LAYING, TESTING AND COMMISSIONING OF 18" DIAMETER BORERI TO CFCL-III, GADEPAN PIPELINE Project No. P.011947 Tender Document No. P.011947 R11050 001 E - Tender No. 8000012699 Gail (India) Limited Noida | INDIA PUBLIC 23 February 2018 TECHNICAL DOCUMENTATION, Tech. Tender - Inst, R0
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16.0 FIRE DETECTION SYSTEM ................................................................................................ 20
17.0 GAS DETECTION SYSTEM ................................................................................................. 24
18.0 INSTALLTION MATERIAL SPECIFICATION ...................................................................... 27
19.0 CORROSION MONITORING SYSTEM ................................................................................ 28
20.0 INSPECTION AND TESTING ............................................................................................. 31
21.0 PAINTING, MARKING AND SHIPMENT ............................................................................ 32
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1.0 SCOPE
1.1 This documents covers design, engineering, testing at works, supply, installation, calibration, erection, testing at site and commissioning, guarantee run, handing over of control and instrumentation system package which includes all field instruments, local control panel, fire and gas detection system , instrument cables ,OFC cables and PLB HDPE Duct for this PROJECT.
1.2 Scope also includes the supply, erection and installation of erection material, fabrication, cable laying, fittings, flanges, connectors, impulse tubing and all the associated accessories as required.
1.3 Refer Instrumentation scope of work as enclosed with tender document.
2.0 REFERENCE
• Scope of work – P.011947/I/11075/01- scope of work C&I
Note –
In the event of any conflict between GTS and PTS, PTS shall prevails over the GTS
3.0 DEFINITIONS
Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this specification are given the following meaning:
AGREEMENT Designates the agreement concluded between the CLIENT and the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.
CLIENT Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.
CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the CLIENT. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.
DAYS - WEEKS – MONTHS Specify the number of calendar days, weeks or months and not of working days, weeks or months.
ENGINEER Designates the individual or legal entity to which the CLIENT has entrusted various tasks in relation with the carrying out of his PROJECT
GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, materiel, equipment, structures, plant, tools, machinery to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The Terms GOODS or SERVICES may by indifferently used one for the other as required by the context.
PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided by one or more CONTRACTORS.
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4.0 REVIEW AND/OR APPROVAL
Whenever CLIENT and/or ENGINEER review and/or approval is requested on a document to be submitted by the CONTRACTOR, or before an action is implemented by the CONTRACTOR, such review and/or approval shall always be requested in writing by the CONTRACTOR to the CLIENT and/or the ENGINEER, before any action subject of this review and/or approval is taken.
CLIENT and/or ENGINEER approval shall always be given in writing.
5.0 APPLICABLE CODES & STANDARDS
The following Indian/ international or relevant codes and standards shall be used for designing the system. In all cases, latest revisions with amendments, if any, to be followed Apart from the specific codes mentioned herein, all other relevant and related codes concerning the specific job under consideration and/or referred to in these codes and technical specifications will be followed wherever applicable. All codes will be of the latest revision as on the date of issuing the tender/ bid document.
In the event of any conflict between this specification, related standards and codes, any other attachment to this tender, the Contractor shall refer the matter to OWNER’S/OWNER’ REPRESENTATIVE for clarification and only after obtaining the confirmation on the same, should proceed with the manufacture/ supply / engineering of the item in question. The decision of the OWNER’S/OWNER’ REPRESENTATIVE shall be binding on the Contractor.
CONTRACTOR shall seek CLIENT final interpretation of any conflicts prior to the execution of work. Rework of engineering and relevant scope arising out of underestimation shall be done at no additional cost to the CLIENT.
Sr. No
Codes Description
1 OISD-STD-226 Natural Gas Transmission Pipelines and City Gas Distribution Networks.
2 ANSI/ISA S 51.1 Process Instrumentation Terminology.
3 ISA 5.4 Instruments Loop diagrams.
4 IEC 60529 / IS 2147 / NEMA
Specification for Weather Proof Enclosure.
5 IEC 60079 Specification for Flame Proof Enclosure
6 IEC 61000 Electromagnetic Compatibility for Industrial Process Measurement and Control equipment.
7 IEC 60801 EMI and RF interference
8 IS-1554 Part 1 PVC insulated (heavy duty) electric cables- working voltage up to and including 1100V.
9 BS-5308 Part 1, Type 2
Specification for PVC insulated cables.
10 IS 8130 Conductors of insulated cables
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Sr. No
Codes Description
11 IS 5831 Specification for PVC insulation and sheath of insulated cables.
12 IS-3975 Mild steel wires, formed wires and tapes for armoring of cables.
13 ASTM D 2843 Test method for Max smoke density for cable
14 ASTM D 2863 Test method for measuring of Temp and O2 Index.
15 IEC 60754 Acid generation test
16 IEC-332-3 Part 3 Tests on bunched wires and cables.
17 BS 6121, EN 50262
Cable gland – flame proof Ex”d” or Exe increase safety.
18 DIN- 50049 Document on Material Testing.
19 ASME PTC 19.3 Temperature Measurement- calculation of natural frequency.
20 IEC 751 / DIN 43760
RTD
21 IEC 584/DIN 43710 / ANSI MC 96.1
Thermocouple
22 ISO 5167 Measurement of fluid flow by means of orifice plates, Nozzles and
Venturi tube inserted in filled piping circular profile.
23 ASME B 16.36 Orifice flange with flange pressure tap.
24 ASME B16.5 Pipe line flanges and flanged fittings
25 API-RP-520 Sizing and selection of safety relief valves.
26 IS 3624 / BS EN 837
Pressure gauge
27 AGA 3 Orifice flow measurement
28 AGA 9 Ultrasonic flow measurement
29 AGA 8 Compressibility factor of natural gas.
30 AGA 10 Calculation of Speed of sound in Natural gas
31 API Spec 6A Valve design methodology
32 API 6D Petroleum and natural gas valve
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Sr. No
Codes Description
33 ISA 75.01 Flow equation for sizing of control valve
34 ISA 75.02 Testing of CV rating , control valve capacity test
35 ISA 75.05 Control valve terminology
36 ISA 71.07 Laboratory measurement of aerodynamic noise generated by control
valves.
37 FCI 70.2/ANSI B 16.104
Control valve seat leakage.
38 ASME/ANSI B 16.34
Valves-Flanged, Threaded and welding end.
39 IEEE 802 The LAN standards.
40 IEC-60870-5-104/101
SCADA Communication protocol
41 DNP 3 (TCP/IP), DNP 3 (Modbus)
SCADA Communication protocol
42 IEC 61131 RTU, remote terminal unit
43 IEC 60870-5-101 Modbus serial RS232/Rs485
44 ISA 5.3-1983 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic, and Computer Systems.
45 ISA-5.5-1985 Graphic Symbols for Process Displays
46 TIA/EIA 58 Communication standard
47 OISD Oil Industry Safety Directorate Government of India
47.1 OISD 118 Layouts for Oil & Gas installations
47.2 OISD 152 Safety Instrumentation for Process System in Hydrocarbon Industry
47.3 OISD 153 Maintenance and Inspection of Safety Instrumentation in Hydrocarbon Industry
47.4 OISD 163 Process Control Room Safety
47.5 OISD 195 Safety in Design, Operation, Inspection and Maintenance of Hydrocarbon Gas Compressor stations and Terminals
48 NFPA National Fire Protection Association
48.1 NFPA-70 National Electrical Code
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Sr. No
Codes Description
48.2 NFPA-497 Electrical installation, classification of Class1 & Class 2 hazardous locations
48.3 NFPA-101 Life Safety Code
48.4 NFPA 325M Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solids for LEL of Gases
49 PNGRB Technical & safety standards statutory requirements for natural gas
6.1 The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments and instrumentation systems.
6.2 Equipment / instrument / systems located in electrically hazardous areas shall be certified for use by statutory authorities for their use in the area of their installation. In general, following certification shall be provided by the bidder.
a. For all flameproof equipment / instrument / systems, which are manufactured abroad (outside India) certification by any approving authority like BASEFA, FM, UL, PTB, LCIE, CENELEC etc. shall be required.
b. For all flameproof equipment / instrument / systems manufactured locally (within India), certification shall be carried out by any of the approved testing houses – Central Mining Research Institute (CMRI) etc. The manufacturer shall hold a valid Bureau of Indian Standards (BIS) license.
c. Approval certificate from Chief Controller of Explosives (CCE) or Petroleum and Explosive Safety organisation (PESO) is mandatory for all electronic / electrical instruments / equipment to be installed in India, irrespective of country of origin.
7.0 ABBREVATIONS
• ISO (International Standards Organisation)
• IS (Indian Standards).
• IEC (International Electro technical Commission).
• ASTM (American Society for Testing Materials).
• EIA (Electronics Industry Association).
• BIS (Bureau of Indian Standards).
• IEEE (International Electrical and Electronics Engineers).
• CCE (Chief Controller of Explosives, Nagpur).
• PT – Pressure transmitter
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• TE – Temperature element
• TT – Temperature Transmitter
• RTU – Remote terminal unit
• SCADA – Supervisory control and data acquisition system
• GOOAV – Gas over oil actuated valve
• HOV – Hydraulic operated valve
8.0 ENGINEERING UNITS
a
Flow
Gas Sm³/hr / MMSCMD
Mass flow kg/hr.
Volumetric flow m³ / hr.
b Pressure Barg
c Temperature °C.
d Level %.
9.0 DESIGN PRINCIPLES
9.1 GENERAL
Instrumentation and control and monitoring systems shall be in accordance with this specification and as defined in the P & I Diagrams.
9.2 INSTRUMENT SELECTION
Instruments and instrumentation systems of proven reliability and latest technology shall be used.
Selection of instrumentation shall be made from the RECOMMENDED Instrument Supplier Lists.
Any exception has to be justified and is subject to approval by the CLIENT.
9.3 TAGGING
All instruments and instrumentation equipment shall be permanently identified by tags, labels and/or nameplates. Use of adhesive tapes shall not be allowed.
9.4 PAINTING
Manufacturer's standard colours shall be used for all instrumentation equipment in control and instrument rooms, unless otherwise specified.
Field instruments shall generally be epoxy painted, unless otherwise specified.
9.5 TRANSMISSION SYSTEMS
Transmission of the process variables shall generally be by means of electronic or low level signals. The output signal for electronic instruments shall be 4 to 20 mA DC or digital.
No process fluid shall be piped into the control rooms or the instrument rooms.
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9.6 ENCLOSURES AND MATERIALS
All instruments shall be suitable to withstand the environmental conditions specified for the plant location.
All parts subject to moisture, fungus growth or insect attack shall be suitably treated (Tropicalisation).
Local instrument housings shall be weather-proof (IP 65 minimum) and meet the electrical area classification requirements.
All parts of instruments exposed to process fluids shall be resistant to corrosion by the corresponding fluid.
9.7 ELECTRONIC INSTRUMENTATION IN HAZARDOUS AREAS
In hazardous areas, intrinsically safe instrumentation shall be provided in general.
If not possible or not practical, flameproof protection concepts may also be used wherever applicable.
All electrical instruments to be installed in hazardous locations shall be ATEX certified. Contacts shall be encapsulated, hermetically sealed and, if used in intrinsically safe circuits, contacts shall be gold plated.
9.8 R.F. IMMUNITY
All instruments and control systems shall be immune from the effects of any R.F. interference that may occur at the plant location in accordance with IEC 801 "Electromagnetic compatibility for industrial-process measurement and control equipment".
Equipment to be installed inside the control room shall be in compliance with the European Community directive requirements, denoted by the "CE mark". This compliance shall extend to each relevant item.
9.9 ELECTROMAGNETIC INTERFERENCE
The equipment offered shall incorporate the most effective techniques available to minimize the electromagnetic interference effects to ensure that other electronic systems neither adversely affect nor get adversely affected by the system supplied by the contractor. The contractor shall ensure that the electromagnetic interference generated by the system is well below the permissible levels as per applicable standards.
The equipment shall be required to meet one or more of the following standards:
a) IEC 801 – 3 –Latest edition
b) BS 6667- PART 3 - Latest edition
c) ANSI/ IEEE C 37.1- Latest edition
d) MIL – STD - 461
e) VDE 0871
The equipment to be supplied shall be type tested for Electromagnetic Compatibility if certificate of compliance from an independent test authority or test laboratory cannot be furnished.
9.10 ENGINEERING AND DESIGN DOCUMENTS & DRAWINGS
The documents and drawings to be prepared by the CONTRACTOR are listed hereunder.
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9.10.1 DOCUMENTS
As a minimum requirement, the following documents shall be provided, whenever applicable.
• Instrument data sheets
The data sheets shall comprise all necessary technical data associated with the Instruments as per the enclosed format.
• Certification files
They shall contain copies of all electrical safety certificates and all documents applicable to the safety of electrical equipment installed in hazardous areas (e.g. intrinsically safe loop specifications, " Explosion proof certificate, CCOE certificate etc").
9.10.2 DRAWINGS
As a minimum requirement, the following drawings shall be prepared, when applicable.
• Logic drawing
Plant logic drawings with all the interlocks details for GOOAV, fire detection system, gas detection system and wherever applicable.
• Cable schedule
The cable schedule shall indicate details of the required cables (e.g. cable number, type, length, termination points, pair no, colour code etc.).
• Cable layout drawings
The cable layout drawings shall show the main routing of instrument cables and the location of all instrument junction boxes and local panels.
• Wiring diagrams
The wiring drawings shall show all cable termination details for junction boxes, cross boards, control cabinets, power supply cabinets, auxiliary cabinets, control panels, desks, etc.
• Earthing drawings
The earthing drawings shall show the requirements of earth strip / cable cabling up to the earthing systems.
• Loop diagrams
The loop diagrams shall show the connections between components of each loop with identification of terminals and cables.
• Control room layout drawings
Those layout drawings shall show the location of panels inside control room, front and rear arrangements and all the main sizes of panels, cabinets and desks.
• Process hook-up drawings
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The process hook-up drawings shall show installation details for the various instruments, complete with a schedule of required material. Contractor to refer attached standard drawings.
10.0 INSTRUMENTATION EARTHING SYSTEM
10.1 General
The earthing for electrical earth and electronic earth shall be arranged to provide safe installations, and to prevent electrical interference with their operation.
All earthing and shielding shall comply with the requirements of all standards applicable to the area classification in which the equipment is installed.
10.2 Instrument cases, panels. etc.
a) All parts of field installations, e.g. Cable trays, junction boxes, local panels, instrument housings, conduits, cable armour, etc.., shall be effectively grounded via the general plant earthing system.
b) Earthing of cable trays shall be in accordance with the IEC requirements as a minimum.
10.3 Each supplied instruments, local control panel, fire detection panel, gas detection panel system shall have earthing lugs with their frames. All these lugs/ strips shall properly secured to the electrical earthing bus.
10.4 All system grounds of various cards and equipment, shields of signals (instrument) cables shall connect to system ground bus, which is electrically isolated from the AC mains earthing bus. The equipment shall provide separate earthing strip for the same. The system ground bus will have independent ground buses through insulated wires.
a) System grounding (earth resistance less than 1 ohm)
b) Frame and AC mains grounding (earth resistance less than 5 ohms)
10.5 Lightning protection
Where connections between control systems and/or distant equipment may be affected by lightning surges or by other inducted high voltages, the connection cables shall be equipped with over-voltage arresters.
11.0 ENVIRONMENTAL SPECIFICATIONS
All equipment shall be designed for operation, storage and transportation under the following environmental condition:
Max. / Min. Temperature : 0 °C / 55 °C
Design temperature : (-) 20 °C to 60 °C
Relative Humidity : 95%
Hazardous Area Classification : Zone 2, Gas Group II A or B, Temp. Class T 3
Control Room & Electrical Room : Safe Area
12.0 POWER SUPPLY
Electrical power supply shall be provided at one point inside the battery limit as per the details provided below. Further distribution shall be in the scope of the CONTRACTOR. If any other voltage levels are required, then all necessary conversions shall be in the scope of CONTRACTOR.
Normal supply : 24 V DC SOLAR power supply shall be provided at all the stations for local control panel, RTU, Telecom and F&G panel.
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Contractor shall arrange to convert the power supply from 24 V DC to 48V DC, and all required voltages as per their system/equipment requirement.
13.0 INSTRUMENTS SPECIFICATION
13.1 PRESSURE GAUGES (PG)
PG shall be Direct-mounting type having element of bourdon tube and dial size of 150 mm. It shall have shatterproof glass. Connection shall be ½” NPT (M) from bottom. Enclosure shall be weather proof to IP65. Protection shall be 130% over range. Accuracy shall be ±1% of FSD. PG shall have blown out disc facility. For higher pressure applications (above 60 Barg), it shall be solid front type.
Pressure gauge dial shall be white, non-rusting plastic with black figures. The dial face shall be marked with pressure element material. Pointers shall have micrometer adjustment.
Pressure gauge sensing element shall be of SS 316 and moving elements of SS 304, as a minimum.
13.2 PRESSURE TRANSMITTER (PT)
PT shall be intrinsically safe electronic SMART type transmitters compatible with HART protocol of latest version. All transmitters shall be 2-wire type with integral digital indicator. Enclosures shall be Weather proof to IP 65. Pressure transmitters shall be capacitance / piezo-resistance type. Process entry and cable entry shall be ½” NPT (F). Accuracy of Pressure transmitter shall be ± 0.075% of span. Transmitters O/P shall be 4-20 mA DC. Surge protection device shall be provided with the transmitter to protect the instruments from lightning or any kind of hazardous surge
13.3 TEMPERATURE TRANSMITTERS (TT)
TT shall be intrinsically safe electronic SMART type transmitters compatible with HART protocol of latest version. All transmitters shall be 2-wire type with integral digital indicator. Transmitter shall have dual compartment housing. Enclosures shall be Weather proof to IP 65. Two Cable entry shall be provided, one ½” NPT (F) for output signal and one ½” NPT (F) for RTD input. Accuracy of Temperature transmitter shall be ± 0.18% of FSD. Transmitters O/P shall be 4-20 mA DC. Surge protection device shall be provided with the transmitter to protect the instruments from lightning or any kind of hazardous surge
13.4 RESISTANCE TEMPERATURE DETECTOR (RTD)
Temperature element shall be immersion type and skin type with temperature transmitter. Skin type element shall be provided at vent line as per P&ID along with weld pad and associated accessories
Resistance temperature detector (RTD) shall be spring loaded, mineral insulated and shall have stainless steel sheath as a minimum.
RTD are four wire type and element shall be Pt100 as per DIN 43760/IEC 60751 & accuracy class A. RTD shall be thermowell mounted. All RTDs shall have duplex elements with Pt-100 ohms, Type A. Cable entry shall be ½” NPT (F). Two separate cable entries shall be provided with one plug. RTD sheath OD shall be 10 mm and material SS 316.
All temperature measuring instruments shall be provided with thermowell. The process connection shall be flange type. Minimum line size for thermowell connection shall be 4”. For lower line size, same shall be expanded to 4”.
The thermowell shall be constructed from drilled bar stock of SS316 material. Thermowell shall have a sufficient internal bore to properly accommodate the devices, which are to be placed in the bore.
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All thermowells shall be stress analysed for velocity conditions. Calculation shall be done as per ASME PTC 19.3 code. 100% radiography shall be conducted for all fabricated thermowells. Thermowells of long length shall be provided with alternate arrangements as per standards.
Immersion length of thermowell shall be a follows
Line size Immersion length
From 4” to 6” 280mm
From 8” onward 320mm
Vessel/ Column 400mm
13.6 DIFFERENTIAL PRESSURE SWITCH
Differential pressure switch enclosure will be Weather proof IP65, process entry from Bottom /side entry, Process connection ½” NPT (F), Pressure element will be Diaphragm (material SS316), Setting adjustable, Switch DPDT switch, Cable entry ½” NPT (F). Differential pressure switch shall be intrinsically safe.
13.7 All instruments impulse line (1/2” tubes) shall be consist of tubing and piping. The impulse tube shall be SS316 and all the impulse pipes shall be CS/LTCS. Compressed type ferrule fitting such as ½” NPT (M) , NPT (F) fittings (male/female connectors), ½” tee, ½” union including ½” isolation needle/ball valves & other accessories shall be SS316.
13.8 A universal type Hand Held Configurators for transmitters with carrying case, rechargeable batteries (one working and one standby), and battery charger shall be provided for this project.
13.9 SOLENOID VALVES
The solenoid valve shall be of 3 way, universal type with manual operation facility. The body and internals shall be of SS 316. Valve shall be made leak proof with 'O' ring seals. The solenoid valve shall have weather proof and intrinsically safe, suitable for the hazardous area. The power supply shall be 24VDC. Instrument natural gas supply connection shall be 1/4" or 1/ 2” NPT (F). Solenoid valve shall be provided with integral junction box, having 1/2" NPT (F) cable entry. Surge suppression diodes shall be provided across the coil. Coil class shall be Class “F”
13.10 VALVE POSITION SWITCH
Valve position switches for open / close position indication shall be of sealed micro type lever operated. The switch shall be of DPDT type with contact rating 24V DC, 2 Amp suitable for inductive load. The switch enclosure shall be dia cast aluminium, weather proof and intrinsically safe suitable for hazardous area. Valve position switch shall be provided with integral junction box having 2 nos. of 1/2" NPT (F) cable entries.
14.0 LOCAL CONTROL PANEL
14.1 GENERAL
14.1.1 Refer -INSTRUMENTATION OPERATIONAL PHILOSOPHY enclosed with tender document.
14.1.2 This specification covers the design, manufacturing, testing at works and dispatch in well packed condition of Local Control Panels. Contractor’s scope shall also include the panel erection, commissioning, test at site.
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14.1.3 However, this does not absolve vendor of their responsibility for proper design of the control panel to meet all the functional requirements as per the tender specification.
14.1.4 All the instrumentation cables including laying, glanding, and termination & ferruling from local instrument to JB, JB to Control Panel shall be in Contractors Scope for making the system functional.
14.2 SPECIFICATION OF PANEL
14.2.1 The panel shall be self-standing/wall mounted (Refer scope of work) supplied in dust & vermin proof, floor mounted, sheet steel enclosure. Minimum degree of protection for panel shall be IP 42 as per IS-2147.
14.2.2 Enclosure shall be fabricated with cold rolled closed annealed (CRCA) steel sheet of minimum thickness 1.6 mm and gland plate thickness shall be 3 mm. Panel door shall be 2mm thick.
14.2.3 Mounting height of equipment/components inside the floor mounted panel requiring operation and observation shall not be lower than 300 mm and higher than 1600 mm. Size of the self-standing panel cabinet shall be 2100 (including 100 mm base frame) (H) x 1000 (W) x 800 (D) mm and size for wall mounted cabinet shall as per vendor design.
14.2.4 Cabinet shall have single door from front and double door from back for self-standing. Doors shall be provided with lockable handles (flush pull chrome plated handles) and concealed hinges with pull pins for easy door removal. Panel Doors shall be provided with pockets for storing of manuals/ drawings etc.
14.2.5 Panel shall be liberally designed. All components shall be so mounted that they are easily accessible for inspection & maintenance.
14.2.6 Colour of panel: RAL 7035 for the panel exterior and interior. Black for the base frame.
14.3 Panel shall have the following minimum accessories (as applicable):
a) Door switch
b) Cable glands
c) M.C.B.
d) 15A Power supply socket
e) Panel light
f) Lugs
g) Cooling Fan
h) Instrument / Electronic Earth bus 25 x 6mm copper
i) Body Earth bus 25 x 6mm copper
14.4 PANEL CONFIGURATION
14.4.1 Panel shall have the following minimum components:
• Pushbuttons,
• Indicating lamps,
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• Selector switches,
• Digital display indicators,
• Power supplies,
• Barriers,
• Relays,
• Contactors,
• Terminal strips,
• Trough etc.
14.4.2 The panel shall be configured for instrumentation scheme as shown in the tender P&ID. The quantity of indicators, lamps, push buttons, selector switches, barriers and signal multiplier shall be selected accordingly to fulfil the operational requirement of instrumentation scheme.
14.4.3 Panel shall have microprocessor based digital type channel indicator, LED, Push buttons, 3 position selector switches etc. as per requirement.
14.4.4 All the signals from hazardous area shall be routed through suitable isolator/ barriers. The isolator / barriers shall be capable of powering the two wire transmitters in the field. All isolated 4-20 mA DC analog signals & potential free Digital signal shall be available for SCADA system. These signals shall be available at terminal block of instrument local control panel.
14.4.5 The barriers used shall be of isolator type and 1 in 2 out analog input barriers shall be used. Output from isolator/barrier shall be connected to display unit in local control panel and repeated to SCADA/RTU as per requirements.
14.4.6 The isolator/barrier for digital input shall be 1 in 1 out type and the multiplication of signal if required for digital input shall be through interposing relays.
14.4.7 All field digital input/output (Non-IS) shall be connected through interposing relays.
14.4.8 The relays shall be of miniature type and shall have LED indication lamps with minimum of 2 NO and 2 NC contacts. The digital signals repeated from local control panel to SCADA RTU shall be through potential relay contact.
14.4.9 Three position (P/S/M) selector switch shall be considered in the local control panel for selection of Panel mode (local panel), SCADA mode (SCADA) & Maintenance mode.
14.4.10 All the panel instruments shall be mounted on the panel as indicated in P&ID and instrument index/IO list including utilities like UPS/battery charger on/off, DG on/off, MEDB on/off, etc.
14.5 DATA SHEET OF INSTRUMENTS
14.5.1 Item : LED
Function Status display
Mounting Flush mounted
14.5.2 Item : Signal Multiplier & Barrier
Function To repeat signal to RTU /SCADA
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14.6.1 All wiring shall conform to API-RP-550 Part I Section 7 & 12. Different signal level cables shall be routed under false flooring with separation distances as recommended by API-RP-550 Section 7.
14.6.2 All wiring inside racks, cabinets and back of the panels shall be housed in covered, non-flammable plastic raceways arranged to permit easy accessibility to various instruments for maintenance, adjustments, repair and removal.
14.6.3 All wiring in the raceways shall be properly clamped. Total wiring cross-sectional area shall not exceed 50% of the raceway cross-sectional area. Rubber / plastic grommets shall be used for wire entry into individual instrument and entry / exit of wires through raceways.
14.6.4 Separate wiring raceways shall be used for power supply wiring, DC and low level signal wiring and intrinsically safe wiring. Parallel runs of AC and DC wiring closer than 300 mm shall be avoided.
14.6.5 Vendor can alternately offer prefabricated cables for interconnection between different cabinets and panels.
14.6.6 Wire termination shall be done using self-insulating crimping lugs.
14.6.7 No more than two wires shall be terminated on one side of single terminal. Such a practice shall be avoided as far as possible. The use of short-links for looping shall be avoided.
14.6.8 Terminal housing shall be strictly sized with considerations for accessibility and maintenance. Following points shall be considered:
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Description Distance
Distance between terminal strip and side of the cabinet parallel to the strip up to 50 terminals
Min 50 mm
Distance between terminal strip and top & bottom of the cabinet Min 75 mm
Distance between two adjacent terminal strips Min 100 mm
Addition distance for each additional 25 terminals Min 25 mm
Distance between cable gland plate and the bottom of the strip Min 300 mm
14.6.9 All terminal strips shall be mounted on suitable anodized metallic or plastic standoff.
14.6.10 No splicing is allowed in between wire / cable straight run.
14.6.11 Terminal strips shall be arranged group wise for incoming and outgoing cables separately.
14.6.12 Cabinet and rack layout shall be made considering proper accessibility and maintenance.
14.6.13 Entire panel wiring including internal wiring shall be cross-ferruled.
14.6.14 All the instruments, switches, relays, timer as required shall be in the bidder’s scope to complete operational scheme.
15.0 INSTRUMENT CABLES
15.1 DESIGN & CONSTRUCTION
15.1.1 All cables shall be Flame retardant low smoke (FRLS) type.
15.1.2 Voltage Grade of cables shall be 650/1100 V.
15.1.3 1Px1.5 mm², 1Qx1.5mm², 2Px1.5 mm², 12Tx1.5mm², 6Px 0.5 mm², 12Px0.5 mm², 1Tx1.5mm² cables shall be used for instrumentation purposes. No other combination shall be acceptable.
15.1.4 Cable shall be supplied in drum and negative tolerance in cable length for each drum shall not be acceptable.
15.1.5 1T x 1.5mm² shall be used for gas detection system. Quad cable shall be used for RTD. Single pair or two pair cable shall be used from field instruments to junction box.
15.1.6 Multi pair cable individual and over all shielded shall be used for all the along signals from junction box to control room and panel to panel inside the control room as applicable
15.1.7 Multi pair over all shielded cable shall be used for all the digital input /output signals from junction box to control room and panel to panel inside the control room as applicable.
15.2 SINGLE PAIR AND QUAD SHIELDED CABLE
15.2.1 Each core shall be 1.5 mm2 made of 7 stranded annealed electrolytic copper conductor. Each strand shall be 0.53 mm dia.
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15.2.2 For Intrinsically safe application, primary insulation shall be low density poly ethylene (LDPE). For non-intrinsically safe application, primary insulation shall be 85°C polyvinyl chloride (PVC) as per IS5831 Type C. Thickness shall be 0.5 mm minimum.
15.2.3 A pair shall have twisted cores and number of twists shall be not less than 10 per metre. Colour of core insulation shall be black blue in pair and black, blue and brown in triad.
15.2.4 Individual pair shall be shielded. Shield shall be Aluminium backed by Mylar/polyester tape with the metallic side down helically applied with either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be 0.5 mm2 multi-strand bare tinned annealed copper conductor. The drain wire shall be in continuous contact with Aluminium side of the shield.
15.2.5 Inner and outer jacket shall be made of extruded flame retardant 90oC PVC to IS 5831-Type ST2. Oxygen index of PVC shall be over 30%. Temperature Index shall be over 250°C. The thickness of the jacket shall be as per IS-1554 Part 1.
15.2.6 Inner jacket colour shall be black. Outer jacket colour shall be black except, for cables to be used in intrinsically safe systems it shall be light blue. A rip cord shall be provided for inner jacket.
15.2.7 Armour over inner jacket shall be galvanized steel wire as per IS-1554 Part 1.
15.3 MULTIPAIR CABLE WITH INDIVIDUAL PAIR SHIELD AND OVERALL SHIELD:
15.3.1 Generally the cable shall be same as single pair shielded cable except conductor sizes shall be 0.5 mm2 made of 7 strands of annealed electrolytic copper conductor. Each strand shall be of 0.3 mm dia.
15.3.2 Overall shield shall be of Aluminium backed up by Mylar/polyester tape helically applied with the metallic side down with either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be similar to individual pair drain wire and shall be of the overall shield.
15.3.3 A pair of communication wire shall be provided for multipair cables. Each wire shall be 0.5 mm2 of plain annealed single or multi-strand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shall be green and red colour coded.
15.3.4 Pair identification shall be with numbers at interval of not more than 250 mm as per vendor’s standard.
15.4 MULTIPAIR CABLE WITH ONLY OVERALL SHIELD
15.4.1 These cables shall be same as above except that the individual pair shall not have shielding.
15.5 ELECTRICAL CHARACTERISTICS
15.6 RESISTANCE:
Maximum DC resistance of the conductor of the completed cable shall not exceed 12.3 Ω / km at 20oC for cables with 1.5 mm2 conductors and 39.7 Ω / km at 20oC for cables with 0.5 mm2 conductors.
15.6.1 Capacitance:
Mutual Capacitance:
The mutual capacitance of the pairs or adjacent cores shall not exceed a maximum of 250 pF / m at a frequency of 1 kHz.
Capacitance between any core or screen:
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The capacitance between any core or screen shall not exceed a maximum of 400 pF / m at a frequency of 1kHz.
15.6.2 L/R ratio of adjacent core shall not exceed 40 µH / Ω for cables with 1.5 mm2 conductors and 25 µH / Ω for cables with 0.5 mm2 conductors.
15.6.3 The drain wire resistance including shield shall not exceed 30 Ω / km.
15.6.4 Electrostatic noise rejection ratio shall be over 76 dB.
15.7 INSPECTION AND TESTING
CLIENT reserves the right to test and inspect all the items at the manufacture’s works.
Manufacturer shall furnish documents such as test certificates to prove the quality and composition of the materials used for manufacturing the cable to the satisfaction of CLIENT/CLIENT’s Representative during expediting and inspection.
15.7.1 Type Test:
a) Type Certificates shall be furnished.
b) Cable shall be flame retardant to IEC 332-3 Part 3 Cat A.
