instrumentation technical specification...

SPEC. NO.

STATUS ENQUIRY WORK ORDER

PROJECT

LOCATION

CLIENT

PURCHASER

VENDOR

W.O.NO.

NAME OF WORK :

INSTRUMENTATIONDEPARTMENT

TECHNICAL SPECIFICATIONFOR INSTRUMENT INSTALLATION

M/s.HPCL

MANGALORE

PAGE 1 OF 1

8122-14-TS-001

ON LINE LPG BLENDING FACILITIES

ERECTION TENDER SPECIFICATION - INSTRUMENTATION

M/s.HPCL

REV.

MS SG1MJ

REVISED ON CLIENTS COMMENTS MJORIGINAL ISSUE SGMS

14F

T60

3/94

-R1

DATE

0 14.01.10

FACT ENGINEERING AND DESIGN ORGANISATION

APPROVEDCHECKEDPREPAREDDESCRIPTION

12.02.10

OF 1

1 2 3

000

000100

0

00000

000

Datasheet for DP Transmitter

03

1111

Spares List

Datasheet for Hydrocarbon Detector 1

Datasheet for Control Panel

R1

8122-14-DA-000088122-14-DA-000108122-14-DA-000118122-14-DA-000128122-14-DA-00013

00

INSTRUMENT SCHEDULE

8122-14-DA-00015

1

18122-14-HD-001 Index Sheet

Datasheet for Analyzer8122-14-DA-000210

0Datasheet for Pressure SwitchDatasheet for Coriolis Mass flow meterDatasheet for Orifice

Process Hook up

3

00

0

0

8122-14-DA-00016

Datasheet for Flow ComputerDatasheet for Temperature Element

0

Datasheet for Temperature Transmitter

DATASHEETS8122-14-IS-001

8122-14-TS-001

TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION

25ES 403/98

0

0

5

1

111

0

3

1

8 8122-14-DA-00007 Datasheet for Pressure Transmitter

05 8122-14-TS-001 SIW-I SCHEDULE OF ITEMS OF WORK-INSTALLATION

7

0

0

9

4 8122-14-TS-001 SIW-S 3

No.

0

No. of pages

DescriptionDoc. No.Sl. Rev. No. with issue

8122-14-TS-001 SPL

0

1

10

1

8122-14-HD-003 to 009 ,011

SCHEDULE OF ITEMS OF WORK-SUPPLY

8122-14-DA-00023 Datasheet for Junction box

8122-14-DA-00006 Datasheet for Pressure Gauge

2

INSTRUMENTATION CONTENTSTECHNICAL SPECIFICATION FOR

1

DEPARTMENT

DRAWINGS

25ES 401/94INSTRUMENTATION WORKS - GENERAL SCOPE

1 14

ENGINEERING SPECIFICATION2 INSTRUMENT ERECTION 22

INSTRUMENT INSTALLATION

23

6

16 1

Hook up Diagram2

1 0

023

101112131415

17

1918

22

8122-14-DA-0002016

20

8122-14-DA-00022

8122-14-DA-00024

8122-14-TS-001 SPR8122-14-TS-001 SV

Datasheet for Cable 2 021 2Subvendor List 0

Instrument Location and Cable routing Diagrams

Instrument Location and Air routing Diagram

Note : 1. The receipt of all attachments shall be checked and asertained.

2. All attachments of this Erection Tendor spec. shall be read as a package

REV.

30 8122-11-PD-003 P&I Diagram for LPG Blending Facilities 1 - 0

25 8122-14-AR-001 1 - 0

18122-14-HD-018 0 -

1

7

Process Hook up

PREPARED

SG

MS14.01.10

42

APPROVEDCHECKED

REVISED ON CLIENTS COMMENTS

FACT ENGINEERING AND DESIGN ORGANISATION14F

T65

9/95 DATE

0 ORIGINAL ISSUE

MJ

DESCRIPTION

28 8122-14-CS-001 Cable Schedule

8122-14-HD-012, 014 to 0178122-14-HD-003 to 009 ,011

8122-14-MD-001 to MD-016

Inst.Air supply Distribution diagram 1

MJ

Electrical Hook up

Calibration Record Sheets (For Instrument loop))

8122-14-HD-010

SG1 12.02.10

MS

( 5 sheets)24 8122-14-CL-001 toCL-005 15

0 0

0

1

0

1610

1

Typical Installation Drawings

1

10126 8122-14-JB-001 to JB 007

29

270

JB termination Connection drawings 17

Pneumatic Hook up 2 0

0

1 12.02.10 REVISED ON CLIENTS COMMENTS MJ MS SG

0 15.01.10 ORIGINAL ISSUE MJ MS SG REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

Page 1 of 14 R1

8122-14-TS-001 INSTRUMENTATION DEPARTMENT

TECHNICAL SPECIFICATION FOR

INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION 14FT

606/

94

GENERAL

1.0 HPCL has an LPG import facility at Mangalore which has been set up in 1996 and is presently handling a throughput of approx. 1.4 MMTPA (Million Metric Tonnes per Annum). Presently HPCL is importing LPG/Butane through New Mangalore Port Trust’s (NMPT) LPG jetty .Now HPCL plans to import Propane and Butane in different compartments of the same ship and blend the same and dispatch it as LPG.

1.1 The objective is to provide necessary facilities required to produce 400T of blended LPG .Propane and butane are to be unloaded from the ship through different unloading arms and to be mixed in static mixer (Max. 40% by weight of Propane and 60% weight Butane).to produce 400 T/hr of LPG.

1.2 In the jetty control room, presently one no. RTU is present which is connected to the DCS at MLIF through OFC. The vendor has to study the existing control system before finalizing the requirement of control sytem.

1.3 The scope of work include design, supply, erection and commissioning of the complete instrumentation, for the satisfactory completion of the project. This includes design, supply, testing, installation and commissioning of instrumentation system complete with all accessories, installation materials and cables. The supply of valves is not in the scope of the tenderer. The scope of work of vendor is given under but not limited to

• Design of the Instrumentation.

• Supply of field instruments.

• Supply of cables, cable Glands, Pultruded FRP cable trays, Junction Box and other erection materials like ferrules etc

• Supply of one number HMI and RTU with necessary I/O cards.

• Erection/Installation of instruments, Junction boxes, laying of branch cables in the field up to the Junction boxes and main cables upto marshalling box in the control room.

• Calibration of the instruments.

• Termination and loop Checking in co-ordination with Purchaser’s personnel/ DCS Vendor.

• Associate with DCS vendor & Purchaser for the implementation of controls and configurations of I/O in control system; instrument database , graphics etc in HMI software.

• Commissioning of the complete system.

of 14 R1


TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

14FT

606/

94


• Guarantee run for the instruments.

• Training & documentation as required for the operating personnel.

1.4 All control functions will be implemented in the existing DCS system located at Jetty.

1.5 Vendor shall submit the interlock drawing/cause effect diagram to be incorporated in the PLC.

1.6 Repeat indications shall be provided at the MLIF control room situated 12 Km away through existing OFC cable.

1.7 All data to be incorporated in DCS such as I/O list, tag details, alarm points, graphics etc shall be submitted by vendor for review and approval of FEDO and actual implementation by the DCS vendor.

1.8 Mass flow meters FT201 and FT101 with flow computers are provided to monitor the flow of propane and butane. Propane and butane are mixed on volumetric ratio basis. The flow computers and flow meters are to be located near the proposed blending station and to be connected to the DCS system at Jetty terminal for operation. Repeat indication / control shall be provided in MLIF control room also.

1.9 Flow control valves are provided in the two unloading lines at the blending station to record and control flow to the static mixer. The control valves shall be operated by new controllers and a simple flow ratio controller.

1.10 One no. LPG analyser shall be provided in the sea water line to sea. The typical schematics for the analyser is attached vide drawing no: 8122-14-MD-016. Vendor shall design suitably and shall submit the scheme proposed by him for approval. The arrangement shall be housed in a panel with purging. Suitable enclosure shall be provided for the panel for Ingress protection.

1.11 Vendor shall supply 1 no. of HMI station . The PCs shall have the following minimum configuration: Desk Top PC; WIN XP Professional(SP3), with original license, Intel Core 2 duo 6M Cache, 3.0 G Hz (min) CPU, Intel Original/ OEM motherboard based on Q35 or better chipset, 8 GB DDR2 RAM, 21” TFT 500 GB HDD, 1.44 FDD, Keyboard, Optical mouse, Multimedia Ext. , intel graphics media accelerator, integrated Ethernet card, One no. portable 22x DVD-RW Drive, USB ports.

1.12 The sea water inlet to the heat exchangers is controlled through Temperature control valves based on the temperature of outlet propane and butane.

1.13 All instrument and accessories supplied shall be so designed taking into consideration the ambient conditions and the specified nature of the Plant.

1.14 The instruments supplied shall be of high quality and shall be from manufacturer of good repute. All similar instruments shall be supplied from same sub-vendor and to the extent, possible and the number of sub-vendor to be kept minimum

1.15 The general Philosophy to be adopted for the Instruments shall be strictly adhered to, deviation if any that the bid propose to take shall be clearly indicated in the bid.

1.16 Actual selection of the Instrument, Material of construction etc. shall be based on the various aspects such as type of material handled, operating condition, environmental condition etc.

1

of 14 R1



14FT

606/

94


1.17 All Instruments required for guarantee purpose shall be provided and details to be furnished.

1.18 All vendor supplied instruments shall be wired to the marshalling panel through necessary field JB. Cabling to instrument JB and marshalling box are in the scope of the vendor. Also any interconnecting wiring/cabling/tubing between vendor supplied instruments/JB shall be done by the vendor.

1.19 Field erection of all instrumentation items shall be in the vendor’s scope. Vendor shall include erection materials including cables, cable trays, junction boxes etc as required in their scope.

1.20 Vendor shall furnish detailed BOM, Datasheets, and Cable routing/wiring drawings for approval for the Instruments in his package. All the erection materials required also shall be covered in the BOM.

1.21 All documents as per VDR attached shall be supplied by the vendor. Specification for all instruments shall be submitted for approval, prior to ordering.

1.22 Spares: Vendor shall supply recommended spares and consumables for commissioning and 2 years trouble free operation for all instrumentation items supplied. Spare shall be supplied as per the Spare sheet attached as a minimum.

2 GENERAL POINTS ON INSTRUMENTATION

2.0 All instruments supplied shall be weather proof to IP 65.

2.1 All electrical connections shall be ½” NPTF and double compression cable glands shall be used. SS and copper tube fittings used for this package shall be double compression type ferrule fittings.

2.2 All cable terminations shall be with single tubular ferrules crimping lugs on Wago terminal blocks . All ferrules, cable glands, crimping lugs etc. for termination at JB and marshalling box shall be arranged by vendor.

2.3 For all Instruments QAP/Test reports shall be submitted for review and approval prior to dispatch to site as also site calibration shall be witnessed by HPCL/FEDO.

2.4 For temperature measurement, integral head mounted temperature transmitters, with RTD shall be used. Thermowell to be provided for all temperature elements and gauges.

2.5 A stainless steel nameplate having the following minimum details shall identify field instruments. Tag number, manufacturer’s name, model number, type, serial number, electrical classification, certification mark, range, rating, set point.

2.6 For all field switches, alarm contact shall open on alarm condition.

3 GUIDELINES FOR INSTRUMENT INSTALLATION

3.0 For the scope of work of supply, erection, fabrication, Calibration and loop/logic checking of instruments and related accessories, please refer to the Engg. Specification 25 ES 401 / 94 enclosed. The scope of the work shall cover all the aspects specified therein. For each of

of 14 R1



14FT

606/

94


the schedule of item respective clause indicated in Engg. Specification shall be referred to. The scope of work for erection contractor is inclusive of calibration, fabrication, field instrument erection, cabling, termination in marshalling racks and at instrument end, PLC panel erection, loop checking, and commissioning of the whole system, as an integrated entity for lining up the unit.

3.1 Process hookup drawing shall be referred to for installation of field instrument where-in the scope of piping and instrumentation are indicated. All fabrication work involved is in the scope of contractor.

3.1 All the field cables to the control room from the field shall be laid as per the cable routing diagrams and duly terminated at the PLC Racks in the control room. All installation documents and drawings, such as hookup dawing, routing drawing etc. to be got approved by FEDO before starting any work.

3.2 The description given under Engg. Specification for instrument erection (general ) covers most of the prevalent type of instrument, some of which are not required for this project. Hence only those applicable items shall be referred to the schedule of the work. In case of any contradiction between the Engg. Specification 25 ES 401 / 94 and Technical Specification for Instrument Installation, Technical Specification for Instrument Installation will supersede.

3.3 The offer shall include unit rates for all Field fabrication, Erection, Calibration and loop/functional checking activities of the instrument system.

3.4 The bio-data of the contractor’s key personnel shall be enclosed with the offer for scrutiny. Also the details of major similar jobs executed shall be furnished.

3.5 The offer shall include a preliminary manpower deployment plan for the complete job. (Inst .Engr/ Inst. Technician/ skilled workers category qualification wise) as also the site calibration equipments/calibrators/tools to be deployed for this project.

