IEC for the calibration check and re-fix back.
All instruments shall be mounted as close as possible to the process
connection provided. Maintenance and accessibility requirements are to
be taken into account. The length of the impulse line shall be minimal.
The location of instruments shall be such that direct drainage of
condensate, water or process fluids from adjacent equipment has no
adverse effect on surrounding equipments, instruments or human beings.
All instruments shall be accessible either from ground or from a
permanent finished floor and/or permanent platforms.
Instruments shall be mounted on a vibration free place. Special care shall
be taken for heat expansion.
Local converters, amplifiers, switches, etc., shall be installed near the
corresponding instrument.
Local indicating instruments shall be readable from where the related
equipment is operated or from where the primary instruments are to be
tested or calibrated.
Pressure gauges shall be preferably installed direct mounted. Offline
installation shall be preferred when the direct readout is not possible or
instrument is subjected to high vibrations. In all such cases, all PG shall
be mounted with 2 pipe stanchion and required tubing/supports.
Instruments shall not be direct mounted on handrails. No support of
instrument stanchions, cable tray, etc. shall be taken from any type of
handrails.
Plates welded to structures, yokes and similar support arrangements shall
be used for mounting of off-line instruments/stanchions. Instrument
supports attached to process piping or vessels shall not be allowed. Apart
from mandatory in-line instruments, no direct mount instruments are
acceptable, except RADAR type Level transmitters installed from tank top
nozzles, level switches installed from top of the thanks.
On prefabricated skids, modules or packages, instrument cabling and/or
tubing leaving or entering the unit, as well junction boxes, bulkheads or
panel plates, shall terminate at a central location near the edge. All cables
shall be protected in closed tray of FRP MOC tray/cover. The closed
cable trays are minimum requirement of all cables within any skid.
All instrument supports, cable ladders/trays, conduits and other iron
supporting materials shall be hot dip galvanized and painted as per
specifications given in this chapter.
Page 5 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.1.24
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.3
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4
5.4.1
5.4.2
5.4.3
5.4.4
Manifold Type
-Block/Equalizing/Drain/Vent(3-valve
manifold)
Pressure Block/Drain/Vent
-2-valve manifold
Differential pressure Block/Drain/Vent -(3-valve manifold)
Position of transmitters (based on API RP 551):
Phase
Liquid
Gas
Vapor
Steam
5.4.5
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
5.4.12
5.4.13
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.4.14
5.4.15
5.4.16
5.4.17
5.5
of up to one week, adhesive tape may be used, for a longer period caps
or plugs shall be used.
Where instrument tubing is run parallel to each other, joints should be
systematically staggered and neatly offset. There must be at least two
pipes / tubes diameter space between adjacent joints.
Threaded fittings will have their threads specified in the purchasers
documentation. All threaded joints shall have Teflon tap as sealing
medium.
Where compression fittings are used, the fittings shall be installed in strict
accordance with the manufacturers recommendation.
The number of joints in the tubing shall be kept to a minimum consistent
with good practice and also to keep the wastage to the minimum.
5.5.1
5.5.2
NUMBER OF USERS
1-5 users *
6-12 users *
13-20 users *
21-50 users *
* In case off large air consumers (on/off valves etc.) air consumption must
be calculated and number of users shall be adjusted.
5.5.3
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.5.10
5.5.11
5.5.12
5.5.13
5.6
6.0
6.1
6.1.1
Cabling
6.1.1.1
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
6.1.1.2
6.1.1.3
6.1.1.4
6.1.1.5
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
h. Junction Boxes shall be preferably installed at ground level. Material
shall be FRP. Junction box segregation philosophy shall be used for
various category of I/O as under
- Analog Input/ Analog Output ( 4-20 ma)
- Digital Input (0-24 V DC)
- Digital Output ( 0-24 V DC, lamps)
- Digital Output ( 110 V AC for Solenoid valves)
- Power distribution ( 110 V AC)
Separate junction boxes shall be provided for control and interlock
category of signals, which are destined for ESD or DCS marshalling
cabinets. Intrinsic safe and flameproof instrument signals shall be
mounted in separate junction boxes. All junction boxes shall have WAGO
make, screw less, side entry, DIN rail mounted terminals with 0.5 to 4.0
sqmm size.