15.7.2 Routine Tests:
a) These tests shall be carried out by manufacturer during various stages of manufacturing. CLIENT shall review the related documents.
b) Insulation and Sheaths: All tests as per IS-5831 except insulation resistance, voltage and spark test shall be as per BS-5308 Part 2.
c) Armour test as per IS-3975.
d) Conductor resistance.
e) Cable capacitance, L/R ratio.
15.7.3 Acceptance Test:
These tests shall be carried out in the presence of CLIENT / CLIENT’s Representative.
15.7.4 Continuity test:
a) Voltage test as per BS-5308 Part 2.
b) Conductor resistance and drain wire resistance.
c) Cable capacitance and L/R ratio test.
d) Electrostatic noise rejection test, type wise for each lot.
e) Tests for uniformity of galvanization of armour as per IS-2633.
f) Oxygen index test as per ASTM D 2863, temp. index test, smoke density rating test, acid gas generation test and flammability test.
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g) Dimensional check for overall diameter and under armour/over armour diameter.
h) Overall finish check. In case of any lump purchaser shall have the right to cut outer sheath for lump portion and reject the cable.
i) Check of Drum length and overall length tolerances.
Immediately after completion of electrical tests, the ends of the cable shall be sealed to prevent ingress of moisture with suitable PVC/Rubber caps.
15.8 CABLE GLANDS
15.8.1 Cable gland shall be provided for all the above mentioned cables both at field instrument, junction boxes and local control panel.
15.8.2 Instrument cable gland shall be ½” NPTM insulating glands double compression type, weather proof (WP) IP 65 in field instrument side only for underground instruments tapping to protect the CP current drainage.
15.8.3 Except that, all other shall be standard metallic gland. All cables glands shall be of nickel-plated brass WP IP65 and they shall be double compression type suitable for armoured cables.
15.8.4 Flame proof Ex (d) glands in hazardous area shall be supplied and along with Ex (d) certification.
15.8.5 Cable gland shall have PVC shroud.
15.8.6 Reducer/adapter & plug shall be supplied as per requirement. These shall be Nickel plated brass, Weather proof and Flame proof as require.
15.9 CABLE TRAYS AND CABLE DUCTS
15.9.1 All branch cables/trench cable shall run on cable trays.
15.9.2 These cable trays shall be made out of galvanized iron-perforated type of 2.5 mm thickness. These trays are supported with suitable clamps shall be supplied for binding the cables/tubes at every 500 mm interval. All the cable/tubes will be laid in trench, false flooring/ ceiling trays, instrument support structures and supported with 50 mm x 50 mm angles as a minimum.
15.9.3 Maximum width of the cable tray shall be 600mm and height 50mm, 75mm or 100mm as applicable. 25% spare capacity shall be provided in cable trays.
15.9.4 The above ground outdoor field cables shall be laid in durable, non-corrosive hot dipped galvanized perforated cable trays of suitable sizes shall be provided for cable routing between junction boxes/ instruments and buried trench in the station/unit facilities. The cable trays shall be supported at regular intervals.
15.9.5 Contractor shall submit details of cable trays including size, layout drawings etc. during detailed engineering stage. Supply, installation and fixing of Prefabricated hot dipped galvanized perforated cable trays of width 50 mm / 100 mm / 150 / 300 mm as per site requirement for laying of cables. The work includes cutting to size, fixing with all accessories on concrete / wall / structures etc.
15.9.6 The proper NEMA strength classification trays shall be used in accordance with loading requirements. The tray shall be installed with standard vendor/contractor components and shall be covered with perforated covers (of same material) after laying cables.
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15.9.7 Cable tray shall be rigidly supported to carry the weight of the cables laid within, as well as any vibrations which may be experienced in normal operation of work. At no time shall the cable tray be used to sit or stand on, nor shall tools or pipe be placed on the tray.
15.9.8 Cable trays and supporting steel structure etc. to be painted as per standard procedures of painting to meet the corrosive area requirement. Proper color shall be provided in the cable trays. Epoxy based paint is to be applied on the all MS structures including support structures. Cable trays shall be installed with cabling etc as per site requirements. Cable laid in horizontal trays shall be fixed to the trays by means of suitable detachable type, non-corrosive straps at intervals not exceeding 500 mm.
15.9.9 Cable trays shall be supported at each 2500 mm or less of horizontal run and shall be so routed that there is no danger of mechanical damage. Routing shall follow major structure axis.
15.9.10 Cable trays for Hydrocarbon detectors cabling etc as per site requirement.
15.10 JUNCTION BOXES
15.10.1 Junction boxes shall be provided for intrinsically safe and non-intrinsically safe instruments also as required for packages such as gas detection system, fire detection system etc.
15.10.2 For non-intrinsic safe signals, junction box shall be explosion proof to Exd. IIA/IIB, T3 and weather proof to IP 65 and made up of dia cast aluminium.
15.10.3 For intrinsic safe signals, junction box shall be weather proof to IP 65 made up of di-cast aluminium.
15.10.4 Enclosure: Cast in corrosion resistant light aluminium alloy (LM-6) suitable for Group C & D gases. The construction shall comply to IS: 2148 - 1981 and relevant international standard (IEC - 79.1), BS: 229 - 1957). The enclosure shall have ample space for proper termination of cables as per summary of requirement attached and as mentioned in these specifications.
15.10.5 In addition, the enclosure shall be totally dust, vermin and weather proof suitable for outdoor installation without any canopy. Degree of protection should be minimum IP-65 as per IS/IEC: 60529 – 2001.
15.10.6 Terminals: Junction boxes shall be provided with vibration proof terminals (as per vendor list) clip on type 2.5 sq.mm suitable for 500 VAC working voltage. Arrangement of fixing terminals strip shall be made such that cable connections can be made easily.
15.10.7 Earthing: External and internal earthing terminals complete with set of washers shall be provided.
15.10.8 Mounting: The junction boxes shall be suitable for field mounting on M.S supporting structures.
15.10.9 Painting: Junction boxes shall be pre-treated by first coat of epoxy zinc chromate primer followed by anti-corrosive industrial epoxy grey paint shade IS 631.
15.10.10 Cable entries: The junction boxes shall have bottom entry and should be of NPT threads only.
15.11 MUTICABLE TRANSIT
15.11.1 MCT will be provided at cable entry to control room from field (hazardous area).The MCT frames shall be of standard modular variable diameter RGB type, steel construction MCT frames shall be suitable to withstand blast intensity. The MCT shall be supplied complete with insert blocks, spare blocks, stay plates, end packing etc. The MCT shall be sized considering 20% spares for each cable size/cable OD. Intrinsically safe cables and non-intrinsically cables shall be suitably separated within the MCT frame. For HT cables, LT cables/power cables and other electrical cables separate MCT frame shall be provided. Spare space shall be filled with dummy block of suitable size.
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15.11.2 MCT block shall be peel type.
15.11.3 In addition to installed spares, contractor shall also provide 30% spare insert block for each cable size/OD as loose supply.
15.11.4 Contractor shall also consider MCT blocks for the System Cables of Electrical Control system, telecommunication system, SCADA/RTU, Fire alarm system, any other system and repeat signals between control rooms while considering the requirement.
15.11.5 One additional separate MCT frame with 12 Nos. dummy blocks suitable for 12 Nos. 12P x 1.5mm2 multi core cable complete with frames, dummy blocks, plate inserts, clamps etc. shall be provided and installed all stations.
16.0 FIRE DETECTION SYSTEM
16.1 Fire detection system shall be Conventional Type Microprocessor based system. Fire detection system shall be comprised of multisensory detectors, includes optical photo electric type smoke detectors and heat detectors based on rate of raised. Multi sensor detectors shall be installed in the miscellaneous rooms like electrical room, control room/equipment room battery room, false ceiling, and false flooring as applicable of the different stations along the pipeline network. Two detectors shall be connected in loop to avoid false notification.
16.2 Multi sensor shall have combined feature of smoke detectors and thermal sensor (heat detectors). Smoke activity shall be monitored by optical sensing technology in a single detectors/base assembly. Heat detectors shall be fixed with selectable rate of rise setting.
16.3 Optical/photo electric type smoke detectors for timely detection of smoke/fire. Smoke detectors installed above the false ceiling and below false flooring wherever applicable in order to sense the fire occurred in the electrical wiring & fittings etc. The smoke detectors above the false ceiling and below false flooring are not be visible, these detectors shall be fitted with remote Response Indicators located below the false ceiling, and above false flooring (on adjacent wall) which shall glow in the event of actuation of these detectors.
16.4 The Fire Detection and Alarm System shall be of high quality fast-acting conventional system. The system shall consist of compatible microprocessor-based fire alarm control panel, repeater panel, junction boxes, detectors, hooters, beacons, exit signs, response indicators, siren with starter, Break glass unit (Manual call points) etc. with associated wiring.
16.5 The detecting units shall be installed, tested and commissioned in accordance with NFPA-72, IS & other international standards on Automatic fire detectors.
16.6 All system components and devices shall be connected to two wire loop circuits in such a way that removal or disconnection of any device from the loop shall not affect the functioning and performance of the system.
16.7 The system should also have provision to give fault signal which shall be a distinct signal audible and/or visual indicating a failure of electric supply, presence of a break, an earth or other electrical fault on a circuit or system of circuits.
16.8 Devices like hooters, horns, sirens or like which give the sound signals shall be installed to give sounds with the electrical alarm signals from the detectors or when there is fault in the system.
16.9 Electrical wiring must conform to IS: 732-1963 or equivalent International Standards.
16.10 All electrical cables shall conform to IS: 1554 / BS: 5308 Part 2 or equivalent international Standards with latest amendments. All cables to be laid underground in the field shall be armoured type. Cables laid inside conduits in buildings may be unarmoured type
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16.11 On the alarming, two red flashlights located in the Control Room and in the guard room at site and two horns one inside and other outside will be actuated at the same time.
16.12 A break glass unit (BGU) shall be installed at the outer side of each rooms and in field wherever feasible (decided during engineering stage) for manual actuation of the fire alarm.
16.13 When a detector is in alarm condition, the information shall be sent to the central unit and the central unit shall send to SCADA through RTU. The alarm situation of the detector shall remain “ON” until a manual reset device is activated on the central unit. An indicating LED shall permit the direct identification of the detector that is the cause of alarm.
16.14 The fire control panel will derive its power from a 24V DC main, which will be converted to require voltage (DC) level by the contractor inside the panel if require. The fire control panel shall provide the required power to the sensors and accessories and will monitor the zonal circuits for open and short circuit faults. The fire control panel shall also be provided with a secondary power source comprising two nos. of Maintenance free batteries, which automatically takes over the system in the event of 24 V DC power failure to the panel.
16.15 Contacts used in intrinsically safe circuit shall be gold plated. All electronic circuits used in the system shall be free from the effects of any RF interference.
16.16 Fire detection system shall be suitably hooked up with CO2/Clean agent fire suppression system for auto/manual flooding in control room/equipment room and electrical.
16.17 Field mounted Electrical operated Siren with audible range of min 1 KM integrated with fire detection system.
16.18 fire detection system shall have provision for interface with RTU/SCADA system on RS 485/RS232
16.19 HEAT DETECTORS
Heat detectors shall be used negative temperature coefficient thermistor for sensing and for reference. The detectors shall be designed to give a response that depend on both absolute temperature and rate of raise.
The rate of raise element shall be carefully calibrated to ignore any normal fluctuation in temperature, but to respond quickly when the temperature rise is 9 °C or more per minute (also decided during detailed engineering stage).
The fixed temperature feature should be entirely independent of the rate of raise element. The operating temperature of fixed temperature element should be factory set at 57 °C ±5 °C.
The detectors shall be self-restoring type ensuring repeated use and easy maintenance.
16.20 OPTICAL/PHOTO ELECTRIC SMOKE DETECTORS
Optical smoke detectors shall work on the principle of light scattering utilizing a light emitting diode.
16.21 Input/output signals
The input signals of the central unit of the fire detection system shall be from:
a) Smoke detectors and Heat detectors, (Multisensor) etc.
b) Break glass units for a manual actuation of the fire alarm,
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c) Break glass units connected in series, located in the plant and actuated manually when fire is detected.
16.22 SYSTEM COMPONENTS
The system shall for each site comprise:
a) Smoke detectors and Heat detectors (Multisensor)
b) Red flash lights (common for fire and gas detection system by gas detectors vendor) in control rooms & Guard room.
c) Two horns (common for fire and gas detection system by gas detectors vendor) in control rooms & Guard room
d) Break glass units, (Exit gate of each room & Field)
e) Electrical operated Siren with audible range of min 1 KM
f) A central unit equipped with “silence alarms” and “reset” key push-button. RS 485 port for communication interface with third party system.
16.23 THE FOLLOWING TECHNICAL DATA SHALL BE SUPPLIED BY THE CONTRACTOR:
a. Power supply:
• Operating
• minimum
• maximum
b. Consumption during normal condition.
c. Consumption during alarm condition.
d. Operating temperature range.
e. Operating humidity range.
f. Sensibility,
16.24 DETECTOR
The detector shall consist of:
a) an I.R. source LED,
b) a SI-diode receiver,
c) electronic connections and electric contacts with high impedance,
d) heat sensor
e) a metallic protection,
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f) sensitive elements impregnated with silicone rubber,
g) an anti-condensation system,
h) an indicating LED,
i) A mounting base.
16.25 CENTRAL UNIT
The central unit shall consist mainly of:
a) A power supply module comprising power supply and charger for one 24 V safeguard battery.
b) A monitor module for earth leak faults, short-circuits, lamp or LED test and general reset push button,
c) A monitor module for power supply and battery failures associated with a general alarm switch and an indicating lamp or LED,
d) A general alarm module associated with a reset push button of the audio signal,
e) A module able to monitor the state of the input signals and to generate the right action with regard to the output signals,
f) A front panel with lamps or LEDS to indicate the state of the input and output signals.
g) Sensor fault shall be provided from Fire Alarm Control Panel (FACP) to SCADA.
h) All devices connected at the inputs of the central unit shall be supplied with electronic connections and electric contacts with high impedance to facilitate the immediate detection of short-circuit or line cuts.
i) Fire detection panel shall be wall mounted for all unmanned station. Size of the wall mounted panel as per the vendor standard.
16.26 Input supply and battery backup
• Input Supply 24 V DC
• 24 hrs backup (normal state) & 15 min in alarm state
• Batteries VRLA
16.27 Battery charger provided in the FACP shall be modular mounted on a draw out chassis. Charger module shall be located on the front allowing withdrawal with the help of handle bars for maintenance.
16.28 Logic of operation shall be preferably built on "Fail safe" feature i.e. NC contact of field devices shall be considered as healthy condition and NO as fire condition. 1 NO+ 1 NC contact of output relays shall be wired to terminal block for interface with Owner's other equipment.
16.29 It shall be possible to test lamps, hooters, flasher circuit, and carry out functional tests etc. through common "Test" push button.
16.30 The circuit shall be so designed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarm received from any other location.
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16.31 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiring because of proximity with power cables. Cables for field devices shall be multicore copper conductor, unscreened, armoured, copper conductor cable.
16.32 Detectors and BGUs shall be wired through 1.5 mm2 multi-core, copper conductors, PVC insulated, armoured FRLS cable.
16.33 LEDs shall be provided for fire/ fault visual annunciation on the panel front. LED shall also be provided for Power supply healthy, Battery backup ON, Battery/ Charger status.
16.34 If zone is protected with clean agent/CO2 system, the detectors and BGUs of the zone shall be wired in cross-zones by providing minimum two signaling circuits in a zone. The last device in each circuit shall be provided with end of line resistor of suitable value as per circuit design to facilitate cable open circuit and short circuit detection.
16.35 Vendor shall decide the zones according to area/rooms. These zones shall be created in coordination with CO2/Clean agent supplier. Zone wise alarm output signals shall go to the Beacon, Hooter, Siren actuation, CO2/Clean agent flooding system and RTU.
16.36 FDS shall be interface with RTU on RS 485
16.37 SCHEME FOR FIRE/ FAULT ANNUNCIATION:
System condition AUDIO VISUAL
NORMAL OFF OFF
FIRE ON (tone 1) Flasher ON, Fire LED Steady ON
Accept OFF Flasher steady, Fire LED steady ON
Reset OFF Flasher OFF, Fire LED OFF
FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON
Accept OFF Flasher OFF, Fault LED Steady ON
Reset OFF Flasher OFF, Fault LED OFF
16.38 Repeater panel
Repeat fire alarm panel shall be similar to FACP except providing zones for detector. Fire/ fault annunciation of FACP shall be repeated at repeater panel. Depending on the size Repeat Fire Alarm panel may be floor mounting type or wall mounting type. Repeater shall also have the facility to acknowledge the alarms and hooter
These panels shall be required for repeat of alarm in Guard rooms at approx. 100 meters from FACP.
17.0 GAS DETECTION SYSTEM
17.1 Addressable type Hydrocarbon Gas detection system shall consist of point detectors and one control unit.
17.2 Addressable IR type Point gas detectors shall be considered for metering & filter skid, piping instruments, station sectionalisation valve, pig launcher/ receiver terminals, tap-off node and else wherever needed in hazardous area.
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17.3 The equipment which is nearest to Insulating joint (IG), the Point gas detectors shall be placed in such way that, same shall also cover the IJ leakages area wherever applicable or if it is not possible to cover IJ area with same PGD, then separate detectors shall be provided. Contractor shall explore the possibility and provide the PGD as per site conditions and requirement.
17.4 All the PGD shall be multidrop in field mounted junction and main/trunk cable shall be connected with gas detection controller.
17.5 The LEL indication for high, high high gas concentrations and a failure/default state shall be detected and signalized by the control unit.
17.6 Gas detectors cabinet shall be wall mounted. Size shall be decided by vendor. The outer and inner colour of the gas detection panel shall be as per RAL 7035.
17.7 Gas detectors output will be digital communication. Control unit will be interface with RTU/SCADA system on RS 485/RS232
17.8 Potential free contacts for alarm at 20% and 40% LEL per channel and sensor fault. Adjustable high, high- high alarm (SPDT free potential relay contacts) and sensor fault alarm per channel shall be provided and interface with RTU.
17.9 SYSTEM COMPONENTS
a) Field Mounted flame proof point gas detectors
b) Monitors / controllers for Gas Detectors.
c) Gas detection Panel
d) Ex”d” Junction box
e) Portable hydrocarbon gas detector
f) Calibration kit
g) Alignment kit
h) Beacon flasher and hooter.
17.10 TECHNICAL DESCRIPTION OF THE COMPONENTS-REFER DATA SHEET ENCLOSED WITH THIS DOCUMENT-APPENDIX-3
17.10.1 FOLLOWING INDICATIONS SHALL BE AVAILABLE ON EACH DETECTOR/CHANNEL:
a) Power-on indication.
b) Alarm high indication.
c) Alarm high high indication.
d) Malfunction indication (this shall include short circuit, line-breaking, over-range and earth fault).
e) Latched type of relay contacts shall be provided for each channel for;
Alarm high
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Alarm high high
Malfunction alarm
f) Each channel shall also have calibration switch to allow sensor calibration without alarm output.
17.11 PORTABLE GAS DETECTOR
One number portable gas detectors shall be supplied for hydrocarbon, complete with its controller, audio-visual alarm. The portable gas detectors shall be suitable (intrinsically safe/Ex Proof) for use in hazardous area specified. Hand-held type Portable Gas Detectors shall be supplied for measuring Methane from 0% to 100% by Volume, 0% to 100% LEL and 0% to 25% by volume of Oxygen as well
These units shall be supplied with rechargeable batteries and 230 V AC Battery charger. Sufficient number of battery charger/number of points per charge shall be provided based on quantity of such portable units. These units shall be supplied complete with its accessories like carrying case, maintenance kit, calibration kit etc.
17.12 CALIBRATION KIT
Contractor shall supply calibration kit for calibration of open path and point gas detectors along with all the necessary equipment require completing calibration activity. Contractor shall provide the list of calibration equipment comprise in kit.
17.13 COMMISSIONING /ALIGNMENT KIT
The commissioning/alignment kit along with telescope shall be provided. Contractor shall provide the list of commissioning/alignment equipment comprise in kit.
17.14 BEACON AND HOOTER
Beacon flasher and hooter shall be provided as per requirement. Infield Placement of flasher in such a way that, it should be easily visible to Person/guard present there. Consideration of beacon and hooter in gas detection system same shall be applicable for fire detection system. Contractor shall provide necessary provision to integrate alarm signals with hooter and flasher.
1 no. beacon/hooter shall be provided in control room.
1 no. beacon/hooter with reset push button shall be provided in Field.
The hooter shall be electronic type and shall have sound intensity of 100dBA, as a minimum. Different tones shall be provided for fire/smoke and hydrogen carbon gas releases.
Both Beacon and hooter units shall operate at 24 V DC and shall be certified explosion proof (flame proof) when installed in hazardous area. The beacon shall be of stroboscopic type and shall have sufficient intensity to provide the visibility and clear contrast during full daylight".
Beacon light shall follow the following sequence:
Gas leakage/smoke detect - Flashing beacon light
Different tone for gas /smoke-Hooter continues
Control room acknowledge - Flashing beacon light
Hooter stops
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Gas leakage stops - Flashing beacon light
Hooter off
Control room reset - Beacon Off
Hooter Off
17.15 Minimum No. of Detectors / Manual call points / Hooters at each station Below given quantities are tentative, this may vary as per site condition. Contractor shall ascertain the quantity as per site requirement and supply accordingly without additional cost to client
Sr. No
Description
Point Detector
Multi sensor Detector
Manual call point
Beacon/Hooter
1. Station Control Room 2 1 WP - 1
2. Electrical Room 2 1
3. Battery Room 2 1
4 Maintenance room 2 1
5 Pig launcher/ receiver 2 1
6 IJ/ leakage prone point 1
7 Metering skid 2
8 Guard room/site Ex”d”-1 Ex”d”-1
9 Siren-site Ex”d” -1
18.0 INSTALLTION MATERIAL SPECIFICATION
18.1 All instruments impulse line (1/2” tubes) shall be consist of tubing and piping. The impulse tube shall be SS316 and all the impulse pipes shall be CS/LTCS. Compressed type ferrule fitting such as ½” NPT (M) , NPT (F) fittings (male/female connectors), ½” tee, ½” union including ½” isolation needle/ball valves & other accessories shall be SS316.
18.2 Instrument Impulse tubing
1/2" OD x 0.065" and 1/4" OD x 0.065" (if applicable) wall thickness, seamless, fully annealed 316
stainless steel tubing shall be used.
Tubes shall be cold drawn as per ASTM A 269.
Hardness of the tubes shall be Rockwell RB 70 – 79.
18.3 Compression fittings
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001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 28 of 32
• Compression fittings shall be of the two-ferrule type in 316 stainless steel.
• Fittings shall be of flareless compression type and four-piece (for double compression type) construction consisting of two ferrules, nut and body suitable for use on SS tubes conforming to ASTM A 269 TP 316 with hardness in the range of RB 70 to 79.
• Hardness of the ferrules shall be in the range of RB 85-90 so as to ensure a hardness difference of the order of 5 to 10 between tubes and fittings for better sealing.
• Nuts and ferrules of a particular size shall be interchangeable for each type.
• Spanner hold shall be metric.
• Threaded ends of fittings shall be NPT as per ANSI B 1.20.1
• Specific techniques like silver plating shall be used over threading in order to avoid jamming and galling.
• It shall be ensured by the contractor that all fittings shall match the seamless ½” OD SS 316 instrument tube with wall thickness of 0.065” conforming to ASTM A 269
• Body rating shall be as per piping class or higher.
• Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim material shall be selected as required by process conditions. Packing material in general shall be of PTF
• The isolation valves for instrument service shall be 316 stainless steel, unless process conditions require another material.
18.5 Instrument Sunshades
Instrument sunshades shall be made from Fiber glass reinforced, polyester/Metallic, supplied with mounting clamp (epoxy coated) suitable for a 2" instrument stand.
For instruments located in hazardous area, sunshades shall be as described here above but anti-static type.
18.6 Instruments supports/structural steel
The supports for instruments and junction boxes shall be in accordance with the “Instrumentation Standard hook up drawing “as attached. Vendor shall supply instrument stands, stanchions and other structural steel material required for supporting the cable trays, impulse line and instruments.
18.7 Cable Ties
• All cable ties shall be constructed from black PVC and have a breaking load greater than 20 kg. They shall be of a self-locking style and non-slip, but shall be releasable for the addition of extra cables. Cable ties for use on trays shall fix into the tray slots (two piece ties).
18.8 Nameplates Tags labels
• The nameplates, tags and labels for identifying junction boxes, instruments, panels, cabinets, etc shall be made from engraved trifoliate and shall be in accordance with the specification as mentioned in GTS.
19.0 CORROSION MONITORING SYSTEM
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001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 29 of 32
19.1 General
The corrosion monitoring system shall be used to establish the internal corrosion profile of the pipeline using electrical resistance (ER) corrosion probes and corrosion coupons in conjunction with inspection technology.
ER-Probes and coupons shall be located as per the P&ID’s.
1. Despatch
2. Receiving
19.2 SPECIFICATION
The electrical resistance (ER) type probes and coupons to be installed at the stations as mentioned above shall be retrievable from the line under pressure. The probes and coupons shall be flush mounted on the pipeline. All materials in contact with fluid shall be in accordance with NACE Standard MR-01-75. Pipeline inlet pressure may vary according to pipeline pressure drop due to different flow rates. The corrosion monitoring system shall be suitable for operation under this fluctuating pressure conditions.
Each probe shall be connected to a transmitter (2 wire systems) to give an output of 4-20 mA, proportional to corrosion rate.
Local monitoring equipment of CMS shall be mounted in the local control panel.
Barrier, display unit, terminal blocks etc shall be provided in the LCP cabinet. Single shall be repeated through dual output channel repeater or barrier to provide the independent signals to RTU as well local indicator.
19.3 MATERIALS
The scope of supply shall consist as a minimum requirement the following components:
19.3.1 ER Probe
Probes shall be high pressure retrievable type, flush, mounted, body in SS-316 with element of carbon steel for installation with high pressure hollow plug access fitting assembly. The probe shall be suitable for measurement of corrosion rate in the range of 0-10 Mils Penetration Per Year (MPY).
Probe life shall be at least 2 years at 2-3 MPY corrosion rate.
Access Fitting Assembly – for ER Probe
2” NB, 5.25” height, flare weld Access Fitting Assembly (Non-Tee), body carbon steel, and ACME thread outlet with hollow plug assembly of AISI-316 along with heavy duty protective C.S. cover complete with essential spare.
Transmitter – for ER Probe
Transmitter shall be 2 wire types to give an output of 4-20 mA, proportional to corrosion rate, to panel mounted corrosion meter.
19.3.2 Coupons
Mild steel flush disc coupons 1.25” dia. x 1/8” thickness with one mounting hole of ID 0.312”.
Retrievable coupon holder shall be of SS-316.
Access Fitting Assembly – for Corrosion Coupon
2” NB, 5.25” height, flare weld Access Fitting Assembly (Non-Tee) carbon steel, acme threat outlet with solid plug assembly in AISI-316 along with heavy duty protective C.S. cover complete with essential spare.
PTS – INSTRUMENTATION WITH APPENDICES
P.011947 I11097
001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 30 of 32
19.3.3 Retriever kit complete with repair and seal kit for ER probes and coupon holders
Service Valve Kit, complete with blanking plug, extension lever, 1 hammer, spare face-to-access fitting O-ring, heavy duty field service box, essential repair and seal kit.
19.4 DOCUMENTATION TO BE PROVIDED BY VENDOR
- All components data sheets.
- Engineering, Purchasing and Construction Schedule.
- Spare Parts List for Erection and commissioning
- Operating and maintenance Manual
- Quality Control Plan
19.5 ANNEXURE I – PROBE DATA SHEET
General
Tag no.
Line no.
Wall thickness 10.3 mm
Pipe material API 5L GR.X-70 PSL 2
Service Hydrocarbon
Probe
Type Retrievable ER probe with temperature compensation
Material Body : SS-316
Element: Carbon steel
End connection 2” FLARE WELD
Probe element type Flush mounted
Element thickness – 10 mil min.
Probe length To be decided by vendor
Access fittings
Type 2” NB, 5.25” height flareweld (Non-Tee), ACME thread outlet with hollow plug assembly
Material Body : carbon steel hollow plug assembly : SS-316
Accessories
Protective cover Required
Retriever & service valve kit
Required
Monitoring Type Mounted in CMS cabinet.
NOTES:
1. Vendor to note that manufacturing flaw, if any, of ratio between sample reference elements shall be normalized by an ‘intelligent’ in built device.
2. Probe length and Retriever size shall be decided by Vendor.
3. 1 no. coupon holder with corrosion coupons will be installed on each line. Coupon holder length shall be decided by the vendor accordingly.
PTS – INSTRUMENTATION WITH APPENDICES
P.011947 I11097
001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 31 of 32
19.6 ANNEXURE II – TRANSMITTER DATA SHEET
Tag no.
Line no.
Type 2 wire / 4 wire type
Input From retrievable ER probe with temperature compensation
Output 4-20 mA.
Cable lead 5’ for ER probe connection
Power supply 24 V DC from receiver unit
Mounting At site near probe by bracket/yoke support
Intrinsically safe Yes
Safety barrier to be provide between transmitter and receiver
Yes,
Signal from Corrosion Monitoring System shall be repeated through dual channel isolator/barriers. Corrosion Monitoring System shall be hooked up with LCP & RTU.
20.0 INSPECTION AND TESTING
20.1 The manufacturer shall carry out inspection and testing as per relevant codes and service requirements of this specification, for all items of work prior to shipment. Manufacturer’s test certificates in proper format must be sent with the despatch paper of all supply items.
20.2 All instruments and system oriented items shall undergo factory testing and inspection by Contractor’s authorized representatives, Owner/Consultant unless specified otherwise.
20.3 Wherever inspection at manufacturer’s shop is waived because of any reason, the sub vendor’s own testing reports shall be verified before dispatch. In no case, items shall be released without proper inspection/ verification.
20.4 The instrumentation inspection and testing shall be carried out as per inspection and test plan attached with bid document, other specifications and documents. Where, the inspection and test plan is not available, Contractor shall develop the inspection and test plan and submit for review/approval by the Owner/Consultant.
20.5 Testing and inspection of all instrumentation items shall be carried out as per approved factory testing procedures. For instrumentation items where no testing is witnessed by the Owner/Consultant, following test certificates shall be forwarded for review before dispatch of such instrument:
Verification of certificates as applicable for the material certificates, NDT reports like radiography/ X-ray/ die-penetration/ MP etc., statutory certificates for Intrinsic safety and explosion proof, certificates of conformity etc.
Visual verification for quantity, quality and workmanship.
Hydro testing and pneumatic testing as applicable.
Functional and performance test certificates including calibration, accuracy, and repeatability testing of instruments.
Test certificates for pressure relief valves, set pressure & seat leakage test
PTS – INSTRUMENTATION WITH APPENDICES
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001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 32 of 32
Radiographic test for pressure relief valves and thermowells.
20.6 Contractor shall submit all instrumentation test records / test results for records to Owner/Consultant as bound volume along with the test procedure for each test carried out.
20.7 Acceptance test
After completion of the CONTRACTOR tests, the CONTRACTOR shall perform, at the CONTRACTOR's facility, a functional test on 100 % of inputs and outputs with simulation panel provided and wired up by the CONTRACTOR.
All deficiencies shall be recorded, and corrections made.
Appropriate tests shall be run to demonstrate that the deficiencies have been corrected and that there has been no degradation to the system.
20.8 On-site acceptance test
These tests shall be basically a repeat of the system factory acceptance test. To the extent possible, the simulation of I/O signals shall be replaced by the actual signals.
21.0 PAINTING, MARKING AND SHIPMENT
All items shall be painted and marked as per manufacturer’s standard before shipment. All items shall be properly packed and protected to avoid damage during shipment. Insurance during shipment shall be ensured by the manufacturer.
Σ Σ Σ
PTS – INSTRUMENTATION WITH
APPENDICES
P.011947
I 11097
001
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 1 of 1
APPENDIX - 1
SPARE CAPACITY
Spare capacity is depending on the type of equipment and is defined in the following table. Spare quantity is minimum
one number or as specified whichever is higher.
ITEM DESCRIPTION SPARE QUANTITY
1 Multicore cables
• Spare cores (all cores have to be connected to the terminals of
junction boxes, marshalling racks or any other terminal strip)
20 %
2 Cable ladders and trays
• Spare room for additional cables
20 %
• Spare opening for cable entry in JB and all panel/cabinets with blind
caps.