3.6 All necessary scaffolding as required for installation of instruments, cables and impulse lines must be provided by contractor at no extra cost. In case of non-availability of electricity, contractor shall make his own arrangement in order to avoid delay in progress of work.

3.7 All consumables like welding electrodes, paint, sealing tape, wire/cable markers, ferrules, crimping legs, cable fasteners, bolts and nuts etc., shall be provided by the contractor and included in the contract price as specified in the NIT.

3.8 The contractor shall provide his staff with necessary and adequate tools of good quality. In case of failure due to do so, the client may choose to provide the special tools at the contractors cost on chargeable basis. All tools shall be used for the purpose for which they are intended.

3.9 A suitable insurance covering the damage on the materials entrusted in the contractor’s protection, damage to the third parties material or personnel as well as own personnel shall be drawn up by the contractor. The coverage shall be subjected to HPCL approval.

3.10 The contractor shall establish his own storage facility for intermediate storage of equipments at site. The storage shall always be kept clean and neatly arranged of easy

of 14 R1



14FT

606/

94


retrieval of materials. It shall be suitable for all prevailing weather conditions and stainless steel materials shall be stored separate from other materials. Representatives of HPCL/FEDO have full authority to check the storage at any time. Alternately, the instruments stored at HPCL stores shall be drawn/returned on authorization from HPCL.

3.11 On the allotted land at site, the contractor shall establish workshop at his own cost for prefabrication and necessary office and dining facilities for his staff.

3.12 The contractor shall familiarise himself with the local trade union rules and do his best not to be the cause of any conflict/industrial dispute affecting site work.

3.13 As required, during peak construction, the contractor shall be prepared to arrange shift work and mobilise more manpower round the clock. Extension shall not be entertained due to the reason of rain, non-availability of electricity, etc. The project has to be completed in the earliest instant.

3.14 The contractor shall ensure that all people employed by him observe and obey the site safety regulations and guidelines issued by HPCL/FEDO site personnel.

3.15 The contractor appointed site manager shall attend regular weekly site meeting for review of the work and planning future work. He shall endeavor to meet the schedules and be well prepared with information about the project status and his work force capabilities. All the meetings and writings shall be in English language. All shortcomings notified shall be corrected immediately.

3.16 No work must be started by the contractor without clearance from HPCL/FEDO appointed site in charge.

3.17 Work front clearance will be given based on a planned erection sequence and the actual progress of equipment, structures and piping installations. The contractor shall adjust his workforce based on available workfronts.

3.18 Twice a month, at dates decided by FEDO, work progress reports should be submitted by the contractors, at his cost, prepared in EXCEL.

3.19 The correctness of the report will be verified and counter signed by consultant’s (FEDO) representative at site.

3.20 All site work will be checked and monitored/controlled by supervisors appointed by HPCL/FEDO. Any discrepancy from specification, drawings or instructions given to the contractor, revealed during these checks and in the process of work shall be rectified immediately by the contractor at no extra price. All claims are admissible as listed vide schedule of works with unit rates. No excess rate claims shall be entertained at all, from contractor side.

3.21 On completion of installation works all excess materials shall be returned to HPCL storage. The contractor shall endeavor to optimize the use of erection materials and avoid needless wastage especially on structural steel, trays, tubes/pipes and cables.

3.22 Upon issue of valves from HPCL stores the contractor shall ensure himself of the correctness and healthiness of the same. Any visible incorrectness or damage shall be reported on the spot and the instrument left in the store until further notice by HPCL.

of 14 R1



14FT

606/

94


3.23 All instrument cabling work including instrument signal/control/ power cable laying, dressing, and tagging inside and outside of the control room is included in the scope of contractor.

3.24 Contractor shall terminate all field cables in the control panel rack with due cable / wire marking/tag at both ends. Cross ferruling shall be followed in terminations. Identification sleeves/tags/ferrules to be arranged and shall be fitted to each end of cables or wires and shall be inscribed with the cable number and terminal number.

3.25 The cables must not be taken off the side of the drum while laying, but drums shall be installed on rollers to avoid twisting of the cable. Cable laying scope shall include cable cutting, megguring, continuity checking, laying, dressing, tagging, glanding, crimping and termination, ferruling, loopchecking etc.

3.26 All cable entries shall be properly sealed and fastened around the cable to prevent ingress of water and dust. Any improper sealing shall be replaced / rectified by the contractor.

3.27 The tube laying scope of work shall include cutting, bending, dressing, including tube fitting, continuity testing, hydrostatic testing. All welding on impulse lines, if required shall be performed by certified welders only. The contractor shall present the certificates and prior to commencement of welding the relevant POR and WPS for scrutiny of HPCL/FEDO site in charge.

3.28 All mounting of structures, brackets, support trays etc., shall be drilled, as gas cutting is not allowed/recommended.

3.29 Fixing of branches and supports to concrete structures shall be by drilling of holes and use of expansion bolts. Chipping and use of wooden rawplugs are not allowed. Grouting of pedestal bases are covered in fixing scope

3.30 The contractor shall be prepared to undertake minor civil work related to the instrument erection, vide above and including wall openings and closing/replastering, conduit burial, structural modifications etc. as required to complete the erection work .

3.31 Wherever welding of supports is required to be done on painted steel structures, the contractor shall apply touch up paint after careful wire brushing of the affected area. The paint application shall confirm to the original with respect to type and thickness.

3.32 All brackets, supports, etc., fabricated of corrodable materials shall be painted in accordance with project specification. The complete painting shall be done prior to the installation of instruments or trays / ducts or impulse lines so all surfaces can be properly covered with the specified layer.

3.33 The contractor should establish his own instrument calibration and fabrication facilities at site.

3.34 All instruments used for calibration shall in general have one decimal better accuracy than the specified accuracy of the instrument to be calibrated.

3.35 Instruments used for calibration shall be traceable to a standard and the stamping/ certification shall be valid/ produced for verification. All instruments to be loop checked

of 14 R1



14FT

606/

94


from the control system and sourced from the field end as well using calibrator (hot loop check).

3.36 A list of various types of instruments shall be calibrated by the contractor is enclosed with NIT. The contractor shall judge which calibration instruments he requires for the calibration and use the proper one, and furnish listing for approval of HPCL/FEDO.

3.37 Each instrument shall prior to its final installation be calibrated at site at 0-25-50-75-100-75-50-25-0 % range and the results shall be within the specified accuracy of the instruments under witness of HPCL/FEDO site engineer. Any instruments failing, shall be replaced by the contractor. The calibration certificate/report for each instruments prepared thereby, shall be documented and submitted.

3.38 All successfully calibrated instruments shall be clearly labelled by the contractor after certified OK by HPCL site engineer, which can then be installed as per work front availability.

3.39 The contractor shall include all necessary equipments for hydrostatic testing of impulse lines, continuity test of cables and megger test of cables, prior to installation field instruments and termination work.

3.40 It is expected that there should be a variation of + 25% in overall quantity of erection work, and the contractor shall be prepared to execute the work for the unit rates indicated for the enclosed quantity Any site Revisions/change notes issued by HPCL/FEDO at site shall be billed only as per unit rates indicated herein vide the schedule of work.

3.41 It is expected that instrument erection will be completed within 6 weeks of commencement. However if the installation work extends due to non-availability of front the rates shall be valid for an expected period upto 10 weeks from the commencement of the work at site.

3.42 Pipe and pipe fittings :Instruments pipes used for impulse lines shall be ½” plain, sch. 80 with SS304 material. Pipe fittings like union, nipple, half nipple, coupling, reducing coupling, equal tee, Elbow, cap etc. may be considered with suitable rating.

3.43 Tubes shall be fixed with stainless steel tube clamps. These clamps shall be bolted to a stainless steel support with M8 stainless steel bolts. The clamps and fixtures are to be supplied and erected by the instrument contractor at site.

3.44 If MS clamps / supports are used for stainless steel pipes or tubes, a woven glass fiber sheet material shall be installed between the clamp and the pipe / tube to avoid contact with any carbon steel surface.

3.45 50 * 50 mm angles should be used as a standard support attachment, preferably in stainless steel for tubes and pipes

3.46 Handling and Storage

3.46.1 All stainless steel shall be handled and stored in such away that the corrosion properties are not deteriorated. It should therefore be ensured that the stainless steels do not get in contact with non-stainless during handling and storage. All tools or material, which gets in contact with stainless steel shall be made of stainless steel, nylon, wood or the tools

of 14 R1



14FT

606/

94


shall be coated with textile. Tools previously used on non-stainless steel shall not be used.

3.46.2 All erection materials shall be stored in a dry and clean area, where it is protected against particles and grinding dusts. Stainless steel and carbon steel shall be stored separately. After completion of site work, contractor shall remove all unused materials, as also the scrap from site and accounted.

3.47 All instruments shall be mounted on 2 inch GI Pedestals/stanchions for easy access and maintenance. Necessary supports to be provided for all instruments and Junction boxes. As far as possible prefabricated and painted supports to be used.

3.48 Cables shall be routed in pultruded FRP cable trays on pipe/cable racks wherever available and in other places through structurals ISMC/Angles as appropriate. All nuts and bolts used shall be SS304/316.

3.49 Other erection materials: Isolation valves for impulse lines shall be ½” NPT (F) with body, bonnet, seat, plug, handle and spindle of SS 304 material with 3000#, pressure rating.

3.50 All valves shall be located so they are easily accessible for operation. Refer hookup drawings for each instrument.

3.51 Welding

3.51.1 The welding procedure and the welder shall be qualified under the provisions of ANSI/ASME B 31.3 for fillet welds, which shall be used to attach the socket, welded components and to sealed the threads. The weld quality shall confirm to the code requirements for visual inspection.

3.51.2 Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) shall be submitted to and approved by the owner before commencing the welding

3.51.3 All surfaces shall be cleaned and free from rust, paint, scale, etc. prior to fit up.

3.51.4 Minimum welding dimension for socket welds including correct bottom expansion gap distance shall be observed. Cardboard distance pieces are not permitted due to risk of clogging of pipes and valves.

3.51.5 The pipe shall be fully inserted in to the fitting, marked and retracted to the right distance.

3.51.6 All threaded joints shall be seal welded, except for compression fittings and the instrument connections. Thread sealing compound or tape shall not be applied and the seal weld shall cover all exposed threads.

3.51.7 It should be checked for all valves, prior to welding that this can be done without damaging the gaskets. If not, the gasket must be removed during the welding.

3.51.8 The weld at the connections to the block valve at the process tapping must only be made after the hydraulic test of the process pipe/equipment is finished so that the valve is proved leak tight.

3.51.9 The preferred welding process is GTAW (tungsten inert gas), but GMAW (metal arc) is also acceptable. OFW (oxy-fuel gas) is not permitted and it is not permitted to cut the pipes with a blowtorch.

of 14 R1



14FT

606/

94


3.51.10Welding material and heat treatment procedures for the welding on impulse lines are shown below:

Welding Group Numbers for Steel Combinations

CS-CS CS-316SS CS-347SS 316SS-316SS 316SS-347SS 347SS-347SS

1A 12A 12A 11H 10H 10H

Welding Materials

No. Material Coated electrodes Bare wires

ASME SFA Classification ASME

SFA Classification

1 CS 5.1 E7018 5.18 ER70S-2

10 18Cr 10Ni Cb (347) 5.4 E347- 16 or 15 5.9 ER347

11 18Cr 10Ni Mo (316, 316L) 5.4 E316- 16 or 15

E316L- 16 or 15 5.9 ER316 ER316L

12 25Cr 12Ni (309) Inconel

5.4 5.11

E309- 16 or 15 ENi Cr. Fe-3

5.9 5.14

ER309 ER Ni Cr-3

The figure in the group number refers to the filler metal while the letter refers to the preheat and post-weld heat treatment:

Thermal Treatment

Treatment Letter Preheat Postweld Heat Treatment

Temp. (°C) min Temp. (°C)

A 10 None

H 10 None

3.52 Painting

3.52.1 All carbon steel installations shall not be painted until after successful completion of hydrostatic test whereas stainless steel installation and galvanized surfaces shall be left properly cleaned and unpainted.

of 14 R1



14FT

606/

94


3.52.2 Surfaces to be painted shall be wire brushed to a degree of “St 3” in accordance with ISO 8501-1, i.e. The surface shall have a pronounced metallic sheen. Oil, grease, salt, and other contaminants shall be removed. The paint shall be applied by brush to the dry surface under favorable conditions and in accordance with the paint manufacturer’s instructions. The coats shall be uniform without bare patches, pinholes, runs, etc. and they shall reach the final thickness specified for each type of coats.

3.52.3 The various types of paint applicable for instrument installations have been given the following code numbers:

T-1 Alkyd Hi-Build Primer

Heat resistant up to 940C Thinned to workable consistency only

Dry film thickness: 70microns Hempel equivalent: 1320

3.52.4 The paint shall be applied in accordance with the table below

Impulse Lines, Supports and Attachments

Temperature/painting Primer Intermediate Coats Finish

Final Finishing Color

RAL Color Code No

Surface temp. under 94° C (200° F) Paint thickness in microns

T-1 70

F-1 25

F-1 25

Aluminum Total 120

9006

Installation requiring insulation shall only be permitted.

