SPECIFICATIONS FOR INSTRUMENTATION ERECTION & COMMISSIONING JOB

SPECIFICATIONS FOR INSTRUMENTATION ERECTION & COMMISSIONING JOB PART 1: GENERAL SPECIFICATION OF INSTRUMENTATION 1. SCOPE 1.1. This specification covers the design of instruments & control system, complete with all accessories and materials along with special test equipment. 1.2. Vendor shall be fully responsible for design, material selection, sizing and selection of the proper instruments for their system. 1.3. All equipment supplied shall be of field proven quality both with respect to design and materials. 1.4. Vendor shall prepare & submit P&ID for the system within the scope of his supply, showing all the instruments and interlock / trip operations. Each instrument shall be given individual tag numbers. Symbols shall be as per ISA S5.1. 1.5. The vendor s scope includes Erection, testing & calibration of all the instruments of the Rim Seal fire protection system. The scope includes laying of Cable trays and instrumentation & other cables (including erection of cable tray structural supports) and cable termination in the JB mounted field PLC as per the Refinery standards and practices. The scope also includes monsoon protection for all instruments and Junction Boxes. The scope of jobs to be carried out as a part of this contract includes but is not limited to the following: Calibration of all types of Instruments like Flow / Pressure / Temperature / Level Transmitters, I/P Converters, Pressure/Temperature Gauges, Pressure / Level switches, Control Valves, Thermo elements etc., Providing structural supports for cable trays wherever cables are running above ground along the cable route as marked in the drawing. Installation and supporting of cable trays. Laying & clamping of single pair cables / Multicore cables upto control room. Installation of Explosion proof Junction Boxes. Installation of all Instruments as per the field job specifications. Glanding and cable termination in Instruments, Junction Boxes & in Marshalling Panels. Laying & connection of Copper tubes. Laying of GI pipes for Instruments Air header. The tie point and the tentative route will be as given in the drawing. Impulse piping for instruments. Hydro-testing of impulse lines. Installation of stanchions / supports for instruments. Continuity checking of cables. 1

All these jobs are to be carried out as per the guidelines given in the subsequent sections. 2. DESIGN PHILOSOPHY 2.1. The design & installation of instruments shall be generally in accordance with ISA / API recommended practices and other applicable standards like ISI, IBR etc., Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards, code of practices shall be of the latest edition. 2.2. All instruments and equipments shall be suitable for use in a hot, humid & tropical industrial climate in which corrosive gases and / or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4X (IP66). All external surfaces shall be suitably treated to provide anti-corrosion protection against plant atmosphere. 2.3. All instruments and equipments shall be suitable for area classification as per IEC / NEC codes. In hazardous area, in general, certified intrinsically safe equipment shall be used. In case where this is not possible, explosion proof enclosures may be considered. All intrinsically safe instruments shall be certified by the statutory bodies like CENELEC, BASEFA, FM, PTB etc. 2.4. Materials of construction of instruments shall be consistent with temperature, pressure, corrosion conditions and other process requirements. 2.5. Instrument power circuits shall be individually protected from fault with the help of fuses. Power supply to the individual instrument shall be disconnectable with the help of switch and protected with the help of fuse. 2.6. Ranges for instruments shall be selected, in general, such that in normal operation the indication on the indicator is between 40% to 60% of span for linear and 60% to 80% of span for square root. 2.7. The complete instrument system shall be designed for safe operation, by using normally closed contacts, which open on fault conditions. 2.8. Automatic trip circuits shall meet the following requirements. 2.8.1.1. All trips shall have a pre-warning alarm and alarm to indicate the trip condition. 2.8.1.2. All the solenoids and relays shall be normally energized. 2.9. Adequate alarms shall be provided to give audible & visual warning of malfunction. 2.10. Gauge glasses shall be provided for all level measurements requiring automatic control or monitoring. They shall have atleast the same pressure & temperature rating as that of equipment on which they are to be installed. They shall have ball check off-set valve. 2.11. All process switches shall be provided with DPDT switches with contact rating, as a minimum of 110V, 0.5 ADC. 2