20%
• Spare cable gland for JB and panel/cabinets 20 %
3 Spares terminal blocks are required in junction boxes and in all panel/cabinets.
20%
4 Spare digital and analog isolators/barriers and relay in local control panel
10%
5 Spare channels, slots in gas detection system. Spare slot shall be plugged
10%
6 MCT shall be sized considering spare for each cable size/ O.D. In addition to
install spares.
50%
7 Spare insert MCT blocks for each cable size/O.D. as loose supply.
30%
8 Power distribution system shall have equipped spares and capacity.
20%
9 The racks to be sized to assure spare capacity (in each station) after
implementation of all present and known future requirements. The spare
capacity shall be distributed strategically throughout the logic shelves to
facilitate “in the field” modifications.
20%
10 Electrical switches/ MCBs considering minimum 1 no. for each rating
20%
11 Electrical terminals/ TBs 20%
12 Electric connectors 20% 13 Fuses, LEDs with full assembly, and other electrical accessories. 20% 14 1 in 2 out analog Safety barriers 20% 15 Safety barrier for Digital inputs 20% 16 Relays 20%
One additional separate MCT frame with 12 Nos. dummy blocks suitable for 12 Nos. 12Px1.5mm2 multi core cable
complete with frames, dummy blocks, plate inserts, clamps etc. shall be provided and installed all stations.
It is Contractor’s responsibility to have commissioning spares as required for commissioning of total Instrumentation
System. It is deemed to be included in his scope of supplies/ work.
Σ Σ Σ
Tag Number Instrument Type Service LocationP&ID
NumberSource Destination
Indication in
LCP
Type of Signals
in RTURange Remarks
PT-0201 Pressure Transmitter Upstream Pressure of GOV 0201 Field 002 0-140 Barg
PY-0201ADual output Channel Galvanic
IsolatorLCP
PI-0201A SCADA Pressure indication at SCADA SCADA Channel-1 RTU AI
PI-0201B Indicator Pressure Indication at LCP LCP Channel-2 LCP Digital Indicator
PG-0201 Pressure Gauge Upstream Pressure of GOV 0201 Field 002 0-140 Barg
TE 0201 Temp Element- RTD Upstream Temp of 1GOV 0201 Field 002 -20 to 100 deg C with thermowell
TT-0201 Temp Transmitter Upstream Temp of 1GOV 0201 Field 002 -20 to 100 deg C
TY-0201ADual output Channel Galvanic
IsolatorLCP
TI-0201A SCADA Temp indication at SCADA SCADA Channel-1 RTU AI
TI-0201B Indicator Temp Indication at LCP LCP Channel-2 LCP Digital Indicator
PT-0202 Pressure Transmitter Downstream Pressure of GOV 0202 Field 002
PY-0202ADual output Channel Galvanic
IsolatorLCP
PI-0202A SCADA Pressure indication at SCADA SCADA Channel-1 RTU AI 0-140 Barg
PI-0202B Indicator Pressure Indication at LCP LCP Channel-2 LCP Digital Indicator
PG-0202 Pressure Gauge Downstream Pressure of GOV 0201 Field 002 0-140 Barg
TE 0202 Temp Element- RTD Downstream Temp of 1GOV 0201 Field 002 -20 to 100 deg C with thermowell
TT-0202 Temp Transmitter Downstream Temp of GOV 0201 Field 002 -20 to 100 deg C
APPENDIX 2
INSTRUMENT INDEX WITH SIGNALS
SIGNALS FROM FIELD INSTRUMENTS TO LOCAL CONTROL PANEL AND RTU
Despatch Station, Boreri
P.011947
I 11097
001
Rev. 0 - 15.02.2018
Boreri to CFCL - III, Gadepan Project Pipeline
Page 1 of 22
Tag Number Instrument Type Service LocationP&ID
NumberSource Destination
Indication in
LCP
Type of Signals
in RTURange Remarks
APPENDIX 2
INSTRUMENT INDEX WITH SIGNALS
P.011947
I 11097
001
TY-0202ADual output Channel Galvanic
IsolatorLCP
TI-0202A SCADA Temp indication at SCADA SCADA Channel-1 RTU AI
TI-0202B Indicator Temp Indication at LCP LCP Channel-2 LCP Digital Indicator
GOV 0201Isolation Valve ON/OFF Type (Gas
Over Oil actuated valve)
Isolation Valve ON/OFF Type (Gas
Over Oil actuated valve)Field 002
ZSH0201 Limit Switch (OPEN) Valve GOV 0201 Open Field
ZYH-0201A Galvanic Isolator LCP
ZYH-0201B Relay Multiplier/Repeater LCP
ZLH-0201A SCADA Open Position Indication at SCADA SCADA Relay Multiplier/Repeater RTU DI
ZLH-0201B Indicator Open Position Indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp
ZSL-0201 Limit Switch (Close) Valve GOV 0201 Close Field
ZYL-0201A Galvanic Isolator LCP
ZYL-0201B Relay Multiplier/Repeater LCP
ZLL-0201A SCADA Close Position Indication at SCADA SCADA Relay Multiplier/Repeater RTU DI
ZLL-0201B Indicator Close Position Indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp
XSOV-0201A Open Solenoid Valve Valve GOV 0201 open command Field DO
XYSOV-0201A Galvanic Isolator LCP
XSOV-0201B Close Solenoid Valve Valve GOV 0201 close command Field DO
XYSOV-0201B Galvanic Isolator LCP
HS-0201A SCADA Open command from SCADA SCADA RTU Pot free contract to LCP
HS-0201C SCADA Close command from SCADA SCADA RTU Pot free contract to LCP
Rev. 0 - 15.02.2018
Boreri to CFCL - III, Gadepan Project Pipeline
Page 2 of 22
Tag Number Instrument Type Service LocationP&ID
NumberSource Destination
Indication in
LCP
Type of Signals
in RTURange Remarks
APPENDIX 2
INSTRUMENT INDEX WITH SIGNALS
P.011947
I 11097
001
HS-0201B Push button open Open command from LCP LCP LCP XSOV 0201APress to release
PB
HS-0201D Push button close Close command from LCP LCP LCP XSOV 0201BPress to release
PB
HS-0201F Local/Remote Selection switch Local/Remote selection Field
HY-0201A Galvanic Isolator LCP
HY-0201B Relay Multiplier/Repeater LCP
XI-0201G SCADA L/R indication at SCADA SCADA Relay Multiplier/Repeater RTU DI
Boreri to CFCL - III, Gadepan Pipeline Project Page 1 of 18
1 * 14 1/2" NPT(F)
2 4 Wire RTD 15 Two
3 Duplex 16 WP to IP 65 as per IEC 60529 / IS 2147
4 As per IEC 60751
5 Pt100 17 SS316
6 100 Ohm 18
7 Hermatically Sealed 19 Welded
8 20 1/2" NPT(F)
10 mm 21 TEIND-STD-G-J-4002
SS316 22
9 SS316
10 Four Wires a) 150 mm
11 Mineral(MGO)Insulated b) ________________
12 c) ________________
13 Accuracy Class A 23 Quantity :-
NOTES: 1 Element length shall be suitable for thermowell.
2
3 Vendor shall submit wake frequency and other test related test certificates,T/W drawings etc for approval during detailed engineering stage
4 RTD to be provided with 2 nos cable entries with one no. cable entry provided with suitable plug
5 Thermowell shall be of 900# rating
6 Refer the applicable PTS - P.011947/I/11097/001
* VENDOR TO FURNISH
DEVIATION NO DEVIATION VENDOR'S SIGNATURE WITH SEAL
MA SHD0 15.02.18PROJECT: BORERI TO CFCL-III
SK
VENDOR: REV. DATE PREP
P.011947/I/11097/001
CHKD APPD
Sheet No. 2 of 18 CLIENT: GAIL
APPENDIX 3
Thermowell's immersion length shall be selected in such a way that tip of the thermowell shall preferably be at the centre of pipe to sense temperature properly.
FLANGELINE NO. / VESSEL
NO. / PIPING CLASSOPTION
NOR. MAX. DES. U T MATERIALRATING, FACING,
FINISH
SL. NO. TAG NO.
TEMP.°C WELL DIM.
No. of Wires:- Extra Nipple Extens
Insulation
Head Cover Type:- Screw Cap of Die Cast Aluminium with SS Chain
Matl.:- Options:-
Nipple & Union Matl.:-
Sheath: Inst. Conn.:-
O.D.:- Thermowell Dwg:-
Resistance at 0°C:- Construction:-Drilled bar stock upto immersion length 500 mm,
otherwise fabricated
Leads:- Process Conn:-
Calibration:- Thermowell:
Element Material:- Material:-
Element: No. of Entries:-
No. of Elements:- Enclosure Type:-
RESISTANCE TEMPERATURE DETECTORS ALONG WITH THERMOWELL
XI-Spare-3G SCADA Panel mode selection at SCADA SCADA LCP RTU DI
XI-Spare-3F SCADAMaintainence Mode selection at
SCADASCADA LCP RTU DI
XI-Spare-3E SCADA SCADA Mode selection at SCADA SCADA LCP RTU DI
Corrosion Monitoring
ProbeCMS system 0402-NG-18"-6C1-N LCP 004 0-10 MPY
CM-A SCADA CM indication at SCADA SCADA LCP RTU AI
GDS SYSTEM Gas detection system GDS system Control room 004 GDS RTU RS 485
METERING SYSTEM Metering system Flow Computer-1 Control room FC RTU RS 485
METERING SYSTEM Metering system Flow Computer-2 Control room FC RTU RS 485
Gas chromatograph GC system GC-1 Control room GC RTU RS 485
Gas chromatograph GC system GC-2 Control room GC RTU RS 485
Note
Spare -1 , 2 & 3 Exisitng GOV signals to be connected with LCP and RTU
CMS SYSTEM
EXISTING GAS DETECTION SYSTEM
EXISTING METERING SYSTEM
Rev. 0 - 15.02.18 Boreri to CFCL - III, Gadepan Project Pipeline Page 13 of 13
1 AI(4-20mA) Analog input card 40 20 6 0 14
2 DI(24 V DC) Digital Input card 64 20 11 0 9
3 DO(24 V DC) Digital output card 24 8 2 0 6
4 ModbusModbus serial master
port 8 6 1 0 5
1 AI(4-20mA) Analog input card 20 0 6 7 33
2 DI(24 V DC) Digital Input card 32 0 29 16 77
3 DO(24 V DC) Digital output card 12 0 8 5 25
4 Modbus RSModbus serial master
port 4 0 5 3 12
New Input
OutputRemarks
Remarks
Total Input / output
in RTUType
Spare in existing
Input Output
NEW RTU- CFCL STATION
Sl. No.Total Input / output
in RTU
spare 25%Sl. No.
EXISTING RTU - BORERI STATION
Total IOS IN NEW
RTU
Total Available in
Existing RTU
Existing Input
Output
Existing Input
Output
New Input
Output
P.011947
I 10797
003
Spare in existing
Input Outputspare 25%
ANNEXURE II
TYPICAL I/O COUNTS DETAILS FOR RTU SYSTEM
Type
Rev. 0 - 15.02.18 Boreri to CFCL - III, Gadepan Project Pipeline Page 1 of 2
P.011947
I 10797
003
ANNEXURE II
TYPICAL I/O COUNTS DETAILS FOR RTU SYSTEM
1 AI(4-20mA) Analog input card 0 0 5 2 6
2 DI(24 V DC) Digital Input card 0 0 43 11 52
3 DO(24 V DC) Digital output card 0 0 6 2 8
4 ModbusModbus serial master
port 0 0 3 1 4
1 In addition to above, RTU shall have dual ethernet communication port for telecom modem , dedicated diagnostic and USB port etc.
2 Modbus serial port RS 485 shall be master and slave configruable
3 Modbus serial port RS 485/RS232 shall be configruable either RS 485 or RS 232
4
Note
Total IOS IN NEW
RTU
Spare in existing
Input Output
New Input
Outputspare 25%TypeSl. No.
Existing Input
Output
Spare slot shall be compatible/configurable for inserting all type of cards as analog input, analog output , digital input or digital out cards or modbus
Total Input / output
in RTU
NEW RTU-SV STATION
Remarks
Rev. 0 - 15.02.18 Boreri to CFCL - III, Gadepan Project Pipeline Page 2 of 2
PTS – TELECOMMUNCATION
SYSTEM
P.011947
I 10797
003
BORERI - CFCL-III PIPELINE PROJECT
TRACTEBEL ENGINEERING PVT. LTD.
DOC. NO. P.011947 I 10797 003
PTS – TELECOMMUNCATION SYSTEM
0 15.02.2018 Issued for RFP MA SD SK
Rev. Date Subject of revision Prepared By Checked By Approved By
PTS – TELECOMMUNCATION
SYSTEM
P.011947
I 10797
003
Rev. 0 – 15.02.18 Boreri to CFCL – III,. Gadepan Pipeline Project Page 1 of 1
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 1 of 22
1.0 INTRODUCTION
1.1. This document presents the technical specification for the Armoured Optical Fibre cable required for this Pipeline Project.
1.2. Optical Fibre Cable is proposed to be laid along the pipeline between Dispatch station, SVs to Receiving station.
2.0 SCOPE
2.1. Design, Engineering, Manufacturing, Testing and Supply and laying of armoured Single Mode Optical fibre cable (18 Fibres as per ITU-T G652 & 6 Fibres as per ITU-T G655) and blowing/pulling through PLB-HDPE duct from dispatch station to receiving Station including SV stations.
2.2. Design, Engineering, Manufacturing, Testing and Supply and laying of PLB-HDPE duct throughout the pipeline and stations. Additional PLB-HDPE duct shall be laid at all crossing, river, nalah, culvert, road/railway, canal etc. inside the separate 6” CS casing pipes.
2.3. Supply and installation of 24 F splice encloser. The splice enclosures shall be placed in the joint pit/inspection chambers after splicing of the Optical Fibre cable at every 4 Km intervals along the optical fibre route.
2.4. Supply and installation of joint pit/ inspection chambers of required dimensions, at every 4 Km intervals along the pipeline route marker. The inspections chambers may either is constructed on site or provided readymade. Chamber shall be filled with sand after joining of cable.
2.5. Supply of underground electronic markers along the Optical fiber cable. Electronic marker shall be kept inside the joint pit/ inspection chamber and capable of being located from a distance of minimum 2.5 meter. Marker quantity shall be as per the requirement. Two number electronic locater shall be provided and have capability to locate the marker from minimum distance of 2 meter.
2.6. Supply and installation of route markers of required dimensions, along the pipeline route. The route markers shall be placed at every inspection chamber, crossings etc as per pipeline laying practices.
2.7. Supply of 48/24 FTC with FCPC type connectors, end plug & cable sealing for HDPE duct and other accessories as per requirement. FTC shall be installed inside the control room and fiber shall be splice/terminate in the FTC by contractor.
2.8. Supply of special tools & Tackles as per requirement of the project.
2.9. Supply of complete technical literature, drawing, rout map & documentation as per requirement of the project.
2.10. Total quantity of OFC shall be as per SOR including the loop length at each station, joint pit/inspection chamber + 1 km extra length. Extra length shall be used for hooking up of OFC to telecom unit at all stations. CONTRACTOR shall lay the OFC upto inside the control room.
2.11. Contractor shall provide the extra length of OFC at least 15 meter loop on both sides (IN & OUT) in each station inside the control room wherever applicable. The extra OFC length shall be properly covered in the metallic casing inside the control room. FTC (Fiber termination closure) to be provided at each end of the cable for cable protection in the control room/Equipment room.
2.12. Contractor shall provide the extra length of OFC at least 30 meter loop (15 meter each side) inside the inspection chamber at both end side of the OFC before splicing.
3.0 REFERENCE
a. Scope of work – P.011947/I/11075/01- scope of work C&I
Note –
In the event of any conflict between GTS and PTS, PTS shall prevails over the GTS
PTS – OPTICAL FIBER CABLE P.011947
I 11097
004
Rev. 0 – 15.02.18 Boreri to CFCL – III, Gadepan Pipeline Project Page 2 of 22
4.0 APPLICABLE CODES & STANDARDS
The optical fibre cable / materials provided shall conform to the latest editions of standards like ITU-T, TIA, IEC, EIA, ASTM & BS.
In case of any conflict between the above standards and the specifications, the matter shall be referred to Owner/Owner’s Engineer.
CONTRACTOR shall proceed with design of the cable/equipment only after obtaining clarifications from Owner /Owner’s Engineer in all such cases.
Latest revisions and amendments of following codes and standards shall be applicable, and the requirements specified in the standards shall strictly confirm to by the CONTRACTOR.
IS 2530 Methods for test of polyethylene molding material and
polyethylene
IS 7328 HDPE material for moulding and extrusion
IS 14151 (part 1) Polyethylene pipes for sprinkler irrigation systems (part – 1 pipe).
IS 12235 (part 9) Methods of tests for unplasticized PVC pipes for portable water
supplied impact strength at zero degree centigrade.
IS 9938 Recommended colours for PVC insulations for LF wires and
cables.
ASTM D 1693 Test methods for environmental stress cracking of ethylene plastics
ASTM D 1505 Test methods for density
ASTM D 3895 Methods for oxidation induction test
ASTM F 2160-01 Standard specification for Solid Wall, High Density Polyethylene
(HDPE conduit based on controlled outside diameter OD)
ASTM D 638 Standard test methods for tensile strength of plastics
5.0 GENERAL GUIDELINES
a) CONTRACTOR shall be totally responsible for the offered Optical Fibre, cable/ materials / equipment’s.
b) CLIENT/ Consultant reserve the right to modify/ revise/ alter the specifications of cable/ equipment’s prior to acceptance of any offer.
c) If during the course of erection of the work any discrepancy of inconsistency, error or omission in any of the provisions of the contract is discovered, the same shall be referred to the CLIENT/ Consultant who shall give his decision in the matter and issue instruction directing the manner in which the work is to be carried out. The decision of the CLIENT/ Consultant shall be final and conclusive and the contractor shall carry out the work in accordance therewith.
d) The model numbers of jointing closure offered for this project must have been in successful field use for more than one year.
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6.0 SPECIFICATION OF OPTICAL FIBRE CABLE
6.1. The 24 core optical fiber cable will be armoured type comprising 18 fibres as per ITU-T-G-652 specifications and 6 fibres as per ITU-T-G-655 specifications, suitable for working in 1550 / 1310 nm wavelength and laid through silicon coated PLB-HDPE duct by blowing technique. The cable shall be fire retardant, chemical resistant, termite & rodent proof and moisture proof.
6.2. Single Mode Optical Fibre, Fully ITU T rec. G652 and G 655 Oct 2000, IEC 60793-1 and Telecordia GR – 20 core compliant.
6.3. The types of optical fibre cable required are as follows:
a) Desired operation life of cable : Better than 40 years
b) Length of O F Cable drum : 4 Km ± 2.5%
c) Cable weight in single drum : Bidder to provide. No splicing shall be permitted on any fiber in a drum length of the cable
d) Cable identification:
The outer surface of the cable shall be permanently & legibly marked with colour in contrast to the outer sheath at regular intervals not exceeding one meter with name of Owner, Logo of the Owner, name of manufacturer, part number and OPTICAL FIBRE CABLE.
The outer surface of each completed cable shall have sequentially numbered metric length markers spaced at regular intervals of one meter.
6.4. CABLE MARKING
a) A suitable marking which can last long shall be applied in order to identify this cable from other cables. The cable marking shall be imprinted/ indented (the impression shall not exceed the depth of 0.15 mm). The marking on the cable shall be indelible of durable quality and shall be provided at regular intervals of one-meter length.
b) The marking shall be in contrast colour over the black HDPE sheath and shall be done by hot foil indentation method. The colour used must withstand the environmental influences experienced in the field.
c) The accuracy of the sequential marking must be within –0.25% to +0.5% of the actual measured length. The sequential length markings must not rub off during normal installation and in lifetime of optical fibre cable. The total length of the cable supplied shall not be in negative tolerance.
d) The legend marking on Optical Fibre cable shall be as follows:
• Company Legend
• Legend containing telephone mark & internationally acceptable Laser symbol.
• Type of Fibre (G.652D & G.655)
• Number of Fibres.
• Year of manufacture
• Sequential length marking at every one meter.
• Drum number
6.5. COLOUR CODING IN OPTICAL FIBRE CABLE
a) The colorant applied to individual fibres, fibre units and binders shall be readily identifiable throughout the lifetime of the cable and shall match and confirm to the Munsell colour standards (EIA-359-A) and also IEC Publication 304 (4).
b) Colour code to be adapted for individual fibres in each loose tube shall be:
Blue
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Orange
Green
White/ Natural
c) Colour Code to be adapted for individual loose tubes shall be:
When the loose tubes are placed in circular format, the marking to indicate the loose tube no. "1" shall be in Blue colour followed by loose tube no. "2" of Orange colour and so on for other tubes as per the colour scheme given below-
Loose tube No. 1 shall be of Blue colour
Loose tube No. 2 shall be of Orange colour
Loose tube No. 3 shall be of Green colour
Loose tube No. 4 shall be of Brown colour
Loose tube No. 5 shall be of Slate colour
Loose tube No. 6 shall be of White colour
Note-
The G.652 Fibres (Total 18 nos.) shall be housed in Loose Tube No. 1 (Blue colour), Loose Tube No. 2 (Orange colour) & Loose Tube No. 4 (Green Colour).
The G.655D Fibres (Total 6 nos.) shall be housed in Loose Tube No. 3 (Brown Colour),
The primary coated fibres shall be protected by loose packaging within a tube, which shall be filled with thixotropic jelly
• Number of fibres: 24
• Number of loose tubes: 4
• Number of Filler/ Dummy: 2
• Number of fibres per loose tube: 6
• Material for loose tube shall be Polybutylene terephthalate.
• The outer diameter of loose tube shall be 2.0 mm + 0.2 mm without any negative tolerance. The inner diameter of loose tube shall be minimum 1.2mm.
Bidder/vendor/contractor to specify the outer and inner diameter of the loose tube.
6.6.2. STRENGTH MEMBER:
Solid FRP non-metallic strength member with a minimum diameter of 2.0 mm in the cable core shall be provided. The strength member(s) in the cable shall be for strength & flexibility of the cable and shall have anti buckling properties. These shall also keep the fibre strain within permissible values.
6.6.3. CABLE CORE ASSEMBLY:
Primary coated fibres in loose tubes stranded together around a central strength member using helical or reverse lay techniques shall form the cable core. Four fibres shall be placed loosely in each loose tube.
6.6.4. CORE WRAPPING:
The main cable core containing fibres shall be wrapped by layer/ layers of Polyester foil/ tape. Nylon/ polyester binder thread shall be used to hold the tape. The core wrapping shall not adhere to the secondary fibre coating and shall not leave any kink marks over the loose tube.
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6.6.5. MOISTURE BARRIER (PROTECTION):
The main cable core (containing fibres & core wrapping) shall be protected by flooding compound (Jelly) having properties of non-hygroscopic dielectric material.
6.6.6. FILLING COMPOUND:
The filling compound used in the loose tube and in the cable core shall be compatible to fibre, secondary protection of fibre, core wrapping etc. The drip point shall not be lower than +70 °C. The fibre movement shall not be constrained by stickiness & shall be removable easily for splicing. Reference material test method to measures drip point shall be as per ASTM D 556. The filling and the flooding jelly compound shall be as per the TEC Specs No. TEC/GR/TX/ORM 01/04/ SEP-09 and subsequent amendment issued, if any.
6.6.7. INNER SHEATH:
A non-metallic moisture barrier sheath shall be applied over and above the cable core. The core shall be covered with tough weather resistant High-Density Polyethylene (HDPE) sheath black in colour (UV stabilised) and colour shall conform to Munsell Colour Standards. Thickness of the sheath shall be uniform & shall not be less than 1.2 mm. The sheath shall be circular, smooth, free from pin holes, joints, mended pieces and other defects. Reference test method to measures thickness shall be as per IEC 189 Para 2.2.1 and Para 2.2.2.
Note: HDPE material, black in colour, from the finished cable shall be subjected to following tests(on sample basis) and shall conform to the requirement of the material as per GR No.TEC/GR/TX/ORM-01/04 SEP.09.
i. Density
ii. Melt Flow Index
iii. Oxidative Induction time
iv. Carbon Black Content
v. Carbon Black Dispersion
vi. ESCR
vii. Moisture Content
viii. Tensile Strength and Elongation at break
ix. Absorption Coefficient
x. Brittleness Temperature
6.6.8. GLASS REINFORCEMENT:
Impregnated Glass Fibre Reinforcement shall be used to achieve the required tensile strength of the optic fibre cable over the cable inner sheath to provide peripheral reinforcement along with solid rigid FRP Rod in the centre at cable core. These flexible strength members shall be Non-water blocking type. Impregnated Glass Fibre Reinforcement used shall be equally distributed over the periphery of the cable inner sheath. It shall be applied helically and shall provide full coverage to inner sheath to provide rodent protection. The quantity of the Impregnated Glass fibre Reinforcement used per km length of the cable shall be minimum 20kg per KM cable. The specification of the glass roving shall be as per Section XII of GR No. TEC/GR/TX/ORM-01/04 SEP.09.
6.6.9. OUTER SHEATH:
A non-metallic moisture barrier sheath (black in colour) shall be applied over the inner sheath and glass roving layer, which shall consist of tough weather resistant made High Density Polyethylene compound (HDPE) with anti-termite and anti-rodent properties. The outer sheath shall be UV stabilized and the colour shall confirm to Munsell colour standards. The thickness of the outer sheath shall not be less than 1.6mm. The outer sheath shall be uniform, circular, smooth; free from pin holes, joints mended pieces and other defects. The reference test method to measure thickness shall be as per IEC 811-5-1.
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Note: HDPE material from finished product shall be subjected to following tests (on sample basis) and shall confirm to the requirement of the material as per the GR no. TEC/GR/TX/ORM-01/04/SEP-09 (Section-III):
• Density
• Melt flow index
• Oxidative Induction time
• Carbon black content
• Carbon black dispersion
• ESCR
• Moisture content
• Tensile strength and elongation at break
• Absorption Coefficient
• Brittleness Temperature
• Anti-termite and Anti-rodent dopants shall be added in the outer sheath to resist termite attack and rodent attack on the cable.
Bidder/vendor/contractor shall provide the details of doping material used and same shall be verified during testing.
6.6.10. Protection against rodents
For protection against rodents, HDPE sheath shall have rodent repellent properties with the use of an eco-friendly, non-toxic rodent repellent additive. 2%-3% master-batch of rodent repellent material consisting of 5% additive & 95% HDPE/ LDPE shall be mixed in the HDPE sheath material/ granules (If otherwise, bidder/vendor/contractor to submit details of additive with OEM recommendation for mixing).
6.6.11. Protection against termites
For protection against termites, HDPE sheath shall have termite repellent properties with the use of an eco-friendly, non-toxic termite repellent additive. The termite protection shall be as per DIN EN117.
A copy of Invoice from OEM of rodent repellent material & termite repellent material shall be submitted with the pre-FAT internal inspection reports and bidder/vendor/contractor to evidence Original Invoice from OEM of rodent repellent master-batch & termite repellent material during Factory Acceptance Test of finished cable.
6.6.12. Termite & Rodent Test
Termite & Rodent test shall be carried out at any recognized lab on finished cable samples. The reports shall be submitted by the bidder/vendor/contractor. Termite resistance shall be provided with an additive in outer sheath and rodent protection shall be provided with an additive in outer sheath and by use of Glass roving yarns around the periphery of inner sheath. These yarns should spread uniformly around the periphery of inner sheath. Bidder/vendor/contractor to note that apart from the above test report, it shall be
Owner’s prerogative to get sample of finished cable tested at OEM/ Other recognized test labs to establish presence of rodent & termite repellent additives in specified proportion.
6.6.13. CABLE DIAMETER:
a) Bidder/vendor/contractor to specify the cable diameter.
b) Bidder/vendor/contractor to note that the overall cable diameter shall be between 13-14mm.
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6.6.14. RIP CORD:
a) Three suitable ripcords shall be provided in the cable, which shall be used to open the HDPE sheaths of the cable. Two ripcords shall be placed diametrically opposite to the each other at below the outer sheath & one ripcord shall be placed below the inner sheath. It shall be capable of consistently slitting the sheath without breaking for a length of 1 meter at the installation temperature. The ripcords (3ply & twisted) shall be properly waxed to avoid wicking action and shall not work as water carrier.
b) The ripcords used in the cable shall be readily distinguishable from any other components utilized in the cable construction.
6.7. Mechanical Characteristics Of Cable
a) Temperature Installation & Operation : 0 Deg. C to 65 Deg.C
Storage : 0 Deg C to 65 Deg C
b) Tensile strength:
The cable shall have sufficient strength to withstand a load of value T (N) = 9.81 x 2.5 W Newton or 2670 N whichever is higher. (Where W=mass of 1 km of cable in Kg). The load shall not produce a strain exceeding 0.25% in the fibre and shall not cause any permanent physical and optical damage to any component of the cable. The attenuation shall be noted before strain and after the release of strain. The change in attenuation of each fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength. Test Method: IEC 60794-1-2-E1 :
c) Cable weight in Kg/ Km : Bidder to specify
d) Minimum bending radius : 20 x cable diameter
6.7.1. Average splice loss of all the splices shall be less than 0.1 dB (as per the Bell core Generic Requirement GR-20 Core, Issue 2 July 1998.)
6.7.2. Bidder should submit the proposed / offered cross section diagram of the cable with the bid giving full details. It should conform to the general practice followed internationally.
6.8. ABRASION RESISTANCE:
Specs: The cable surface & the marking printed on the surface of the cable shall be abrasion resistant.
Test Method: IEC 60794-1-2-E2 or by any other international test method
6.9. RESISTANCE AGAINST CRUSH:
Spec: The fibres and component parts of the cable shall not suffer permanent damage when subjected to a compressive load of 2000 Newton applied between the plates of dimension 100 x 100 mm the load shall be applied for 60 secs. The attenuation shall be noted before and after the completion of the test. The change in attenuation of the fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength.
Test Method: IEC 60794-1-2-E3
6.10. RESISTANCE AGAINST IMPACT:
Spec.: The cable shall have sufficient strength to withstand an impact caused by a mass weight of 50 Newton, when falls freely from a height of 0.5 meters. The radius R of the surface causing impact shall be 300 mm. ten such impacts shall be applied at the same place. The attenuation shall be noted before and after the completion of the test. The change in attenuation of the fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength.
Test Method: IEC 60794-1-2-E4
6.11. BENDING ABILITY/RESISTANCE:
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Specs: The cable sample shall be able to bend to a diameter equal to 20D (where D is outer diameter of OFC). The change in attenuation of the fibre after the repeatedly bending OFC as per test plan in QAP shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength. It shall be possible to make figure of 8 of minimum 1000 meters of the cable uncoiled from the cable reel without any difficulty. No visible damage shall occur.
Test Method: EIA-455-104
IEC 794-1-2-E11 (Procedure –I)
As per the Clause no. 4.8 of the GR alternatively as per ASTM D790
6.12. TORSION RESISTANCE:
Object: The purpose of this test is to determine the ability of an optical fibre cable to withstand torsion.
Test Method: IEC 794-1-2-E7
Specs: The optical fibre cable shall be able to withstand torsion by the load shall be 100 N. The cable shall be free from any cracks, tearing on the outer sheath and for the damage to other component parts of the cable after application of twist/torsion as per test plan in QAP. The twist mark shall not be taken as damage. The change in attenuation of the fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wave length.
6.13. KINK RESISTANCE:
Specs: Kinking of an optical fibre cable shall not result in breakage of any fibre, when a loop is formed of dimension small enough (minimum bend radius) to induce a kink on the sheath. The kink should disappear after normalising the cable. The change in attenuation of the fibre after test shall be ≤ 0.05 dB both for 1310 nm & 1550 nm wavelength.
Test Method: IEC 794-1-2-E10
6.14. TEMPERATURE RANGE:
Specs: The optical fibre cable shall be suitable for temperature range from –20°C to +70°C for storage and operation.
Test Method: IEC 794-1-2-F1 (To be tested on standard cable length & drum i.e. 4 Km ± 2.5%)
6.15. RESISTANCE AGAINST WATER PENETRATION:
Specs: The optical fibre cable shall have sufficient components like jelly filling/flooding inside optical fibre cable that will not allow water passage along its length.
Test Method: IEC 794-1-2-F5(Fig. B) 1992.
6.16. FLEXURAL RIGIDITY:
Specs: The fibre and the component parts of the cable shall not suffer permanent damage in the cable subjected to Flexural Rigidity Test as per QAP. The change in attenuation of the fibre after the test shall be ≤ 0.05 dB for 1310 nm and 1550 nm wavelengths. The sheath shall not show any cracks visible to the naked eye.