6.1.1.6
6.1.1.7
6.1.1.8
6.1.1.9
Color of terminals shall be grey for non-Exi signals, color blue for Exi
signals. Each junction box shall be tagged by means of a screwed SS tag
plates with tag number engraved on it.
The scope shall include the IR test before and after laying the cables,
for all multi pair cables, IR test for single pair cable before laying,
installation, glanding and termination of cables using cable glands at
both the ends for all single and multi pair cables, grounding of junction
boxes & cable glands, supply of bootlace lugs, continuous ferrule
sleeves, insulation tapes, Teflon tapes, etc., laying of cables on trays,
dressing, clamping, supporting, continuity checking, meager testing
and all related activities.
IEC will supply all the consumable items & accessories for the
grounding of junction boxes & cable glands and other items shall also
be included in the scope of supply of IEC like insulation tape, Teflon
tape, Teflon paste, silicon rubber paste, bootlace ferrules, lugs,
earthing/shielding cable sleeves, of all types/size, etc.
The IEC must ensure that whenever an electrical specification is
issued the appropriate sections shall be read in conjunction with these
specifications and any omission or ambiguities should be resolved
with the OWNERs engineer-in-charge.
The cable installation drawings and documentations provided by the
engineer will normally specify or incorporate regulations for the
electrical noise pick up. However following general rules apply,
a.
Parallel runs of the instrument cables and power cables
should be avoided where parallel runs must be made cable
spacing specified in this ITB documentation must be
maintained.
b.
Where instrument and power cable cross in close proximity
the cross shall be made at right angle.
c.
Multi core / multi pair cables shall be cut after the exact site
measurements are taken between ends the cable drum
schedule shall be followed before cutting the length to avoid
Page 12 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
6.1.1.10
6.1.1.11
6.1.1.12
6.1.1.13
6.1.1.14
Page 13 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
6.1.1.15
6.1.1.16
The cable laid on the cable tray shall be properly dressed in such a
manner that the crossing of cables shall be minimized and only one
tier/layer of cables in one tray is permitted (of any size). The cable on
the cable tray shall be clamped with THICK PVC straps at every 0.5
mtrs in vertical trays/ducts & 1 mtrs in the horizontal cable tray.
6.1.1.17
6.1.1.18
6.1.2
Types of Cable
The number of types of cable shall be restricted to a minimum. The
broad, general specifications shall be as per Volume-3, Section-9,
Chapter-II.
6.1.3
Cable Glands
6.1.3.1
Cable glands shall suit the selected instrument cable and shall be suitable
for the area classification concerned, standard Ex-d IIC/T6 and
weatherproof to IP65 as a minimum with PVC hood for all flameproof
instruments and weatherproof to IP65 for all intrinsically safe instruments.
The thread of cable gland shall be ISO metric in accordance with BS
3643/IEC 60423 and with the applicable classified area concerned. The
size shall be in general NPT for various branch cables on JB and
instrument side and 1 or 1 NPT for various multi pair cables,
unless otherwise specified
All the field Cable glands shall be made of Stainless Steel (SS304) and
double compression type only. The cable glands to be used inside central
cabinet room and various panels shall be anodized aluminum MOC and
shall be with check nuts. Other specifications shall remain same for
indoor cable glands.
6.1.3.2
6.1.3.3
6.2
CABLE ROUTES
6.2.1
General
6.2.1.1
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
Inside the cabinet room, engineering room and control room, cables shall
be laid in perforated FRP cable trays below the false flooring. The depth
of false flooring shall be minimum 800 mm. The cable entry for all panels
shall be from bottom only.