3.53 Instrument impulselines inspection, Examination and Testing:

3.53.1 The inspector/site engineer shall perform a 100% visual examination of all impulse line welds as defined in ASME B31.3. The examination shall further include check-off correctness of the routing inclusive supports and verification of correct components / pipes by means of marking / colour coding of pipe identification.

3.53.2 Each impulse line shall be hydrostatic tested with potable water at a pressure of not less than 1.5 times the design pressure of the process pipe or equipment. The pressure tester shall be arranged by the instrument contractor at site.

3.53.3 All instruments must be removed during the test. A test pressure gauge with dial diameter of φ 150mm and an accuracy of 1% shall be used for the test. The range shall preferably be twice the intended test pressure.

3.53.4 The installation shall be cleaned by the blowing or flushing prior to the test and all joints shall be left unpainted and uninsulated. Vents shall be opened on all high point (for

of 14 R1



14FT

606/

94


installation with the instruments mounted below the tapping, the impulse lines may be vented in to the process pipe by opening of the block valves to evacuate all air.

3.53.5 The installation shall be subjected to the test pressure for a minimum of 5minutes and an examination of leakage for all joints shall be made. There should be no detectable drop in pressure on the test gauge during the test. Each side of an installation for differential pressure instrument shall be tested separately to prove the tightness of the manifold-equalizing valve.

3.53.6 The paint application shall be checked for compliance with the instruction and for first class workmanship. At least two coats of paint application is mandatory.

3.54 Erection requirement for cable trays, ducts and supports:

3.54.1 Whenever practicable, all metal structures such as frames, brackets, etc. should be prefabricated and properly surface treated in order to obtain maximum protection against corrosion before transportation to site.

3.54.2 Welding on site of galvanized material shall not be permitted except where the welded joints can be easily painted after welding and deslagging with the appropriate number of coats of zinc rich primer / paints.

3.54.3 Drilling of holes and welding on structure and process equipment shall only permitted with the approval of the mechanical site engineer.

3.54.4 All galvanized material shall be painted on site after erection but before installing trays, junction boxes etc. The paint to be used shall be of type, which will ensure good adhesion to the galvanized surfaces.

3.55 Cable trays:

3.55.1 Pultruded cable trays shall be used wherever required. Cable wherever is buried in the trench shall be filled with sand after laying and covered with concrete slabs. For Trench inside the control room proper cover to be provided. The most appropriate route shall be decided during detailed engineering by the vendor. Cable trays free from burrs and other irregularities of sizes to suit the individual/ overall cable routing may be selected. Required cable tray bends like flat bends, inward/outward bends etc. may be considered as per requirements in the routing. The supports shall have required mechanical strength to support the cables.

3.55.2 All cables through trays shall be clamped using suitable fasteners. All cables shall be tagged using SS Tags.

3.55.3 Cable tray installation must be constructed in such a manner so as to facilitate easy cable laying maintenance and additional cable trays. Please refer the cable duct/tray routing drawing. All duct/tray of pultruded GRP as also the structural steels supports supply, fabrication and laying are in the instrument contractor’s scope of work.

3.56 Support for Cable Trays.

3.56.1 Prefabricated support brackets or hangers for trays and ladders must be made from hot dip galvanized sheet steel with a minimum thickness of 2mm.

of 14 R1



14FT

606/

94


3.56.2 Whenever being cut on site, all supports and accessories must be suitably primed and painted with zinc-rich paints on the exposed steel surface.

3.56.3 The minimum average thickness of zinc coating should be 64 micron corresponding to 460-g/m2 metal surfaces.

3.56.4 For large free span installation, brackets made from standard angle or channel iron bolted or welded to the structures or to building structures shall be the minimum acceptable installation.

3.56.5 The distance between tray supports shall be such that, apart from imparting sufficient mechanical strength under all conditions, the deflection of the tray shall not exceed 3mm.

3.56.6 Single cables shall be supported and protected by conduits, straight length of angle iron, or Pultruded GRP trays. The support must have sufficient mechanical strength to protect the cable against accidental abuse. Angle iron must be primed and painted, by one coat of Zinchromate primer and subsequent two coats of enamel paint.

3.57 Support for Equipment

3.57.1 Necessary support for equipment such as junction boxes should be large possible extent prefabricated and galvanized. Welded construction to be galvanized after the welding process.

3.57.2 All supports should be mechanically strong and well protected against corrosion. Where supports are welded on to structures, etc. the design must be so that all surfaces of the structure and the support itself can be easily primed and maintained.

3.57.3 Small size junction boxes, etc. may be bolted direct on to walls and steel structures, whereas larger items must be mounted on an intermediate sub-frame, bolted or welded to the steel structure in such a way that all metal surfaces can be easily painted and maintained.

3.58 Installation of cables:-

3.58.1 All trays & ducts shall be installed, cut for the entry for branching trays where necessary and cleared of debris before introduction of cables. The cables shall be installed in a straight and neat manner clamped to the tray with a maximum distance between the clamps of 500 mm.

3.58.2 The cables shall be installed in the tray using cable-pulling equipment, together with the cable manufacturer instructions, to prevent any damage to, or abuse of the cables. Unless the manufacturer states otherwise the cables shall be installed with a minimum bending radius of 8 times the outside diameter of the cable.

3.58.3 Cables entering instruments and junction boxes shall not be coiled but taken direct from the support observing the minimum bending radius requirements for the cable. FRP/GRP clamps shall be used for clamping/dressing the cables on trays/ducts, which shall be supplied by the instrument contractor.

of 14 R1



14FT

606/

94


3.58.4 Crimping lugs and ferrules shall be used for termination of cables at instrument head, field junction box and at marshalling racks in the control room; which shall be supplied by the instrument contractor at actual quantity.

3.59 All instruments shall be provided with suitable rain guard/ canopy.

3.60 All terminals shall be easily accessible. The terminals shall be of Wago make mounted on DIN TS 35 standard rails. Each terminal strip / terminal box shall be foreseen with spare terminals equal to 20 % of the total terminals in panels as well as in junction boxes.

3.61 Terminal for power wiring and others having a potential higher than 48V shall be covered by transparent Perspex to protect the maintenance personnel from accidental contact.

3.62 Earth pit of R < 5 O for the control system logic earth shall be provided by the instrument contractor as per IS 3043. Earthing cable of 6 mm2 to be laid from control system to earth pit. Earth tester to be arranged by the instrument contractor demonstrate the R value of the earth pit.

3.63 For all items in the in the Schedule of items of Work- Supply, 8122-14-TS-001-SIW-S, the contractor shall include unit rate

3.64 Cable entry to control room shall be through Multi cable transit blocks.

3.65 Further the structural steel as detailed vide schedule of work herein is to be supplied, fabricated, welded/bolted/fixed and painted. Painting shall follow standards described elsewhere in the document.

3.66 The impulse tubes and pneumatic tubes shall be clamped to angles using Aluminium clamps at 1.5 Meter intervals.

3.67 The RTU cabinet erection inside the control room shall be in the scope of the contractor. Base frame for panels shall be fabricated and installed by the contractor. Operator console – 1 no.. also shall be installed in the control room.

3.68 The supply and erection of complete power and earthing cabling as well as termination works for the control panel shall be in the scope of the vendor.

3.69 Typical installation drawings are attached for reference. Note :-

All the work detailed herein generally covers the scope of work envisaged under the instrument contractor. However any specific omissions/new works likely therein shall be indicated in the offer with unit rates applicable for consideration.

A. General List of types of instruments to be configured/ calibrated, installed and loop checked

by the instrument contractor for LPG Blending unit:

1. Pressure gauges (Bourdon type& diaphragm seal) 2. Electronic Transmitters ( Pressure & DP.) 3. Temperature Transmitters, Thermowell-RTD

of 14 R1



14FT

606/

94


4. Coriolis type mass flow meter with flow computer 5. Pressure switches 6. Gas detector 7. Control valves, On-off trip valves

B Major fabrication works/laying works at field :

1. Structurals, fabrication, laying, painting. 2. Cable Tray laying, clamping/fixing. 3. Junction box and transmitters fixing. 4. Cable laying, dressing, routing, clamping, tagging, glanding and terminating. 5. Installation of pipe lines mounted instruments-supervision and hookup 6. Earthing , powering, interconnection inside control room. 7. Cold loop check. 8. Hot loop check – line up – commissioning – integration.

NOTE:-

The description under scope of supply will begeneral in nature and covers most of the prevalenttypes of instruments, some of which may not be re-quired for this particular Project. Hence only the ap-plicable items shall be referred to. For actual list ofinstruments, refer schedule of work.

PART A - GENERAL

1.0.0 SCOPE OF WORK

The scope of work shall include but not belimited to :-

1.1.0 Unpacking, checking, cleaning and withdrawalof instruments, instrument accessories anderection materials at owner’s stores and / orfrom places of storage any where within theboundary wall of project and existing factory.Return of left over materials to owner’s stores.

1.2.0 Transportation and handling of instruments, in-strument accessories and erection materials atowner’s stores and / or from places of storageany where within the boundary wall of project towork site and / or contractor’s stores.

1.3.0 Installation of field mounted instruments such aspressure / vacuum gauges, dial thermometers,pressure switches, blind switches, manometers,differential pressure indicators, local flow in-dicators / recorders, local indicating controllers,flow transmitters, pressure transmit ters, dif-ferential pressure transmitters, temperaturetrans mitters, Rotameters etc.

1.4.0 Installation of vessel mounted instruments suchas level gauge glass, magnetic level gauges,bi-colour level gauges, torque tube level instru-ments, level switches, dial thermometers, pres-sure gauges etc.

1.5.0 Installation of instruments on vendor’s equip-ments such as speed indicators, speed control-lers, vibration / Axial displacement / Axial thrustmonitoring systems, Ammeters, Antisurge con-trols etc.

Supervision of installation of on line instrument(by other contractors) such as orifice flow ele-ments, control valves ,PD / Turbine metersRotameters,etc.

1.6.0 Installation of Analytical instruments such asinfrared Analysers, Paramagnetic Analysers, y-Thermal conduct ivi ty Analysers, NOXAnalysers, H2S Analysers, Silica Analysers,Density Analysers, PH Analysers, Electricalconduct iv i ty Analysers, Dissolved O2Analysers, On line Gas Chromato graphs,Oxygen analysers etc.

1.7.0 Installation of miscellaneous instruments suchas Belt weighers, Flame safe guard instru-ments, pneumatic change over switches, Airsets, thermocouple assemblies, thermo resis-tance assemblies, purge type liquid levelmeasuring systems, volume tanks for doubleaction piston actuators etc.

1.8.0 Installation of local panel mounted instrumentssuch as receiver indicators, indicating control-

25ES401 / 94


ENGINEERINGSPECIFICATION INSTRUMENT ERECTION

PRPD. BY: CHKD. BY: APPRD. BY: ISSUED ON: APRIL ’94

PAGE 1 OF 22

iso2.sty

CONTENTSPART A - GENERAL

1.0.0 SCOPE OF WORK

2.0.0 CONTRACTOR’S OBLIGATIONS

3.0.0 OWNER’S SUPPLY

PART B - TECHNICAL REQUIREMENTS

4.0.0 INSTRUMENT INSTALLATION

5.0.0 ON-LINE INSTRUMENTS

6.0.0 FIELD MOUNTED PRIMARY MEASURINGELEMENTS

7.0.0 FIELD MOUNTED TRANSMITTERS

8.0.0 FIELD MOUNTED CONTROLLERS

9.0.0 FIELD MOUNTED GAUGES

10.0.0 FIELD MOUNTED SWITCHES

11.0.0 ANALYSERS

12.0.0 MISCELLANEOUS INSTRUMENTS

13.0.0 JUNCTION BOXES,PDB’s,MB’s

14.0.0 CONTROL PANELS

15.0.0 FABRICATION WORK AND MOUNTING OF IN-TRUMENTS

16.0.0 GENERAL NOTES FOR INSTRUMENT PIPINGAND TUBING

17.0.0 GENERAL NOTES ON TERMINATION,ELECTRICAL INSTALLATION AND GROUND-ING

18.0.0 GENERAL NOTES ON CABLE TRAY, DUCTSAND CONDUIT INSTALLATION

19.0.0 CIVIL WORKS

20.0.0 CALIBRATION AND FUNCTIONAL CHECK

21.0.0 TESTING AND LOOP CHECKING

PART C - JOB COMPLETION REQUIREMENTS

22.0.0 COMPLETION OF ERECTION JOB

23.0.0 COMMISSIONING AND START - UP

24.0.0 BILL OF QUANTITIES AND MATERIALS

PART D - PROCEDURES AND STANDARDS

25.0.0 GENERAL REQUIREMENTS AND RECOM-MENDATION FOR PIPE WELDING.

26.0.0 SPECIFICATION FOR PAINTING WORK

27.0.0 INSPECTION AND TEST PROCEDURE FORINSTRUMENT INSTALLATION WORK.

28.0.0 APPLICABLE STANDARDS

PART E - ATTACHMENTS

29.0.0 DRAWINGS - ANNEXURE I

30.0.0 SCHEDULE OF WORK - ANNEXURE II

31.0.0 ITEMS TO BE SUPPLIED BY CONTRACTOR -ANNEXURE III

lers, pneumatic / electronic receiver recorders,manual loaders, ratio control stations, comput-ing / selector relays, temperature indicators /recorders, receiver switches, alarm annun-ciators, timers, analyser recorders, etc.