Test Method: To be tested as per ASTM D-790
6.17. CABLE AGING TEST:
Objective: To check the cable material change dimensionally as the cable ages.
Method: The test cable shall be exposed to 85+2 degree C for 168 hours. The attenuation measurement at 1310 & 1550 nm wave length to be made after stabilisation of the test cable at ambient temperature for 24 hours.
Requirement: The increase in attenuation allowed: ≤ 0.05 dB at 1310 & 1550 nm.
Note: The attenuation changes are to be calculated with respect to the base line attenuation values measured at room temperature.
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6.18. CABLE JACKET YIELD STRENGTH AND ULTIMATE ELONGATION:
Specs: yield strength and elongation of the polyethylene (HDPE) cable sheath (jacket) shall be as per table below:
Jacket Material Minimum Yield Strength Minimum Elongation (%)
(MPa) (psi)
HDPE un-aged 16.5 2400 400
HDPE aged 12.4 1800 375
6.19. EASY REMOVAL OF SHEATH:
Easy removal of both the outer jacket and the inner sheath shall of the optical fibre cable shall be possible by using normal sheath removal tool.
6.20. TECHNICAL SPECIFICATIONS OF FIBRES
Single Mode Optical Fibre, Fully ITU T rec. G652 Oct 2000, IEC 60793-1 and Telecordia GR – 20 core compliant. The specifications referred below are generally for ITU T 652 standard single mode optical fibre cable. There is a difference in dispersion value, Mode field diameter and other characteristics for optical fibre cable of ITU T 655 specifications. The specifications referred below are notional. The vendor shall specifically and separately comply with each of the specifications for ITU T 652 and ITU T 655 optical fibre cable standards in his response.
SINGLE MODE OPTICAL FIBER AS PER ITU T G.655
S N Parameter Requirement 1.0 Transmission characteristics 1.1 Attenuation coefficient
At 1550 nm At 1625 nm Note :
1. Sudden irregularity in attenuation at 1550 nm shall be ≤ 0.05 dB.
2. The spectral attenuation shall be measured on un-cabled fibre.
3. The spectral attenuation in the 1525 nm – 1625 nm band shall be measured at an interval of 10 nm and the test results shall be submitted.
4.
In Fiber <0.22 dB/Km <0.24 dB/Km
In Cabled Fiber <0.23 dB/Km <0.26 dB/Km
1.2 Attenuation Vs Wavelength Ref λ Maximum α difference
db/km 1525-1575 nm 1550 nm <0.03 dB/Km
1.3 Mode field diameter Nominal
Tolerance @ 1550 nm 1550 nm 9.6 µm + 0.4 µm
1.4 Cut-off wavelength on 2 mt sample of fiber ( in cable)
< 1480
1.5 Chromatic dispersion 1530-1565 nm 1565-1625 nm zero dispersion wavelength
2-6 ps/nm.km 4-11.2 ps/nm.km < 1530 nm
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1.6 Polarization mode dispersion at 1550 nm Individual (un-cabled) Fibre : Cabled Fibre : Dispersion Slope at 1550 nm :
≤ 0.1 ps/ ÖKm ≤ 0.3 ps/ ÖKm ≤ 0.09 ps/(nm2..km)
1.7 Attenuation with bending 100 turns on a mandrel of 60 mm diameter
Attenuation coefficient At 1310 nm At 1550 nm At 1625 nm
In bare Fibre ≤ 0.34 dB/Km ≤ 0.19- 0.20 dB/ Km ≤ 0.20-0.23- dB/ Km
In Cable ≤ 0.36 dB/ Km ≤ 0.21 dB/ Km ≤ 0.26 dB/ Km
1.2 Attenuation Vs Wavelength 1285- 1330 nm 1525- 1575 nm Attenuation coefficient in cable at 1625 nm shall be :
≤ 0.03 dB/ Km ≤ 0.02 dB/ Km </= 0.26 dB/ Km
1.3 Mode field diameter at 1310 nm 1550 nm
Any single value 8.6 – 9.5µm Any single value 9.0- 11.0 µm
1.4 Water Peak Attenuation after cabling i) At 1383 nm : ii) Between 1360 – 1480 nm : Note: Water Peak Attenuation after cabling shall be measured either at 1383 nm or between 1360 – 1480 nm.
≤ 0.34 dB/Km ≤ 0.34 dB/Km
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S.No Parameter Requirement
1.5 Water Peak Attenuation before cabling Between 1360 – 1480 nm: Note : 1. Sudden irregularity in attenuation shall be less than 0.1 dB 2. The spectral attenuation shall be measured on un-cabled fibre. 3. The spectral attenuation in the 1250 nm – 1625 nm band shall be measured at an interval of 10 nm and the test results shall be submitted.
≤ 0.34 dB/Km
1.6 Cut-off wavelength on 2 meter sample of fibre (In Cable)
Optical fibres shall be coated with UV cured double Acrylate Resin. It should not have any reaction with cladding or core material
The coatings should provide max resistance to micro bending & abrasion and ensure mechanical & optical strength. The coatings shall easily stripped with mechanical tools.
b) Fiber Identification
The coatings shall be in various distinct colours in order to facilitate fibre identification. Fibre colours shall correspond to IEC publication 793-2 and 304. The colours shall correspond reasonably with standard colours and shall readily be identifiable and shall be durable. The colours used should have fast colours properties and should not fade during the lifetime of cable. The coating and the colour shall not react with surrounding jelly. The vendor shall take prior approval from purchaser/consultant for the
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colour scheme for fibre identification before commencement of manufacture of OFC. Vendor is required to provide fibre Ids (Manufacturing details etc.) for all individual fibres in cable. These fibre Ids should be sent to purchaser/consultant along with internal test report of the cable.
6.21. Mechanical Characteristics of G.652D & G.655 Fibres
a) Proof test for minimum strain level (Test method IEC–60793-1-30) : 1%
Peak Strippability force to remove primary coating of the fibre (Test method IEC–60793-1-32) : 1.3 ≤ F ≤ 8.9 N
Note:
The force required to remove 30 mm ± 3mm of the fibre coating shall not exceed 8.9 N and shall not be less than 1.3 N.
b) Fibre macro bend : ≤ 0.05 dB at 1550 nm for G.652D & G.655 fibres ≤ 0.5 dB at 1625 nm for G.655 fibre.
Change in attenuation when fibre is coiled with 100 turns on 30 ±1.0 mm radius mandrel
(Test method FOTP– 62/ IEC- 60793-1-47)
c) Fibre macro bend: ≤ 0.5 dB at 1550 nm for G.652D & G.655 fibres≤ 1.0 dB at 1625 nm for G.655 fibre
Change in attenuation when fibre is coiled with 1 turn around 32 ± 0.5 mm diameter mandrel
(Test method FOTP– 62/ IEC- 60793-1-47)
d) Fibre Curl : ≥ 4 meters radius of curvature
(Test method as per IEC-60793-1-34)
6.22. Material properties of G.652D & G.655 fibres
a) Fibre Materials
The substances of which the fibres are made. : Bidder/vendor/ contractor to specify
b) Protective materials requirement : It shall meet the requirement of fibre coating stripping force To be indicated by the bidder/vendor/contractor.
The physical and chemical properties of the material used for the fibre primary coating and for single jacket fibre.
The best way of removing protective coating material. : To be indicated by the bidder/vendor/contractor.
7.0 JOINTING CLOSURES:
7.1. Jointing closures shall be suitable for the offered Optical Fibre cable. Jointing closures should be Dust proof (No dust ingress) and protected against – immersion in water (Suitable for continuous immersion in saline water) and should be complete with all accessories including splice cassettes, splice protection and all other items including electrical continuity of metallic layer of optical fibre cable. The jointing closures shall be provided with suitable jointing pit support hardware to secure the jointing closures.
7.2. Bidder to specify Dimensions. Bidder to note that the dimensions length shall be suitable for installation in the RCC joint enclosure specified elsewhere in the document.
7.3. Capacity
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• No. of cable entry points: 4 ports (2 incoming and 2 outgoing cables)
• Diameter of cable entry: Suitable for optical fibre cable of diameter 15mm approx.
• No. of splices per tray: Splice tray shall be suitable for splicing 2 cables of 24 fibres each
• No. of trays per closure: 2 Nos.
• No. of fibres / closure: Maximum 48 Fibres
7.4. Sealing: Water tight and dust free.
7.5. Cable entries: Normally closed and shall be opened as and when required.
7.6. Material metal parts exposed to environment, if any: Stainless Steel and corrosion resistant
7.7. Properties of plastic material used: Light weight, corrosion resistant, high impact bearing and compatible with metal and other materials used in splice closure like connectors, trays etc.
7.8. Following tests shall be conducted on the closure as per procedures given elsewhere in the tender:
• Impact Test
• Closure to cable integrity test
• Pulling test
• Chemical Test
• Biological test
• Water Ingress Test
• Drop and topple test
• Static load test
8.0 FIBRE TERMINATION CLOSURE
The Fibre shall be properly terminated on Fibre termination closure FTC. FTC Shall be wall mounted type as suitable for Optical Fibre Cable. The FTC shall have grounding arrangement for both the metallic layers of the cable. The cable shall be spliced to pigtails on trays provided in the FTC. The connector side of the pigtails shall be secured with suitable coupler/through adapter provided as integral part of the FTC itself. The FTC shall have trays suitable for splicing maximum of 6/12 fibers per tray. FTC for all stations shall be installed with trays for minimum 48 fibers.
The complete Fibre Termination Closure including trays, joint protection sleeves, pigtails, couplers, etc. After termination, each pig tail/patch cord shall be properly ferruled for identification of station & fibre type.
9.0 LOOP BOX
After entering the telecom room/control room/equipment room, the cable shall be secured on ‘Loop Box’ by the help of cable ties (~5m cable from each side being kept in turns in oval form). This Loop Box shall have suitable chemical coating/ painted to prevent corrosion. Further, the cable shall be terminated on Fibre Termination Box (FTB) / Fibre Termination Closure (FTC)
10.0 OFC JOINT PIT/INSPECTION CHAMBER
10.1. The cable joint pit/inspection chamber shall of RCC of 600mm height.
10.2. The cable joint pit/inspection chamber shall be circular having internal diameter of 1200 mm & wall thickness of 50 mm and made of reinforced concrete with lifting lugs cast into the lids during construction itself.
10.3. Pit shall be provided with suitable arrangement for the entry of one number of HDPE conduit from both sides so that HDPE conduit and buried OFC should enter the pit at a height of 150 mm above the bottom level of the pit. The pits shall be provided with suitable GI brackets to facilitate storage of Optical fiber cable loop. Thickness of TOP LID shall be 75 mm.
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10.4. The pit shall be completely filled with sand up to 30mm from bottom level of the pit to prevent entry of rodents. After jointing of OFC, covered joint enclosure and HDPE conduit completely. The pits shall have arrangement to prevent entry of mud, insects etc.
10.5. HDPE conduit shall be sealed with the help of end plugs at jointing pit locations
10.6. HOP TESTING OF OFC
After back filling of the trench, the cable shall be tested for attenuation over the laid length. The test shall be conducted both before and after the splicing. It shall be ensured that the cable attenuation does not exceed as recommended for G 655 or G 652 cables (excluding the splice loss) and the splice loss on each fiber shall be 0.07 db per splice (max.). Contractor shall provide the detailed procedure for cable testing.
The cable test-results shall clearly provide the attenuation for Each cable section
1310 nm wavelength for each fiber
1550 nm wavelength for each fiber
Individual splice.
A total = (wavelength λ loss dB/km x fiber length) + (connector loss x number of connectors) + (splice loss x number of splices).
Results should be within permissible limits. After the testing hop testing results with average losses shall be recorded and report of results as per approved procedure for each fiber shall be submitted hop wise for client review.
11.0 ELECTRONIC JOINT LOCATION MARKERS.
11.1. Contractor shall provide electronic locating system suitable for field use to locate underground-buried OFC joint locations.
The system shall consist of:
a) Electronic marker (to be buried underground along-with OFC joints)
b) Marker locator (including probe & locator electronics)
11.2. The electronic markers shall be placed at all joint pit/inspection chamber locations (planned and unplanned).The electronic markers shall be lightweight and shall have a passive tuned resonant circuit, enclosed and sealed within a casing. The marker locator shall be able to locate the electronic markers with the help of audio and visual signals. The electronic locator system shall be capable of locating Cable/Pipe and location of sheath (earth fault) fault. The markers shall be of color suitable for Oil & Gas application.
11.3. The marker locator and the probe shall be of lightweight and portable enough to be carried (in suitable carrying case, to be provided) on shoulder. The locator shall be able to work on batteries (dry alkaline) for continuously 8 hours. The electronic locating system shall be able to work in saline atmosphere in coastal area and shall be protected against corrosion. The electronic locating system shall not be affected by any metal, alternating current, etc. The casing of the electronic marker shall be resistant to chemicals, minerals, water ingress and temperature variation normally encountered in underground environments. The material used for the manufacture of electronic markers shall be protected against any damage due to rodents or any other insects in the underground environment.
11.4. The marker should be detectable by marker locator unit from anywhere within radius of min. 2 meter from the centre of marker.
11.5. Each marker locator provided shall be complete with its set of accessories (i.e., necessary interfaces, connecting cables, software, etc). The electronic markers shall be buried underground 30 mm below the lid of each jointing pits and shall not be in direct contact with any metallic body.
11.6. Apart from the features stated above, the Electronic Marker Locator Unit should have the following additional features:-
• Locating conductor or sheath (earth return) faults.
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• Tracing the path of underground cables and metallic pipes with estimated depth measurement.
• The Electronic marker locator unit with cable/ pipe locator & sheath fault locator shall consist of the following main sub-systems/ parts:
• Electronic Marker Locator/ Cable, Pipe Locator Unit (Receiver Unit)-Bidder can offer two separate units for electronic marker locator & pipeline /cable locators) to meet tender specifications.
• Transmitter Unit
11.7. GENERAL REQUIREMENTS:
a) The Electronic Locator System shall be fully solid state and field proven employing state of the art technology.
b) The instrument shall be portable and light weight. The actual dimensions and weight of the instrument shall be furnished by the contractor.
c) All connectors and cables shall be of low loss, suitably shielded, reliable and of standard type to ensure failure free operation over long periods and under specified environmental conditions.
d) The mechanical design and construction of each card/ unit shall be inherently robust and rigid under all conditions of operation, adjustment, replacement, storage and transport.
e) The instrument shall have self cooling arrangement without use of fans.
f) All controls, switches and indicators shall be clearly marked to show their circuit designation and functions.
g) Marker Locator Unit should have the facility of writing/ storing data in the electronic markers such as Joint no., Chainage, location, placement date etc. The locator should also have the facility to read the data stored in the iD electronic marker.
h) All required software along with cables, connectors and accessories shall be supplied with the unit for interfacing the Electronic Marker Locator Unit with Laptop/ Computer and storing/ downloading, uploading electronic marker related data.
i) The Electronic Marker Locator Unit shall be supplied with Transmitter, two sets of transmitter connection leads, capacitive coupler/ clamp, ground rod, earth frame for locating earth return faults, carrying case, cables, connectors and accessories complete in all respects required for carrying out the features/ functions as detailed in specifications.
j) Installation of Electronic Markers at OFC Joint Pit locations, writing/ storing data in the Electronic Markers during installation shall be the responsibility of contractor.
11.8. OPERATIONAL REQUIREMENTS:
a) The Electronic Locator System shall be able to pin-point earmarked buried telecom facilities such as cables, joints etc. using the electronic markers.
b) It should also be able to locate the route of pipes/ cables with depth estimation, locating conductor or sheath (earth return) faults.
c) The Marker Locator shall generate and transmit a specific frequency signal to the buried electronic marker. The Electronic Marker, tuned to this frequency, reflects the signal back to the locator. The locator verifies the reflected signal picked up through the probe and the location is indicated with an audible & visual indication.
d) The instrument shall be provided with sensitivity control facility.
e) All switches / controls on front panel of shall have suitable safeguards against accidental operation.
f) The instrument shall be adequately safeguarded to prevent entry of dust, insects and lizards.
12.0 PROCEDURE FOR OF CABLE BLOWING
12.1. CABLE BLOWING:
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12.1.1. Joint pit/Inspection chambers marked during PLB-HDPE duct laying shall be exposed for blowing the cable. The PLB-HDPE duct, left exposed with end caps, at every 2 Km intervals where the O F Cable shall be brought out after blowing and re-inserted for expose and splicing at every 4 Km intervals.
12.1.2. There may be a situation where the O F Cable may have to be brought out at less than 2 Km intervals. Under such circumstances the PLB-HDPE duct shall be exposed and sealed back after running the OF Cable through the duct.
12.1.3. The existing 6 mm PP rope shall be replaced by with PP rope of 8mm dia. between the two consecutive joint pit/ inspection chambers. This is to ensure that the PLB-HDPE coils are cleaned for blowing the cable without exerting tension on the OF Cable. Excessive pressure should not be put which may result in breaking of PP rope and this may require opening of additional inspection chambers. However, in case the cleaning rope gets stuck up during pulling, the location of digging of HDPE pipe should be measured and located accurately. The trench at that location should be opened and the HDPE Pipe should be cleaned properly or if not possible it should be replaced by a clean new HDPE Pipe to facilitate easy cable blowing at a later stage without any obstruction. If digging of HDPE Pipe is in the location where the pipes are protected either by RCC Pipe or by concreting and the protection is broken for cleaning/changing the HDPE pipe, the protection thus removed should be brought back to normal by the contractor without any extra cost. All tools and machinery for such repair work shall be arranged by the contractor.
12.1.4. The Optical fibre cable is available in drums in length of 4 Kms. The cable shall be blown through the laid PLB-HDPE duct by the contractor. If required, the cable may also be pulled by using the 8 mm P.P. rope. This work is to be carried out under the strict supervision of engineer-in-charge of the contractor so that sharp bends, twists and turns can be avoided or kept well with in limits. At a time, maximum three persons at every joint pit/ inspection chamber should be deployed to slowly pull the cable as more tension to cable may lead to damage of fibre cable. Cost of such damages shall be recovered from the contractor.
12.1.5. The O F Cable may be pulled out at a distance of 1 Km and re-inserted for the next length of 1 Km, where the fibre is spliced with the next cable drum. The splice encloser is placed in the joint pit/inspection chamber with properly coiled extra length of O F Cable.
12.1.6. After the blowing is completed, both ends of the PLB-HDPE duct and the entry points in each joint pit/inspection chamber should be sealed by hard rodent resistant rubber bush, to avoid entry of rodents/mud into PLB-HDPE duct.
12.1.7. Guide lines shall be based on international standards of practice for installation of optical fibres. All machinery like cable blowing machine, compressor, lifting jack for cable drum, transport vehicle, tools, tackles shall be arranged by the contractor to complete the job in all respect.
12.1.8. For HDPE laying and OFC blowing the contractor shall ensure and carry out the activities but not limited to the following:
• Transportation of machinery and materials to different work sites.
• Minimize joints and identify joint locations.
• Placement of route markers
• Methods of room entries for termination.
• Identify physical hindrances and taking suitable action.
• Recommended best method of installation and plant/ machinery required.
• Determine exact bill of quantities for HDPE and other accessories.
12.1.9. Rotation of the cable drum shall be controlled to ensure that there is always some slack in the cable during pay-off so as to ensure cable installation at near zero tension.
12.1.10. During blowing it shall be ensured that there is no dust or obstacles remaining in the duct which can damage the cable. Lubricant shall be used during blowing of the cable in ducts if required.
12.1.11. The cable shall be tested in each hop of pipeline section for individual splice loss, fibre loss, connector loss using appropriate test instruments and the records of the values so obtained shall be furnished to the Owner.
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Hop-wise OTDR traces for each fibre shall be taken for each hop from both directions and the printouts to be submitted to Engineer-in-charge for review.
12.1.12. In case of joint failure/ cable fault / damage of the cable, it shall be the responsibility of the contractor to locate the cable fault, rectify the same and establish the specified performance.
12.1.13. Sealing of RCC Joint Box/ Transition Pit- Proper sealing of the entries of RCC Joint Box/ Transition Pit with hard rubber bush of suitable size shall be ensured to prevent entry of insects, rodents and rainwater. Also, the RCC Joint Box/ Transition Pit shall be filled up with clean sand to prevent any rodent/ insect/ pest entry into the enclosure.
12.1.14. Sealing of HDPE Ducts- Cable Sealing plug shall be used to seal the ends of the duct perfectly after the cable is installed in the duct in order to prevent the entry of dirt, water, moisture, insects / rodents etc. This is required to be installed at all the places where cable has come out of the duct either for jointing or entry into the building as required.
12.1.15. The cable shall be spliced/ jointed by skilled personnel using fully automatic splicing machines (fusion splicer) to achieve the specification of joint loss of not more than 0.07 dB/splice. It should also be ensured that during splicing no fibres are interchanged and hop to hop continuity of all 24 fibres in each hop is be maintained. All splices shall be protected by heat shrinkable sleeves. Dust free environment shall be ensured for fusion splicing. The joints shall be housed in appropriate joint kit and the location of the same shall be indicated by providing suitable joint markers. The route markers suitable for the purpose for indicating the position of the cable shall be provided along the length as defined elsewhere in the tender.
12.1.16. Each splice joint should be coated with epoxy resin to protect against moisture and increase the mechanical strength. As an alternative to joints coated with epoxy resin, bidder may provide satisfactory method for permanently protecting each splice joint against moisture and providing mechanical strength.
12.1.17. Contractor shall submit methodology for HDPE laying & OFC blowing, QA/ QC procedure to Engineer-In-Charge for Owner’s review & approval prior to installation of HDPE and blowing of OFC.
12.1.18. Contractor shall submit a detailed deployment plan giving details of pipeline segment (chainage etc.), mobilisation plan for excavator, vehicles, machinery, OTDR, splicing machine, truck/ trailer for carrying OFC, lifting jacks, engineering, supervisors, labours etc. for each pipeline segment to EIC before start of job.
12.1.19. While laying cable, the tensile load of the OFC must not be exceeded.
12.1.20. In all sections, it shall be ensured that during back filling first 20 cm of the soil shall not contain any stones which can damage the HDPE pipe.
12.1.21. After 40 cm of back-filling a warning tape of 200 mm wide marked as “WARNING –OPTICAL FIBRE CABLE BELOW” in English, Hindi and local language shall be provided throughout the length of the HDPE pipe. Same shall not be required if wider warning tape is being provided over both Line pipe/ Line pipe + OFC
12.2. Jointing / Splicing
12.2.1. The OFC cable drums are usually of 4 Kms. in length hence optical fibre joints shall be at every 4 Kms. The 24 fibre are to be spliced at every 4 Kms. and placed in the joint pit/inspection chamber with some extra length for future maintenance work. The infrastructure required for cable splicing is as follows:
• Splicing machine
• Air Conditioned van
• OTDR
• Optical Talk Set
• Tool kit etc.
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12.2.2. These instruments and tools shall be arranged by the contractor at his own cost. Any additional item like engine-generator required at site for splicing or other works shall be arranged by the contractor at his own cost.
13.0 JOINTING KIT TESTS
13.1. Water Ingress Test
The cable joint kit shall be assembled along with a continuous piece of cable passing through. The jointing kit shall then be secured at the bottom of an immersion tank containing water upto a height of 3.0 m with the help of UV detectable dyes added to the water and joint kit shall be immersed for duration of 24 hours at normal room temperature. The joint kit will then be opened as per the specified procedure and visually examined for any ingress of water. It shall be declared to have passed in case there is no water present inside the kit. The joint kit shall be closed again and the same test shall be repeated. The joint kit shall pass the test in case there is no water present inside the joint kit.
13.2. Impact Test
The cable joint kit shall be kept on a metal platform. A weight of 2 kgs cylindrical type having radius of R 50 mm at striking end will be made to strike the joint kit at the middle after having been released from a height of 500 mm for 5 times at approx. 10 secs interval. The joint kit will be declared to have passed the test in case there are no cracks or fracture inside or outside of the kit.
13.3. Drop and topple test
A drop test platform consisting of a steel plate not less than 6.5 mm thick is to be used. The steel plate is bolted to a fully set concrete block at least 460 mm thick. The joint kit shall then be allowed to topple and fall freely from a height of 2000 mm. The joint kit will be declared to have passed the test in case there is no visible damage to the jointing kit.
13.4. Pulling test
The joint kit should be assembled with a long length of cable so that it can be pulled to the required tension of 100 kgs to check the strength of fixing arrangement inside the joint kit.
13.5. Static load test
The assembled cable joint kit shall be kept on a platform with dimension more than that of cable joint kit. A curved hollow profiled mandrel shall be used for application of load and the mandrel shall be at the middle straight part of the joint kit. Weights shall be gradually placed on the mandrel till the weight becomes 250 kgs. The joint kit shall be kept under the weight for a period of 24 hours. The joint kit shall be declared to have passed the test in case there is no visible damage.
14.0 BUILDING ENTRY
14.1. All building entries shall be done through MCT Blocks.
14.2. A warning marker tape of plastic with a warning message marked as “WARNING –OPTICAL FIBRE CABLE BELOW” in English, Hindi and local language shall be placed 40 cm above the cable in the trench (from transition pit to cable entry point) to protect during digging after installation.
15.0 QUALITY ASSURANCE PROGRAMME
15.1. CONTRACTOR shall submit the details of Quality Assurance Programme followed by him beginning with raw materials, fabricated components, assemblies, etc. CONTRACTOR shall obtain and forward the Quality Assurance Programme for equipment supplied by Sub-contractor, if any.
15.2. The Owner/Owner’s representatives and /or third appointed agency reserves the right to inspect and test cable, jointing closures, etc at all stages of production and testing. The inspection and testing shall include but not be limited to materials, sub- assemblies, prototypes, produced units, guaranteed performance specifications etc.
15.3. For Factory inspection and testing, CONTRACTOR shall arrange all that is required e.g., quality assurance personnel, space, test gear etc. for successful carrying out of the job at the CONTRACTOR / Manufacturer’s works.
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15.4. Owner/Owner’s representatives shall have free entry and access to any and all parts of the CONTRACTORs facilities associated with manufacturing and testing of the system at any given time.
15.5. It shall be explicitly understood that under no circumstances that any approval of the Owner/Owner’s representatives relieve the CONTRACTOR of his responsibility for material, design, quality assurance and the guaranteed performance of the system and its constituent.
15.6. CONTRACTOR shall invite the Owner/Owner’s representatives, at least 10 days in advance, of the date on which system shall be ready for inspection and testing. All relevant documents and manuals, approved engineering drawings, etc shall be provided well in advance of the start of inspection and testing.
15.7. Owner/Owner’s representatives shall after completion of inspection and testing to their satisfaction, issue factory acceptance certificates to release the cable/ jointing closures for shipment. No cable/ jointing closures shall be shipped under any circumstances unless a factory acceptance certificate has been issued for it, unless agreed otherwise by Owner/Owner’s representatives.
16.0 TESTING THE OFC
16.1. The CONTRACTOR shall provide factory tested OFC in nominal drum length of 4 Kms per drum. Prior to installation, the Contractor shall physically see the cable for any damage and test the OFC using the Optical Time Domain Reflectometer (OTDR). The contractor shall be responsible for taking the OTDR traces and other test parameters for each drum and
16.2. Keeping record of the OFC traces of such tests. OTDR Trace results shall be submitted to the Site Engineer/ Engineer-in-charge for review.
16.3. After blowing of the each cable drum through the HDPE, the Contractor shall again test the cable and take OTDR traces. The post installation OTDR traces (hard copy and soft copy) shall be submitted to Engineer-in-charge for review. Testing shall be performed on each fibre and on all the drums.
16.4. No variation in the test parameters indicates the quality of the cable blowing works. The cable laying is liable for rejection if the variation in test parameters is observed. Under such conditions, the contractor shall be responsible to supply and install tested cables in the defective stretch / section without any extra cost to the Owner. The above testing procedure shall be performed for replaced cable also. All costs towards replacement of the damaged cables including supply of the cable shall be borne by the contractor. Contractor to note that the cable to be supplied as replacement shall be similar in design to the originally supplied cable.
16.5. After splicing and termination, the contractor shall test the OFC for each fibre as stated in previous section. The splice loss shall be recorded by the contractor. For each splice, loss of 0.07 dB is allowed. If splice loss is more than 0.07 dB, such splices shall be rectified in consultation with the Engineer-in-charge/ Site Engineer.
16.6. The Contractor shall be equipped with the following minimum equipment for testing the OFC:
• Optical Fibre Fusion Splicer
• Fusion Splicer Tool Kit
• Optical Time Domain Reflectometer.
16.7. In all cases, the Contractor shall notify the Owner ten working days in advance for testing of the cable so that the Owner or his representative may be present on mutually agreed date.
16.8. The record of the OFC laid during the day shall be maintained on daily basis. To facilitate the traceability after installation at a later date, this record should contain OFC drum No., sequential meter reading of the OFC laid, pipeline chainage between which the OFC has been laid along with the sequential meter reading. The OFC shall have sequential marking at every 1 meter to facilitate the record maintenance. Record of Cable laying at HDD Crossing shall be maintained.
17.0 PACKING
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17.1. All equipment/ instruments/ cable drums shall be individually packed in suitable containers/ crates designed to avoid damage to the equipments during transit and storage in accordance with best commercial practice and with the requirements of applicable specifications. The materials used for packaging, wrapping sealing moisture resistant barriers, corrosion preventers etc. shall be of recognized branches and shall conform to best standards in the areas in which the articles are packaged. The packing shall protect the equipment from impact, vibration, rough handling, rain, dust, damp, insects, rodents, etc Each container/ crate shall be subjected to impact, vibration and other mechanical tests.
17.2. Each container shall have a copy of factory acceptance test report enclosed in it. Packages for optical fibre cable shall make provision to allow for two (2) meters of excess cable on the inner end of the package to be accessed from outside. The outer end of the cable shall have pulling eye with heat shrinkable sleeves attached to it. The inner end of the cable shall be provided with a heat shrinkable sleeve. The ends shall be adequately protected to allow for normal handling during shipment.
18.0 DOCUMENTATION
18.1. CONTRACTOR DATA REQUIREMENT AND DOCUMENTATION
18.1.1. Six sets of Documentation shall be supplied with each submission. Prices for all documentation shall be inclusive in the supply/installation charges and no separate prices shall be applicable for documentation.
18.1.2. All documents shall be in English language only.
18.1.3. During engineering stage, ENGINEER-IN-CHARGE shall review/approve drawings/documents.
18.2. After the award of work, the following documents shall be supplied for review and approval in order to start OFC installation at site:
18.2.1. Experience & Proven Track Record details.
18.2.2. OFC construction-showing cross section of the offered OFC, providing details of each layer (specifically mentioning, material used, thickness, fibre color, etc).
18.2.3. Contractor shall submit HDPE laying methodology and cable blowing methodology to EIC for approval before starting the HDPE laying and OFC blowing works. The methodology shall be submitted well in advance (minimum three weeks before start of job). The delay in submission / approval due to incomplete / incorrect document shall be to contractor’s account
18.2.4. Fibre manufacturing test reports and supplier test certificates of raw materials to be used in cable manufacturing.
18.3.1. Supply of OFC as built route map OFC as built route map shall comprise the following as a minimum:
• Detailed measurement of length of OFC route along-with details of road, nullah, river crossings etc.
• Location of Terminals, repeaters and planned location of joints.
• Various rail, road, canal, river crossings, etc.
18.3.2. The Contractor shall thereafter prepare OFC route sheet for the entire route with proper scale showing all the crossings and topographic details as needed to define the route and its characteristics. (For the sections where the OFC route may leave the pipeline route, the Contractor shall make a proper topographic survey to define the route and to determine the existence of over ground or underground services that could interfere with the installation (Contractors bid should be inclusive of all such survey/requirements and no separate payment shall be done).The print outs shall be on A2 sheets
18.3.4. List of all the materials to be used during OFC installation.
18.3.5. Any other data, document not specifically mentioned, but required for the satisfactory completion, operation and maintenance of the system shall be provided.
18.4. Documents to be supplied before ‘Final acceptance certificate’ issued by OWNER:
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a) As built OFC route map with the following additional details at each joint location.
• Progressive OFC length, including the additional length at each joint location.
• Fibre length, fibre length between joints, as measured by OTDR.
• Progressive pipeline chain age
• Distance of joint from nearest pipeline markers & crossings, etc.
b) Final OFC test reports (individual OFC drums, hop to hop between repeaters, section and end to end, as applicable).
c) Final location of OFC w.r.t the pipeline along the entire route.
d) All final documents for this project in hard as well as electronic (CD) form.