2.12. Orifice plate calculations shall, in general, follow the procedure in Principles and Practices of flow meter engineering by L. K. Spink. Orifice diameter shall be selected so that d/d ratio is between 0.2 to 0.7 for gases and steam and upto 0.75 for liquids. Vendor shall submit the sizing calculations for orifice plates. 2.13. Zener barriers shall be used for isolating signals between hazardous area mounted intrinsically safe transducers and safe area mounted receivers. 2.14. All transmitters shall be provided with Output meter / output gauge at the transmitter end. 3. APPLICABLE NATIONAL / INTERNATIONAL STANDARDS 3.1. The installation work shall comply with the latest applicable standard and regulation, Electricity rules and safety codes of the locality where the installation is carried out. Nothing in this specification shall be construed to relieve the contractor of this responsibility. 3.2. Design & Terminology shall comply, as a minimum, with the latest edition of following codes & standard practices and publications: AGA ANSI American Gas Association, Gas Measurement Committee Report no. 3 American National Standard Institute B 2.1 Pipe threads B 16.5 Steel pipe flanges and flanged fittings. B 16.104 Control Valve leakage classification MC 96.1 Temperature element / Thermocouple. API American Petroleum Institute RP 520 Recommended practices for design and installation of pressure relieving system in refineries RP 550 Manual on installation of Refinery instruments and control system. S 1101 Measurement of Petroleum liquid hydrocarbon by Positive Displacement meter. S 2534 Measurement of liquid hydrocarbons by turbine meter systems. ASTM American Society for testing and materials. BS British Standards. 1042 Measurement of fluid flow in pipes. DIN 43760 Temperature V/s Resistance curves for RTDs. IEC International Electrotechnical Commission. BS codes for Instrument piping IS Indian Standards IS 5 Colours for ready mixed paints. All applicable Indian standards ISA Instrument Society of America Standards & Practices of Instrumentation. 3

NACE National Association of Corrosion Engineers NEC National Electric Code NEMA National Electrical Manufacturer s Association ICS6- Enclosure for Industrial Controls & Systems NFPA National Fire Protection Association NFPA 496 Purged and pressurised enclosures for electrical equipment. 4. GENERAL SPECIFICATIONS OF INSTRUMENTS 4.1. INSTRUMENT CONCEPT : 4.1.1. Major instrumentation shall be electronic type but final control elements shall be pneumatic. 4.1.2. Electronic instruments shall generally operate on 24 V DC and shall have transmission and output signal generally of 4 to 20 ma DC. Transmitters shall be two wire and shall be capable of delivering rated current into external load of at least 600 ohms when powered with 24 V DC. All receivers shall be suitable for voltage input of 1 to 5 V or 0.25 to 1.25 V DC. Solenoid operates on 110VAC All electronic instruments shall be immune to radio frequency interference. 4.2. INSTRUMENT CONNECTION: 4.2.1. Pneumatic connection for signal and air supply shall be ¼ NPTF. 4.2.2. Electrical connection shall be ½ NPTF. 4.2.3. Threaded end connection shall be to NPT as per ANSI B 2.1 4.2.4. Flanged end connections shall be as per ANSI B 16.5 4.3. PRESSURE INSTRUMENTS : 4.3.1. Pressure gauges shall have an accuracy of +- 1 % of FSD. These shall be WP to IP 66 with dial size of 150 mm and shall have features like screwed bezels, externally adjustable zero, over range protection and blowout discs. Pressure gauge sensing element shall be minimum of SS 316 and movement of SS 304. 4.3.2. Pressure transmitters with local indicator shall be electronic balance / capacitance / strain gauge type with minimum of SS 316 element material with an over range protection of minimum 130% of range. 4.3.3. Direct mounted pressure switch shall have element either diaphragm or bellow of min SS 316 material with ½ NPT F connection. 4