1.9.0 Interconnecting field & panel mounted instru-ments.

1.10.0 Cutting gaskets of various materials to suitablesizes and fixing the same along with the fittingsor flanged connections.

1.11.0 Any modification jobs during installation of instruments.

1.12.0 Erection and interconnection of control panels,cubicle boards, control desks etc. locally and inthe control rooms.

1.13.0 Fabrication and Installation of frames, supports,mounting stands, clamps, brackets, cable racks,cable trays and bends, tees and crossings etc.for the racks and trays.

1.14.0 Fabrication and installation of instrumentprotective boxes.

1.15.0 Laying and supporting of cable trays and ducts.

1.16.0 Laying and supporting of instrument Air headersand distribution lines.

1.17.0 Laying and supporting of multicore tubing andsingle run tubing on racks and their termination.

1.18.0 Laying and supporting of multicore and singlepair electrical cables, multicore and single paircompensating cables and any other specialcables on racks / trays and their terminations.

1.19.0 Fabrication, laying and supporting of impulse,piping and sample lines for the analysers andfor Laboratory.

1.20.0 Fixing in position electrical Junction Boxes, dis-tribution boxes and relay boxes in the field andbehind the control panels, conduit pipes, fittingsand flame proof boxes.

1.21.0 Any civil job involved in the installation of sup-ports, mounting stands, control panels, JunctionBoxes, and relay boxes air piping, tubes etc.

1.22.0 Cleaning and blowing of main air header anddistribution lines, pneumatic tubing, impulsepiping and sample lines for analysers etc.

1.23.0 Testing of main air header and distribution lines,pneumatic tubing etc.for any leakage andproper connections.

1.24.0 Hydraulic / pneumatic testing of impulse pipingand sample lines.

1.25.0 Testing of electrical cables, compensatingcables, and special cables for proper connec-tions, continuity and insulation, together withDCS Contractor.

1.26.0 Testing of complete instrument loops for properconnections and functioning, together with DCSContractor.

1.27.0 Steam tracing of impulse lines wherever neces-sary and final connections to steam jacketedinstruments. Piping connections for internalwashing of instruments and purging of instru-ment casing.

1.28.0 Cleaning and painting of frames, supports,clamps, mounting stands and racks etc, as per

painting specifications.

1.29.0 Testing, calibration and functional checking ofall the instruments and accessories.

1.30.0 TIG welding, stress relieving and dye penetranttests wherever required. Welding of IBR impulsepipes (C.S), SS - 316 and 316L impulse pipes.

1.31.0 Sealing of cable entries into control panels /room after laying of all cables and tubes.

2.0.0 CONTRACTOR’S OBLIGATIONS

The contractor’s obligations shall include :-

2.1.0 Arrangement and supply of required tools andtackles such as electric welding sets, Gas weld-ing sets, Gas cutting sets, Hydro testing pumps,trailer, Fork lifts, Crane, jumbo trucks, pipe andtube benders, Drilling equipments etc. and allother tools necessary for the installation of instruments according to good international practice.

2.2.0 Arrangement and supply of consumables likewelding electrodes, industrial gases, cleaningfluids such as kero sene, insulation tapes, seal-ing compounds, all clamping materials for cable/ tube trays and racks, impulse piping and airheader such as bolts, nuts, M.S. clamps(straight pin type) / U type lugs of 1.5 mm Sq. /2.5 mm Sq. size in required quantity, SS/aluminium tag plates, PVC cable marking fer-rules etc. and all other consumables necessaryfor execution of the job.

2.3.0 Arrangement and supply of testing equipmentsand other instruments such as Dead weighttester (weight in kg/cm Sq.) manometer, port-able pneumatic / electronic calibrator, standardtest gauge, thermocouple test kit, D.C poten-tiometers, wheatstone bridge, decade resis-tance box, temperature baths with thermostaticcontrol, oscilloscope, telephone sets, signalgenerator, megger, vacuum pump, hydraulicpump, avometer, digital multimeter, testing /calibrating facili ties for panel mounted in-dicators, recorders, controllers, computingrelays, counters, turbine flow meters, transmitters, electro-pneumatic convertors etc.

2.4.0 Planning and maintaining of all activities of thecontract as per PERT network approved byowner. Arranging staff like supervisory staff,skilled and unskilled labour forces etc. as re-quired for timely completion of the entire job.

2.5.0 Maintaining records on daily basis of all theworks as per approved schedule, calibrationand inspection reports as per the advice ofOWNER.

2.6.0 Making arrangement for distribution of electricityand water from supply point to work spots.

2.7.0 Co-ordination with other contractor’s work asrequired by OWNER to complete the instrumenterection work.

2.8.0 Security arrangement for contractor’s office andstores to ensure safety of all equipments and allfree issue mate rials supplied by the OWNER.

2.9.0 Clearing of site after completion of work.

2.10.0 Return of OWNER’S surplus and free supplymaterials and other excess material included inwork order to OWNER after accounting.

25ES401 / 94



PAGE 2 OF 22

3.0.0 OWNER’S SUPPLY

Owner’s obligations shall include :-

3.1.0 Supply of all pipes, pipe fittings, cable trays andducts, valves, flanges, junction boxes, controlpanels, gauge boards, two core and multicorecontrol / power / shielded cables, three core andmulticore resistance thermometer cables, singlepair and multipair compensating cables, twocore and multicore electrical / electronic cablesetc (Except those included in the contractorsscope.)

3.2.0 Supply of all pneumatic, electrical, electronicand analytical instruments, special samplingsystems, resistance thermometers, dial ther-mometers, thermocouples, bi-metallic ther-mometers, thermowells, all the switches foralarm and shut down, Pressure and vacuumgauges, air filter regulators, solenoid valves,output gauges, analyzer cabinets etc.

3.3.0 Supply of water free of cost and electricity onchargeble basis.

3.4.0 Cranes, jumbo trucks, fork lifts etc.. will bespeared by the owner on chargeable basis (onlyif available) other wise contractor has to makehis own arrangements.

PART B - TECHNICAL REQUIREMENTS

4.0.0 INSTRUMENT INSTALLATION

4.1.0 The instrument contractor shall ensure that theinstruments are received in good condition andshall report if any defects to engineer in charge.He will be responsible for the safety of all instru-ments thereafter till the commissioning of theplant. Any loss or damage of instruments whilein his custodyshall be chargeable to the contrac-tor. Contractor shall be responsible for supplyand cost of all replacement material and labournecessary to rectify faults which occur duringinstrument installation testing period due toreasons such as falls or due to faulty workmanship or faulty material in the contractorssupply.

4.2.0 All instruments are to be checked for theircalibration prior to installation in the field andshall be corrected for any calibration misalign-ments that would have occurred duringtransportation or subsequent handling.

4.3.0 All installation work shall be done as perreleased construction drawings, instrument in-stallation drawings and manufacturers instruc-tion manuals that will be supplied after the con-tract is finalised.

4.4.0 If the area in which the installations are to be carried out are partially Hazardous [As per area ofclassification] and partially general purposethen the instrument erection Contractor shallexecute all the electrical works in accordancewith applicable codes of Indian Standards forelectrical installation and Owners safety regula-tions.

4.5.0 Contractor is expected to handover all faultyinstruments and any defects which may arisedue to design omission or discrepancies foundwhich would impede the proper functioning ofinstruments must be brought to the notice ofengineer in charge without undue delay.

5.0.0 ON LINE INSTRUMENTS

Instrument Contractor shall supervise and en-sure correct installation of on-line instruments,by piping Contractor. It will be the responsibilityof the instrument Contractor to see that thefollowing are accomplished by the piping Con-tractor as per specifications and drawings.

5.1.0 FLOW TUBES (Venturi,Nozzle etc.)

5.1.1 The flow tube shall be installed in pipeline witharrow aligned in direction of flow.

5.1.2 The straight pipe lengths adjacent to flow tubeshall conform to figures given by the venderdrawings / standards.

5.1.3 Tapping & fittings shall be as specified in theinstrument process piping drawings.

5.1.4 Measurement of I.D, lengths shall be done inorder to ensure that correct unit is installed foreach line. Change in I.D.if any, shall be reportedto site Engineer.

5.1.5 Ensure that no weld deposit is projecting in thepipe line.

5.1.6 Gasket used shall be that specified for duty andshall not project inside the pipe beyond the limitsspecified by standards.

5.2.0 ORIFICE PLATE

5.2.1 Orientation of tapping & necessary straightlength up stream and down stream of orifice.

5.2.2 Proper gasket (gasket shall not project insidethe pipe and shall be within the limit specified inorifice plate specification.

5.2.3 Proper direction of orifice plate.

5.2.4 No weld material shall project Inside the pipeline near the orifice.

5.2.5 Location of tapping shall be at the proper dis-tance from orifice plate.

5.2.6 Correct orifice plate / unit is installed for eachline.

5.2.7 The drain / vent hole in the orifice plate shall belocated as per specification.

5.2.8 Concentricity of orifice bore with pipe I.D.shall be ensured.

5.3.0 INTEGRAL ORIFICE TRANSMITTERS

5.3.1 Transmitters shall be installed in co-ordinationwith piping contractor with correct flow directionalong with the straight pipe pieces adjacent toflow transmitter. Upstream and down streamlengths shall be checked.

5.3.2 In the case of pneumatic transmitter, connectreceiver gauge and air set with proper air andsignal tubing. Tubings wherever required shallbe done with necessary slopes as stipulated inthe installation standards

5.3.3 In the case of electronic transmitters twin corescreened armored cable / cables as specifiedshall be glanded and terminated as per termina-tion details.

5.4.0 ROTAMETER, PURGE ROTAMETER &ROTAMETER TRANSMITTER

Contractor shall supervise & ensure the follow-ing while piping is in progress.

25ES401 / 94



PAGE 3 OF 22

5.4.1 Verticality of the meter.

5.4.2 The float which is removed for the purpose oftransportation shall be kept in position beforeinstallation.

5.4.3 Proper gaskets are used.

5.4.4 Rotameter scale clearly visible from the opera-tion platform. Reducer pairs supplied with meterto be installed by piping contractor shall besupervised by instrument contractor.

5.4.5 For transmitters after installation, as above,proper air & Signal Connections shall be madethrough junction Box & to control room. [Tubing& tube - Connection are covered separately insection 16.0.0]

5.4.6 Air set if supplied loose shall be installed as perinstrument pneumatic diagrams.

5.5.0 TURBINE FLOW METER / MAGNETIC / VOR-TEX / POSITIVE DISPLACEMENT FLOW-METERS

The flowmeter is to be mounted, wired andtubed as mentioned below :-

5.5.1 Flowmeter shall be installed, in co-ordinationwith the piping Contractor, on pipeline with arrowaligned in the direction of flow.

5.5.2 The straight pipe lengths adjacent to flowmetershall be 10 x D upstream & 5 x D down streamor as recommended by the manufacturer.

5.5.3 Care shall be taken to ensure correct alignmentof the flowmeter with mating pipe work.

5.5.4 Electrical connection from the flowmeter to thesecondary instruments shall be made with twincore screened cable. Do not run the signal leadsin the same conduit as that for supply. [Cable,wiring & conduit work are covered separately].

5.5.5 The complete installation shall be carried out inaccordance with the instruction manual suppliedby vendor & in co-ordination with the pipingcontractor.

5.5.6 The flow meter shall not have any strain on itsbody from adjacent pipes.

5.6.0 CONTROL VALVES, DAMPERS, PRESSUREREDUCING VALVES, DE-SUPERHEATERS

Instrument Contractor shall ensure the followingwhile the control valve is being installed by thepiping Contractor.

5.6.1 Control valve is installed in the correct direction.

5.6.2 The control valve is not under mechanical strainafter erection.

5.6.3 Proper gaskets are used for the purpose.

5.6.4 In the case of Butterfly control valves the vaneshall not be obstructed by any piping parts andshall be free to rotate.

5.6.5 The air supply to the control valve and the signalline from the respective controller to the valvepositioner / valve shall be made by the instru-ment Contractor.

Signal tubing, instrument piping etc. arecovered separately

5.6.6 For valves with air filter set and valve positioner,Contractor shall ensure that the valve positioner& the associated linkages are physically and

functionally in good condition.

5.6.7 When solenoid valves are mounted on the val-ves, the air connections would be provided bythe valve supplier. Contractor shall give allelectrical connections through required fittings.