18.5. DOCUMENTS TO BE SUBMITTED DURING DETAILED ENGINEERING
The details / documents pertaining to offered materials under the tender, as mentioned below shall be submitted by the bidder along with their bid:
a) Make and Model number of the following items as per list of approved vendors for contractor supplied items out of approved vendor list: -
• OFC
• HDPE pipe, end caps, couplers
• OFC Joint kit
• Electronic marker
• Electronic Marker locator
• MS Pipes
b) Telecommunications Engineering Centre (TEC) approval certificate for offered model of items as above (as applicable).
c) Detailed technical literature / technical manual for items in (a) above
d) The name of the party / sub-contractor who shall execute the HDPE Laying, Cable blowing, splicing, testing works along with relevant experience details of the party / sub-contractor of having executed such works in the past 5 years.
e) The details of relevant experience (last 5 years) shall be submitted.
f) List of the equipment to be deployed for OFC blowing
g) List of testing equipment for OFC Splicing & testing works
18.6. DOCUMENTATION for Instruments to be supplied as part of tender
Technical literature in English with complete layout, detailed block schematic of the unit shall be provided. All aspects of installation, operation, maintenance and repair shall be covered in the manual. The manual should include the following:
a) Installation, operation and maintenance manual
b) Safety measures to be observed in handling test instrument:
c) Precautions for setting up, measurements and maintenance;
d) Test equipment required for routine maintenance and calibration including their procedures;
e) Illustration of internal and external mechanical parts.
f) Procedure for trouble shooting of instrument shall be provided. Test fixtures and accessories required for repair shall also be indicated. Systematic trouble shooting charts shall be given for the probable faults with their remedial actions.
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19.0 ACCEPTANCE TESTING
The Optical Fiber shall be terminated at each of the stations to the Fiber Termination Closure (FTC) installed on the entry point of the stations. On completion of blowing, splicing and termination from end-to-end, the optical fiber cable shall be jointly tested as per the agreed test schedule. Like wise the acceptance tests shall be performed on other items supplied and installed by the contractor. The testing schedule shall be as agreed and approved by the owner/consultant. Certificate of provisional acceptance shall be issued on satisfactory testing of all such items. Final acceptance certificate shall be issued only after completion of warranty period of 1 year after provisional acceptance.
Upon successful completion of the `Site acceptance testing', any shortfalls when compared to the contract shall be made good by the Contractor.
The Contractor shall then provide as built documents as asked in this tender document. After this, ENGINEER-IN-CHARGE shall notify the Contractor in writing, his final acceptance of the laid OFC and the OFC shall be considered commissioned.
Nothing herein above provided, inclusive of the `Final Acceptance Certificate; shall absolve Contractor of his full liabilities under the contract inclusive of and relative to the system performance and Warranty.
Σ Σ Σ
PTS – PLB HDPE DUCT P.011947
I-10797
005
0 07.02.18 Issued for RFP MA SHD SK
Rev. Date Subject of revision Author Checked Approved
BORERI TO CFCL-III PIPELINE PROJECT, RAJASTHAN
TRACTEBEL ENGINEERING PVT. LTD.
PARTICULAR TECHNICAL SPECIFICATION (PTS)
PLB-HDPE DUCT
PTS – PLB HDPE DUCT P.011947
I-10797
005
Rev. 0 – 07.02.18 Boreri-CFCL III pipeline Project Page 1 of 1
655 & 18 fibre G-652) of 4 km +/-5% Cable drum length with fiber terminal
closure, inspection chamber, electronic route marker all along pipeline route,
Two number electronic locater as per PTS-Optical Fibre cable (P.011947-I-
11097-004) and Scope of Work C&I (P.011947-I-11075-001).
1. Supply of jointing closure 24 Fiber, 2 way including all accessories (3M,
Siemens, Reychem make only) - 10 nos
2. Supply of FTC with pig tails other accessories for termination of OFC -
24 Fibre in the Telecom Room - 4 nos
3. Electronic marker – 4 nos
4. Electronic locator – 2 nos
OFC Mtrs 32000
18
Supply of 50mm OD permanently lubricated HDPE telecom duct along with
all the required accessories as per PTS-Optical Fibre cable (P.011947-I-
11097-005) and Scope of Work C&I (P.011947-I-11075-001).
HDPE Mtrs 32000
Supply of Instrumentation signal cable, control cable, communication
cable/LAN cable, Power cables along with all sizes cable glands (WP &
Exd), PVC hood, lug, ferrule, etc as per PTS-Instrumentation with
appendices (P.011947-I-11097-001) and Scope of Work C&I (P.011947-I-
11075-001).
1Px1.5mm2 1800
12Px0.5mm2 600
1Qx1.5mm2 150
12Tx1.5mm2 300
1Tx1.5mm2 900
6Px0.5mm2 600
1800
600
150
300
900
600
19 Cables Mtrs
32000
32000
Borei to CFCL - III, Gadepan Project Pipeline Page 4 of 5
Boreri SV CFCLTag Number Instrument Type UnitSr. No TOTAL
INSTRUMENTATION
BILL OF MATERIAL
P.011947
I 11013
001
Quantity
2Cx1.5mm2 300
Cat 5 (LAN) 200
20
Supply of Instruments cable tray with tray cover as per requirememnt and as
per PTS-Instrumentation with appendices and Scope of Work C&I.
Branch Cable tray (50mm x 50mm), Main cable tray 900 mm, cable tray
300mm, cable tray 150 mm.
Tray LS 1
21
Supply tubes and fittings as per requirement and as per PTS-Instrumentation
with appendices and Scope of Work C&I.
SS 316L TEE (1/2”, Class 3000#, Screwed, NPTF, Seamless) ,SS316L
GLOBE/BALL VALVE (1/2”, Class 800#, Screwed, NPTF, Seamless),
SS316L PLUG (1/2”, Screwed, NPTM, Hex head, class 3000#), SS316L
PIPE NIPPLE (½” NPTM, seamless, schedule #160) Length of the pipe
nipple as per requirement, SS316L MALE CONNECTOR (1/2" OD x 1/2"
NPTM), SS316L FEMALE CONNECTOR (1/2”OD x 1/2” NPTF), SS316L
UNION (1/2” OD), SS316L TUBE (1/2" OD x 0.065" WT), SS316L TUBE
(1/4" OD x 0.035" WT)
SS Fittings LS 1
22
Supply of Erection materials, fabrication material, mounting stands,
canopies, MS plates, etc as per requirement
ISMC 100, ISMC-75, CANOPY (400(W) mm x 300(D) mm x 300(H) mm)
MOC is AL (Aluminium) with 2mm thickness, STANCHION PIPE (2”CS)
as per Hook UP, CS Galv. SQUARE PLATE, Anchor Bolt, Nut etc
Erection materials LS 1
23Supply of mandatory spares as per Mandatory Spare (P.011947-I-11087-
001)Mandatory Spares LS 1
Note
1
All above given quantities of equipments and cable sizes are tentative and may vary as per site & functionality requirement. Bidder is also required to
ascertain the equipment & quantity those are not mentioned herein but require according to functionality and their standard practices/ system. No
extra claim will be entertained after award.
300
1
1
1
200
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GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
6 14.09.09 Logo Changed AS SD KNC
5 30.04.07 Logo Changed AR PKS KNC
4 13/09/00 First issue MZJ DNP DNP
3 18/12/98 Changed Company name and logo DNP PCA DNP
2 22/01/98 Updated DNP PCA DNP
1 04/10/94 General revision of SG-96-003 VAH PCA DNP
Rev. Date Subject of revision Author Checked Approved
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 1 of 8
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GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 2 of 8
1.
This specification defines the symbolisation and identification of instrumentation to be used for Piping and Instrumentation Diagrams, for instrumentation documents and drawings and for instrumentation tagging.
2.
2.1.
Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this specification are given the following meaning : AGREEMENT Designates the agreement concluded between the CLIENT and
the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.
CLIENT Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.
CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the CLIENT. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.
ENGINEER Designates the individual or legal entity to which the CLIENT has entrusted various tasks in relation with the carrying out of his PROJECT.
GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, material, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The Terms GOODS or SERVICES may by indifferently used one for the other as required by the context.
PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided by one or more CONTRACTORS.
2.2. !"
The terminology conforms to ANSI/ISA S51.1 "Process Instrumentation Terminology".
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 3 of 8
3.
3.1. "$ %& %&
1) Instrument symbols and functional identification shall be in accordance with ANSI/ISA S5.1 "Instrumentation Symbols and Identification" and ANSI/ISA S5.3 "Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems".
2) The action of a valve in case of electrical or air failure shall be indicated under the symbol of the valve body by one of the following abbreviations :
FC = fail closed,
FI = fail indeterminate,
FL = fail locked (last position),
FO = fail open.
3) The on-off valves shall be identified by :
the letters XV if they are operated by a Process Control System (PCS), a Programmable Logic Controller (PLC), an Emergency Shut-Down (ESD) system or a relay system; the associated solenoid valves shall be identified by the letters XY;
the letters HV if they are only operated by a hand switch (HS).
4) The auxiliary contact of a contactor (e.g. for a motor), which shows if the contactor is energized or not shall be identified by YS.
The control of a motor will be tagged HS in all cases (PCS or panel/local control).
5) Identification letters, typical letter combinations, and function blocks and function designations are given respectively in Tables 1, 2 and 3 of ANSI/ISA S5.1
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 4 of 8
3.2. '%%&
1) Each instrument or function shall be identified by a tag number comprising two groups of characters :
XXXXX - YYYYY Z - W
Optional suffix used to designate a specific function (i.e. B for an intrinsically safe isolator, D for a PCS input/output, P for a PLC input/output, E for an ESD input/output, R for a relay, …)
Optional suffix used when a given loop has more than one instrument with the same functional identification (i.e. A, B, C, ….)
Loop number The two first digits designate the plant area (i.e. 10, 20, 21, …)
The three last digits correspond to the serial loop numbering. The loop numbering sequence starts with 001 for each plant area.
Functional identification comprising five letters maximum (i.e. PDAHH)
2) Inside one plant area, no loop will bear the same serial number.
4.
4.1. & ) %$
1) Each local panel shall be identified as follows :
LP - XXYY
serial number (01 to 99) plant area number (i.e. 10, 20, 21, …) ex. : LP – 2101 2) For local cabinets, the letters LP will be replaced by the two letters corresponding to the cabinet type
(see par. 4.2.).
ex.: PS – 3001
4.2. $%) *%
The cabinets and panels located in the instrument rooms or in the control rooms shall be identified as follows :
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 5 of 8
XX - YYY
the first digit designates the room number; the two last digits are serial numbers from 01 to 99.
(i.e. 101, 102, 201, 202, ...) cabinet/panel identification letters : AL = Alarm Cabinet/Panel AU = Auxiliary Cabinet BA = Barrier Cabinet CC = Control Cabinet CD = Control Desk CP = Control Panel EA = Earthing Cabinet FF = Fire fighting Cabinet/Panel FG = Fire/Gas detection cabinet IF = Interface Cabinet EL/IN MA = Marshalling Cabinet PL = PLC Cabinet PS = Power Supply Distribution Cabinet RE = Relay Panel/Cabinet TU = Termination Unit Cabinet
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 6 of 8
4.3. +& ,
1) The junction boxes shall be identified as follows :
JB - XXYY - ZZ
signal type : IA = Intrinsically safe analogue signals IF = Intrinsically safe frequency signals IL = Intrinsically safe logic signals IR = Intrinsically safe RTD signals IT = Intrinsically safe thermocouple signals NA = Non-intrinsically safe analogue signals NF = Non-intrinsically safe frequency signals NL = Non-intrinsically safe logic signals NR = Non-intrinsically safe RTD signals NT = Non-intrinsically safe thermocouple signals PS = Power Supply SV = Solenoid Valves serial number (01 to 99)
plant area number (i.e. 10, 20, 21, ...)
ex.: JB - 2201 - IA
2) Inside one plant area, no junction box will bear the same serial number even if type of signals is different.
4.4. $
1) A cable between a field instrument and a junction box or local panel shall be identified by the instrument tag number :
e.g. : FT - 23001
2) A cable between a junction box or a local panel and an instrument room or a control room shall be identified by the junction box or local panel identification number :
e.g. : JB - 2309 - SV LP - 4110 - NL
3) Cables in instrument rooms or control rooms shall take the identification of the cabinet to which they are connected with, when applicable, the signal type letters :
e.g. : TC 101 – NL
4) When several cables are connected to the same equipment, a serial number will be added to the cable identification :
e.g. : LP - 2301/1-IL, LP - 2301/2-IA CC 101/1 - IA, CC 101/2 – IL
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 7 of 8
5) For power supply cables, the identification will be completed by the letter "S" :
e.g. : LP - 2101 - S
5.
5.1.
1) Each instrument will be identified by its tag number.
2) The identity plate or tag plate supplied by the instrument manufacturer shall be made of 316 stainless steel. The plate shall have a minimum thickness of 0.5 mm and a maximum thickness of 1.5 mm. The size and shape of the plate is left to the discretion of the equipment manufacturer so that he may supply his own standard item, where one exists.
3) The engraving must be done in upper case letters, with a minimum size of 6mm. The letters may be stamped if this method is preferred.
The engraving or stamping must be heavy duty so that the letters do not become obscured by dirt or tarnishing.
4) The tag plate is to be fixed to the equipment such that it is secure and cannot be accidentally removed.
It must be fixed in such a way that it can be deliberately removed and replaced. This is necessary if a duty is assigned to a spare item, or if it is necessary to reassign an item to another duty.
Acceptable methods of fixing are :
1) Screwing. This shall not be done if it affects the integrity of the enclosure, such as it might be the case with an item which is classified for use in a hazardous area e.g. Zone 1 or Zone 2, or with an item which has an IP (Ingress Protection) rating.
2) Wiring. The wire, which is used, must be 316 stainless steel.
3) Riveting. The rivets used must be 316 stainless steel and they must be capable of being drilled out without creating any danger of swarf entering the equipment.
Glue may not be used to fasten labels to equipment.
4) Complementary to the instrument identity plate, all field instruments shall be equipped with a second and permanent identity plate, fixed to immediate vicinity of the instrument, i.e. on the support itself if possible.
Details on that identity plate are given in standard drawing 70000/734/XX/7001 "Nameplates, tags and labels for instrumentation".
5) Instruments installed in panels, cabinets, racks, etc. shall also be identified by a second identity plate fixed at the location of the instruments.
Details on that plate are given in standard drawing 70000/734/XX/7001.
5.2. ) %$
Panels and Cabinets shall bear an identity label in accordance with standard drawing 70000/734/XX/7001.
GENERAL TECHNICAL
SPECIFICATION
GTS 734 003
Rev. 6 – 14.09.09 Page 8 of 8
The label shall preferably be fixed by screwing at a 1.6 m height.
5.3. +& ,
1) One or two engraved labels per box shall be fixed on the lid.
Label 1 :
Text : JB type and number
Label 2 (When applicable) :
IS application
Text: THIS JUNCTION BOX CONTAINS INTRINSICALLY SAFE CIRCUITS
Voltage above 24 V application
Text: THIS JUNCTION BOX CONTAINS (*) CIRCUITS ALL CIRCUITS TO BE ISOLATED PRIOR TO OPENING
(*) = applicable voltage
2) When applicable, one engraved label per box shall be fixed next to the screen busbar:
Text : SIGNAL SCREEN
3) Details on these labels are given in standard drawing 70000/734/XX/7001.
6.
Reference is made in this specification to the following documents.
6.1. &$ %%%1!
70000/734/XX/7001 Nameplates, tags and labels for instrumentation.
6.2. &"&%%
ANSI/ISA S5.1 Instrumentation Symbols and Identification.
ANSI/ISA S5.3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems.
ANSI/SA S51.1 Process Instrumentation Terminology.
S S S
GTS – INSTRUMENTATION ERECTION J/02/3009
2 14.09.09 Logo Changed AS SD KNC
1 14.03.08 Logo Changed AS NS KNC
0 30.04.07 Logo Changed AR PKS KNC
B 04.03.05 Logo Changed SUB AKJ VVA
A 15.09.03 First Issue SUB AKJ VVA
Rev. Date Subject of revision Author Checked Approved
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 – 14.09.09 Page I of I
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GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 1 of 22
This specification covers the technical requirements for installation, calibration, checking, testing and commissioning of Instrumentation for Gas pipeline project.
Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this document are given the following meaning :
AGREEMENT Designates the agreement concluded between the OWNER and the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.
OWNER Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.
CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the OWNER. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.
DAYS - WEEKS - MONTHS Specify the number of calendar days, weeks or months and not of working days, weeks or months.
OWNER’s REPRESENTATIVE Designates the individual or legal entity to which the OWNER has entrusted various tasks in relation with the carrying out of his PROJECT.
GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, materiel, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The terms GOODS or SERVICES may be indifferently used one for the other as required by the context.
PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided by one or more CONTRACTORS.
$
The Instrumentation erection shall be in accordance with the codes and standards mentioned in the present specification and with the codes, standards and legal requirements listed in various documents for the PROJECT.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 2 of 22
%&%
Whenever OWNER and/or OWNER’s REPRESENTATIVE review and/or approval is requested on a document to be submitted by the CONTRACTOR or before an action is implemented by the CONTRACTOR, such review and/or approval shall always be requested in writing by the CONTRACTOR to the OWNER and/or the OWNER’S REPRESENTATIVE before any action subject of this review and/or approval is taken.
OWNER and/or OWNER’S REPRESENTATIVE approval shall always be given in writing.
1) The technical requirements laid down in this specification do not relieve the CONTRACTOR from any responsibility resulting from the awarded works.
2) The layout drawings attached to the tender document for the PROJECT and the models regarded as part thereof, show approximate locations of instruments, analysers, single and multicore cable routings, junction box locations, and shall be used as a guide by the CONTRACTOR.
They need not to be strictly adhered to, unless so specified, provided that accessibility, accuracy and lag requirements are taken into consideration.
Any drawing showing connection details and dimensions, or containing any specific information, shall be adhered to and any deviation from the drawings shall be approved by the OWNER’S REPRESENTATIVE before starting installation.
3) Any discrepancy between this specification and other documents shall be immediately notified to the OWNER’S REPRESENTATIVE, in writing, for resolution.
4) Protection of equipment and personnel against damage through malfunctioning or mishandling the instrument or instrument system shall be provided by the CONTRACTOR as an integral part of contract. Adequate protection shall be included for ensuring safety of personnel from any possible hazards.
The CONTRACTOR shall perform the following works (unless explicitly excluded in the tender for the PROJECT):
1) Verification of all instruments, when receiving them, to ensure that all components have been delivered and to ascertain any damage suffered.
Failure by the CONTRACTOR to give notice of visible damages or omissions to the OWNER’S REPRESENTATIVE when receiving a consignment of materials and instruments shall be considered as an implicit confirmation that the CONTRACTOR takes upon himself all responsibilities for their soundness until final testing and acceptance.
2) Installation of all instruments and ancillary equipment.
3) Installation and connection to lines and equipment of instrument process piping including, where specified, seal welding of threaded connections.
4) Tracing of instruments, instrument impulse lines, wherever required.
5) Installation of protection boxes for instruments, wherever required.
6) Installation of junction boxes, wherever required.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 3 of 22
7) Installation of ladders, trays, trunking and conduits for cables and tubes.
8) Installation of consoles, desks, panels and cabinets for instruments.
9) Installation of electrical power supply cabinets for the Instrumentation.
10) Installation of all the necessary supports for the instruments, cable ladders, trays, trunking and conduits, impulse lines, pneumatic transmission lines, steam tracing lines, cabinets, panels, consoles, desks, junction boxes, connection boxes, cross boards, synoptic panels, etc.
11) Painting of the supports, frameworks and locally manufactured panels.
12) Installation and connection at both ends of instrumentation cables and conductors.
13) Installation of nameplates and/or labels for identification and numbering of instruments, cables, wires, junction boxes, connection boxes, cross boards, terminals, cabinets, panels, desks, pneumatic transmission lines, lines or cables for tracing, etc.
14) Carrying out any auxiliary work necessary for installation of the instrumentation as per technical specifications (e.g. removing and replacing doors to facilitate work, drilling small holes in walls and floors, filling back the holes, reparation of damages made during installation and repainting all damaged paint work).
15) Handling and properly protecting instruments, cabinets, boxes, panels, desks, consoles after receipt and after installation (especially capillary tubes, proximity switches etc.).
16) Removal of oxidation and, if necessary, greasing of parts oxidized during transportation or storage.
17) Performing additional works upon request of the OWNER’S REPRESENTATIVE.
18) Performing all changes and repairs, as required, resulting from CONTRACTOR'S failure to comply with specifications, standards and/or drawings or from incorrect installation.
19) Checking and testing of all instruments.
20) Calibration and precommissioning of all instruments.
21) Installation and removal as per site regulations of temporary stores, workshops and buildings, for performance of the WORKS and in order to properly protect and store all instruments.
22) Cleaning of the site.
23) Fabrication of pipe nipples as necessary including threading as per installation standard.
24) Drilling of holes in blind flanges including cutting threads as per installation standards.
25) Back/seal welding of screwed fittings as required by standards or as per the instruction of Owner/Owner’s Representative. This may involve welding of dissimilar materials using appropriate electrodes.
26) Civil works including the casting of foundation as required for instrument support.
27) Minor civil works like chipping of pavement, grouting of instrument panels, laying of conduits below pavement after chipping and refinishing of pavement as necessary.
28) Sealing of cables/ tube entries into the control room after laying and testing of all cable/ tubes by installing Multi-Cable Transit block (MCT) including fixing of MCT frame, routing of cables through cable blocks, tightening of cable blocks.
29) Degreasing of impulse lines, valves, instruments and other instrument items in oxygen and chlorine service as per manufacturer’s instructions.
30) Minor modification/repairs required to be carried out on the instruments namely replacement of dial, glass for pressure gauges or any other similar instrument, replacement of damaged signal tubes on
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 4 of 22
valves, tapping of damaged threads on couplings, tees and other fittings; cleaning of nozzles and relays in pneumatic instruments.
31) Painting of all structural supports for trays, pipes, junction boxes, instruments.
32) Punching of tag numbers on items or tag plates.
33) Fabrication and installation of pipe stanchion as per Instrument support standards including casting of concrete pedestal, grouting, welding etc. as necessary.
34) Drilling holes for providing glands/grommets on panels, shut down cabinets, power supply cabinets, local control panels, pneumatic enclosures, junction boxes etc. wherever required for cables/ multitube entry.
35) Grounding of shields cables to respective instrument earth bus provided in the control room/local panel/RTD head etc. as required.
36) Laying and termination of earth cable at both ends between instrument earth bus provided in control room/local panel to instrument earth pits provided by other contractors.
37) Supply of all types of consumables required for the execution of the job without any exception.
38) Sealing of safety valves with standard lead seals after final setting in the presence of Owner/Owner’s representative.
39) Supply and installation of base frames along with necessary civil works for all the panels / cabinets / consoles including the RTU base frame (RTU size shall be provided during execution) envisaged inside the control room are included in the scope of CONTRACTOR.
40) Co-ordination during installation, pre-commissioning and commissioning with mechanical and other sub-contractors for proper installation of line mounted instruments like control valve, ultrasonic flow meters etc. which involve removal of instruments disconnection of tubes/ cables, reconnection of same for alignment and proper installation.
41) Incorporation of all information in drawings/document as per the actual execution of work at site including preparation and submission of as-built drawings.
42) Any other work not specifically mentioned above, but required for the proper execution of the erection work.
The CONTRACTOR shall supply the following materials and documents (unless explicitly excluded in the tender for the PROJECT) in accordance with the requirements for the PROJECT:
1) All the supports for the installation of instruments, cable ladders, trays, ducts, conduits, instrument process lines, pneumatic transmission lines, cabinets, panels, desks, consoles, junction boxes, connection boxes, cross boards, etc.
2) Material for the instrument process piping (except the first isolating valve).
3) Material for the tracing of instruments, instrument process piping.
4) Material for the pneumatic transmission lines.
5) Junction boxes, the connection boxes, the cross boards including terminals and accessories.
6) Protection boxes for the instruments and ancillary equipments, including all required accessories.
7) Cable ladders, trays, trunking, conduits.
8) Cable glands.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 5 of 22
9) Accessories for fixing the cables on cable ladders, trays and trunking.
10) Nameplates and labels for identification and numbering of instruments, analyzers, ancillary equipment, cables, wires, junction boxes, connection boxes, cross boards, terminals, cabinets, panels, desks, consoles, pneumatic transmission lines, air supply lines, lines or cables for the tracing, etc.
Numbers to be used shall be given by the OWNER’S REPRESENTATIVE.
11) All the required accessories for an installation in accordance with the prescriptions, drawings and technical specifications and for the verifications, checks and tests of the Instrumentation.
12) All equipment and material asked for by the OWNER’S REPRESENTATIVE on site.
13) Required equipment for the calibration, testing and the precommissioning of the Instrumentation, when applicable.
14) Consumables (electrodes and welding rods, primer, lubricants, sealants, soldering flux, paint, screws, bolts, expansion bolts, nuts, washers, etc.).
15) Necessary tools, equipment and temporary stores, workshops and buildings, in order to perform the works (including lifting engines, scaffolding, etc.).
16) Required test documents and certificates.
17) As-built drawings (marked up copies).
18) Welding procedures and welders qualification certificates, when applicable.
19) Weekly reports with progress status.
20) Planning and organisation documents such as:
work preparation sheets,
activity bar chart schedule
cable cut program for cables delivered by the OWNER.
21) The precommissioning sheets filled in and signed off "ready for commissioning". Those sheets could be an OWNER’S REPRESENTATIVE standard, an OWNER standard or a CONTRACTOR standard approved by the OWNER’S REPRESENTATIVE.
'()*)+,-.('/01
The CONTRACTOR shall strictly adhere to the site regulations.
.()*'.-1
All materials supplied by the CONTRACTOR shall be in accordance with (but not limited to) the requirements laid down in the Technical Specification for the PROJECT and attached documents and drawings.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 6 of 22
The CONTRACTOR shall ensure that all materials and equipment are adequately protected and stored until they are installed / erected.
/2.-3.4*'2.('/0
All equipment necessary for proper installation of instruments (like supports, frameworks, local panels, etc.) and not supplied in prefabricated form shall be fabricated locally by the CONTRACTOR.
(/*'0+.056.05-'0+/3'01(*,7)0(1
Immediately after receipt, instruments and installation materials shall be stored by the CONTRACTOR (unless stated otherwise in the Particular Technical Specification for the PROJECT).
When instrumentation is taken from stock temporarily (e.g. for testing), it shall be returned to the CONTRACTOR’s store in the original packing.
For preventing damage, the CONTRACTOR shall transport and handle instruments with the utmost care. All covers and plugs on instrument connections and flange facings shall be left in place as long as possible.
Instruments shall be protected against general construction site hazards, and in particular against adverse weather conditions during the construction period, (e.g. extensive use of large size commercial quality polyethylene bags to cover control valves and local instrumentation). All openings shall be properly sealed if the connections are not made immediately after the installation of the instrument, junction box etc.
.4-)1(/*.+)
All cables shall be stored in a locked compound. Partly used drums shall have their ends sealed and an indication of the quantity remaining marked on the drum.
The fenced off area shall be of sufficient size to allow entry of vehicles, and allow the storage of cables by type and size in a neat and orderly manner. The surface of the compound shall be such that it does not get water logged.
)0)*.-
1) The CONTRACTOR shall make a preliminary study of instrument, junction boxes location and instrument cable run.
Locations and runs proposed by the CONTRACTOR shall be in accordance with sound installation practices and submitted to OWNER’S REPRESENTATIVE for approval. The approval of the OWNER’S REPRESENTATIVE cannot be used as an argument for an extra-cost in case of relocation afterwards.
2) All instruments, there measuring elements and their process manifolds and valves shall be safely and permanently accessible from grade, platforms or walkways (2 m above or 1 m either side of).
Where permanent accessibility is impossible, the process connections and measuring elements for instruments may be located so that they are accessible by temporary facilities (ladders or mobile platform, maximum length : 4 m).
In such cases additional block valves shall be provided close to the instrument. This requires approval of the OWNER’S REPRESENTATIVE.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 7 of 22
All instruments, their process connections shall have such orientation and location as to allow easy reading.
Control instruments and transmitters shall also be located in such a way that they are easily accessible for operation and maintenance.
3) The connections to the process lines and equipment shall be made in accordance with the pipe class up to and inclusive of the first block valves. Their orientation shall be selected so that instruments or instrument process piping will not obstruct walkways or platforms.
Seal welding may be requested on threaded connections for special services. That welding shall be performed in conformity with the welding procedure for threaded connections.
The CONTRACTOR shall check the type, size, material and orientation of the instrument process connections.
4) The run of instrument impulse lines shall be such as to avoid liquid pockets in lines containing gas, even if this is not specified on the typical drawings.
Slopes of instrument impulse lines shall be as specified on the engineering drawings. If not specified, they shall be at least 10 cm/meter to the tapping point when the instrument is mounted above the tapping point and to the instrument when the instrument is mounted below the tapping point.
Vertical instrument impulse lines for differential pressure transmitters shall run as close as possible to each other.
Instrument impulse lines shall be properly supported (maximum distance between supports: 1.50 m).
5) When the pipe class calls for welded connections, welding procedure shall be approved by the OWNER’S REPRESENTATIVE.
6) When seal welds on threaded connections are required, such connections shall be installed with the threads perfectly free of any trace of lubricant or sealing tape.
7) Instruments, associated process piping shall be securely fastened in order to avoid vibrations. When applicable, displacement of process pipes or equipment shall be taken into consideration.
8) In general the instrument supports shall either be fixed to concrete or be welded to structural steel.
It is prohibited to weld supports to platforms, handrails, process piping or process equipment.
If supporting from structural steel or concrete is not feasible, supporting of instruments by means of clamping around piping may be considered but approval of the OWNER’s REPRESENTATIVE is required for each individual case
All surfaces of structural steel which could not be painted afterwards shall be made free of rust, cleaned and painted with a layer of primer before supports, trays, cables, etc. are installed.
All brackets and supports shall be finished smoothly, free from sharp and dangerous edges. Pedestal for yoke mounted instruments shall be closed at top to prevent water accumulation.
In order to avoid electrolytic corrosion, insulating barriers shall be provided when instrument and analyser support are clamped on process piping of a different material.
9) Even when no cathodic protection is installed, all instrument connections to underground metallic lines shall be electrically insulated.
10) Instrument and supports, which must be fixed to fireproofed structures, shall be welded to the steel structure before the fireproofing is applied taking into account the thickness of the applied fireproofing.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 8 of 22
When it is not possible, the supports shall be clamped around the fireproofing, if allowed by the OWNER’s REPRESENTATIVE.
As a general rule, the support installation method has to be approved by the OWNER’s REPRESENTATIVE.
11) All outdoor instruments shall be absolutely weatherproof. If required, weatherproof housings shall be supplied and installed by the CONTRACTOR.
In sunny areas, the field mounted instruments and analysers shall be protected from solar radiation.
12) Local pressure and differential pressure instruments shall be mounted so as to avoid vibrations.
13) Individual instrument tracing shall be installed as specified on engineering drawings.
The requirements for heavy or light tracing shall be strictly adhered to.
Isolation valves on steam manifolds and steam trap stations for instrument and steam tracing and local isolating switches for electrical tracing shall be clearly tagged with the instrument loop number even if they are not installed by the CONTRACTOR.
14) Instrument impulse lines shall be installed in such a way that enough space is kept all around the lines to install the required insulation.
15) Stainless steel impulse and sample transport lines will be additionally protected against the climatic conditions by the use of PTFE spray after the hydrostatic test. The spray type and method of application are to be agreed by the OWNER’s REPRESENTATIVE.
16) Instrument equipment shall be located such that it is protected against direct drainage of condensate, water and process fluids from adjacent plant equipment that can make the instruments, instrument components, junction boxes, etc. dirty, wet or inoperable.
17) Care shall be taken that no passage ways are obstructed or access to other plant equipment, electrical lighting panels, other instruments, etc. is impossible. All equipment shall remain easily operable. Ample space shall be available for the removal of covers, protection box doors, etc.
18) When API threadings are made by a thread cutting machine dies shall be properly oiled and threads produced shall be agreed by the OWNER’s REPRESENTATIVE. PTFE tape shall be used for the installation of threaded fittings, except where temperatures in excess of 200 °C occur, as indicated on the process piping details; for these cases a suitable dope shall be used.