6.2.1.2
6.2.1.3
6.2.1.4
6.2.1.5
6.2.1.6
6.2.1.7
6.2.1.8
6.2.1.9
6.2.1.10
6.2.1.11
6.2.1.12
6.2.1.13
6.2.1.14
Page 15 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
Grouping of various Low Voltage Instrument cables:
- Electronic signals (4-20mA), including various field bus trunk and spur
cables, Low Voltage switching (24V DC) for Proximity Switches (EEx-i),
Proximitor (Vibration, Key-phasor, etc.) (EEx-i), Bearing Temp.(EEx-i), 24
V DC Solenoid signals and 24Vdc power supply cables, fire and gas
signals.
Grouping of various High Voltage Instrument cables:
- Other cables like 110 V AC Solenoid valves, PA system signal and
power cables, Telephone - intercom communication cable, Fiber Optic
Cables, 110 V AC supply cables, 230 V AC Utility cable, any other cable
carrying 50 V AC or higher voltage and 30 V DC or higher voltage, etc.
6.2.1.15
6.2.1.16
All the cable exchange between the central cabinet room and field
instrumentations shall be from any one side of the cabinet room through
MCT blocks of Roxtec - Sweden make only with 50% spare MCT blocks
of each category/size of cables.
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
Note 1:
No.
Category
Susceptibility Signals
II
III
Instrumentation
signal cable
Sensitive
Instrumentation
signal cable
Sensitive
relay
Medium
Susceptibility
relay control
Susceptibility
Power
Power
voltage power
Power
IV
When separate trays are Impractical, Category number I and II may be combined, provided the
category and groups are separated by a separation shield. When category numbers I and II run
side by side in tray for more than 1500 mm a minimum distance of 150 mm is recommended.
Note 2:
Category No. III & IV may run in same cable tray provided categories are separated by a
separation shield or the distance between two categories has a minimum of 150mm
Page 17 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
Category No
II
III
IV
Note 1
150
700
700
II
Note 1
150
450
700
III
150
150
Note 2
300
IV
700
450
Note 2
700
700
300
7.0
8.1
8.1.1
8.1.2
8.1.3
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
8.1.10
8.1.11
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.3
Page 19 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
8.4
The IEC shall carry out the work in accordance with the documents
/standards /drawings listed herein, and in accordance with any local
Statutory Regulations, OWNERs safety and environment policy,
clients requirements and supplementary documentation.
The IEC shall instruct his staff. Skilled and semi-skilled, in the
standards required by the purchaser and shall ensure that only
competent persons are allowed to handle or work on instruments or
instrument systems.
All tools and tackles including welding sets, gas-cutting sets required
for carrying out the work uninterrupted shall be provided by the IEC.
Tools and tackles shall be as per Appendix VII(as a minimum) of an
approved type. IEC shall furnish details of all calibration equipment,
their makes, model, calibration certificate etc. to OWNER before
commencement of work. Any instrument without proper and valid
calibration certificate from a recognized/ certifying agency like
ISO9001, NABL accreditation / approval, etc. will not be allowed to be
used.
The IEC shall arrange for the necessary staff, tools and tackles as
and when required for meeting the project schedule in consultation
with engineer-in-charge.
The working hours, holidays, weekly off etc., shall be followed as per
OWNERs rules/ regulations. However, if required IEC shall arrange
their personnel to work extra after office hours and / or in shifts and on
holidays to meet project completion schedule with the prior permission
of OWNER / BIDDER site In charge.
The IEC shall be responsible for all arrangements with respect to
workmens compensation, insurance, food, travel, accommodation
and any other local regulations covering the labor employed by him.
All rules & regulations pertaining to the ISO 14001 certification shall
be followed by IEC skilled/ semiskilled workman. IEC shall follow the
guidelines given by G.N.F.C. site in charge regarding ISO 14001 and
safety rules observed by OWNER.