Receiver pressure switches shall have bellows as measuring element with ¼ NPTF connection. 4.4. LEVEL INSTRUMENTS 4.4.1. All gauge glasses shall be steel armoured reflex or transparent type with body and cover materials of carbon steel as a minimum and tempered borosilicate glass. Integral illuminators shall be provided for transparent gauges with 220 V 50 Hz supply suitable for electrical class. The minimum visible length of single gauge shall not exceed 1500 mm. 4.4.2. External displacer type instruments with rotatable head shall normally be used for level measurement upto 1219 mm. Displacer shall be of SS 316 with Inconel torque tube. Side side connections shall normally be used. 4.4.3. DP transmitters shall be used for level measurements above 1219 mm or for services requiring purge or where liquid might boil in external portion. 4.4.4. Level switches shall generally be external ball float type with flanged head. 4.5. FLOW MEASUREMENTS 4.5.1. Flow measurement shall normally be done with thin plate square edge concentric orifice plate mounted between a pair of weld neck flanges of min 300# ANSI rating with flange taps. The material of orifice plate shall normally be SS 316. Metering orifices shall not be installed in lines less than 40 mm nominal dia. Meter runs shall be for a maximum d/d ratio of 0.75. For larger size pipes actual d/d ratio shall govern the straight run. The recommended practice shall be as per API RP 550 and AGA Report no. 03. 4.5.2. Flow nozzles, venturies, rotameters, target meters, vortex meters, magnetic flow meters, ultrasonic flowmeters etc., may be used wherever required depending on the service. 4.5.3. DP type flow transmitters with local indicator shall be electronic balance / capacitance / strain gauge type with minimum of SS 316 element material with over range protection of minimum 130% of range. 4.6. Isolators: 4.6.1. Isolators Input / Output voltage and current shall be 24 VDC, 4-20 ma DC respectively with maximum fault voltage of 250 V rms on safe area side. Barrier end to end resistance shall be less than 250 ohms accuracy better than +-0.1%. 5

PART 2: SPECIFICATIONS FOR MATERIAL, INSTALLATION, TESTING AND COMMISSIONING FOR INSTRUMENTATION This section covers the scope, technical requirements and essential particulars for the erection, testing, calibration & commissioning of Instrumentation & control system and laying of instrumentation & other cables, cable termination etc. The scope also includes monsoon protection for all instruments and junction boxes. The scope of the jobs to be carried out as part of this contract includes but is not limited to the following. Calibration of all types of Instruments like Flow/Pressure/Temperature/Level Transmitters, I/P Converters, Pressure/Temperature Gauges, Pressure/Level switches, Control Valves, Thermo elements etc., Making of RCC cable trenches for laying cables. Installation and supporting of cable trays. Making opening in DCS control room and installing MCT Blocks, making trenches inside control room for cable laying. Laying & clamping of single pair cables / Multicore cables upto control room. Installation of Flame proof Junction Boxes. Installation of Instruments. Glanding and cable termination in Instruments, Junction Boxes & in Marshalling Panels. Laying & connection of Copper tubes. Laying of GI pipes for Instruments Air header. Impulse piping for instruments. Hydro-testing of impulse lines. Installation of stanchions / supports for instruments Continuity checking of cables. Loop checking of Instruments. 6

Stroke checking of control valves. Commissioning of Instruments. Laying of control cables from various substations to DCS Control room for indications of pumps, Fans and Amperage reading of motors. Preparation of As-Built documents. 1. ERECTION MATERIAL SUPPLY The vendor shall ensure and supply all erection hardware required for installation of all instrumentation, which form a part of the LSTK package. This includes items like cables, cable glands, junction boxes, instrument valves, mounting accessories, impulse piping, pipe fittings, pneumatic signal tubes, air line pipes, filter regulators, insulation materials, cable trays, identification tags, structural material required for instrument supports & trays etc., The above broadly covers the items, however vendor shall supply all necessary items including consumables to make the erection and commissioning work complete in all respects. Following are the minimum acceptable features of some of the erection materials. 1.1. PLC Hardware: 1.2. Cables : All the PLC hardware and software required for hooking up all instruments under Rim seal fire protection system are in vendor s scope All cables shall be PVC insulated and primary insulation shall be 105 deg C PVC. All cables shall be FRLS type as per standard IEEE 383 The insulation grade shall be 600 V / 1100 V as minimum All cables shall be twisted and armoured. 1.3. Signal Cables and control cable Refer attachment for detailed specification 1.4. Cable Glands 7