5.6.8 Instrument Contractor shall ensure the properinstallation of the pressure control valve bypiping Contractor as regards direction and otheraspects as for control valves. The back pressuretapping from the down stream piping shall beproperly connected by the instrument Contrac-tor.

5.6.9 Calibration of control valve shall include all test-ing and calibration of all the accessories also.

5.7.0 MOTOR OPERATED VALVES

The instrument Contractor shall ensure properinstallation of motor operated valve while it isbeing erected by piping Contractor. The electri-cal connection will be provided by the electricalContractor. Instrument Contractor shall also en-sure proper functioning of the limit switches.

5.8.0 SOLENOID VALVES

Work involves installation of solenoid valves onpneumatic signal lines to control valve / damperactuator, and termination of electrical cables. Allnecessary electric & pneu matic connectionsshall be done by instrument Contractor. [Tubing& wiring conduit work etc are covered separatelyunder Sec. 16.0.0 & 17.0.0 ]

6.0.0 FIELD MOUNTED PRIMARY MEASURINGELEMENTS

6.1.0 ANNUBAR FLOW ELEMENTS / PITOT TUBE

6.1.1 Elements shall be so installed that it can beinserted or withdrawn from the pressurizedpipelines under flowing conditions without inter-ruption of service.

6.1.2 Annubar installation shall be as per instrumentProcess piping drawings and instruction manualsupplied by the Vendor.

6.1.3 All the process piping connections shall be givenby the Contractor [Piping covered under 16.0.0].

6.2.0 TEMPERATURE ELEMENTS [T/C and RTD]

6.2.1 T/C shall be installed at proper locations alongwith specified thermowell.

6.2.2 T/W shall be screwed or flanged type and shallbe adequately tightened with use of proper gas-ket , nuts & bolts which will be supplied by theowner.

6.2.3 Each T/C shall be connected by proper signal /extension cable using proper glands from in-dividual temperature element to junction boxes.From junction boxes, multi - core cables shallbe used to connect the instruments to controlroom. [Cables are included separately under18.0.0 ]

6.3.0 MULTIPLE T/C ASSEMBLIES

Work involved is same as above.

6.4.0 RTD ELEMENTS [FOR BEARING TEMPERA-TURE]

R.T.D. elements are already wired up to the local

25ES401 / 94



PAGE 4 OF 22

junction boxes by the equipment venders. Con-tractor shall connect these from junction boxesthrough the multicore leads with the correspond-ing instrument point. [The cabling is includedseparately under 18.0.0 ]. The RTD elementsare already in stalled on machinery / equipment.In case these instruments are removed for ship-ment and are not installed by the vendor in thefield, Instrument Contractor shall arrange to in-stall these instruments as per 6.0.0.

6.5.0 VIBRATION PROBES, AXIAL DISPLACEMENTPROBES & DRIVESPEED PROBES

All the probes are already mounted on themachinery / equipment by the vender and wiredupto junction box and terminated . InstrumentContractor shall provide the electrical connec-tions from the junction box to control panel. Incase these probes are removed for shipmentand are not installed by the vendor in the field,instrument Contractor shall arrange to installthese probes as per drawings.

7.0.0 FIELD MOUNTED TRANSMITTERS

PNEUMATIC

7.1.0 D/P TRANSMITTERS FOR FLOW, LEVEL,DENSITY ETC.

Mounting differential pressure transmitters, airfilter regulator, locally fabricating suitable stands/ supports, tubing them from the first isolationvalves [at the orifice end] with the 3 valvemanifold, giving necessary slopes as stipulatedin the installation diagrams. Provide air supplyusing 6 mm OD SS tubes, connect 1/4" ODCopper tube [output], to a Receiver gauge or tothe secondary local instrument or to junction boxas the case may be. Install air filter set. [Tubing,process piping supports etc are coveredseparately under sec 16.0.0].

7.2.0 LEVEL TRANSMITTERS - FLANGEMOUNTED

7.2.1 FLUSH / EXTENDED DIAPHRAGM TYPE

Mounting of the transmitter on the vessel nozzle/ isolation valve using proper nut, bolts, gaskets,receiver gauge, air set and pneumatic tubingshall be installed as per item 7.1.0.

7.2.2 FLUSH / EXTENDED DIAPHRAGM TYPEWITH REMOTE SEAL -FOR LEVEL AND DEN-SITY

Work involved is identical to item 7.1.0 exceptthat instead of impulse tubing, capillary tubingwith flanged diaphragm to be mounted on to thevessel nozzle / isolation valves. The capillarytube shall be supported properly.

7.3.0 GAUGE / ABSOLUTE PRESSURE TRANSMIT-TERS

The work involved is identical to item 7.1.0except that there will be only one impulse tap-ping.

7.4.0 DISPLACEMENT TYPE LEVEL TRANSMIT-TERS WITH AIR SET

7.4.1 The displacement type level transmitter with airset shall be fitted in such a way that it is sub-jected to minimum vibration.

7.4.2 The installation shall be carried out using neces-sary pipes, isolation valves & other fittings as

specified in the instrument process piping draw-ings.

7.4.3 Connection of Air lines that shall supply air, freeof oil, water & dust at constant pressure of 1.4kg/cm.sq.

7.4.4 Calibration & checking should be carried out inCo- ordination with piping group.

[Installation of valves, pipes & tubes are coveredin sec tion 16.0.0]

7.4.5 The air filter set shall be installed as specified ininstrument pneumatic tubing diagram.

7.4.6 The air filter set shall be installed as specified ininstrument pneumatic tubing diagram.

ELECTRONIC TRANSMITTERS

The details in Item 7.1.0 to 7.4.0 underpneumatic transmitters will be applicable toelectronic transmitters except that cabling isinvolved instead of tubing.

7.5.0 ELECTROMECHANICAL LEVEL TRANSMIT-TERS

Mounting the instrument on the vessel nozzleflange using proper gaskets, nut, bolts, andconnecting the power / signal cables.

7.6.0 RADIO-ACTIVE LEVEL TRANSMITTERS

Installation of the radio-active source, linedetector and 3 nos. point detectors as per thedetails provided by the manufacturer and strictlyfollowing the government regula tions.

7.7.0 TANK LEVEL TRANSMITTERS (FLOAT ANDTAPE TYPE)

Installation of float and tape, guide wires, protec-tor pipe with V-seal and mounting the transmitteron suitable supports. The protector pipe shall beproperly supported and signal cable shall beterminated.

7.8.0 TEMPERATURE TRANSMITTERS

7.8.1 The installation shall be carried out as per in-struction manuals of vendors.

7.8.2 The thermowell with bulb shall be fixed [screwedor flanged] on the pipe line using proper threadsealant or nut, bolts, gaskets as the case maybe as per 6.2.2].

7.8.3 Capillary shall be continuously supported.

7.8.4 Air supply & signal connection shall be made.

[Installation of tubes & pipes is coveredseparately under Sec. 16.0.0].

8.0.0 FIELD MOUNTED CONTROLLERS

8.1.0 INDICATING CONTROLLER FOR PRESSURE- WITH AIR SET

The work involves mounting the transmitter /controller on proper support. Suitable pipingconnections, air supply connections, signal linesshall be provided as specified to correct finalcontrol element. The piping & tubing shall be asspecified in the process piping diagrams. [Thedetails for supports, tubing & piping are coveredunder 16.0.0].

8.2.0 DISPLACEMENT TYPE LEVEL TRANSMIT-TER + CONTROLLER WITH AIR SET

25ES401 / 94



PAGE 5 OF 22

Work involved is combination of 7.5.0 .

9.0.0 FIELD MOUNTED GAUGES

9.1.0 PRESSURE GAUGES

Installing pressure gauge using suitable con-necting tubes / vent / drain / valves etc. from thefirst isolation valves provided on ducts / pipes /vessels / pumps etc.

9.2.0 MANOMETER

Scope includes :-

9.2.1 The installation of instruments with proper sup-ports.

9.2.2 Filling with the proper manometer fluid.

9.2.3 Connecting all the piping and valves as per thedrawings.

9.2.4 Providing final connection using a flexible hose.

(The details for piping fitting and valves arecovered separately.)

9.3.0 LEVEL GAUGE [REFLEX TYPE]

Each level gauge shall be fitted with a pair ofgauge cocks. The piping connection & fittingshall be carried out as per the instruction givenby the supplier and as per the instrument ap-plication diagram.

9.4.0 MAGNETIC LEVEL GAUGES

Work involved is same as item 9.3.0 except thatcare should be taken to handle it properly so thatthe magnetic float is not damaged.

9.5.0 BOILER LEVEL GAUGES

9.5.1 The high pressure level gauges shall be fittedwith proper gaskets & weatherproof open endhood and suitable illuminator, operating on220V, 50 HZ single phase supply.

9.5.2 Process piping connections & complete instal-lation shall be in accordance with Instructionmanual supplied by ven dor. Supply usingcables shall be connected to the illumina torfrom the nearby switch provided by the electricalcontractor. [The details for piping and fixingvalves, conduit & wiring etc. shall be coveredseparately ].

9.6.0 BOILER LEVEL GAUGES WITH REMOTE IN-DICATION

9.6.1 This shall include the erection of condensatechamber.

9.6.2 Process connections & complete installationshould be carried out in accordance with instruc-tion manual supplied by the vender, while pipingwork is in progress.

9.7.0 TANKAGE SYSTEMS

Contractor shall ensure that the instrument islocated in an easily accessible place. Locationshall also be such that ambient temperature iswithin the specified limits as given by the vendor.

Contractor shall install measuring tape, float,protector pipe, local indicator and supports asper the drawings of vendor / instructionmanuals given by vendor.

Contractor shall fix the channel steel or pipevertically, which does not bend due to its weight,

under the side wall of tank, for accurate meas-urements.

The float and tape shall not be subjected tosudden, abnormal vibrations due to a violentstream of feed fluid or while erecting the same.

9.8.0 DIAL TYPE INDICATING THERMOMETERS

The work involves installing of thermometersand thermowells (threaded and flanged) onpipes, vessels using proper nuts, bolts & gas-kets provided by piping group. The threadedthermowell shall be fitted using teflon tapes orpipe ‘Dopes’ as the case may be.

9.9.0 TEST THERMOWELLS

Mounting the thermowells on the pipes / vesselsusing proper nuts, bolts and gaskets.

9.10.0 DIFFERENTIAL PRESSURE INDICATOR

Work involved is same as item - 9.1.0 exceptthat there are two tapping.

9.11.0 THERMOMETERS - CAPILLARY TYPE

Work involved is same as item - 9.7.0 exceptthat the capillary tube shall be supported by tray/ structural.

10.0.0 FIELD MOUNTED SWITCHES

10.1.0 RECEIVER PRESSURE SWITCH(PNEUMATIC)

The pressure switches shall be mounted onsuitable supports. Necessary pneumatic tubingand electrical connections shall be made. Thepneumatic signal shall come from correspond-ing transmitter.

[Pneumatic tubing, electrical wiring are coveredseparately under 16.0.0 & 17.0.0]

10.2.0 DIRECT CONNECTED PRESSURE SWITCH

Work involved is same as 10.1.0 but processS.S. tubing shall be connected from pipe lines /vessels using proper isolation valves instead ofpneumatic copper tubing from transmitters.

Pressure switches shall be installed rigidly toavoid vibration

10.3.0 DIRECT CONNECTED DIFFERENTIAL PRES-SURE SWITCH

Work involved is same as 10.2.0 except that twoprocess S.S tubing shall be provided

10.4.0 DIRECT CONNECTED LEVEL SWITCH [IN-TERNAL / EXTERNAL /FLOAT TYPE]

Scope includes the installation of level switcheson the vessels, making necessary electricalconnections using armoured cable. (Scope forwiring is covered separately under 16.0.0 &17.0.0)

10.5.0 LEVEL SWITCH

TUNING FORK TYPE , PADDLE TYPE,CAPACITANCE TYPE (WITH OR WITHOUTEXTERNAL CHAMBER)

Scope of work is same as item 10.4.0]

10.6.0 TANK LEVEL SWITCHES (FLOAT AND TAPETYPE)

Installation of the float, tape and guide wires,mounting the switch on the vessel flange, con-

25ES401 / 94



PAGE 6 OF 22

necting the cable and terminating the cable.

10.7.0 TEMPERATURE SWITCH

Mounting the temperature switch with ther-mowell on the vessel / pipe line, cabling andtermination.

10.8.0 DIRECT CONNECTED FLOW SWITCHES

Mounting the flow switch on the pipe line, ca-bling and termination.

10.9.0 LIMIT SWITCH

Electrical connection to be made to the limitswitches mounted on control valves, actuatorsetc.

11.0.0 ANALYSERS

Manufacturer‘s instruction manuals shall bestrictly fol lowed for the proper installation andfunctioning of the analyser.

11.1.0 PH ANALYSERS

11.1.1 IMMERSION TYPE

Mounting the electrode with holder using themounting hard ware provided, installing theanalyser transmitter and JB on 2" pipe pedestaland termination.

11.1.2 FLOW THROUGH TYPE

Contractor shall supervise and ensure theproper installa tion of the electrode chamber onthe pipe-line by piping group. Analyser transmit-ter and JB shall be mounted on 2" pipe pedestaland the air supply tubing, cabling and termination done.