WORKMANSHIP, TIDINESS AND SAFETY
Page 20 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
8.4.9
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
The IEC shall not allow rubbish and scrap material from his operation
to lay above the site. Such rubbish and scrap shall be collected daily
and be deposited at a place approved by the engineer in charge.
The IEC shall be responsible for protecting installed equipment from
damage and pilferage, and shall ensure that all covers, caps, screws
and weather protections etc. are replaced at the end of each working
day.
Only the best construction and engineering practices are to be used,
and all work must be done to the satisfaction of OWNER engineer
who should be consulted on any point requiring clarification. The IEC
is free to suggest to OWNER engineer alternative methods for the
execution of the work where this would result in improvement.
The IEC shall take adequate precautions during use and storage of
gas cylinders.
The IEC shall use, ELCB, with each power supply board required for
the installation work.
Upon completion of the work, the IEC shall promptly remove his
equipment and return to the relevant places and shall return any
unused material supplied by the engineer-in-charge. Finally the IEC
must clear the site of all rubbish and scrap deposited by him to the
satisfaction of the engineer-in-charge.
The engineer-in-charge will with due reference to the relevant section
of the conditions of the ITB lay down the safety regulations for the site
and IEC shall ensure all his personals understand and comply with
this regulations. IEC shall make sure that manpower deployed at
OWNER site for this job shall be issued Safety Helmet , Safety shoes
, safety goggles and any other PPE as instructed by OWNER. For
working at height IEC shall provide safety belts , ledders , proper
approach , scaffolding etc at its own cost.
The IEC shall prepare a comprehensive schedule for carrying out the
installation before commencement of actual work.
The IEC shall arrange for the necessary staff as and when required
for keeping to the schedule in consultation with OWNER.
SCOPE OF WORK AND RESPONSIBILITY
The instrumentation erection work covers various jobs listed under the
various schedules. However to ensure proper execution and
completeness of the instrumentation work any or all of the following
shall also form the part of the scope and shall be covered in the
quoted rates.
Fabrication of pipe nipples, including threading wherever required.
Fabrication of seal pot/siphon/drain pot as per standards. Filling of
seal pots with filling liquids as per instructions from engineer-incharge.
Back/seal welding of screwed fittings as required.
Laying of cable underground wherever required including excavation,
sand filling, brick laying and back filling.
Page 21 of 29
PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.6
8.5.7
8.5.8
8.5.9
8.5.10
8.5.11
8.5.12
8.5.13
8.5.14
8.5.15
8.5.16
8.5.17
8.5.18
8.5.19
8.5.20
8.5.21
8.5.22
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.23
8.5.24
8.5.25
8.5.26
8.5.27
8.5.28
8.5.29
8.5.30
8.5.31
8.5.32
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PAC PROJECT
INSTRUMENTATION SPECIFICATION
SECTION-VI
8.5.33
9.0
10.1
10.2
10.3
10.4
10.5
10.6
DFT
Finish coat
Type
DFT
The paints shall be confirm to the specifications given above & first class quality in
their products range of any of the following manufactures
1)
Asian Paints
2)
Bombay Paints
3)
British Paints
4)
Johnson & Nicholson
5)
Shalimar Paints
10.0
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INSTRUMENTATION SPECIFICATION
SECTION-VI
10.1
10.2
10.3
10.4
11.0
11.1
11.2
11.3
11.4
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INSTRUMENTATION SPECIFICATION
SECTION-VI
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.19
11.20
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INSTRUMENTATION SPECIFICATION
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11.21
11.22
12.0
12.1
12.2
12.3
12.4
12.5
12.6
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INSTRUMENTATION SPECIFICATION
SECTION-VI
12.7
13.0
13.1
13.2
13.3
13.4
13.5
13.6
13.7
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INSTRUMENTATION SPECIFICATION
SECTION-VI
13.8
13.9
13.10
13.11
13.12
13.13
13.14
13.15
13.16
13.17
13.18
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