Vendor shall supply all cable glands required for Glanding the above mentioned cables both at field instrument and at control room. All cable glands shall be anodized aluminum alloy or of nickel plated brass and they shall be double compression type suitable for armoured cables. Explosion proof glands wherever required shall be supplied. 1.5. Junction Boxes Refer attachments for detailed specification 1.6. Instrument Valves Vendor shall supply instrument valves (miniature type) and valve manifolds wherever required. Body material and rating shall be as per piping class or SS whichever is better and shall be forged type. Valve trim shall be SS316 as minimum or superior as required by process conditions. Vendor shall supply a minimum of 10% of such instrument valves as spare. 1.7. Impulse Piping In general vendor shall supply seamless pipes of size ½ NB of required thickness with material as per piping class. 1.8. Pipe Fittings Socket weld type forged pipe fittings of suitable material and ratings shall be supplied for pipe fittings. The minimum rating shall be 3000#. 1.9. Copper Tubes Vendor shall supply 6mm OD * 1mm thick PVC covered annealed electrolytic grade copper tubes as per ASTM B 68.74A Cu.No.122 for copper tube. Vendor shall avoid use of intermediate connections and shall estimate single length for each location. 1.10. Instrument Airline fittings & valves. 8

Seamless galvanized inside & outside CS pipes used for instrument air distribution, shall be as per IS 1230 class heavy. Galvanized forged screwed carbon steel fittings 2000 # rating, shall be used. Isolation valves on instrument air service shall be packless gland type full bore ball / globe valve. 1.11. Air Filter regulator Instrument air filter regulator of suitable sizes shall be supplied for each pneumatic instrument. The body of filter shall be anodized aluminum. The filter shall have 25 micron sintered bronze / ceramic filter element and shall be provided with manual drain and 2 nominal size pressure gauge. 1.12. Cable trays Refer attachments for detailed specification 1.13. Instrument Support / structural steel Vendor shall supply instrument stands (Stanchions for supporting field instruments made of 2 IS 1239 heavy steel pipe) and other structural steel material required for supporting the cable trays, impulse lines and instruments. 1.14. Consumables and General items The vendor scope also includes, but is not limited to All consumables like welding electrodes, PTFE tape, ferrules, lugs for termination, clamps for supporting the cables, impulse pipes, copper tubes etc. SS Tagging plates for fixing tags on the instruments, junction boxes. Vendor shall bring their calibration, hydro testing equipment. The calibration equipment shall be duly certified by any standard laboratory like IDEMI etc. Vendor shall bring their equipment necessary for transportation of instruments. 9

All scaffolding equipment necessary for working at elevation. Vendor shall bring their firefighting equipment like fire extinguishers, hose pipe etc. Vendor shall bring their safety equipment like safety helmets, safety belts, safety shoes, gloves, and visors for workmen. Any other item not mentioned, but required to complete the job as per the direction of Engineer in charge. 2. INSTALLATION Vendor shall be completely responsible for installation of all instruments, as per the installation standards. All direct mounted instruments shall be installed in such a way that they have better readability and accessibility. All pressure, differential pressure instruments shall be provided with block and bleed, by-pass, drain / vent valves etc., as per the installation standard and shall have accessibility. All primary piping (impulse lines) shall have a slope of 10% on horizontal run. All impulse connections, mounting nozzles etc., upto and including the first block valve shall be of the same specifications as the process lines to which they are connected. These will be shown in the process piping diagrams and are considered as part of process piping system connections. The first shut off valve shall be located as close to the line as possible. Impulse lines shall be firmly supported by bracketing from valves, instrument supports or stands. In no case shall the instruments serve to support the impulse line. Impulse line shall be fitted carefully and their configuration must be such that minimum stress is imposed on the instrument. All primary impulse piping shall be installed in the best workman like manner and shall be as per the installation standards. Impulse line shall be bent using pipe benders only and hot bending shall be totally avoided. 10

Impulse pipes shall be cut by using cutting device. Threaded joints shall be joined with Teflon tapes and no other jointing compound shall be used. All welding shall be carried out as per the relevant code with proper electrodes. Any testing (non destructive) like D.P. test on root weld and final weld shall be part of vendor s scope. All impulse lines shall be supported at regular interval. Single copper tubes shall be laid as per the standards on trays / angles. Copper tubes shall be clamped to the trays every 500 mm using 20 mm wide aluminum clamps. Trays shall be properly supported from either rigid steel structure or concrete members at regular intervals of 1000 mm. Copper tubes / fittings shall be installed with Teflon tapes. Identification tags plates shall be provided on either side of copper tubes. All cables shall be properly laid on cable trays which shall be properly supported at regular interval. At every vertical dropping to the JBs, they shall be clamped at an interval of 300 mm. Cable entry to DCS control room shall be through MCT Blocks. The scope involves breaking of RCC wall, making RCC trenches inside control room, supply installation of MCT blocks. The job involves making good of all civil work inside control room so as to bring to original shape and condition. At bends, minimum radius shall be maintained as per Manufacturer s standard. Physical separation shall be maintained between signal and control / power cables. Identification tags shall be provided on either end of the cables as per the cable / JB schedule. All brackets fastened to main supports for auxiliary type instruments such as I/P converters, AFR etc., shall be galvanized CS ¼ thick * 4 wide 11