19) When installing steel or stainless steel tubing with compression type fittings, all the fitting manufacturer's instructions shall be exactly followed which shall include, but are not limited to :
proper cutting of tube and deburring,
proper installation of the ferrules,
taking care that all tubes have the required roundness.
When storing tubes, care shall be taken that no mechanical damage can occur, which makes the tubes unround.
In order to avoid unroundness of the tubes at the places where ferrules are to be applied, it is absolutely necessary to cut the tube at least 5 cm from the end of a bend. Mounting closer to the bend shall not be accepted.
To avoid galling of stainless steel ferrules into the tapered end of the stainless steel fittings, the stainless steel ferrules shall be greased slightly at the outside before installation.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 9 of 22
)78)*.(,*)'01(*,7)0(1
All temperature sensing elements shall be firmly bottomed in the thermowells.
*)11,*)'01(*,7)0(1
Refer Standard Drawings enclosed in the tender.
*)026)1
Cable trenches shall be excavated as per requirement and site suitability taking into account the following requirements:
1) The CONTRACTOR shall do all excavation of whatever substances encountered to depth shown on drawings.
Excavated materials not required for backfill shall be removed and disposed of as directed by the OWNER’s REPRESENTATIVE.
2) Unstable soil shall be reported to the OWNER’s REPRESENTATIVE who shall give instructions to the CONTRACTOR for its removal and replacement with suitable material. The CONTRACTOR shall be responsible for the excavation and disposal of this unsuitable material as directed by the OWNER’s REPRESENTATIVE.
3) Unstable materials shall be replaced with approved fill material by the CONTRACTOR as directed by the OWNER’s REPRESENTATIVE who shall approve the replacement fill. All replaced fill shall be compacted as directed by the OWNER’s REPRESENTATIVE.
4) When approved by the OWNER’s REPRESENTATIVE excavated material suitable for backfill may be deposited alongside the trench excavation but at a distance not less than 1 meter from the edge of the trench excavation or as otherwise instructed by the OWNER’s REPRESENTATIVE. When instructed by the OWNER’s REPRESENTATIVE, the CONTRACTOR shall remove all excavated material to a designated dump area.
5) Ground adjacent to all excavations shall be graded to prevent water running in.
6) The CONTRACTOR shall remove by pumping or other means approved by the OWNER’s REPRESENTATIVE, any water accumulated in excavations, and shall keep trenches dewatered until cable bedding is completed to the satisfaction of the OWNER’s REPRESENTATIVE.
The CONTRACTOR shall note that to be effective, dewatering operations may have to be on a 24 hour, round the clock basis to ensure dry working conditions.
7) The CONTRACTOR shall at his own cost supply and install all necessary bracing, sheathing, shoring to perform and protect all excavations as required for conformity with safety regulations and as approved by the OWNER’s REPRESENTATIVE.
8) Temporary crossings shall be built by the CONTRACTOR as directed by the OWNER’s REPRESENTATIVE to maintain traffic on the site. After use, and when instructed by the OWNER’s REPRESENTATIVE such temporary crossings shall be removed by the CONTRACTOR.
9) All open excavations shall be protected at CONTRACTOR'S cost by means of safety barriers, lamps, etc. as required or directed by the OWNER’s REPRESENTATIVE.
10) The depth of the trenches shall be locally increased at crossing or branch-off of large quantities of cables.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 10 of 22
11) The curvature of the trenches shall be compatible with the bending radius of cables.
12) The maximum slope of trench bottoms shall be 10 degrees. The transition to horizontal surfaces shall have a smooth curvature.
13) At crossing, signal cables shall be at least 0.3 m lower or higher than electric power cables.
14) In order to allow future laying of cables, sleeves (200 mm diameter) shall be provided at road and railway crossing and where trenches for signal cables pass under trenches for electric power cables as required on engineering drawings. The sleeves shall be provided with a steel wire in order to allow pulling of cables.
15) Trenches shall be kept (at least 0.5 m) away from buried pipes containing hot fluids and from pipes liable to temperature rise owing to steaming-out.
16) All stones and/or rocks shall be removed from the trench prior to laying of the cables.
17) The CONTRACTOR shall lay a 15 cm thick sandbed to receive the cables.
18) The laying of cables in the trenches shall be approved by the OWNER’s REPRESENTATIVE.
19) The backfill of trenches may only start after approval from the OWNER’s REPRESENTATIVE.
The cables shall be covered with a layer of 15 cm of sand on which red or yellow concrete tiles (300 x 300 x 40 mm) shall be installed, after which the trenches shall be backfilled and covered.
20) The backfill of the trenches shall be carried out using approved excavated materials, compacted in lifts of 30 cm max. When instructed by the OWNER’s REPRESENTATIVE, the CONTRACTOR shall use fill from approved stock pile areas.
The work shall be carried out ensuring that the backfill is firm and compacted, using suitable equipment, and to specification requirements.
21) Backfill material shall be deposited by the CONTRACTOR to specification and as instructed by the OWNER’s REPRESENTATIVE.
22) Puddling or water flooding for consolidating the backfill is not allowed.
23) After backfill of trenches, no surface load shall be placed on the backfill until a period of 48 hours has elapsed.
24) The location of the trenches shall be clearly marked and reported on "as built" drawings.
Markers shall be placed at 15 m intervals (or at intervals agreed by the OWNER’s REPRESENTATIVE) and where the trench changes direction.
For trenches 500 mm or more in width, markers shall be provided on both edges of the trench. For trenches less than 500 mm in width, markers shall be placed at one edge of the trench only.
Markers shall have identification plates of corrosion resistant metal. The plate shall indicate the direction of the cable run and give the voltages of the cables in the trench at the point where the marker is located.
25) Excavation of trenches after cables have been laid requires approval of the OWNER’s REPRESENTATIVE.
.4-)-.55)*1(*.91.05(*,0:'0+
Cable ladders, trays and/or trunking shall be installed as indicated on layout drawings or on models and sectional drawings, taking into account the following requirements.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 11 of 22
1) Cable ladders, trays and/or trunking shall be easily and safely accessible for maintenance reasons.
2) Cable ladders, trays and/or trunking shall be installed in such a way that they do not hinder traffic, nor interfere with accessibility or removal space of pumps, motors, compressors and any process equipment or part thereof.
Minimum required clearances, are:
over railways (from top of rail) 7 m,
crane ways (process area) 6 m,
over elevated walkways or platforms 2.5 m,
where accessibility of mobile lifting equipment is required 4 m.
3) Cable ladders, trays and/or trunking shall be kept away from hot environments and places with potential fire hazards (hydrocarbon process pump, burner fronts).
When cable ladders, trays and/or trunking must be installed where they are subject to fire hazards, suitable fireproofing shall be provided by the CONTRACTOR.
4) Cables ladders, trays and/or trunking shall be located so that they are not subject to mechanical abuse, spilt liquids, escaping vapours and corrosive gases, strong electrical interference.
Ladders, tray and/or trunking riser points which can be damaged by traffic shall be suitably protected.
5) Cable ladders, trays and/or trunking shall be firmly supported.
They shall be suitable for an equally distributed load of 120 kg/m and shall withstand an additional point load of 80 kg.
The supports shall be installed at sufficiently short intervals so as to avoid bending exceeding 0.5 % of span. Wherever possible supports shall be arranged so that cables and multitubes can be laid sideways.
Sufficient free space (minimum 0.5 m) shall be provided above ladders, trays and/or trunkings.
6) Cable ladders, trays and/or trunking shall be internally smooth. Attention shall be paid particularly at changes of directions, both in horizontal and vertical plans.
All fabricated pieces shall be free of burrs and sharp edges (plastic covered ends).
7) The curvature of cable ladders, trays and/or trunking shall be compatible with the bending radius of cables.
8) At site, cable ladders, trays and trunking shall be lengthened by bolting, not by welding.
9) The minimum width of the main cable ladders, trays and/or trunking shall be as indicated on the drawings. The height, if not specified, shall be determined by the CONTRACTOR taking into account the quantity of cables and 30 % spare.
The CONTRACTOR shall base his selection of not specified ladder, tray or trunking sizes taking into account the following considerations. The sizing of the cable ladders, trays or trunking for instrumentation cable depends only on the space required to accommodate the cables at various locations in the system. Space for at least 30 % future cables shall be provided. If mechanical separation is required to separate intrinsic safe cables from other low voltage cables installed on one cable tray or trunking, metal barriers extending approximately 5 cm above the top of the higher shall be used.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 12 of 22
/05,'(1
1) The conduit system shall be installed in such a way that it will be impossible for rain-water to collect at low points. Conduit material shall be as specified in the Particular Technical Specification for the PROJECT.
2) Sharp edges on conduits shall be removed and any conduits ends shall be protected with metal ring collars or polythene inserts to prevent cable damage. All conduits shall be swabbed clean before wire or cable is installed.
3) Following methods are recommended for the supports and arrangement of the conduits.
Conduit shall not be supported from piping that may have to be replaced or removed for inspection nor from high temperature piping. It is sometimes necessary to support conduits from ordinary piping.
Provision shall be considered for thermal expansion or other movement of the supports, such as swaying of towers in high winds.
Conduits are normally fastened to supports with pipe clamp or U-bolts; they shall not be tack welded. Substantial hangers shall be provided for groups of conduits where it is not practicable to clamp directly into building walls or structural members.
Maximum distance between conduit supports : 1.5 m.
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1) The junction boxes shall be installed as indicated in typical block diagram for instrument interconnection and shall be permanently accessible.
2) Junction boxes shall be marked externally with suitable nameplates (corrosion - resistant).
3) Suitable corrosion-resistant cable glands shall be provided in order to house each cable.
4) All junction boxes shall be kept closed except when work is being performed upon them.
Cable inlets shall be kept closed until cables are installed. Spare inlets shall be sealed.
5) Terminals inside junction boxes shall be installed and marked as indicated on drawings.
6) Connections inside the junction boxes shall be aligned so as to allow easy access to any wire.
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1) Installation of multicore cables and multitubes shall not start before all necessary trenches, ladders, trays and trunking are completely ready.
In addition trenches shall be cleared from all foreign matter and a bottom layer of sand shall be applied.
2) The CONTRACTOR shall cut to size cables and multitubes, seal the end remaining on the drum and put a label on the drum indicating taken quantity.
3) Multicore cables and multitubes shall be handled carefully. No excessive pulling or bending forces shall be applied in order to avoid any damage. The CONTRACTOR shall keep in mind the minimum permissible bending radius when handling and installing cables.
4) In order to avoid any damage due to low external temperatures, no cable or multitube shall be installed when the air temperature is below 5°C or less if accepted by the cable manufacturer.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 13 of 22
When it is absolutely necessary to pull cables when it freezes, they shall be heated up at suitable temperature before pulling.
5) Installation of cables and multitubes shall be consecutive and uninterrupted. In case of interruption of cable installation, the trenches shall temporarily be covered and cables shall suitably be protected against damage due to traffic or to installation work.
6) In order to prevent stress, cables and multitubes shall be laid with sufficient slack when trenches are excavated in soft soils.
7) Cables and multitubes shall be suitably fixed in ladders and trays by preformed saddles or plastic ties (e.g. Colson strips). This shall be done :
when changing direction,
every 1.5 m on horizontal runs,
every 30 cm on vertical runs.
If cables are clamped to conduits, pipes, etc. stainless steel cable ties shall be installed every meter in addition to plastic ones.
If cables are directly fixed to the structure, steel clips shall be used every 30 cm.
8) Marking of cables and multitubes shall be as follows :
at approximately 5 m intervals (or at intervals agreed by the OWNER’s REPRESENTATIVE) for underground cables and multitubes, by means of embossed strips of corrosion - resistant material.
at their termination point (outside of junction box where applicable) and in between at places where markers can be easily traced for above ground cables and multitubes by means of suitable label of engraved or embossed plastic. Cables shall anyhow be tagged at the inside and outside of building walls.
9) After completion of the installation of multicore cables and multitubes, all trenches shall be backfilled as mentioned in par. 6.3.1. and all trunking shall be covered.
-)2(*'21'+0.--'0)1
All electric signal lines shall be installed and connected as indicated on engineering drawings, taking into account the following requirements.
1) Plastic markers shall be provided on each side of each terminal for individual marking of all signal lines. Cross ferruling method shall be used.
2) Cable screens shall be interconnected in such a way that the screening is earthed only at the intended location.
3) Installation of special signal cables (e.g. coaxial cables) shall be performed as per manufacturer's recommendations.
4) Electric signal lines shall be laid in conduits or trays provided with supports at every 0.6 m maximum.
Supports shall not in general be attached to piping, nor be attached or supported from instruments or control valves, except supports which are designed for direct mounting on pipes.
Single pair cable shall be run on cable tray when more than 3 cables are run together. They shall be run as one single layer.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 14 of 22
Where three cables or less are to be run (single circuit cables) from the main cable tray bank, these shall be run in straight lengths of conduit, size depending on number of cables. No conduit fittings shall be used, all angles, etc... are to be open. Alternatively the cables may be clipped in angle or channel section. Angle and channel shall be wire brushed and painted.
No cable shall be installed in the conduit until that part of the installation is complete. The conduit shall terminate away from angles to allow the permissible bend of the cable being installed. All conduits shall terminate away from instruments to allow for a loop of cable when terminating the cable.
5) No splicing of thermocouple extension cables is allowed. When absolutely necessary, connections shall be made in approved junction boxes.
6) Cables shall be suitably fixed in trays by plastic ties, every 25 cm on vertical runs and every 50 cm on horizontal runs.
7) Non isolated earthing cables laid on cable trays shall be isolated from the trays. Fixing bolts shall be stainless steel.
)+*)+.('/0/32.4-)1
Instrumentation cables (4-20 mA, mV signals, etc..) shall be adequately separated from power wiring and electrical equipment to minimize interferences. The physical distance between instrumentation cables and power cables in parallel routing shall be as follows :
If required, the instrumentation cables shall cross the power cables at right angle and with a minimum distance of 300 mm.
! '*'0+()*7'0.('/01.05'01(.--.('/08*.2('2)1
1) Cutting wire or cable to required lengths as it comes off a reel requires a location free from sharp objects.
A paved area is usually ideal, but if not available, a grassy or sandy area is adequate.
Crushed stone, muddy, and shelled areas shall be avoided.
Where traffic must cross wire as it is laid on the ground, temporary board ramps shall be provided to keep vehicles from damaging the wire.
2) The Instrumentation cable list gives an indication of the cable lengths for information only, not to cut cables.
3) A cable end preparation shall allow for the following :
terminate jackets and shield material without nicking insulation underneath,
protect cable ends against moisture infiltration prior to connecting the cable to its permanent terminations.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 15 of 22
4) Stripping insulation from wire shall be done without nicking the conductor. Although this is of greater importance with solid wire than with stranded wire, it is a matter of concern with stranded wire also. The simplest way of avoiding nicks is to use stripping tools of proper design.
5) Insulated taper pins or spade lugs shall be used for all sizes of stranded wire. CONTRACTOR shall have proper tools to make these connections.
6) All wires or leads terminated at a connection shall have sufficient slack to reduce the effects of vibration. In application where multiple wires are routed from a common cable trunk to equally spaced terminals, the vibration bends shall be uniform in length to prevent stress on any one wire. Proper cable support is necessary to avoid having cable weight supported from wire terminations.
7) All cable or cable tray runs with entries into walls shall be sealed after installation of cables. To avoid any gas entering the control room(s) a special sealing box shall be installed in the wall of the control room(s).
8) Stainless steel kicking plates, sleeves or steel pipes shall be provided at least 500 mm above floor level where cables emerge from ground or from below steel structures.
9) In order to comply with the requirements for grounding at only one point, terminals are used to carry each shield through the junction boxes.
Accidental shorting or grounding of this shield within a junction box shall be avoided. This can be done by insulating both the shield end and the shield drain wire between the end on the cable jacket and the terminal strip.
Tubular heat shrink sleeves shall be installed on stripped pairs. The sleeves shall be applied immediately after stripping to prevent unravelling of the aluminum adhering mylar tape.
Since only one end of a shield is grounded, each cable has an ungrounded end. This cable end is finished with no ground, and insulation is applied over the trimmed cable end to avoid accidental grounds on any exposed shield or the shield drain wire. Each shield shall be grounded in the control room or in the instrument room.
Special care shall be taken to ground to the correct system, as indicated on the drawings.
10) Hot air heating equipment shall be provided to heat up the cables if connections have to be made when temperature is lower than 5°C.
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1) Single pneumatic lines shall be laid in trays, provided with supports at every 0.6 m maximum.
Supports shall in general not be attached to piping nor be attached or supported from instruments or control valves.
2) The single pneumatic lines shall be marked with the instrument tag number at the point of connection to the multitube.
3) Sufficient slack shall be provided in all air tubing to avoid strain on the instrument connections and to facilitate dismantling of the instruments (provide extra loop, 8 cm diameter).
4) When PVC covered copper tubing is used copper tubing ends shall be coated with PVC spray and plastic tape and all copper or brass valves and fittings with PVC spray.
The copper tubing shall be straightened and installed carefully to avoid kinking and unroundness.
5) In case the use of black polyethylene air tubing is specified (see air piping detail drawings) adequate tools shall be available for installation. Only careful handling of polyethylene tubing will result in a good installation. Elbow connectors shall be used for attaching the tubing with short bends to solenoid
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 16 of 22
valves, etc. to avoid that plastic tubing is bent with a small radius. Joints made with compression fittings shall have metal inserts to supports the tubing. Single polyethylene tubing shall be routed in open conduit.
6) Plastic sealing plugs shall be kept firmly fixed in air supply input, output and other connections, except during test and immediately before final plant connection.
7) Any air system, permanent or temporary used for energizing instrumentation shall be blown down thoroughly before making connections to the instruments and shall be from an oil free source.
Any connections between any air supply system and an instrument under test shall be via adequate filter and regulator. No temporary compressor shall be connected to the permanent instrument air distribution system.
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1) All cable entries inside control room shall be through MCT.
2) Actual sizing of MCT frame with blocks shall be the responsibility of CONTRACTOR based on actual no. of cables. While sizing MCT, CONTRACTOR to note that 50% spare block for each size / O.D. of cable shall be considered. MCT entries shall be closed with a thick CS plate which shall be removed by CONTRACTOR whenever the MCT shall be installed. The supply of MCT includes insert blocks, spare blocks, stay plates, end packing etc. For flexibility in engineering “ peel of sleeve” type design shall be used to accommodate certain range of cable O.D. in the same size of insert block.
3) MCT shall be installed by CONTRACTOR as per the recommended practice of supplier. No spare space shall be uncovered in the frame.
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Instrument installation work in control room and instrument rooms shall only start after completion of civil work (including air conditioning when applicable).
01(.--.('/0/32/0(*/-4/.*51.055)1:1
1) The control boards and/or desks shall normally be delivered to site completely piped and wired up to bulkhead plates and/or to terminal strips. The CONTRACTOR shall install them in the control room upon their arrival on site in order to minimize storage time.
If not possible, they shall be stored by the CONTRACTOR under suitable ambient conditions.
2) The CONTRACTOR shall duly protect front and back of control boards and/or desks during installation and all construction phases in order to avoid any possible damage.
3) Any damage to control boards and/or desks occurring during installation shall be repaired at CONTRACTOR'S costs.
4) The CONTRACTOR shall clean front and back of control boards and/or desks and shall be responsible for maintenance until plant turnover.
5) The CONTRACTOR shall, if required by the OWNER’s REPRESENTATIVE, make additional cut-outs on boards and/or desks after installation.
No flame cutting or welding is allowed on boards and/or desks.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 17 of 22
Cutting shall be made using the most adequate tools so that board or desk finish be not damaged, and that cut-out will be neat and regular with smooth edges.
6) Any other authorized alteration that must be carried out to boards or desks shall be made in such a manner as to avoid shock or damage to instruments already installed.
7) If repairs have to be performed to the finishing of boards and desks, the procedure shall be submitted to the OWNER’s REPRESENTATIVE before to proceed with the work.
8) Any holes drilled in walls, floors or ceiling for the passage of cables shall be filled with the appropriate material to prevent the spreading of fires, etc...
1) Racks, cross boards, control cabinets and auxiliary instruments shall be installed as shown on engineering drawings.
The CONTRACTOR shall provide all necessary protection during installation to avoid any damage and shall be responsible for maintenance and repair of possible damage until plant turnover.
2) Cable ladders, trays and/or trunking shall be installed as indicated on layout drawings.
They shall be firmly supported at sufficiently short intervals so as to avoid bending exceeding 0.5 % of span.
They shall be smooth internally in order to avoid any damage to cables.
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Power supply cables for instruments and analysers shall not be connected until complete tests have been performed on power distribution boards in order to avoid damages due to incorrect power supply or to avoid unsafe application of power supply.
Upon arrival of the equipment in the field and prior to storage or installation, the CONTRACTOR shall remove all accessories which have not been shipped separately, mark them with the identification number of the relative equipment and store them in the warehouse.
The same shall be done for spare parts.
The CONTRACTOR is also responsible for the following.
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1) To ensure that all instruments installed in the circuits are mechanically protected, until plant turnover, to prevent damages due to shocks.
2) Cleaning and greasing, with lead free grease, of the instrument flanges and threads oxidized during transport or storage.
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1) Cleaning and greasing, with lead free grease, of block valve flanges and threads oxidized during transport or storage.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 18 of 22
2) Replacement of stuffing in the stuffing boxes, wherever necessary.
/0(*/-*//7.05'01(*,7)0(*//71
The CONTRACTOR shall clean the control room and instrument rooms on a continuous basis. Dust shall be removed from equipment and racks. Rubbish shall be collected and dumped in suitable places indicated by the OWNER’s REPRESENTATIVE.
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Locking keys for control cabinets, cubicles, relay boxes, panels, switches, locking devices shall be clearly identified, removed from their locks and carefully stored until plant turnover.
Upon receipt of instruments, after completion of installation and prior to setting instruments to work, the CONTRACTOR shall carry out adequate calibration, verifications and tests in order to ascertain that all equipment and systems are suitable for the intended duty, have been correctly installed and are in operating conditions.
1) Contractor shall include a list of test and measuring instruments and quote in the price bid.
2) Equipment to be supplied in this contract shall include comprehensive built in diagnostic and test facility for system maintenance.
3) The contractor shall include a list of special purpose test instrument and simulators necessary for the testing, trouble shooting and system maintenance of the equipment and quote in the priced bid.
4) The Contractor shall include a list of all general-purpose test instruments necessary for the maintenance of the equipment and quote in the price bid.
5) Special tools and maintenance accessories such as Card Extenders cable assemblies, card extractors, wire wrapping and unwrapping tools etc. shall be supplied in the form of maintenance kits. The number of such kits shall be 1 (one).
6) It is to be noted that the contractor shall arrange all test equipment, tools, accessories required for the installation and commissioning of the system to be supplied against this contract.
1) Calibration, tests and verifications shall be carried out in accordance with a schedule to be established by the CONTRACTOR and to be approved by the OWNER’s REPRESENTATIVE.
For those calibration, verifications and tests, the CONTRACTOR shall make available, at his expense, all personnel and equipment needed.
2) The OWNER’s REPRESENTATIVE reserves the right to witness all calibration, tests and verifications and shall be advised with one week notice of such calibration, tests or verifications.
3) The results of calibration, verifications and tests shall be recorded on adequate documents by the CONTRACTOR.
Those documents, which shall be approved by the OWNER’s REPRESENTATIVE, shall indicate all works corresponding to calibration, verifications and tests.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 19 of 22
After calibration, verifications and tests, the completed documents shall be transmitted to the OWNER’s REPRESENTATIVE.
4) The CONTRACTOR shall correct at his expense all faults found in his works.
5) Readjustment and/or repair that may be required to instruments, ancillary equipments, mechanical, pneumatic, steam or electrical connections due to damages incurred during test operations and attributable to the CONTRACTOR shall be made by the CONTRACTOR at no extra cost.
Instruments shall be calibrated before (or as soon as possible after) installation.
Calibration shall be carried out as follows.
*.017'(()*1
Zero and range test (0, 25, 50, 75 and 100 %, upward and downward).
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Zero and range test (0, 25, 50, 75 and 100 %, upward and downward).
B
Zero and range test (0, 25, 50, 75 and 100 %, upward and downward).
The calibration method shall be approved by the OWNER’s REPRESENTATIVE.
The CONTRACTOR shall perform the following verifications, using the latest revision of engineering documents.
1) To check, before installation, that instruments are in accordance with the technical specifications (correct tag number, range, size, type, rating, finish etc.).
2) To check all instrument and piping and associated fittings in order to ensure that they are installed in accordance with engineering drawings, are in perfect conditions and are fitted with necessary clamps.
Those checks cover mainly process impulse lines, tracing, insulation and air supply.
To check that all air sets are giving the correct air supply pressure.
3) Check of instrument location and orientation in order to ensure that they are accessible and easily readable.
A check of instrument reading shall also be made during the night and local plant lighting changes suggested to the OWNER’s REPRESENTATIVE, if necessary.
4) Check of all instrument block valves, drain and vent location for accessibility and from safety point of view.
Drain valves shall be located in such a way that they do not contaminate underlaying instruments, machinery or equipment and are not hazardous for personnel.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 20 of 22
5) To check that the high and low pressure taps are connected to the correct side of the respective instruments.
6) Check of all cable ladders, trays, trunking, conduits, supports, junction boxes, local instrument panels and protection cabinets. Attention shall be paid to damage, rust, missing gaskets, screws, bolts, keys, locks etc.
7) Check of terminal connections for proper identification and polarity.
To check that spare wires are identified and properly connected to terminals or coiled inside the equipment.
8) To check that instruments, cabinets, boards etc. are properly earthed, wherever necessary.
9) To check that each instrument is suitably protected against adverse environmental conditions.
10) To examine all gaskets and valve stuffing boxes for tightness and replace if necessary.
11) To check connections for cable screening.
12) To check that correct power supply has been connected to instruments, analysers, relay boxes, control cabinets, control boards and other equipment and that suitable electrical protections are provided.
13) To check that cable entries to junction boxes are sealed and properly weather-proofed.
14) To check that temperature instruments are properly inserted inside thermowells.
The CONTRACTOR shall carry out the tests described in the following paragraphs.
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Each instrument process piping, including sampling and transport lines for analysers shall be pressure tested and leak-tested.
The testing fluid shall normally be water.
However OWNER’s REPRESENTATIVE shall specify the test medium which will be used.
The test pressure shall be 1.5 times the design pressure or equal to the maximum allowable pressure of the instrument whichever is the lower. After pressure testing, the instruments and associated process connection lines shall be drained and blown dry except in case where sealing liquid is used.
Pneumatic transmission lines and air supply lines shall be leak-tested.
Test shall be performed as per ISA RP 7.1. "Pneumatic control circuit pressure test".
During hydrotest, instruments shall be isolated.
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All instrument wiring shall be checked out for insulation, shielding and grounding with megger test (500 volt range).
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 21 of 22
The test shall be made after the wires and cables have been installed but before connection to instruments and to control room termination cabinets or field mounted junction boxes.
Insulation shall not be less than 5 Megohm between wires, wire to shield and wire to ground.
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A control of continuity of pneumatic lines or electrical lines shall be made between field mounted devices and equipment located in control room and auxiliary room.
These tests shall also be used in order to check that each instrument is perfectly working.
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All electronic and pneumatic measurement and control loops shall be fully tested for proper operation.
Special devices such as selection relays, computing relays etc. shall also be adjusted.
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Alarm systems, safeguarding, sequential and control systems shall be fully tested for correct operation.
This includes a careful check of initiating devices and final elements (connections and operation).
All settings for initiating devices, time relays etc. shall be adjusted.
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A complete test shall be performed on electrical supply including automatic switch-over if applicable.
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After inspection and testing, all instrument loops shall be commissioned.
The CONTRACTOR shall make all necessary personnel available for repairs and modifications, which could be necessary during commissioning.
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1) The evaluation of the quantity of work performed, which has to be specified in the provisional work progress reports, shall be calculated by the CONTRACTOR and approved by the OWNER’s REPRESENTATIVE.
2) The works shall be paid as specified in the AGREEMENT.
#
The CONTRACTOR shall work in close cooperation with the OWNER’s REPRESENTATIVE and other CONTRACTORS for necessary interfacing.
GTS – INSTRUMENTATION ERECTION J/02/3009
Rev. 2 –14.09.09 Page 22 of 22
Every day during the erection period the CONTRACTOR'S representative on the site shall meet the OWNER’s REPRESENTATIVE'S in order to receive instructions and comments and to examine all problems in relation to the works.
The CONTRACTOR shall also attend the weekly meetings and any other meeting if required on urgent basis.
S S S
GENERAL TECHNICAL
SPECIFICATION
GTS 734 013
9 14.09.09 Logo Changed AS SD KNC
8 27.03.08 Logo Changed AS NS KNC
7 04/12/98 Changed Company name and Logo DNP PCA DNP
6 11/03/98 Updated DNP PCA DNP
5 15/09/97 Updated DNP PCA DNP
4 24/02/95 Updated DNP PCA DNP
Rev. Date Subject of revision Author Checked Approved
GENERAL TECHNICAL
SPECIFICATION
GTS 734 013
Rev. 9 – 14.09.09 Page I of V RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc
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GENERAL TECHNICAL
SPECIFICATION
GTS 734 013
Rev. 9 – 14.09.09 Page V of V RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc
This specification covers the basic requirements for the design, the selection, the requisitioning and the installation of instrumentation and control systems associated with equipment purchased as a "Package Unit".
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Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this specification are given the following meaning
AGREEMENT Designates the agreement concluded between the CLIENT and the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.
CLIENT Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.
CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the CLIENT. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.
DAYS - WEEKS - MONTHS Specify the number of calendar days, weeks or months and not of working days, weeks or months.
ENGINEER Designates the individual or legal entity to which the CLIENT has entrusted various tasks in relation with the carrying out of his PROJECT.
GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, materiel, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The Terms GOODS or SERVICES may by indifferently used one for the other as required by the context.
PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided by one or more CONTRACTORS.
13,204/34532/3,647,89.5,:,/02
The design, construction, materials, testing of instrumentation and control systems shall be in accordance with the codes and standards mentioned in the present specification and in other applicable General
Technical Specifications (GTS) and with the codes, standards and legal requirements listed in the Particular Technical Specifications for the PROJECT.
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Whenever CLIENT and/or ENGINEER review and/or approval is requested on a document to be submitted by the CONTRACTOR or before an action is implemented by the CONTRACTOR, such review and/or approval shall always be requested in writing by the CONTRACTOR to the CLIENT and/or the ENGINEER before any action subject of this review and/or approval is taken.
CLIENT and/or ENGINEER approval shall always be given in writing.
/2059:,/040.1/,5:./1716>
The terminology shall conform to ANSI/ISA S 51.1 "Process Instrumentation Terminology".
Instrument symbols and identification on P & I Diagrams shall be in accordance with the specification GTS/734/003 "Instrumentation symbols and identification".
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Instrumentation and control and monitoring systems of Package Units shall be in accordance with this specification and as defined in the P&I Diagrams.
The Package Units shall be supplied complete with all instrumentation, fully piped, wired and tested to ensure safe, reliable and effective operation as well as easy maintenance of the complete Package Units.
Protection and packing of all materials shall be suitable for shipment and protection on jobsite during storage prior to erection.
/2059:,/0,7,?0.1/
Instruments and instrumentation systems of proven reliability shall be used.
Selection of instrumentation shall be made from the approved Instrument Supplier Lists.
Any exception has to be justified and is subject to approval by the ENGINEER.
466./6
All instruments and instrumentation equipment shall be permanently identified by tags, labels and/or nameplates as defined in the drawing 7000/734/XX/7001 "Nameplates, tags and labels for instrumentation".
Manufacturer's standard colours shall be used for all instrumentation equipment in control and instrument rooms, unless otherwise specified.
Field instruments shall generally be epoxy painted, unless otherwise specified.
54/2:.22.1/>20,:2
1) Transmission of the process variables shall generally be by means of electronic or low level signals.
The output signal for electronic instruments shall be 4 to 20 mA DC or digital.
As far as possible, a true two-wire transmission system shall be used.
2) Local control loops shall be pneumatic.
The standard analog signal for pneumatic instruments shall be 0.2 to 1 barg.
Each pneumatic instrument shall be provided with its own air filter regulator (air set).
3) No process fluid shall be piped into the control rooms or the instrument rooms.
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All instruments shall be suitable to withstand the environmental conditions specified for the plant location.
All parts subject to moisture, fungus growth or insect attack shall be suitably treated (tropicalisation).
Local instrument housings shall be weather-proof (IP 55 minimum or equivalent) and meet the electrical area classification requirements.
All parts of instruments exposed to process fluids shall be resistant to corrosion by the corresponding fluid.