11.1.3 PH-ANALYSER, CABINET MOUNTED

Installation of the analyser cabinet, air supplytubing, interconnecting cabling and termination.

11.2.0 CONDUCTIVITY ANALYSERS

Contractor shall supervise and ensure theproper installa tion of the electrode chamber onthe pipeline by piping group. Analyser transmit-ter and JB shall be mounted on 2’’ pipe pedestaland the interconnecting cabling and terminationdone.

11.2.1 CONDUCTIVITY ANALYSER WITH SAM-PLING RACK

Installation of the analyser sampling rack, im-pulse tubing for sample inlet and outlet / drain,cooling water inlet and outlet, interconnectingcabling and termination.

11.3.0 DISSOLVED O2 ANALYSERS

Mounting the electrode with holder using propersupport, installing the analyser amplifier and JBon 2" pipe pedestal, mounting the power supplyconverter and interconnecting cabling and ter-mination.

11.4.0 PROCESS TITRATORS

Installation of the process titrators inside thelocal control room and the connected cablingand tubing / piping, as per installation detailsprovided by the manufacturer.

11.5.0 DENSITY ANALYSERS (VIBRATION TYPE)

Mounting the analyser sampling rack and doingthe cabling and termination.

11.6.0 DENSITY ANALYSERS (FLOAT TYPE)

Contractor shall supervise and ensure theproper installa tion of the density analyser on thepipe-line by piping group. Pneumatic toelectronic converter shall be mounted on 2" pipepedestal and the air supply / signal tubing, ca-bling and termination to be done.

11.7.0 MOISTURE ANALYSERS

The analyser probe shall be mounted on theflange provided on the pipe line using propergasket, nuts and bolts which will be supplied bythe owner. The signal cable shall be connectedto the probe and terminated.

11.8.0 OLEUM ANALYSERS

Work involved is same as item 11.7.0 In addi-tion to the above contractor shall mount theanalyser transmitter and Junction box onsuitable support in the field, and interconnectingcable to be terminated.

11.9.0 THERMAL CONDUCTIVITY ANALYSERS

Installation of the sampling cabinet and analysercabinet at locations shown in the layout draw-ings, connecting the sample tubing as per thedrawings provided, and terminating the cables.Manufacturer‘s instruction manuals shall bestrictly followed for the installation and function-ing of the analyser.

11.10.0 INFRA-RED ANALYSERS

Work involved is same as item 11.9.0

11.11.0 PARAMAGNETIC O2 ANALYSERS

Work involved is same as item 11.9.0.

11.12.0NOX ANALYSERS


11.13.0SO2 ANALYSERS


11.14.0ZIRCONIA PROBE FOR O2 ANALYSERS


11.15.0ON LINE GAS CHROMATOGRAPHY

Work involve is same as 11.9.0.

12.0.0 MISCELLANEOUS INSTRUMENTS

12.1.0 FLAME DETECTORS

12.1.1 Fixing the detecting element in such a way thatdirect flame and heat will not damage the same.

12.1.2 Mounting the preamplifier / relay units inside adust tight metal enclosure or local panel sup-plied by others.

12.1.3 Interconnecting cabling between the detectingelement and the relay.

12.2.0 VANE ACTUATORS

12.2.1 Supervision of installation of the vane actuatorcarried out by mechanical contractor and toensure that the same is installed as permanufacturer‘s recommendations.

12.2.2 Terminations of tubing and wiring on to thepositioner, air set, I/P converter etc. of the ac-tuator.

12.3.0 SUCTION PYROMETERS

25ES401 / 94



PAGE 7 OF 22

12.3.1 To install the suction pyrometer assembly on tothe flanged nozzle of the furnace using propergaskets, bolts and nuts, which will be suppliedby the owner.

12.3.2 This is to be connected by proper compensating/ exten sion cable up to the junction box.

12.3.3 Provide necessary tubing with required fittingsfor air connection to the ejector of the suctionpyrometer.

12.3.4 Cabling for suction pyrometer will be similar tother mocouple.

12.4.0 ACTUATOR OF CONTROLLED VOLUMEPUMPS

12.4.1 The control volume pump will be installed bymachinery contractor. Instrument contractorshall supervise the in stallation work and ensurethat the same is installed as per manufacturer‘sinstructions / recommendations.

12.4.2 Provide the termination of signal cable (4 - 20mA signal) and also tubing for all connection tothe positioner unit and the actuator.

12.4.3 Generally, the scope of work will be similar tocontrol valve.

12.5.0 OPERATION BOX

This is required for the local operation of bag-ging machines etc.. This houses the push but-tons and lamps required for the operation ofbagging machine.

Instrument erection contractor shall install theoperation box properly on a suitable structurenear by using brackets if required. Provide ter-mination of all incoming and outgo ing cables tothe operation box as per the wiring scheme ofbagging machine supplier.

12.6.0 MOTION DETECTOR

This is a small electronic instrument providedwith mounting socket, similar to a relay. Contrac-tor shall mount the motion detector inside ahousing provided by purchaser and terminate allincoming and outgoing cables as per manufac-turer‘s wiring scheme.

12.7.0 I/P CONVERTERS + POSITIONERS & E/PPOSITIONERS

Mounting the I/P converters on seperate sup-ports wherever necessary , making the electricaland pneumatic connections.

13.0.0 JUNCTION BOXES, PDB’s, MB’s

13.1.0 ELECTRICAL JUNCTION BOXES, PDB’s,MB’s AND TERMINATION BOXES

13.1.1 Fabrication of necessary supports and weldingit on to the available structures or grouting on tothe floor including the civil work connected withit. Mounting the junction box, connecting theindividual cables and multicore cable usingcable glands and terminating the wires. All theelectrical wires shall be identified using thecable marking ferrules. For termination boxesonly one cable entry and outlet is required.Blinding all other holes if required.

13.1.2 Where cable runs are underground, JunctionBoxes,marshalling boxes shall be mountedabove grade at convenient height for easy ac-

cess.

13.1.3 If wiring is overhead, JB’s/PDB’s/Marshallingboxes shall be mounted a few feet above gradefor easy access.Care shall be taken to ensuresafe working conditions.

13.1.4 Where wiring must enter the top of JB’s / PDB’s/ Marshalling boxes,it shall be brought near thebottom of the box and then back up to terminals,forming a drip loop near the bottom of the JB’s/ PDB’s / Marshalling boxes.

13.1.5 JB’s / PDB’s / Marshalling boxes shall bemounted suitably such that they do not hinderworks like movement of personnel around theplant,removal of equipments like heat ex-changer shell tubes etc.

13.2.0 RTD JUNCTION BOXES

Work involved is same as item 13.1.0

13.3.0 THERMOCOUPLE JUNCTION BOXES

Work involved is same as item 13.1.0, exceptthat compensating cables are used instead ofelectrical cables.

13.4.0 A.C POWER DISTRIBUTION BOXES

Work involved is same as item 13.1.0, exceptthat the distribution box houses isolationswitches and fuse units for distributing 110 VA.C. power to field instrument.

13.5.0 ENCLOSURES FOR INTRINSIC SAFE BAR-RIERS

Work involved is same as item 13.1.0, exceptthat the contrac tor shall mount I.S barriersinside the enclosure and the incoming & outgo-ing cables are to be glanded and terminated.

14.0.0 CONTROL PANELS

The control panel is a prewired, and pretubed,all the wires and tubes being terminated to therespective terminal blocks, and bulk headsrespectively. Instrument contractor shall under-take the installation of panels, mounting theinstruments on the panel and execute all thetermination of wiring & tubing at the back of thepanel.

Instrument erection Contractor‘s scope shall in-clude but not be limited to the transportation,Calibration / testing, loop checking etc. of thepanel mounted instruments. However if the con-tractor has to undertake some of wiring andtubing which are found necessary at a laterstage for which they have to indicate the cost ofthe wiring / tubing per meter basis.The materialswill be supplied by the purchaser.

The local control panels shall be mounted as perthe instru ment location and cable routingdiagrams,IAD’s. All wires and tubes shall beterminated as per the instruction manual,IAD’sand as per termination procedure describedunder M elsewhere. Foundation for panels andracks shall meet the requirements of the equip-ment vendors specifications.

Panels and racks shall be located to allow easyaccess and operation and to permit operator tosurvey the maximum panel area. Panels shallbe arranged and located for easy reading,ser-vicing and maintenance of equipments andpanels / cubicles. Air purging shall be used

25ES401 / 94



PAGE 8 OF 22

wherever neces sary for environmental reasonsas well as for electrical safety. Panels shall beremoved from racks only when ready for instal-lation. Hooks shall be used while lifting andmoving the panels etc. Welding shall not bedone on the panel at site for supports etc. Panelsshall not be used as earth as it may damage theinstruments,especially electron ic. Proper earth-ing for the panel shall be provided sepa rate-ly,otherwise it shall be connected to the mainearth of the plant.

15.0.0 FABRICATION WORK AND MOUNTING OFINTRUMENTS

15.1.0 FABRICATION WORK

Instrument contractor shall fabricate differentsteel struc tures supplied to him as per draw-ings. Unit rates shall be applicable as shown inbid item. Minor civil works like chipping, groutingetc. shall form part of fabrication job like weldingrods and gas shall be included in the fabrica tioncost.

15.2.0 INSTRUMENT AIR LINES

15.2.1 Piping contractor will terminate main instrumentair header lines on the pipe bride with firstisolation valve for branch lines for instrument airdistribution.

The fittings will be of welded type and pipes willbe of galvanised carbon steel type. Contractorsscope includes installing, testing and commis-sioning of these lines.

15.2.2 316L PIPES / 316 SS PIPES, CARBON STEELPIPES

Welding of instrument impulse lines using pipesshall be done by qualified welders as per thestamdard welding procedure.

15.2.3 NOTES ON MOUNTING OF INSTRUMENTS

(a) Mounting of all accessories of field mountedinstruments such as manifolds, air sets,condensate pots etc.. wherever applicable,are included in the installation of the instruments and no extra shall be paid for thereaccessories.

(b) No field mounted instrument shall be in-stalled with support from impulse piping /signal lines.

(c) Hand rails shall never be used for mountingor support ing instruments.

(d) Instruments shall be mounted on pedestalsfabricated using base plate and 2" pipe ofabout 1.5 mt. height.

(e) All field mounted instruments shall bemounted at grade or on platform.

(f) If pedestal is installed at grade,it shall befixed to the concrete paving with anchorbolts.

(g) If ground is un-paved,a concrete base shallbe provided for the pedestal. Pedestalsmounted on top of platforms or processpiping shall be removable.

(h) The instruments shall be mounted onpedestals using “U” clamps,nuts and boltsor as per installation drawings given by en-gineering dept. or vendor.

(i) Pedestals shall be painted to protect fromcorrosive atmospheres and weather condi-tions.

16.0.0 GENERAL NOTES FOR INSTRUMENTPIPING AND TUBING

16.1.0 The sizes of the piping / tubing and also theirmaterials of construction are decided by thedesigner of the instrumen tation and controlsystem.

16.1.1 Instrument tubing [mainly S.S] shall be cutusing only the standard cutter. Use only finesand-paper for polishing the outer edge of thetubes after cutting. Never use a file or grinder.Any burr or scratch will not make a good tight -fit when joining the tube with compression typecouplings. After tightening, softly remove thejoint and inspect for the uniform closure of theferrule on the fitting

16.1.2 Where tubing are adjacent, clearance betweenthem near the coupling portion shall be at least10 cm for easy maintenance.

16.1.3 The pipes shall be supported on angles usingproper U- clamps.

16.1.4 Pipe lines [for impulse lines ] shall be bent onlyafter sandfilling and heating and using a bend-ing machine. Otherwise, it will kink and becomeweak.

16.1.5 Always avoid sharp bends. Use only smoothbends wherever necessary.

16.1.6 Give proper support for the piping for drawingout purposes.

16.1.7 When using pipe connector or couplings, ade-quate space for spanner head shall be provided.

16.1.8 When brazing or welding two pipe ends, careshall be taken to see that the adjacent pipes /vessels are not affected by this heating.

16.1.9 For reference drawing list refer to DocumentControl Index.

16.1.10All instruments on instrument piping details andother instrument drawings are shown symboli-cally. For true picture and location of connec-tions refer to vendor’s drawings.

16.1.11 Instrument connection block valves on lines,orifice flanges, vessels and equipment are to bein accordance with the specification of the line,vessels or equipment to which they connect andthat are furnished by the piping division.

16.1.12 ‘Field’ contractor shall relieve all connections ofany strain by properly supporting all pots, leadsand instru ments. Refer to “Typical instrumentsupport details ” and Standard Drawings at-tached.

16.1.13Instrument pressure leads and flowmeter leadsare to be sloped 1 in 12 minimum in horizontalruns, except that long pressure instrument leadscarried on racks through the yard may be runhorizontally, but without pockets, together withpneumatic leads.