minimum size and fastened to the support by a minimum of ¼ dia SS U bolts & nuts. Instruments supports located on concrete floors shall be installed with 3/8 concrete anchor and 3/8 stud with double nuts to level the supports. Each support to receive a 2 minimum thickness of epoxy concrete grout placed below the support. Painting (minimum one coat of red oxide zinc chromate primer as per IS 2074 and two coats of paints suitable for corrosive atmosphere.) of Impulse piping, cable trays, ducts, instrument supports, all structural supports as per the painting standards to be done before handing over / commissioning. 3. TESTING AND CALIBRATION 3.1. All impulse lines shall be properly flushed after isolating the instrument and vessel /piping. All impulse line shall be tested hydraulically at 1.5 times the maximum operating pressure. Ensure that instrument and vessel / piping are isolated during this test. In case of special conditions where hydro testing is not permitted due to service conditions, the impulse lines testing shall be carried out by using air or nitrogen. All external cage type level instruments shall be tested up to 1.5 times operating pressure by using nitrogen only. After pressure testing all these impulse lines shall be drained and with dry air to remove any moisture. Instruments air lines will be service tested only for any leak after pressurizing and isolating the main root valve, by soap solution. All instruments cables shall be tested for continuity and insulation. While megger is used for insulation testing All instruments supplied by the vendor shall be calibrated using proper test equipment. All instruments shall be calibrated for 0, 25%, 50%, 75%, and 100% and vice versa. All temperature gauges shall be calibrated using temperature baths. 12

All thermocouple-activated instruments shall be calibrated by generating millivolts by a potentiometer. All transmitters shall be calibrated as per instruments ranges. All displacer type level transmitters shall be calibrated with water or fluids and corrected for specific gravity. All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm/trip points and reset points as per the alarm / trip set point schedule. After setting these shall be sealed. All control valve prior to stroke checking shall be externally cleaned thoroughly the all stroke of valve shall be checked for opening and closing. Any adjustments required for obtaining full stroke test and gland leak test. Solenoid valve shall be checked functionally for its operation. All electronics / pneumatic receiver instruments shall be calibrated as per the manufacturer s instruction. Controllers shall be aligned properly. All special instruments like analyzer shall be checked and calibrated as per manufacturer s instruction. Prior to testing, all analyzer sample lines shall be thoroughly cleaned by carbon tetra chloride or any other cleaning liquid. After cleaning, these lines shall be thoroughly purged with dry nitrogen. No oil should be used on oxygen service lines. The accuracy of overall loop shall be within +/-1% for electronic loops. After performing the calibration of the entire instrument, the entire loop shall be checked for proper operation. The entire shutdown scheme shall be simulated for the process trip switches and the scheme shall be tested for its proper operation, prior to commissioning. If no instrument air is available vendor shall provide necessary N2 cylinders to carry out the above activity. 4. Instrumentation commissioning 13