! 7,?051/.?/2059:,/040.1/./"4@4531925,42
In hazardous areas, intrinsically safe instrumentation shall be provided.
If not possible or not practical, other protection concepts (flameproof equipment, increased safety, purging, ...) may also be used where applicable.
All electrical instruments to be installed in hazardous locations shall be certified to CENELEC Standards.
Contacts shall be encapsulated and, if used in intrinsically safe circuits, contacts shall be gold plated.
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All instruments and control systems shall be immune from the effects of any R.F. interference that may occur at the plant location in accordance with IEC 801 "Electromagnetic compatibility for industrial-process measurement and control equipment".
Equipment to be installed inside the European Community shall be in compliance with the European Community directive requirements, denoted by the "CE mark". This compliance shall extend to each relevant item.
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The following electrical power supplies shall be used :
230 V, 50 Hz for control and monitoring system peripherals and for analysers, recorders, indicators, single loop controllers, instruments requiring a separate power supply,...
230 V, 50 Hz or 24 V DC for control cabinets and PLC cabinets,
24 V DC for transmitters, alarm and shut-down contacts, alarm systems, relay systems, switches, safety barriers,...,
24, 48 or 110 V DC for solenoid valves.
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The instrument air quality shall be in accordance with ISA S7.0.01 "Quality Standard for Instrument Air".
The minimum air pressure at any place in the plant shall be 4 barg.
The instrument air receivers shall have sufficient capacity for ensuring the entire instrument load during 15 minutes in case of air compressor failure.
54/2:.00,52
1) In general, transmitters shall be of the negligible displacement electronic type, except where such devices are not available or another type of device of proven superior performance is available for a specific measurement.
Pneumatic transmitters shall be equipped with an air input gauge as part of the supply air filter/regulator set.
2) Transmitter accuracy shall be ± 0.5 % of calibrated range or better. Repeatability shall be ± 0.1 % of calibrated range or better.
For metering stations, accuracy of transmitters shall be ± 0.1 % of calibrated range.
/2059:,/01//,?0.1/2
1) In general, process connections on instruments shall be 1/2" NPT. Adaptors shall not be used.
2) Pneumatic connections shall generally be 1/4" NPT. Larger sizes may be used for special applications, e.g. for high speed actuators.
3) Electrical connections on field instruments shall preferably be 20 mm ISO.
6) Charts for all instruments shall be 0 - 100 linear.
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Spare capacity is depending on the type of equipment and is defined in Appendix 1.
The documents and drawings to be prepared by the CONTRACTOR are listed hereunder. Further details are given in related PROJECT specification.
1?9:,/02
As a minimum requirement, the following documents shall be provided, when applicable.
/2059:,/02?A,397,
The schedule, in .dbf or compatible files, shall list all the instruments of all the loops using their tag numbers.
The schedule shall show, among others, the type of instruments, the range, the P&I Diagram number, the location and service of the instrument, the specification number, the purchase order number, the referenced installation drawing numbers, the loop drawing number, etc..
/2059:,/034042A,,02
The data sheets shall comprise all necessary technical data associated with the instruments. They shall include, as a minimum, the tag number, process data, range, settings, materials of construction, connection sizes and ratings, manufacturer's name and model number.
Calculation sheets for flow primary elements, control valves, safety relief valves, vacuum breakers, rupture disks, shall be provided.
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The following documentation shall be provided by the CONTRACTOR for the Programmable Logic Controllers (PLC) and/or, if applicable, for the Process Control System (PCS) control cabinets.
1) Technical specification of the hardware structure.
2) I/O lists and arrangement in control cabinets.
3) Process specification documents (logic diagrams, sequence descriptions, description of control algorithms and interlocks, definition of mimics, instrument face plates, trending and reports).
4) Programming of PLC's with supply of commented listings of programs. Programming shall be performed in one of the following languages : Instruction List (IL), Structured Text (ST), Ladder Diagram (LD), Function Block Diagram (FBD) or Sequential Function Chart (SFC) (Grafcet). Programs shall be available on floppies.
5) Configuration for the PCS control cabinets (if applicable).
6) Hardware and software final manuals.
.201-4745:4/305.=2,00./62
That list shall show, for the concerned instrument, the tag number, the range, the P&I Diagram number, the setting of alarms and trips in process units and/or percentage.
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The packaged equipment has to be inserted in the overall plant by the ENGINEER. The CONTRACTOR and the ENGINEER shall settle together the interface requirements :
utility consumption,
electrical compatibility of signals,
space required for local panel and/or equipment control panel,
junction box location on skids,
multicore cables (supplied by others) to the local panel remotely installed,
connection to other systems (type of signal, etc),
cause and effect charts interrelation,
remote control and monitoring requirements,
PCS and/or PLC interfaces (hardware and software).
Interfaces shall be defined by the ENGINEER and approved by the CONTRACTOR.
! ,50.-.?40.1/-.7,2
They shall contain copies of all electrical safety certificates and all documents applicable to the safety of electrical equipment installed in hazardous areas (e.g. intrinsically safe loop specifications).
54<./62
As a minimum requirement, the following drawings shall be prepared, when applicable.
9/?0.1/47711=354<./62
The functional loop drawings shall illustrate the process control philosophy.
16.?3.4654:2
Logic diagrams shall be prepared for all interlock and sequencing systems.
The symbols shall be in accordance with IEC 617-12.
4B7,7.202
The cable lists shall indicate details of the required cables (e.g. cable number, type, length, termination points, ...).
4B7,B71?C3.4654:2
The cable block diagrams shall show schematically an overview of the cable interconnections between panels, cabinets, racks, junction boxes and instruments.
4B7,74>190354<./62
The cable layout drawings shall show the main routing of instrument cables and the location of all instrument junction boxes and local panels.
/2059:,/074>190354<./62
The instrument layout drawings shall show the location of instruments, local panels, racks, control valves, junction boxes.
! .5./63.4654:2
The wiring diagrams shall show all cable termination details for junction boxes, crossboards, control cabinets, power supply cabinets, auxiliary cabinets, control panels, desks, etc..
The relay diagrams shall show the connections between components of the relay system in a horizontal ladder format.
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The power supply diagrams shall show, for each instrumentation power distribution board, the allocation and the rating of fuses or circuit breakers.
& 450A./6354<./62
The earthing drawings shall show the requirements of earth cabling up to the earthing systems.
11=3.4654:2
The loop diagrams shall show the connections between components of each loop with identification of terminals and cables.
4/,7?4B./,04/33,2C74>190354<./62
Those layout drawings shall show the front and rear arrangements and all the main sizes of panels, cabinets and desks. They shall include a schedule of instruments.
1/0517511:4/3./2059:,/0511:74>190354<./62
Those layout drawings shall show the location of panels, desks, cabinets, crossboards, racks, inside the control rooms and instrument rooms.
51?,22A11C(9=354<./62
The process hook-up drawings shall show installation details and tracing/insulation requirements for the various instruments, complete with a schedule of required material.
/,9:40.?4.529==7>354<./62
The pneumatic/air supply drawings shall show installation details for pneumatic loops and instrument air supply, complete with a schedule of required material.
/47>2,5A11C(9=354<./62
The analyser hook-up drawings shall show installation details and tracing/insulation requirements, complete with a schedule of required material.
1) Flow measurement shall normally be made using concentric square edged orifice plates with flange taps. In general, type 316 stainless steel orifice plates shall be provided.
Where the nature of the fluid is such as to require other material, it shall be suitable for the service.
If the fluid contains solids, eccentric or segmental orifice plate shall be used.
Quarter circle or conical entrance orifice plates shall be selected where Reynolds number is low.
2) The calculations, the dimensions and the installation of orifice plates, the "upstream" and "downstream" lengths, the tappings shall meet the requirements of ISO 5167.
The minimum upstream and downstream straight lengths required for installation of orifice plates are the values without parentheses ("zero additional uncertainty" values) given in Table 1 of ISO 5167.
3) Orifice plates in liquid service shall be furnished with vent holes flush with the top of the pipe and those in gas service shall be furnished with drain holes flush with the bottom of the pipe. Orifice plates for LNG service shall have a vent hole and a drain hole.
5.-.?,-74/6,24/3:,0,559/2
1) For line sizes up to and including 12", weld neck orifice flanges having flange taps and a minimum rating of 300 lb RF shall normally be used.
2) For line sizes 14" and larger, weld neck orifice flanges having flange taps and the standard line rating shall be used.
3) For accurate measurements, a holder shall be provided in order to fulfil the requirements of ISO 5167 concerning the concentricity of orifice plates.
4) Orifice plates in carrier rings, with integral corner tappings, shall be used where required by service conditions, and/or piping specifications.
5) Metering orifices shall not be installed in lines less than 2". If the line is less than 2", one of the following devices shall be used :
a) integral orifice type instrument,
b) swaged (2") meter run,
c) certified meter run with corner taps,
d) variable area flowmeter.
6) Metering orifices shall be located in horizontal lines. If not possible, the flow in vertical lines shall always be upward for liquids and downward for gases.
1) Flow nozzles or Venturi tubes may be used for measurement of slurries or suspended solids, or when low pressure loss is required in high velocity streams.
2) The requirements of ISO 5167 shall be applied for calculations, dimensions, "upstream" and "downstream" lengths, tappings.
The minimum upstream and downstream straight lengths required for installation of nozzles and Venturis are the values without parentheses ("zero additional uncertainty" values) given in Tables 1 and 2 of ISO 5167.
.01009B,2
Averaging Pitot tubes may be used for non-critical flow metering in large pipes and for applications where a low pressure loss is required.
/0,654715.-.?,0>=,./2059:,/02
For low flow rates in lines less than 2" diameter, integral orifice type instruments may be used.
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1) The meter differential range shall be selected so that the d/D (Beta) ratio falls between 0.25 and 0.75. For custody transfer flow measurement, the d/D ratio shall be ≤ 0.6.
The standard differential range shall be 250 mbar.
If required, other differential ranges may be used (50 mbar, 125 mbar, 500 mbar).
For compressible fluids, the differential range in mbar, divided by the upstream pressure measured in bar absolute, shall not exceed 36.
2) The meter range shall be selected so that
the normal flow rate falls between 70 % and 80 % of the meter range;
the minimum and maximum flow rates fall between 30 % and 95 % of the meter range.
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The differential pressure produced by the primary flow element shall be measured by a differential pressure transmitter (differential capacitance type, inductance variation type or similar).
Transmitter process connections shall be 1/2" NPT.
For local measurement , bellows type displacement instrument may be used.
1) Variable area flowmeters shall generally be used when wide rangeability (10 to 1), linear output or the measurement of very low flow rates is required.
2) Variable area flowmeters shall generally be used in pipes sizes 2" or smaller.
3) Variable area flowmeters are available as indicators, transmitters or a combination of the above, with or without alarms.
4) Variable area flowmeters range shall be selected so that normal flow falls between 50 and 60 % of the maximum scale.
5) Fluids containing solids shall be adequately filtered before entering the instrument interior.
6) Unless otherwise stated, material and rating shall be in accordance with the piping class.
7) Metal tube meters shall be used for process application or in hazardous service.
Glass tube meters shall only be used on low pressure service for small flows of liquid or gas for the measurement of purges to instrument tappings or analyser sample flows.
7,?051:46/,0.?71<:,0,52
Electromagnetic flowmeters are used for flow measurement of liquids having some degree of electrical conductivity.
They are mainly suitable for measurement of slurries, corrosive fluids or dirty fluids.
Vertical mounting is preferred.
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Turbine meters are used for accurate measurements and wide rangeability.
They are commonly used in custody transfer of light products or crude oils.
12.0.;,.2=74?,:,/0,0,52
Positive displacement meters are used when high accuracy over a wide flow range is required. They shall be installed in horizontal lines with an adequate upstream strainer.
They are commonly used in custody transfer, especially for heavy or viscous fluids.
150,D71<:,0,52
Vortex flowmeters are used in steam, liquid and gas services where large turn-down is required.
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Depending upon the application, the following flowmeters may be considered :
mass flowmeters (for mass flow and accurate measurement).
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Field mounted flow switches are only used for detection of a flow limit when no other flow measurement exists. Thermal type is preferred.
Variable area flowmeters with contact may be used as flow switches.
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Except for differential pressure elements, the different flowmeters here above listed shall be installed according to the manufacturer's recommendations.
! 54/2:.00,52
The pressure and differential pressure transmitters shall be of the capacitance type, piezoresistive type or similar.
If required by service conditions, other types may be used.
Transmitter process connections shall be 1/2" NPT.
! 5,2295,496,2
Pressure gauges (mostly Bourdon tube type) shall have 100 mm dial, stainless steel pressure element and stainless steel case with blow-out disc.
Differential pressure gauges shall be of the bellows or diaphragm type.
Pressure gauge process connection shall be 1/2" NPTM.
Pneumatic receiver gauges may have a 1/4" NPTM connection.
! 5,2295,<.0?A,2
Pressure switches shall be snap acting type with dry SPDT contact. Switch differential shall be adjustable.
Internal setting adjustment shall be provided.
Process connection for pressure switches shall be 1/2" NPT.
Where pressure switches are not suitable, switching will be achieved by a trip amplifier using an analog signal.
1) Range shall be selected so that normal pressure be in the middle third of the span, if possible.
2) Suppressed ranges may be used to obtain better sensitivity where required.
! ;,5(4/6,/3/3,5(4/6, 510,?0.1/
1) Instruments shall have over-range protection to the maximum pressure to which they may be exposed.
2) Instruments exposed to vacuum shall have under-range protection to full vacuum.
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1) Diaphragm seals shall be used for pressure instruments on slurries, viscous or highly corrosive fluids.
2) For all pressure instruments and gauges on the suction and discharge of reciprocating pumps or compressors, liquid-filled gauges or close coupled pulsation dampeners shall be used.
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Due consideration is to be given to the installation of all pressure and differential pressure measuring devices to eliminate errors due to static head, condensation, gas, etc...
$ .--,5,/0.47 5,2295,,;,754/2:.00,52
Wherever possible differential pressure transmitters (differential capacitance type, inductance variation type or similar) shall be used for level measurements.
The transmitters shall be provided with elevation/suppression kit.
Transmitter process connections shall be 1/2" NPT.
$ .2=74?,5>=,,;,754/2:.00,52
External displacer type level transmitters shall be used for liquid/liquid interface measurement. They may also be used for narrow measuring ranges up to 1524 mm. They shall be fitted with 2" flanges.
Internal displacer type level transmitters shall normally be supplied for open tanks and sump. They shall be fitted with a 4" flange.
$ 0A,5>=,2
Depending on the application, other level instrument types (internal displacement or ball float type, capacitance type, conductivity type, radioactive type, ultrasonic type, ...) may be used.
Displacer or float type level switches are used for alarming or shut-down.
The external displacer or float type shall be fitted with 2" flanges and the internal displacer or float type with 4" flanges.
Vibrating fork type, ultrasonic type, capacitance type or conductivity type level switches may be used for specific applications.
$ ,;,7496,2
1) Magnetic type level gauges are preferred on hydrocarbons and organics and shall be used where application does not allow glass.
2) Gauge glasses shall be reflex type except for interface service and for liquids which may coat the inner surface of the reflex glass.
In the latter cases, transparent gauge glasses shall be used.
The gauge glasses shall be provided with gauge cocks.
3) The visible length of a level gauge must overlap the range of any associated level transmitter or controller.
4) Process connections shall be 1" flanged.
$ 4/C496,2
Storage tank level measurement shall normally be performed by float and tape type instruments (servo-gauges). For some applications, radar systems shall be considered.
For local tank level indication, a float type level indicator may be used.
$! 0.77./6,772
Stilling wells shall be provided inside vessels and tanks for internal displacer instruments and float type instruments.
The design shall include a retaining device to prevent loss of displacer or float.
The wells shall have vertically overlapping slots throughout their length.
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1) Temperature elements shall generally be installed in thermowells and be removable during plant operation.
2) The design of thermowells, temperature transmitters and temperature elements shall be in accordance with the ENGINEER specification.
% A,5:1<,772
1) Screwed thermowells (3/4" NPT) shall generally be used. They shall be drilled and machined from stainless steel bar stock.
They shall be foreseen for all temperature measurements except for thermocouples in concrete and for skin sensors.
Flanged thermowells shall be used when piping or vessel specification requires flanged connections.
2) Thermowell immersion shall be at least half of the nominal ID of the line up to and including 12" line size. In lines above 12", the thermowell immersion shall be 6" minimum.
For temperature measurements in vessels and tanks, the immersion length shall be 10" minimum.
3) Thermowells shall be provided with an extension when used on insulated pipes and vessels.
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Pt100 Resistance Temperature Detectors shall be used for remote temperature measurements.
They shall be specified for temperature from minus 200°C to plus 500°C.
RTD shall be 3-wire type and conform to IEC 751 grade 1.
% A,5:1?19=7,2
Thermocouples shall be used for temperature measurements above 500°C. They shall generally be NiCr-Ni (type K). Depending on the application, other types may be used.
The thermocouples shall conform to IEC 584.
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Skin sensors shall be used for wall temperature measurement on tanks, vessels and pipes.
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Temperature measuring elements (RTD or thermocouples) used in control loops shall be supplied with an industrial head housing including a two-wire transmitter.
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Temperature gauges shall be used for local indication and shall be bimetallic every angle type or filled system type. They shall be stainless steel and shall have 100 mm dial. They shall be fitted with a 1/2" NPT adjustable union for connection to well.
All capillary tubing shall be stainless steel armored.
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Temperature switches shall only be used for alarming or shut-down when no other temperature measurement exists.
They shall be snap acting type with dry SPDT contact.
Switch differential shall be adjustable.
Internal setting adjustment shall be provided.
& 47;,,7,?0.1/
1) For general service, single seated globe type control valves (with heavy top, top and bottom, or cage guiding), shall normally be used. Double seated globe valves with top and bottom guiding or rotary shaft (eccentric rotary plug) type valves, may be used where required by process operating conditions.
2) Diaphragm, plug, butterfly, ball, or angle valves shall be used where required by line piping specifications.
Typically, butterfly valves shall be used for large volume flows at low shut-off differential pressures, and ball valves for large volume flows at high shut-off differential pressures. Angle valves shall be used to avoid solids accumulation and on erosive and flashing services. Diaphragm valves shall be applied for slurry service.
3) Self acting valves may be used for local control of utilities.
4) Control valve location, type, size and trim shall be carefully selected in order to avoid cavitation.
& 47;,40,5.472
The materials selected for the valve components shall be conform to the process requirements and shall be specified in the data sheets.
Steel valve bodies shall be forged (from 1 1/2" and below) or cast (from 2" and above).
Valves manufactured from rolled plates or from assembly by welding of cast parts are prohibited.
Asbestos and/or asbestos compound are not acceptable for packing. Teflon ring type packing shall be used up to 230°C.
& 47;,.@./6
Sizing of control valves shall be performed by using the flow equations given in ANSI/ISA - S 75.01 or by using the method recommended by the valve Manufacturer. The Cv of the valve shall be calculated on basis of 1.3 times the operating flow or of 1.1 times the maximum flow (the highest value is chosen).
The calculated Cv value shall be corrected taking into account pipe reductions, cavitation and/or critical velocity.
& 1.2,
The noise level of control valves shall not exceed 80 dBa, as measured 1 meter downstream of the valve within 1 m radially from the pipe outside diameter.
& ?0940152
1) Wherever possible, valves shall be operated by spring return pneumatically operated diaphragm actuators.
2) Spring return piston actuators shall be used to provide longer strokes or greater thrust than is available from spring diaphragm units. They shall normally be sized to operate at an air supply of 4.0 barg.
3) Double-acting piston actuators which do not automatically fail to a safe position in the event of air failure shall be supplied with local air receiver, having sufficient capacity for at least three operations over the full travel of the valve. The use of such actuators shall not jeopardise plant safety.
4) Valve action on control signal or air failure shall be as indicated on P&ID. Shut-down valves shall move to a safe position on actuator power failure or on electrical signal failure.
5) Motor operated valve actuators shall have integral reversing starters and interposing relays.
The actuator shall be fitted with a torque switch, thermostat and space heater.
The actuator shall have position limit switches (open/closed) for stopping the motor at limit of travel.
6) Valve actuators shall be suitable for operating the valve with a differential pressure equivalent to the full upstream pressure.
& ??,2215.,2
& 12.0.1/,52
The control valves shall be fitted with electro-pneumatic positioners.
The positioners shall be provided with :
integrally mounted pressure gauge for air supply and positioner output air pressure,
air/filter regulators integrally mounted and piped by the manufacturer.
& .:.02<.0?A,2
Limit switches shall be of the inductive proximity type.
They shall be external to the actuator, not an integral part of it.
Solenoid valves shall be suitable for the specified DC supply.
& 1120,55,74>2
Booster relays shall be fitted where necessary to ensure speed of response of valves and shall be close coupled to the valve actuator.
& 1?C(9=5,74>2
Lock-up relays may be used where process conditions demand and where they cannot give rise to a hazardous situation.
& /,9:40.?09B./6
Stainless steel 1/4" or 3/8" OD tubing shall be used for pneumatic connection between the positioner and the valve actuator.
Fittings shall be stainless steel compression type (two-ferrule type).
&! 1//,?0.1/2
1) Control valves shall have flanged connections. The flange rating and facing shall be in accordance with piping class. The face-to-face dimensions shall comply with ANSI/ISA S 75.03.
2) Except for cryogenic and gas applications, butterfly valves shall be of the wafer type designed to fit between piping flanges. Face-to-face dimensions shall be in accordance with ANSI/ISA S 75.04, where possible.
3) Connections for on-off valves shall be in accordance with piping class.
4) Pressure regulators may be of flanged type or of screwed type. Screwed type is subject to ENGINEER approval.
4-,0>,7.,-47;,2
1) Safety relief valves may be either of the conventional or balanced type. For specific applications, pilot operated relief valves may be considered.
For steam and high temperature service, open spring safety valves may be required.
2) Lifting levers shall be used on safety valves in steam generation service, on safety valves for air receivers and on other safety valves when required by codes or when specified.
Test gags shall not be provided.
3) Orifice area calculation shall be made in accordance with ASME VIII and API RP 520.
1) Vacuum breakers shall be of the diaphragm type pallet seating design.
2) Pallets shall have drip rings to eliminate condensate collecting at seats.
9=095,.2?2
Rupture discs may be used, alone or in conjunction with a safety valve, as protective devices against over-pressure or vacuum.
! !
/47>2,52
1) The analysers shall be furnished, when required, with pre-assembled sampling system and calibration system.
2) Analyser selection shall be made according to the following criteria :
principle of operation for use in the application,
type of output signals for data transmission,
serviceability,
reliability,
ease of installation,
utilities required,
simplicity of design.
4:=7./6/347.B540.1/>20,:2
1) Sampling systems shall comprise all necessary equipment to extract from the process a sample that truly represents the process fluid characteristics, to deliver it to the analyser at the required temperature, pressure and flow rate, to dispose of spent sample and wastes, and to provide a means of calibrating the entire system.
2) Means shall be provided for checking the calibration of the analyser.
3) Analyser sampling and calibration systems shall be in accordance with API 555, "Process Analyzers".
/47>2,5>20,:/2047740.1/
Suitable protection shall be provided for ensuring reliable, accurate and safe operation of the analyser systems.
When the analyser case is not sufficient to provide the required protection, a housing is required.
The type of housing (cabinet, shelter, house) will depend on the analyser, the environment in which it will operate, the sample line length, the ease of maintenance and the economics.
!
=,540.1/471/0517 A.7121=A>
The main control and monitoring functions will be carried out by a Process Control System (PCS) which will act as the operator interface for the whole plant.
The tasks covered by the PCS will be related to continuous loops, on/off devices control, sequencing control, recipe handling, …, and to operator interface requirements like real time and historical trending, alarming functions, interactive mimics, ...
1/0517/31/.015./6>20,:215A, 4?C46,/.02
1) The monitoring and remote operation of the Package Units shall be carried out from the main control room by means of the PCS in three possible ways.
Type 1 : All safety functions, sequences, control functions are achieved by the PCS and/or the Emergency Shut-Down (ESD) system foreseen by the ENGINEER;
Type 2 : All safety functions, sequences, control functions are achieved by systems provided by the CONTRACTOR.
Supervisory functions and remote controls (start-stop) are achieved by the PCS if required;
Type 3 : Safety functions and sequences are achieved by systems provided by the CONTRACTOR.
Control functions, supervisory functions and remote controls are achieved by the PCS.
The type of control and monitoring system is defined in the Particular Technical Specification for the PROJECT.
The CONTRACTOR shall be responsible for :
the complete engineering and detailed design for the Package Unit instrumentation, control cabinets and local control panel (if required); interface terminal blocks shall be submitted to the approval of the ENGINEER,
the connections to the skid mounted junction boxes and to the Package Unit control cabinets or local control panels if mounted in the vicinity of the equipment,
the detailed design of cables and wiring from instrumentation or skid junction boxes to Package Unit cabinets or Package Unit control panels mounted remotely or in instrument rooms.
2) If applicable, the CONTRACTOR shall supply a programmable controller (PLC) in order to perform the functional sequences, controls, interlocks, safeguardings (non critical shut-downs) associated with the Package Unit.
The PLC will be interfaced to the PCS by serial link, or in case of a small number of exchanged information by discrete I/O's.
The serial link type and the communication protocol shall be as agreed between the CONTRACTOR, the ENGINEER and the PCS manufacturer.
3) When specifically required, the CONTRACTOR shall provide, as an alternative to PLC, a PCS control cabinet which shall be integrated in the overall plant control system.
4) Local panels shall be provided, if necessary, for the minimum local operation and monitoring of the equipment requested by the CONTRACTOR. Those panels shall contain push buttons, switches, lamps, indicators, annunciator lamp boxes and pneumatic instruments (if any).
1?47745:2/3A90(1</1/3.0.1/2
1) Visible annunciator systems shall generally be of the solid state back-lighted nameplate type. The system shall be provided with common "acknowledge" and "test" push buttons. Twin lamps shall be provided for each window.
The alarm sequence shall be in accordance with ISA S18.1. It shall include a first-out feature of sequence number F3-A-3 when applicable.
2) Contact initiating alarms or shut-down shall be closed in normal operation and shall open in case of fault conditions.
The shut-down actuators (solenoid valves, relays, ...) shall be energised under normal operation and de-energised for shut-down.
3) The shut-down functions shall be carried out by the PLC associated with the Package Unit, but emergency shut-down conditions shall be implemented using safety relay logic and/or safety PLC.
??,22.B.7.0>
1) The installation of instrumentation shall be such as to minimise the effects of fire, solar radiation, vibration, heat from process equipment, condensation, spillage, rain, and maintenance activities, etc.
2) Instruments and their connections shall always be accessible from ground level, floors, platforms, walkways (2 m above or 1 m either side of).
/2059:,/01//,?0.1/2/ .=./6/3,22,72
Instrument connections on piping and vessels shall be as indicated in Appendix 2.
Connections for items such as analysers, and those required in ducts, heater stacks, etc., shall be determined to suit each type of application.
The location of flow and pressure instruments connections on horizontal pipes shall preferably be as indicated in Appendix 3.
1) The instrument impulse lines shall include facilities for isolation, maintenance, protection, testing and calibration.
2) The primary isolating valves shall meet the piping specification requirements.
The requirements for double block valves shall apply to primary piping or vessel connection only.
3) Vent and drain facilities, as required for maintenance and/or test and calibration, shall be fitted with valves.
4) The instrument impulse lines shall be designed to compensate the expansion or contraction of the process pipes due to temperature variations.
5) Flow and pressure transmitters and pressure switches in gas service shall be mounted above the tapping points.
In liquid and steam service, they shall be mounted under the tapping points.
In cryogenic service, all flow and pressure transmitters and pressure switches shall be mounted above the tapping points and the level transmitters above the top tapping point.
/2059:,/0.59==7>
1) Air supply headers and sub-headers shall be sized as follows :
Number of consumers Nominal pipe size
4 1/2"
10 3/4"
25 1"
80 1 1/2"
150 2"
300 3" 2) Main line take-offs for sub-headers shall be from the top of the line and shall be fitted with isolating.
Drain valves shall be provided at each low point on the sub-headers.
3) Each pneumatic instrument shall have its individual air supply line equipped with an isolating valve and an air filter or an air filter-regulator.
5,?0.1/15C2
The installation, calibration, checking and testing of instrumentation shall be performed by the CONTRACTOR, except otherwise specified.
If the erection works are performed by others, the CONTRACTOR shall provide supervision and remains responsible for the erection works until completion.
316 stainless steel tubing, compression fittings, manifolds and valves shall be used for instrument process piping connected to the isolating valves on process lines and equipment, unless process conditions require another material.
/2059:,/04.5=.=./64/309B./6
a) Galvanised carbon steel pipes, fittings and valves shall be used for the main air distribution.
b) For pneumatic signals and individual air supply lines, copper tubing PVC covered and brass compression fittings and valves shall be used.
If required by environmental conditions, 316 stainless steel tubing and fittings will be used.
0A,5./2047740.1/:40,5.47
The other instrumentation installation material (junction boxes, marshalling cabinets, auxiliary cabinets, power distribution cabinets, cable glands, push-buttons and lamps, protective housings, supports, cable trays and ladders, cable conduits, etc…) shall comply with the ENGINEER specifications.
!
The supports for instruments and junction boxes shall be in accordance with the standard drawing 70000/734/XX/7002 "Standard supports for instrumentation".
$ /2059:,/0 510,?0.1/
Weather protection and, when applicable, mechanical protection shall be provided.
The method of protection shall be carefully selected in function of the fluid properties, toxicity and hazard.
Fragile instruments shall be supported independently of equipment which may generate nuisances (e.g. possible damage by mechanical vibrations).
,/,547
1) All field mounted electrical and electronic instruments shall be connected by means of individual cables to field mounted junction boxes.
2) The field mounted junction boxes shall be provided for the connection of multicore cables and of individual cables to local instruments.
Different types of signals shall be segregated into separate junction boxes :
A further segregation shall be made between intrinsically safe and non-intrinsically safe signals.
3) Multicore cables shall be used between each field mounted instrument junction box or panel and the marshalling terminations in the instrument rooms or in the control rooms.
4) All field cable runs shall be designed to prevent ingress of moisture. Side or bottom entries to instruments or junction boxes should be used to ensure this. Cables shall have drip loops.
5) Spare capacity to be provided in multicore cables is defined in Appendix 1. This spare capacity is applicable to the as built situation.
6) The cables shall be installed above ground on cable trays and/or ladders made of heavy duty galvanised steel. Cable runs shall be designed to avoid all possible fire hazards. Where this is not practical, cable runs shall be fireproofed using metal trunking, mineral wool and galvanised cladding.
7) The numbering system for cables, junction boxes, crossboards, panels, cabinets, consoles, shall be specified by the ENGINEER.
8) All cables and wires shall be numbered. All cables shall be marked at each end. Each wire shall be labelled (terminal strip reference).
9) Where field cables are run in areas with little available means of support (e.g. structural steelwork), cables shall be laid in trenches.
10) All cables shall pass through a compression type cable gland before being terminated.
Glands shall meet the requirements of the area in which they are installed and certification shall be required where applicable.
4B7,2
The instrumentation cables shall be selected in function of the application on basis of the ENGINEER specification.
,5:./40.1/2
1) Screw clamp type terminals shall be used. Conductor ends shall be fitted with crimped end-sleeves.
Only one wire shall be connected to each terminal side.
Terminal straps shall be used for bridges between terminals.
2) Sufficient slack cable shall be left neatly coiled or looped at terminals to allow for the re-making of terminations, additions and testing.
3) Attention shall be given to the location of terminal rails in junction boxes, etc.., in order to provide sufficient space to install field cables without bunching or congestion. All cable and terminal numbers shall be clearly visible.
4) All spare wires of instrument cables shall be terminated to terminals in junction boxes, local panels, cabinets, control room panels, etc..
,65,640.1/-4B7,2
Instrumentation cables (4-20 mA, mV signals, etc.) shall be adequately separated from power wiring and electrical equipment to minimize interferences. The physical distance between instrumentation cables and power cables in parallel routing shall be as follows :
Voltage (V) Min. distance (mm)
110 400
230 400
400 600
690 600
6000 1200 If required, the instrumentation cables shall cross the power cables at right angle and with a minimum distance of 300 mm.
450A./6
Earthing of instruments, panels, consoles, shall be carried out in accordance with the applicable code requirements.
?5,,/./6
Screens on instrument cables carrying 4-20 mA and on-off signals (low level, low impedance signals) shall be interconnected and earthed at one point (preferably in the instrument room).