16.1.14When a pressure lead rises above the pressureconnection and the instrument it serves, a min-imum slope of approxi mately 1 in 12 from thehigh point of the lead toward the pressure con-nection and the instrument must be maintained,

25ES401 / 94



PAGE 9 OF 22

except as specified in note ‘m’ above.

16.1.15 ‘Field ’ contractor shall provide sufficientflexibility for pressure leads and pneumaticleads to allow for thermal expansion of vessels,lines or equipment to which they connect.

16.1.16Use bends in all pressure leads and keepthreaded joints to a minimum.

16.1.17Bends in tubing for pneumatic leads are to bekept to the absolute minimum required.

16.1.18All pressure leads and pneumatic leads to andfrom instruments are to be thoroughly cleanedof burrs and foreign matter before being put intooperation.

16.1.19All pressure instruments in wet service are to becor rected for liquid head pressure.

16.1.20Instruments, instrument pressure leads, flowmeter leads and pneumatic leads shall not bemounted on, nor supported from platforms, rail-ings, steel supports, equipment and process orutility lines that are subject to abnormal vibrations, part icularly vibrations caused byreciprocating machines, unless absolutelynecessary. Additional bracing and / or supportsshall be provided for instruments and instrumentleads to assure rigidity under such abnormalconditions.

16.1.21Where rack is not provided, pneumatic leads[generally 3 or less ] shall be strapped to airheaders or branches.

16.1.22Elevations shown in instrument locations and airsupply header drawings are to bottom of pipingunless otherwise noted.

16.1.23The quantities given in the bill of material forpipes and tubes are for straight pieces only.Installation of fittings like elbows, tees, valvescondensate pots etc. shall be included in thecost of erection and no separate charges will beapplicable for these items.

16.1.24Locations and facing of instruments shall beadhered to as closely as possible.

16.1.25Air supply piping will be supported on existingsteel. ‘Field’ contractor shall provide additionalsteel wherever required.

16.1.26 ‘Field’ contractor shall provide all materials re-quired for mounting and supporting instruments,instrument pots, piping etc. Refer to “ TypicalInstrument support details ” drawings.

16.1.27Unless otherwise noted, pedestal type mountedtransmitters, indicators, recorders and control-lers shall be located with the center line of theinstrument, 1.3 M above grade or platform.

16.1.28All elevations given are based on the gradeelevation indicated on the lay out drawings.

16.1.29All tube fittings shall be used as specified ininstrument hook up & layout drawings. The Con-tractor shall ensure material, dimension andphysical condition of all items before puttingthem to service.

16.1.30For D/P transmitters with capillary extension,the capillary tube shall be insulated usingglasswool with aluminum cladding as indicatedin the instrument application diagrams.

16.1.31Welding as per the standard procedure /specifications shall be followed. Any preheating

/ postweld heat treatment shall be donewherever required as per standards.

16.1.32All pipes shall be thoroughly checked for clean-liness and moisture before and after installation.

16.1.33After testing, all C.S. pipes shall be epoxypainted.

16.1.34The take off points shall be from top of theheader.

16.1.35While brazing or welding two pipe ends,careshall be taken to see that adjacent pipes / ves-sels do not get affected due to heating.

16.1.36Even when dryers are supplied to keep the airdry,a drain or drains shall be installed at lowpoint(s) in the system to provide drainage.

16.1.37No hicks or cuts shall be made on any of theenclosed tubes as these will be points of poten-tial failure.

17.0.0 GENERAL NOTES ON TERMINATION,ELECTRICAL INSTALLATION ANDGROUNDING

17.1.0 TERMINATION

17.1.1 Wires of the cable shall be cut as it comes offthe reel at a location free from sharp objects.

17.1.2 Jacket and shield material shall be terminatedwithout nicking insulation underneath.If no pairjacket is used and pairs are individually shieldedthen insulating tape or sleeving shall be appliedto exposed shielding in order to protect acciden-tal grounds.

17.1.3 All cable ends shall be protected against mois-ture entry prior to connecting the cable to itspermanent terminations.

17.1.4 Stripping of insulations from wires shall be donewithout nicking the conductor.Standard strip-ping tools of proper design shall be used.

17.1.5 Screws shall be torqued adequately to get goodcontact with wires inserted under the screw.

17.1.6 Proper compression of the terminal screws shallbe done to prevent corrosion which may latercause poor continuity,galvanic, or rectificationaction.High quality terminal strips and insulatingmaterials shall be used.

17.1.7 All wires or leads terminated at connection shallhave sufficient slack to reduce the effect ofvibrations.

17.1.8 Necessary cable supports shall be provided toavoid having cable weight supported from wireterminations.

17.2.0 ELECTRICAL INSTALLATION

17.2.1 The equipment erection and their installationshall conform to the latest Indian ElectricityRules and Indian Factories Act, as regardssafety, earthing and other essen tial provisionsspecified therein for installation and operation ofthe electrical part of the instrumentation loop.

17.2.2 Fittings, switches, distribution boards, junctionboxes etc. for electrical lines shall be installedat places as indicated in drawings.

17.2.3 The cable termination shall be done usingsolderless crimping type closed eyelet connec-tors [Contractors supply].

25ES401 / 94



PAGE 10 OF 22

17.2.4 Cables carrying 110 volts or above shall not runin the same conduit, metal or PVC ducting,trunking or trays as cables carrying lower volt-age.

17.2.5 Cables carrying alternating current shall not berun in the same conduit, metal or PVC ducting,trunking or trays, as cables carrying direct cur-rent.

17.2.6 Laying of earth conductors, fixing on cable duct/ tray structural, clamping / jointing by brazingwherever necessary, testing and commission-ing including supply of earth conductors, crimp-ing lugs, bolts, nuts, washers etc. and supplyand installation of earth pits as per drawing.

17.2.7 Where cables are run through pipes, the entryto and exit from pipes shall be smooth and freefrom burrs. Cables shall be pulled into suchpipes in such a way that there is no damage tothe cable.

17.2.8 Where space is left in pipes for cables to bepulled in at a later date, a galvanised draw wireof adequate size shall be left in the pipes.

17.2.9 There shall be no intermediate joints in anycable. Joints shall be made only at terminals ininstruments or approved equipment.

17.2.10Temperature compensating cables, alarm andtrip system wires shall be run in conduit or oncable tray as specified on drawings.

17.2.11 Elevations shown for horizontal conduit / trayruns are the elevations of the platforms, steelor piping from which these are to be supported.Contractor shall provide any additional supportsif required.

17.2.12Vertical conduit / tray runs at structures shall besupported from ladders unless otherwise noted.

17.2.13Location and elevation of conduit / cable tray runmay be changed when necessary to avoid in-terference.

17.2.14Cables shall be located at a minimum distanceof 300 mm from hot piping or equipment.

17.2.15Vents and drains shall be furnished at high andlow points in conduit runs. Conduit shall besloped toward drain fittings.

17.2.16All sealing fittings shall be dammed with fiberand filled with sealing compound after wiring iscompleted.

17.2.17The 24 V / 110 V alarm, control and instrumentpower wiring shall be run in conduit from localinstruments to centrally located terminal boxes.Wire shall be copper, single conductor, PVCinsulated rated 600 volt.

17.2.18Conduits in main runs shall be supported on asuitable steel rack.

17.2.19Minimum size of conduit shall be 20 mm.

17.2.20All spare wires shall be tagged and placed inconvenient place or terminated suitably.

17.2.21All cables shall be tagged with aluminiumtagplates.

17.3.0 GROUNDING

17.3.1 All exposed non-current metallic parts that couldbecome energised with hazardous potentialsshall be reliably connected to the equipmentgrounding circuits.

17.3.2 On complex interconnected instrumentationnetworks caution shall be exercised when engrounding the circuits to ensure that multiplegrounds are not established.

17.3.3 Shielded type instrument wiring shall begrounded at only one end.

17.3.4 All instrument grounds shall be checked forsame potential if tying between instrument cir-cuit grounds to the same earth electrode bedsthat are used for power grounding is done.

17.3.5 All spare conductors in a multicore cable shallbe grounded to avoid induction of large voltagesurges on signal circuits when nearby lightningstrikes occur.

17.3.6 Shields or signal wires shall never be left uncon-nected,grounded indiscriminately, connected totheir signal pair at two or more points, or tied toother signal leads.

17.3.7 Instruments, junction boxes , cable gland platesshall be properly earthed wherever applicable.

18.0.0 GENERAL NOTES ON CABLE TRAY,DUCTS AND CONDUIT INSTALLATION

18.1.0 Changes in direction of cable trays / cable ductsshall be achieved by use of cable tray bends andtee pieces or by efficient clamping. For cabletrays, generally available supports will be usedfor routing. But wherever it is not available,Contractor shall make necessary supports forrouting the cable trays / cable ducts.

18.2.0 Main cables shall be laid through cable ducts.Contractor shall provide proper covers after in-stallation of all the cables inside the duct.

All pneumatic tubing and electrical cables shallbe clamped on the cable tray at intervals of notmore than 500 mm.

18.3.0 Grease shall be applied to all machine boltsbefore tightening. Necessary quantity of greaseshall be supplied by Contractor. Cable trays &Cable ducts shall be fixed on structural supportsfabricated at site by Contractor.

18.4.0 Contractor shall fabricate at site the bends, tees,crossings, suitable and required clamps fromsheets / strips etc. for the trays and ductswherever required according to the routing re-quirement. The cables taken along trays /angles alone will have to be clamped. The cableinside the duct shall be neatly arranged. Thisshall also include laying under ground cablethrough the trench wherever re quired.

18.5.0 The quantities given in the bill of material forcable trays, cable conduits and cable ducts arefor straight pieces only. Installation of fittingslike bends, tees, reducers etc. shall be includedin the cost of erection and no separate chargeswill be applicable for these fittings. Asbestoscovering shall be provided for cable ducts atlocations where fire proofing is required.

18.6.0 Trays are not designed as walk ways or hoistingbeams and persons shall be advised not to usethem as such.

18.7.0 All runs of ducting and conduits shall bemechanically and electrically continuous.Run-ning threads shall be secured by lock nuts.

18.8.0 Under ground conduit banks which cross

25ES401 / 94



PAGE 11 OF 22

beneath roadways,railways or other areas sub-ject to heavy loading or having poor soil condi-tions shall be adequately supported or the en-velope reinforced using concrete cover slabs topre vent shearing,crushing or damage from un-even settlement.

18.9.0 All underground runs in process plants shall beclearly marked for run location and iden-tified,using pointer and service identificationsigns as per the installation stand ards.

18.10.0Cable conduits shall be supported at least every1.5 mtrs.Supports shall never be tag welded toconduits.

18.11.0 Conduits shall not be supported from piping thatmay have to be replaced or removed for inspec-tion nor supported from high temperature piping.

18.12.0Conduit runs shall be solidly connected to as-sure conti nuity for their entire length.Groundjumpers shall be installed where physical condi-tions cast any doubt as to the required electricalcontinuity.

18.13.0All underground conduits shall be arranged inbanks and should have protection and identify-ing concrete envelope.

18.14.0Conduit banks shall be installed about 2 feetbelow grade,12"below drainage ditches inprocess areas,or below the frost line,whicheveris greater.

18.15.0The ends of cables shall be properly sealedbefore pulling in to prevent moisture and damag-ing substances from entering.

18.16.0Cables normally shall be pulled directly from ashipping reel into position in the tray. Smallcables (2" and smaller in diameter), can be laidwith a basket grip. The pulling tension shall notexceed the cable manufacturers recommendations. Pulleys,rollers etc. shall be used to guidethe cables into positions in a tray.

18.17.0Specific care shall be taken while installing Spe-cial cables like co-axial cables,as electricalcharacteristics may change due to improperhandling.

18.18.0Care shall be taken to see that there are no kinksor loops that may scrape the edges of conduitfittings,cover plate surfaces and edges etc. andresult in damaged insula tion and even brokenwire.

18.19.0Covers on trays shall be used to prevent ac-cumulation of dirt,debris,snow,ice etc.

18.20.0A minimum of 5 feet clearance shall be presentbetween noise generating equipments andcable tray on which signal cables will be laid.

18.21.0Cable trays shall be run with the breadth of thetray in a vertical plane.Where FEDO’s site en-gineer agrees that a vertical run is not possible,ashort horizontal section shall be used but the runshall revert to the vertical plane at the nearestpoint.

18.22.0The contractors scope shall include cable layingharnessing / dressing, clamping on trays,making aluminium tags with cable numberspunched on it [as per cable schedule] and fixingthem on either end of the cables before enteringthe instruments, junction boxes or control room.The tags may be tied to the cable using G.I.

wires. PVC marking ferrules [ Contractors scopeof supply ] shall be used at the termination endof the cables. All single / multicore tubing /cables connecting the field instruments / junc-tion boxes with bulk heads / junction boxes ofcontrol panel are to be laid on cable trays andproperly clamped at intervals not exceeding1000 mm on horizontal runs and 300 mm onvertical runs.