4.1. This activity shall be carried out in a systematic manner so as to avoid any accident to plant and operating personnel. During the plant start up all the instrument calibration, controller alignment, trip point setting shall be trimmed so as to meet the operation requirement. Prior to guarantee run, the vital instrument as required by vendor have to be recalibrated and the result recorded. 5. INSTRUCTIONS TO THE VENDOR 1. The vendor should make all arrangements to ensure that sufficient manpower is available to complete the job within the time stipulated in the tender. 2. The vendor should strictly follow all the safety rules & regulations in the refinery. 3. Vendor to ensure that no job is being carried out in the plant without a valid work permit. 4. The vendor shall employ qualified technician, instrument fitters and helpers to complete the job in a professional manner and ensure good workmanship to the satisfaction of HPCL. 5. The vendor shall follow HPCL s timing of work. However in case of requirement of working holidays or working beyond the normal working hours, the vendor shall make arrangements for obtaining necessary entry permits in advance. 6. Vendor shall arrange for the monthly gate passes for entry into Refinery. 7. Vendor shall supply all items, which are in his scope with necessary test certificates. 8. The vendor is responsible for proper storage of all his material. All instruments stored in open area shall be adequately protected. 9. All fabrication & prefabrication shall be done at one place. 10. Vendor to ensure that while mounting instruments, trays etc., other structures are not damaged. 11. Bends for trays shall be gradual & uniform. 12. Trays shall not be installed below drain valves, above vent valves or near hot surfaces. 13. The trays shall be joined with SS304 nuts & bolts. These nuts & bolts are to be supplied by the vendor. 14. Instrument impulse lines shall not be fastened to process lines. They shall not hang out when either the instrument or the process line is removed. 15. Clamping of Cables shall be done at every one meter interval. 16. Clamping of copper tubes shall be done at every 50 cm. 17. SS-304 bolts shall be used for clamping. 14

18. The tubes shall run in a streamlined way. The bends shall be minimum 4 times OD for copper tubes. 19. All impulse line bending shall be done by pipe bending machine. 20. Only wheel type tube cutters shall be used. 21. All instruments shall be tagged with a proper SS tag plate bearing the tag no. of the instrument. This shall be securely tied to the instruments. 22. All wires shall be properly tagged with sleeve type labels. 23. Instrument supports shall be either grouted or welded to the structures. 24. All instrument supports shall be of 1.5 m height and shall be of structural steel. They shall not be welded to process lines or vessels. 25. Instruments shall not be mounted below drain valves or above vent valves. They shall be mounted on such places where mechanical damage will not occur and will not cause disturbance for free movement of personnel. 26. All instruments shall be pre calibrated and installed. 27. All testing & calibration equipment shall have proper certificates from standard laboratory. 28. For calibration of pressure instruments, inclined tube manometer shall be used. Oil bath & calibration thermometer shall be used for calibration of temperature instruments. 29. All switches shall be set at the required setting by the vendor before installation. 30. Vendor shall have all the calibration / testing equipment like Multimeter, Voltage / current source, megger, manometers, deadweight tester etc., 31. All calibration shall be witnessed by HPCL engineer. The calibration certificates shall be submitted in duplicate to HPCL. 32. Loop checking shall be carried out by simulating input & output signal. 33. Vendor shall maintain good housekeeping in and around the work place on day to day basis. 34. Total job shall be carried out so as not to cause any hindrance to other agencies working / operating in the area. 35. If any damage is caused to HPCL property by any act of commission or omission or negligence of the vendor or their workers, the same shall be made good at no cost to HPCL. 36. Vendor shall be fully responsible for their workmen and HPCL shall have no responsibility for the vendor s workmen during or after the job. 37. All working permits will be arranged by HPCL. The job has to be carried out only during normal working hrs i.e. 8.00 am to 4.30 pm, Monday to Friday. However, if found necessary and subject to the availability, provisions of work permits during extended hours / holidays will be considered. 6. DOCUMENTS UNDER INSTRUMENTATION 15

After the completion of installation & commissioning of all the instruments, vendor shall hand over the following documents in 6 sets along with the soft copies for the entire documentation. A. As- Built documents for the following: P & Ids. Instrument Plot plans showing physical locations of all field instruments including the sensors, transmitters, Junction Boxes etc., Cable routing and tray layout. Cable schedule & JB wiring details. Instrument air header distribution drawing. DCS I/O list / Point Data base giving full details like signal type, Range, engineering units, source tag, location, Destination, Alarm settings, CV fail action, controller action etc., I/O assignments. Cause & Effect details. Control schemes. Interlock & Logic diagram Loop Diagram for all types of signals. DCS Wiring details. All test & calibration reports. B. Purchase Requisitions / Specifications of all the instrumentation items. C. Operation and Maintenance manuals for all the instrument items. D. Catalogues of all the instruments. E. All Warranty / Guarantee / statutory certificates. F. Spares list / spare parts list along with the cost. 16