Exception shall be done for cables carrying digital (serial) signals, high frequencies, etc. In those case, the screens shall be earthed at both ends to prevent against electromagnetic interferences caused by HF radiations.
! +9/?0.1/1D,2
Junction boxes shall be of approved design with components to meet the requirements of the area classification.
g)Weather proofness test MA/CR Testing Sample of design IP 65 IS 13947 IP 65 IS 13947 Testing certificates P W
Thermowell
1 Raw materials of
thermowell
Chemical Composition MA analysis _
Applicable Specification To applicable specifications
Test Reports P R
a) dimension MA measuring 100% Applicable Specification to Applicable Log book test report P W
b) hydro test MA testing 100% Applicable Specification No leakage Log book test report P W
c) bore concentricity test MA/CR go- no gauge 100% Applicable Specification/ within 10% of walll thickness Log book P W
d)visual MA/MT observation 100% Co. Std. To Co. Std. Log Book P W
e)workmanship/finish MA/MT observation 100% Co. Std. To Co. Std. Log Book P W
f) Spec/ tagging MA visual 100% Applicable Specification/
Drawing
to Applicable
Specification/Drawings
Log book P W
g) threading MA thread gauge 100% STD TO STD Log book P W
h) surface finish MT visual 100% STD TO STD Log book P W
3 IRN P
Note:
1) Material and Type shall be as per tender specification / datasheet.
Note:
M-Manufacturer P-Perform
TPIA-Third Party Inspection Agency R-Review
C-Client/ Counsaltanr W-Witness
Agency
RTD Assemblies
The results logged
in the log book
would be issued in
the form of test
certificates as per
DIN
2 thermowell
No leakage at 40
kg/cm2
1 RTD assemblies
QUALITY ASSURANCE PLAN
FOR RTD AND THERMOWELL
P.011947-Q-11098-003 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Boreri to CFCL - III, Gadepan pipeline project Page 1 of 1
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4
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67
8
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
A
1 Core ( Mode Field) Diameter
a) @1310 nm
b) @ 1550 nm
Geometry Test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
2 Cut of Wavelength on 2 meter
sample of fiber (In Cable)
Spectral Test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
3 Attenuation Co-efficient
@ 1310
@1550
@1625
Attenuation Co-
efficient Test
100% ITU-T-G652 ITU-T-G655 Vendor to
specify
As per PTS Vendor to specify P W
4 Chromatic Dispersion
a) 1285 - 1330 nm
b) 1270 - 1340 nm
c) 1550 nm
d) 1625 nm
e) Zero Dispersion wavelength
f) Zero Dispersion Slope
Chromatic
Dispersion
100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
5 Geometrical Parameters
a) Primary Coating Diameter
b) Cladding Diameter
c) Clad non Circularity
b) Mode Field Concentricity error
Geometrical Tests 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
6 Fibre PMD Maximum Individual
fibre
PMD Test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
FOR FIBRES CABLE
Ref. std & Cl.no.
Boreri to CFCL - III, Gadepan pipeline project 1 of 6
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
Ref. std & Cl.no.
22
23
24
25
2627
2829
30
31
32
7 Fibre Proof Test Fibre Proof Test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
8 Fibre Curl Fibre Curl Test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
9 Attenuation Vs Wavelength
@1285 - 1330 nm
@ 1525 - 1575 nm
Spectral Attenuation
Test
100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
10 Attenuation with bending
a) 100 turns on a mandrel of 60mm
diameter
b) 1 turn on mandrel of 32mm
diameter
Attenuation test 100% ITU-T-G655 ITU-T-G652 Vendor to
specify
As per PTS Vendor to specify P W
B
1 Visual Inspection
a) Cable lay up and fibre
identification
b) Identification and length marking
on outer jacket
c) Colour contrast of the marking
with the outer sheath of the Cables
d) Overall diameter of the cable
e) Length
Visual Tests &
Dimentional test
5% GR 409 -
CORE
GR 409 -
CORE
Vendor to
specify
As per PTS Vendor to specify P W
FOR FINISHED CABLES (Unarmoured)
Boreri to CFCL - III, Gadepan pipeline project 2 of 6
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
Ref. std & Cl.no.
33
34
35
36
37
38
39
40
41
42
2 Tests for Moisture barrier
a) Thickness of layers
b) Extent of overlapping
c) Electrical Continuity of metallic
layer
d) Water swellable tape on power
e) Water immersion
Moisture barrier
tests
a) 5%
b) 5%
c) 100%
d) 100%
GR-20 -CORE
IEC - 60793 -
1 - 53
GR-20-CORE
IEC - 60793 -
1 - 53
Vendor to
specify
As per PTS Vendor to specify P W
3 Tensile Performance
(Tensile load of 9.81 W Newton or
2700 N whichever is higher , Where
W = weight of 1Km Cable in Kg)
Tensile Test 5% IEC - 794 - 1 -
E1
IEC - 794 - 1 -
E1
Vendor to
specify
As per PTS Vendor to specify P W
4 Crush
(200Kg of load to be slowly placed
and held for 60 sec)
Crush Test 5% IEC - 794 - 1 -
E3
IEC - 794 - 1 -
E3
Vendor to
specify
As per PTS Vendor to specify P W
5 Impact
(Mass of 5 Kg to fall freely from
500mm height on the cable sample
10 times repeatedly with a gap
between 1 impact to another approx.
at 60 sec)
Impact Test 5% IEC - 794 - 1 -
E4
IEC - 794 - 1 -
E4
Vendor to
specify
As per PTS Vendor to specify P W
6 Torsion
(Weight of 7.5Kg attached to the
stationary chuck and shall be
subjected to 10 cycles)
Torsion Test 5% IEC - 794 - 1 -
E7
IEC - 794 - 1 -
E7
Vendor to
specify
As per PTS Vendor to specify P W
Boreri to CFCL - III, Gadepan pipeline project 3 of 6
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
Ref. std & Cl.no.
43
44
45
46
47
48
49
50
51
52
7 Bend
(To be performed preferably with
procedure 1(of IEC) with a mandrel
diameter of 20 D , where D is the
diameter of the cable and testing
shall be done with 4 turns of cable
wrapped and then unwrapped for 10
complete cycles)
Bend Test 5% IEC - 794 - 1 -
E11
IEC - 794 - 1 -
E11
Vendor to
specify
As per PTS Vendor to specify P W
8 Snatch
(With a load of 10 N)
Snatch Test 5% IEC - 794 - 1 -
E9
IEC - 794 - 1 -
E9
Vendor to
specify
As per PTS Vendor to specify P W
9 Kink
(Radius: 10 x Cable Diameter)
Kink Test 5% IEC - 794 - 1 -
E10
IEC - 794 - 1 -
E10
Vendor to
specify
As per PTS Vendor to specify P W
10 Temperature Cycling Tested on 200m
Cable length with
temperature cycle as
follows:-
a) At room
temperature
: 1 hr
b) At 0°C
: 12 hrs
c) At 65°C
: 12 hrs
d) From 65°C
to room
: 1 hr
temperature
5% IEC - 794 - 1 -
F 1
IEC - 794 - 1 -
F 1
Vendor to
specify
As per PTS Vendor to specify P W
11 Water Penetration Water Penetration
Test
10% IEC - 794 - 1 -
F 5
IEC - 794 - 1 -
F 5
Vendor to
specify
As per PTS Vendor to specify P W
Boreri to CFCL - III, Gadepan pipeline project 4 of 6
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
Ref. std & Cl.no.
53
54
55
56
57
58
59
60
61
62
63
64
12 Water Immersion Water Immersion
test
5% IEC - 60793 -
53
IEC - 60793 -
53
Vendor to
specify
As per PTS Vendor to specify P W
14 Sheath Integraty (Spark test) As Per PTS One
Closure
GR.No.
G/OJC - 01 /
01 AUG 92
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
15 1. Polarization Mode Dispersion
2. Abrasion Test
3. Flexural Rigidity Test on the
optical fibre cable
4. Test of Figure of 8 (Eight) on the
cable
5. Cable Aging Test
6. Check of easy removal of sheath
7. Effect of aggressive media on the
cable surface (Acidic and Alkaline
behavior)
8. Check of the Quality of the Loose
Tube (Containing Optical Fibre)
9. Drainage Test for Loose Tube
and Drip Test on the Cable
As Per PTS 5% GR.No.
G/OJC - 01 /
01 AUG 92
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
C
1 Water Ingress Test As Per PTS One
Closure
GR.No.
G/OJC - 01 /
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
2 Impact Test As Per PTS One
Closure
GR.No.
G/OJC - 01 /
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
3 Drop and Topple test As Per PTS One
Closure
GR.No.
G/OJC - 01 /
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
4 Pulling Test As Per PTS One
Closure
GR.No.
G/OJC - 01 /
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
FOR JOINT CLOSURES
Boreri to CFCL - III, Gadepan pipeline project 5 of 6
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A B C D E F G H I J K L
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test
Frequency
Procedure No. Acceptance
Criteria
Document /
Report
Manufacturer TPI agency Remark
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
P.011947-Q-11098-004 Rev.0
09.02.18
SKH
Checked :SHDQUALITY ASSURANCE PLAN
(24 F) ARMOURED OPTICAL FIBER CABLE
Ref. std & Cl.no.
65
66
67
68
69
70
71
72
73
74
75
76
77
78
5 Static Load Test As Per PTS One
Closure
GR.No.
G/OJC - 01 /
01 AUG 92
GR.No. G/OJC -
01 / 01 AUG 92
Vendor to
specify
As per PTS Vendor to specify P W
LEGEND :
R : Review
W : Witness
P : Perform
WR : Vendor Witness
TPIA : Third Party Inspection
Agency
Notes :
1) The above mentioned testing and acceptance criteria are minimum requirements for Optical Fiber Cable complying ITU-T 652 and 655 specifications ,
however , supplier shall ensure that the product also comply to the additional requirements as per technical specifications and data sheets.
2) The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA. Any item
deemed to have been left out may also be included in the QAP of the vendor.
3) TPIA shall have right to inspect minimum 10% of all manufacturing activities on each day or as apecified above.
4) TPIA along with Owner / Owner's representative shall review / approve all the documents related to QAP / Quality manuals Drawings etc. submitted by
supplier.
5) TPIA shall also review the test certificates submitted by the manufacturer.
6) Supplier shall in coordination with sub vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitate
Owner / Owner's representative to organise Inspection.
7) Supplier shall submit their own Detailed QAP Duly Signed and Stamped.
Boreri to CFCL - III, Gadepan pipeline project 6 of 6
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test Frequency Ref. std & Cl.no. Procedure No. Acceptance Criteria Document / Report ManufacturerTPI
agency
Control
Authority
1 Dimension Dimensional outside
diameter wall thickness
As Per Table 1 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
2 Ovality Dimensional outside
Diameter
As Per Table 1 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
3 Tensile Strength Tensile Elongation
Property
As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
4 Reversion Test Shrinkage As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
5 Environmental Stress Crack
Resistance
Chemical Property of
Product
As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004 & ASTM D
- 1693
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
6 Impact Strength Impact Strength Test As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
7 Crush Resistance Test Deflection of Duct As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
8 Mandrel Test Internal Dia of Duct As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
9 Oxidation Induction Test Oxidation of HDPE
material
As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
10 Hydraulic Characteritic Test Leakage , Swelling ,
Weeping and Brust and
Crack in test duration
As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
11 Internal Co- efficient of friction Co-efficient of friction
HDPE material
As Per Table 2 of GR /
CDS - 08 / 02 NOV
2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
QUALITY ASSURANCE PLAN
PLB - HDPE DUCT
P.011947-Q-11098-005 Rev.0
Checked :SHD
09.02.18
SKH
1 of 3
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test Frequency Ref. std & Cl.no. Procedure No. Acceptance Criteria Document / Report ManufacturerTPI
agency
Control
Authority
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
QUALITY ASSURANCE PLAN
PLB - HDPE DUCT
P.011947-Q-11098-005 Rev.0
Checked :SHD
09.02.18
SKH
12 Ash Content Ash content of finished
products
As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
13 Maximum Pulling Strength Pulling force on coupler As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
14 UV Stabiliser of content of Resin Identification of UV
additive
As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
15 UV Stabiliser of content of Duct As Per PTS As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
16 Fading of colour of Duct GR / ASTM D - 1712 As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
17 Bending Radius As Per PTS and
GR / CDS - 08 / 02 NOV
2004
As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
18 Thickness of inner lubricant As Per PTS and
GR / CDS - 08 / 02 NOV
2004
As Per PTS and
GR / CDS - 08 / 02
NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS and
GR / CDS - 08 / 02 NOV
2004
Vendor to Specify P W W / R
19 Density of finished product As Per PTS As Per IS 7328 As Per IS 7328 Vendor to Specify As Per PTS Vendor to Specify P W W / R
20 Melt flow rate of finished duct As Per PTS As Per IS 2530 As Per IS 2530 Vendor to Specify As Per PTS Vendor to Specify P W W / R
21 Change in MFR As Per PTS AS Per GR / CDS - 08 /
02 NOV 2004
GR / CDS - 08 / 02
NOV 2004
Vendor to Specify As Per PTS Vendor to Specify P W W / R
LEGEND :
R : Review
W : Witness
P : Perform
TPIA : Third Party Inspection
Agency
2 of 3
QAP No
Date
Prepared by MA
Approved by
Project
Client
Consultant
S.No Activity Description Description of Test Test Frequency Ref. std & Cl.no. Procedure No. Acceptance Criteria Document / Report ManufacturerTPI
agency
Control
Authority
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
QUALITY ASSURANCE PLAN
PLB - HDPE DUCT
P.011947-Q-11098-005 Rev.0
Checked :SHD
09.02.18
SKH
Notes :
1) The above mentioned testing and acceptance criteria are minimum requirements , however , supplier shall ensure that the product also comply to the additional requirements as per
technical specifications and data sheets.
2) The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.
3) TPIA shall have right to inspect minimum 10% of all manufacturing activities on each day or as apecified above.
4) TPIA along with Owner / Owner's representative shall review / approve all the documents related to QAP / Quality manuals Drawings etc. submitted by supplier.
5) TPIA shall also review the test certificates submitted by the manufacturer.
6) Supplier shall in coordination with sub vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitate Owner / Owner's representative to
organise Inspection.
7) Supplier shall submit their own Detailed QAP Duly Signed and Stamped.
3 of 3
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
SL. No. Component/Operation Charachteristics Type of CheckQuantum of
CheckReference Doc Acceptance Norms
1Raw Material
Inspection
Manifacturer
/Vendor
Contractor's
TPIARemark
1. Surface Finish Visual
2. Diameter/Dimension Physical
3. Resistance Electrical
4. Chemical property (Persulphate test
for tinned copper )Chemical
5. Annealing Test Physical
1. Tensile & Elongation before & after
ageingVisual
2. Type of compound Visual
3. Thermal Stability Physical
1. Oxygen Index Enviro Min. 30%
2. Temperature Index Enviro Min 250deg C
1. Surface Condition Visual
2. Uniformity of Zinc Coating Chemical
3. Tensile strength & elongation Physical
4. Torsion/ Winding Physical
2 Process Inspection
1. Type of Material Visual
2. Thickness of Insulation (Avg. Min.) Physical
3. Core Identification Visual
4. Surface Finish Visual
5. Spark test Electrical
6. Volume Resistivity Electrical
1. Sequence of laying Visual
2. Continuity of conductor Electrical
3. Continuity of common pair Electrical
4. Dimension Physical
5. Lay Length Physical
1. Tape thickness Physical
2. Tape overlap Visual
3. Drain wire size Physical
1. Type of PVC Visual
2. Dimension Physical
3. Thickness of Inner Sheath Physical
4. Surface finish & Colour Visual
5. Embossing/ Printing/Sequential
Markingon outer sheathVisual
QUALITY ASSURANCE PLAN
FOR
INSTRUMENT CABLES
P.011947-Q-11098-006 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Each setting &
at the running
of M/c
Each setting &
during run of
M/c
Inspection Agency
100% Sample
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
IS 8130/ BS 5308(P-2)
Relevant Standard as per
Specification
One sample per
batch
IS 5831/ BS 5308(P-
2)Relevant Standard as per
Specification
IS 5831/ BS 5308(P-
2)Relevant Standard as per
Specification
ASTM-D2863
P
Copper / Aluminium
wire (As Applicable)
Insulation & Sheathing
compound1.2
FR Test for FR PVC
only
1.1
One sample per
batch
IS 3975/ BS 5308(P-2)
Relevant Standard as per
Specification
IS 3975/ BS 5308(P-2)
Relevant Standard as per
Specification
P R
R
Insulated core2.1
Pair/Triad screeing &
Overall screeing
2.2
2.3
Armour-Galvanised
steel round wire/strip1.3
P R
P R
Pair/Triad- laying
Inner sheath and outer
sheath2.6
Setting &
During Process BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
P R
P R
Boreri to CFCL - III, Gadepan pipeline project 1 of 4
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
SL. No. Component/Operation Charachteristics Type of CheckQuantum of
CheckReference Doc Acceptance Norms
QUALITY ASSURANCE PLAN
FOR
INSTRUMENT CABLES
P.011947-Q-11098-006 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Inspection Agency
1. No. of strips/wires Visual
2. Dimension of strips/wires Physical
3. Direction of lay Visual
1. Make up Visual
No. of strands counting
2. Size/Dimensions Physical
3. DC Resistance at 20deg C Electrical
Annealing (Before stranding) for
copperPhysical
1. Conductor Resistance Electrical 100% Drums
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
P W
2. Mutual Capacitance Electrical 10% Drums
3. Capacitance between core & screen Electrical 10% Drums
4. L/R Ratio Electrical 10% Drums
5. HV Test
a) Core to core
b) Core to shield/Armour
Electrical 100% Drums
6. Spark Test
a. Core
b. Sheath
BS 5308(P-2) / BS 5099 &
Relevant Standard as per
Specification
Relevant Standard as per
SpecificationP W
7. Test for rodent & termite repulsion P W
1. HV Test
a) Core to core
b) Core to shield/Armour
Electrical 10% Sample
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
2. Conductor Resistance Electrical 10% Sample
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
3. Continuity test Electrical 10% Sample
4. Insulation Resistance (Before &
After HV)
a. Individual Conductor
b. Individual Screens
ElectricalOne sample per
lot
5. Tensile Strength & Elongation for
Insulation & sheath before ageingPhysical 10% Sample
6. Dimension Visual 10% Sample
7. Cable Capacitance between core &
screen & L/R ratio testElectrical 10% Sample
8. Spark Test
a. Core
b. Sheath
BS 5308(P-2) / BS 5099 &
Relevant Standard as per
Specification
Relevant Standard as per
Specification
9. Test for rodent & termide repulsion. ChemicalOne sample per
lot" "
10. Uniformity of zinc coating on
armourChemical " " "
11. Oxygen Index test as per
ASTMD:2863Chemical " " "
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
IS 8130/ BS 5308(P-2)
Relevant Standard as per
Specification
Starting of M/c
& during
process
Routine Test3
Acceptance Test4
2.8 Conductor
Armouring2.7
WP
P R
P R
100% spools at
start & end
P W
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
Boreri to CFCL - III, Gadepan pipeline project 2 of 4
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
SL. No. Component/Operation Charachteristics Type of CheckQuantum of
CheckReference Doc Acceptance Norms
QUALITY ASSURANCE PLAN
FOR
INSTRUMENT CABLES
P.011947-Q-11098-006 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Inspection Agency
12. Temperature Index test as per
ASTMD:2864Chemical " " "
13. FR test as per IS:10810 Thermal " " "
14. Overall finish & drum length Visual " " "
1. Oxygen Index Enviro Min. 30%
2. Temperature Index Enviro Min 250deg C
3. Flammability test Fire IEC 332-1 Shall Pass
4. Smoke Density As Applicable ASTM 2843
5. Acid Gas Generation As Applicable IEC-754-1
6. Swedish Chimmney Test As Applicable As per Relevant Staandard
6 Type Test
1. Conductor Resistance Electrical
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
IS 8130/ BS 5308(P-2) &
Relevant Standard as per
Specification
P R
2. Annealing Test on Cu Physical
BS 6360 & Relevant
Standard as per
Specification
BS 6360 & Relevant
Standard as per
Specification
P R
1. Tensile strength Physical
2. % Elongation Physical
3. Torsion/Winding Physical
4. Wt. of zinc coating Chemical
5. Dimensions Physical
6. Uniformity of coating Chemical
6.3Thickness of Insulation
& SheathThickness of Insulation & Sheath Physical
One sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
1. Elongation & T. S. Before & After
AgeingPhysical
2. Ageing in Air oven Physical
3. Shrinkage test Physical
4. Hot Deformation Physical
5. Heat Shock Physical
6. Thermal stability Physical
7. Flammability Test Physical
8. Loss of Mass Physical
6.5
Insulation Resistance
test at room & rated
temperature
Volume resistivity ElectricalOne sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
6.6H.V. test at room
temperatureH.V. test at room temperature Electrical
One sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
6.7 Noise Test Electrostatic noise rejection ratio test ElectricalOne sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
Finish
Visual
Tests For Conductor6.1
6.2Test on Armour
wire/strip
Flammability Test for
FRLS PVC only5 P W
One sample per
lot
One sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
P R
BS 5308(P-2) & Relevant
Standard as per
Specification
One sample per
lot
ASTM-D2863
As per Relevant Standard100% As per Relevant Standard P R
One sample per
lot
BS 5308(P-2) & Relevant
Standard as per
Specification
BS 5308(P-2) & Relevant
Standard as per
Specification
P R6.4
Physical tests on
Insulation & Outer
Sheath
packing in drum7
Boreri to CFCL - III, Gadepan pipeline project 3 of 4
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
SL. No. Component/Operation Charachteristics Type of CheckQuantum of
CheckReference Doc Acceptance Norms
QUALITY ASSURANCE PLAN
FOR
INSTRUMENT CABLES
P.011947-Q-11098-006 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Inspection Agency
Marking on drum
C: Critical M-Manufacturer,
W: Witness
Visual
P-Perfomer,LEGEND: R: Review of Docs B: Major RW-Random witness
A: Minor TPIA-Third Party Inspection Agency H-HOLD
As per Relevant Standard100% As per Relevant Standard P Rpacking in drum7
Boreri to CFCL - III, Gadepan pipeline project 4 of 4
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
Manifacturer
/VendorTPIA Client
1
1.1
Material Identification, Visual,
Pressure test on castings for
hazardous area Junction boxes.
100% P R R
2
2.1 Visual, Dimensions 100% P R -
3
· Visual, dimensional, clearance &
Paint shade check for all items.
JB TAG no. Plate
· Verification of Terminal Nos.,
sizes and no. of entries
· Bill of material verification.
· Warning plate for junction boxes
and marking on cable glands,
Adapters, Plugs etc.
· Pressure test on casting for
flameproof junction boxes.
· High Voltage and insulation
resistance test.
· Air leak test report on pneumatic
JBs.
4
3.1 100% by SupplierFinal Inspection
Painting
Remark
QUALITY ASSURANCE PLAN
FOR
JUNCTION BOX
P.011947-Q-11098-007 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Sl.No Description CharacterisitcQuantum of
CheckRecord
Inspection Agency
Machining of components
Final Inspection
Material Test Certificates / Lab
test certificates /Relevant
Standard as per Specification
Test Records / Relevant
Standard as per Specification
Material Inspection
Incoming materials like Castings,
Terminals etc.
In process Inspection
W/R
Supplier’s Test Records /
Relevant Standard as per
Specification
WP
Boreri to CFCL - III, Gadepan pipeline project 1 of 2
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
Manifacturer
/VendorTPIA Client
Remark
QUALITY ASSURANCE PLAN
FOR
JUNCTION BOX
P.011947-Q-11098-007 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
TE-IN
Sl.No Description CharacterisitcQuantum of
CheckRecord
Inspection Agency
4.1Pre treatment, primer, final paint
shade, thickness100% P R R
5
· Certificate from authority like
BASEEFA, FM, PTB, ATEX, UL,
CIMFR etc. for use in specified
hazardous area.
· Statutory approval certificates for
instruments from CCOE/PESO for
use in specified hazardous area.
· Degree of protection certificate for
instrument housing.
· Traceability of record.
· Suppliers Internal Test Records
LEGEND
:
C: Critical M-Manufacturer,
W: Witness
(Painting of JBs prior to
assembly)
5.1
Prototype for type
tests / 100% for
others
P
Documentation and IC
Documentation and IC
Statutory Approval Certificates /
Type Test Certificates /
Suppliers Internal test records
R
Suppliers Internal Test Reports
R
P-Perfomer,
R: Review of Docs
A: Minor H-HOLD
B: Major
TPIA-Third Party Inspection
Agency
RW-Random witness
Boreri to CFCL - III, Gadepan pipeline project 2 of 2
QAP No
Date
Prepared by MA Checked by SHD
Approved by
Project
Client
Consultant
Manifacturer
/VendorTPIA Client
1.0 Material Inspection
1
Incoming materials like Gas
detectors, Gas monitors /
Controllers, Portable gas
detectors, System cabinets,
Power supply units, Hooters,
Beacons, Data loggers, Junction
boxes etc.
Visual 100%Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
Manufacturer’s test
Certificates P R R
2.0 Final Inspection
2.1 Final Inspection Visual 100%Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
P W
Visual /
electrical100%
Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
P W
Visual /
electrical100%
Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
P W
Type of
CheckSL. No.
Functional Check
Make, Model Number
CharacteristicsComponent / Operation
2.3
Calibration check of gas detectors including alarm, repeatability,
response time.
- Redundancy check for power supply units
-Functional check of gas monitors / controllers with gas detectors.
Functional check of portable gas detectors
- Functional check of portable purge calibrators.
-Functional checks of GD system with PCs, Data loggers, Printers,
Hooters, Annunciators, Beacons etc.
-Verification of system diagnostics, System and application
software including Graphics (if configured), Interface with third
party devices.
-Performance test as per standard specification
P.011947-Q-11098-008 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
Visual , Dimension check
- Bill of Material
- Tag Plates
- Wiring check of cabinets with all accessories
QUALITY ASSURANCE PLAN
FOR
GAS DETECTION SYSTEM
Inspection Agency
GAIL
TE-IN
Format of PlanAcceptance
Norm
Referrence
Document
Quantum of
Check
Boreri to CFCL - III, Gadepan pipeline project Page 1 of 2
QAP No
Date
Prepared by MA Checked by SHD
Approved by
Project
Client
Consultant
Type of
CheckSL. No. CharacteristicsComponent / Operation
P.011947-Q-11098-008 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
QUALITY ASSURANCE PLAN
FOR
GAS DETECTION SYSTEM
Inspection Agency
GAIL
TE-IN
Format of PlanAcceptance
Norm
Referrence
Document
Quantum of
Check
2.4 Certification / Documents Visual
Prototype for each
model
100 % Statutory Approval
Certificates/Type Test
Certificates
Statutory Approval
Certificates/Type
Test Certificates
P R
3 Packing Visual 100% Packing List P R
NOTE:
LEGEND: R: Review of Docs C: Critical B: Major RW-Random witness
A: Minor W: Witness TPIA-Third Party Inspection Agency H-HOLD
Visual check and Proper packing to prevent entry of foreign
material
Certificate from testing agency like BASEEFA, FM, PTB, CIMFR
etc. for instruments for gas detectors, portable detectors, junction
boxes etc. for use in specified hazardous area
- BIS approval for gas detectors, junction boxes etc. manufactured
indigenously for use in specified hazardous area.
- Statutory approval certificates for instruments from CCOE/PESO
for use in specified hazardous area.
- Degree of protection certificate for instrument housing.
- Electromagnetic & Radio frequency compatibility requirements
for gas detectors, gas monitors/controllers.
-Test certificate for calibration gases
ALL TESTING AND MEASURING EQUIPMENTS/INSTRUMENTS SHALL HAVE VALID CALIBRATION WITH CALIBRATION CERTIFICATES & TRACEABILITIES.
M-Manufacturer,
P-Perfomer,
Boreri to CFCL - III, Gadepan pipeline project Page 2 of 2
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
Manifacturer
/VendorTPIA Client
1.0 Material Inspection
1Incoming sheet steel for panel
fabricationVisual 100%
Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
Manufacturer’s test
Certificates P R R
2.0 Final Inspection
2.1 Final InspectionVisual /
electrical100%
Approved Datasheet /
Job Specification
Approved Datasheet
/
Job Specification
P W R/W
2.2Certification / Documents as
pplicableVisual
Prototype for each
model
100 % Statutory Approval
Certificates/Type Test
Certificates
Statutory Approval
Certificates/Type
Test Certificates
P R R
3 Packing Visual 100% Packing List P R -
P.011947-Q-11098-009 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
Visual , Dimension check
- Bill of Material
- Tag Plates
- Wiring check of cabinets with all accessories
- High Voltage test and insulation test
- Functional check of instruments and accessories, shut down &
interlock system by simulation
- Earthing check
- component layout arrangement.
- Easy accessibility for maintenance/replacement of components
QUALITY ASSURANCE PLAN
FOR
LOCAL CONTROL PANEL
Inspection Agency
GAIL
TE-IN
Format of PlanAcceptance
Norm
Referrence
Document
Quantum of
Check
Type of
CheckSL. No.
Certificate from testing agency like BASEEFA, FM, PTB, CIMFR
etc. for instruments use in specified hazardous area
- Statutory approval certificates for instruments from CCOE/PESO
for use in specified hazardous area.
- Degree of protection certificate for instrument housing.
- Electromagnetic & Radio frequency compatibility requirements
Visual, Surface Finish, Dimensions, Chemical treatment.
CharacteristicsComponent / Operation
Visual check and Proper packing to prevent entry of foreign
material
Boreri to CFCL - III, Gadepan pipeline project Page 1 of 2
QAP No
Date
Prepared by MA Checked by : SHD
Approved by
Project
Client
Consultant
P.011947-Q-11098-009 Rev.0
09.02.18
SKH
BORERI - CFCL-III PIPELINE PROJECT
QUALITY ASSURANCE PLAN
FOR
LOCAL CONTROL PANEL
Inspection Agency
GAIL
TE-IN
Format of PlanAcceptance
Norm
Referrence
Document
Quantum of
Check
Type of
CheckSL. No. CharacteristicsComponent / Operation
4Documentation and inspection
certificateVisual 100%
Supplier test
records/Inspection
certificate
Supplier test
records/Inspection
certificate
Supplier test
records/Inspection
certificate
P R R
NOTE:
LEGEND: R: Review of Docs C: Critical B: Major RW-Random witness
A: Minor W: Witness TPIA-Third Party Inspection Agency H-HOLD
ALL TESTING AND MEASURING EQUIPMENTS/INSTRUMENTS SHALL HAVE VALID CALIBRATION WITH CALIBRATION CERTIFICATES & TRACEABILITIES.
M-Manufacturer,
P-Perfomer,
Review of internal test report
Certificates for all bought out component
Calibration test certificate for all instrument
Inspection certificate issuance
Boreri to CFCL - III, Gadepan pipeline project Page 2 of 2
QAP No
Date
Prepared by MA Checked By: SD
Approved by
Project
Client
Consultant
M VENDOR TPI
Consultant /
Owner
1 Internal Test/Inspection Enclosure material ,
Process connection
Set point,
Make and Model ,
Sr. No. and customer tag. No.
Calibration
Verification 100%
vendor approved
datasheetLog Sheet Report P R R R
2 Functional check Accuracy,
Repeatability,
Range ,
Switching action
Visual 100%
vendor approved
datasheetLog Sheet Report P R R R
2 Documentation weather proof and Flame proof
certification , ATEX and
IP - 65 certificate
100%vendor approved
datasheetTest Certificate P R R R
M Manufacturer P Perform
C Client - GSPL R Review
TPI Third Party Inspection Agency W Witness
A For Approval W/R Witness of Test / Review of Certificates & Documents as per QAP
Format Of Records
Inspection By
Remarks
Legend
Sr.No. Description Characteristic Type of CheckQuantam of
CheckReference Document
SKH
BORERI - CFCL-III PIPELINE PROJECT
GAIL
QUALITY ASSURANCE PLAN
DIFFERENTIAL PRESSURE SWITCH
P.011947-Q-11098-010 Rev.0
09.02.18
TE-IN
Boreri to CFCL - III, Gadepan pipeline projectPage 1 of 1
At the helm of the Energy Transition, Tractebel provides a full range of engineering and consulting servicesthroughout the life cycle of its clients’ projects, including design and project management. As one of the world’slargest engineering consultancy companies and with more than 150 years of experience, it's our mission to activelyshape the world of tomorrow. With about 4,400 experts and offices in 33 countries, we are able to offer ourcustomers multidisciplinary solutions in energy, water and infrastructure.