19.0.0 CIVIL WORKS

All civil works such as grouting, chipping of thewall / concrete floor as required for some fixturesof instruments, cable racks, instrument pedes-tals, etc. will have to be undertaken by theContractor. All the chipped areas shall bereplastered to attain the same finish as before.For opening up the walls at any place priorpermission shall be obtained & the same shallbe closed neatly after completion of said workto the same specification & finish as before sucha work was undertaken.

20.0.0 CALIBRATION AND FUNCTIONAL CHECK

The instrument Contractor shall possess allrelevant test instruments and shall test the in-stallation in the following manner in thepresence of site engineer.

20.1.0 All pneumatic signal lines shall be disconnectedand blown through with instrument air.

20.2.0 The signal lines shall be blanked off and pres-surised pneumatically using bubble bottle to 1.5Kg/cm2. The bubble rate after pressurising shallbe less than 1 bubble in ten minutes.

20.3.0 All instrument air mains shall be isolated fromthe instrument and pressurised pneumatically1.5 times maximum working pressure and iso-lated from the source of pressure. The pressureshall not fall by more than 0.1 Kg/cm2 in tenminutes.

20.4.0 All impulse lines shall be isolated from the in-strument, and hydraulically tested to 1.5 timesthe working pressure and isolated from thesource of pressure. The pressure shall not fallby more than 0.1 Kg/cm2 in ten minutes.

20.5.0 All the installations will have to be checked andtested by the method of simulation for workingof entire instru mentation loop and its circuit toinclude the relevant primary, secondary andcontrol elements.

20.6.0 All RTD electric and electronic instrument wiringshall be tested for resistance between conduc-tors and earth and for 500 DC. These tests shallbe carried out with all con ductors disconnectedexcept from the test instruments. The insulationresistance shall not be less than 10 mega ohms.

20.7.0 Transmitter connections to the correctreceivers and polarity shall be checked.

20.8.0 Controller connections to the correct controldevices shall be checked.

20.9.0 Correct connection of pneumatic and electricswitches shall be checked.

20.10.0Correct operation of all alarms and functioningof inter locks shall be checked. This testing shallbe coordinated with site engineer.

25ES401 / 94



PAGE 12 OF 22

20.11.0 The written results / certificates of all tests (looptests and group tests) shall be approved by siteengineer in writing.

20.12.0Reasonable evidence of the satisfactory condi-tion of the test equipment shall be provided, ifrequired.

20.13.0All errors of faulty workmanship regarding theinstallation discovered during the testing shallbe corrected.

20.14.0All pneumatic, electro-pneumatic and electronictransmit ters, indicators and recorders shall becalibrated taking eight check points throughoutthe instrument range. Four each shall be takenon the upscale run and downscale run.

20.15.0Contractor shall have signal sources and otherprecision calibration equipments for allpneumatic and electronic instruments as per theinstrument list given. The ranges of the instru-ment shall be set as per the specifications. Theinstruments shall have required characteristicsthroughout their range as per the specifications,within the tolerance. Any deviations shall bebrought to the notice of Engineer-in-charge.Contractor shall undertake any minor repairs ofinstruments found necessary, as part of calibration work. However such work may be under-taken only with the consent of the Engineer-in-charge.

20.16.0Precaution shall be taken to see that no instru-ment is subject to overloading or unwanted sig-nal is supplied to the instrument.

20.17.0Calibration work shall be undertaken only afterstudying the instruction manuals and other spe-cial instructions from manufacturer‘s regardingeach instrument.

NOTE:

(a) All the hydraulic test fluid shall be drainedoff from the impulse line when hydraulic testis over.

(b) All impulse line shall be blown off usinginstrument air before testing.

(c) For float type level instrument the test pres-sure shall be the rated pressure.

20.18.0 Procedure for testing and checking of in-struments.

1. Pressure /Vaccumgauge

Dead weighttest andvacuumgauge test

By comparing with mastergauge

2. Pressuregauge

Pneumaticrig

By comparing with Hgmanometer

3. ReceivingInstrument(Pneumatic)

Using testrigs with ac-curate gauge - do -

4. ReceivingInstrument(Electr.)

UsingElectroniccalibrator &test rig.

- do -

5. ReceivingPressureswitch

Hydrolic /Pneumatictester

Check the operation & set-ting using multimeter

6. ReceiverSwitches

Pneumatictest rig. - do -

7. ElectronicSwitch

Signal gener-ator - do -

8. Dial ther-mometer &Temp.Transmitter

Temp. bathstandard ther-mometer

Checked at various Tempera-ture

9. Tempera-tureSwitches

Multivoltsource orResistancesource

Checked increasing &decreasing the valve

10. Vibration /Axial dis-placementsystem

BentlyNevada test-ing equipment

This is to be calibrated as permanufacturers instruction.Ifcontractor does not have theinster. he shall do this on sub-contractor under his respon-sibility by BN Indian Agent.

ANALYSER1. 02,H2,CO2

etc.Zero / Spangas & outputmeter

Calibration shall be checkedusing zero & span gases &noting the output meter.

2. PH, Con-ductivitydisolved 02

Solution &output meter

Using these std solution & out-put meter calibration to bechecked.

3. Controlvalve

Pneumatic /Electric testrig.

Lubricated stoped & checkedfor smooth operation & Hyster-sis I/P SOV, Limit switch,valve opening & closing timeetc. to be checked.

4. Controller Electronic &Pneumaticrigs.

Manufacturers instructionmanuals.

5. Tempera-ture in-dicator

Poten-tiometer/Decade resistancebox.

Calibration to be checked giveknown input of T/C or resis-tance and comparing outputwith std. curves.

6. Differentialpressure &Pr.transmit-ters Hgmanometer

Hydraulic orpneumatic rigoutput meter(Elect orPneumatic )

Out put shall be measuredusing master output gauge.

7. E/Ptransducer

Fieldcalibratorstandard out-put gauge forHgmanometer.

Checking shall be done byfeeding input field calibrate &noting the output reading re-quired the output.

20.19.0To identify the stage of inspection done thedifferent colour of the small label shall be at-tached on the field instructions as follows :-

(a) Bench calibration

(b) Pressure test flushing of the impulse line.

(c) Electrical test (Megger continuity etc).

(d) Blowing in air supply.

(e) Loop tester.

21.0.0 TESTING AND LOOP CHECKING

21.1.0 TESTING

21.1.1 For analog instruments testing of wire shall bedone after installation to verify freedom fromgrounds.

21.1.2 After all connections are given the completeloop shall be checked for satisfactory perfor-mance.

21.1.3 Where “meggers” are used,care shall be takennot to use a voltage in excess of the insulation’srated voltage.

21.1.4 While testing the wires, all the instruments shallbe disconnected to avoid damage to the instru-ments.

21.1.5 Wire to wire and wire to ground resistance shallnormally not exceed 10 M.ohms in most applica-

25ES401 / 94



PAGE 13 OF 22

tions.

21.1.6 The shield drain shall also be tested for acciden-tal shorts or grounds as just another conductorrequiring high resistance to ground.

21.1.7 Grounding circuits shall be tested for resistancelow enough to operate overcurrent devicesshould a ground fault occur within the instru-ment.

21.1.8 This is part of the instrument installationwork(see item 22.0.0)

Instrument erection will be considered 100%complete only after all the checks as indicatedbelow are complete.

21.1.9 All instrument loops are to be checked for com-pliance of the installation drawings. Whereverpossible signals are to be simulated at the trans-mitter end and shall be followed at the indicator/ controller / alarm / interlock components uptothe final control element. Loop check shall becarried out by simulation of signal from transmit-ter end at minimum four points, 25%, 50%, 75%and 100%. All defects such as leaks at theinstrument process piping / tubing, instrumentair lines / fittings etc, insulation / connectionfaults at the electrical wiring shall be rectified tothe satisfaction of the Owner. All the calibrationvariations, misalignment of linkages of final con-trol elements are to be rectified.

21.1.10All the joints in the air lines and the signal linesare to be tested for leaks using soap solution.All checking shall be done as per the generalnotes on wiring & tubing.

PART C - JOB COMPLETION REQUIRE-MENTS

22.0.0 COMPLETION OF ERECTION JOB

The completion of the entire erection job onInstrumentation will be considered in followingthree major stages and the payment will beaccordingly made subject to the other commer-cial terms.

a. 60% of the job will be considered completewhen erection of the instrument material ismechanically completed.

b. 20% of the job will be considered completedon completion of checking and calibration ofindividual instruments.

c. 20% of the job will be considered completeafter loop checking of instruments.

22.1.0 MATERIAL RECONCILIATION / WASTAGE AL-LOWANCE

The contractor shall plan and execute the workin such a manner that wastage of material shallbe limited to minimum. The contractor shouldtake precaution to ascertain the actual route andlengths required before laying of cables andtubes so that the lengths of cut pieces are keptto the minimum possible, and not exceed 0.5%of total Qty., for cables and SS tubes as far aspossible. Total wastage / scrap which cannot beaccounted for in receipt, consumption returnstatement should not exceed following % al-lowance itemwise. Items supplied by owner asfree issue shall be returned to store with properreturn notes. He shall also furnish reconciliation

statement for the material supplied to him. Thework will be deemed incomplete without submission of proper material reconciliation report. Theresponsi bility of submitting ’Material Reconcilia-tion report’ with out any delay towards the endof the job lies solely with the contractor. Thestatement prepared by the contractor withproper references of receipts dates etc. shouldbe submitted which will be verified for the totalquantum of job carried out and material / itemsinstalled. After checking all the three statementswith due allowance for wastage / scrap, materials tatements can be accepted byFEDO/OWNER/CLIENT. This marks the com-pletion of the job and final payment will be madeonly after this activity is completed. Allowancefor unaccountable wastage for variouscategories of material will be as given below :-

Item %allowance

Length of S.S.pipes,tubes alloysteel pipes. 0.5%

Electrical cables.(3 meter perlength of cable or which ever isless)

2%

C.S.pipes, aluminium trays 1%

Structural material 2%

Valves, pipe fittings, compressionfittings cable glands etc. NIL

Nut, Bolt, gasket material 2%

NOTE :-

For wastage over and above the figures indi-cated, contractor will be charged at the cost ofprice+over heads+taxes.

22.2.0 QUANTITY VARIATION

Quantities indicated in the bill of quantities aretentative and are likely to vary subsequently.The unit rates shall remain firm for any variationin the scope of work to the extent + or - 25% oftotal contract value.

23.0.0 COMMISSIONING AND START-UP

For commissioning and start up contractor shalldeploy qualified skilled, semi-skilled and un-skilled personnel at the rates quoted under’schedule of labour rates’.

The approximate number of personnel thatwould be required are also indicated in theschedule of labour rates. The owner will haveoption to engage partially, fully or additionalpersonnel as required by him and the contractorshall provide the personnel at the rate indicated.Actual requirement will be intimated to the con-tractor at least 15 days in advance. These ratesshall be applicable for any additional work doneon “labour supply basis”.

24.0.0 BILL OF QUANTITIES AND MATERIALS

24.1.0 RATES

The rates for installation of instrumentation shall

25ES401 / 94



PAGE 14 OF 22

include for :-

24.1.1 Handling, transportation, care and protection ofowner issued equipment and materials fromowners stores to con tractors store or point ofinstallation.

24.1.2 All installation works, fixing and testing.

24.1.3 Maintaining proper inventory of owner suppliedequipments and materials and returning allsurplus equipments and materials to stores ofowner, after completion of work.

24.1.4 Provision of adequate and proper storage forowner’s equipment and materials.

24.1.5 Provision of complete Instrument workshop withtesting and calibration equipments.

24.1.6 Provision of all installation equipment, tools,scaffold ing, workshops and offices and anyother equipment and / or appliances necessaryto complete the installation, in ac cordance withthe specifications.

24.1.7 All consumable materials, other than thoseseparately enumerated in the bid items.

24.1.8 Removal, re-calibration and re-installation of in-stru ments as required during pre-commission-ing.

24.2.0 MEASUREMENT

24.2.1 As far as possible, all measurements for pay-ment shall be taken from “Good for constructiondrawings” released for construction’’ andschedules provided by owner.

24.2.2 Only the items listed in the schedule shall bemeasured for payment. All other labours andactivities necessary to complete the installationshall be deemed included in the items in theschedule.

Note: For measurement & billing refer formats25 FT 407 & 25 FT 408.

PART D - PROCEDURES AND STAND-ARDS

25.0.0 GENERAL REQUIREMENTS AND RECOM-MENDATION FOR PIPE WELDING

25.1.0. SCOPE

25.1.1 This specification covers the requirements andrecommendations for welding procedurequalification test and welder’s performancequalification test of piping / instrumentationstructural work.

25.2.0. REFERENCES

25.2.1 The following codes, standards and specifica-tions in the latest editions as of November 1984shall form a part of this specification unlessotherwise specified herein.

a. ANSI/ASME B31.3

b. ASME CODE SECTION IX

c. “SPECIFICATION FOR FABRICATIONAND INSTALLATION OF STEEL PIPING”.

d. “PIPING MATERIAL CLASSIFICATION”

25.3.0 WELDING PROCEDURE

25.3.1 GENERAL

a. TABLE-1 includes the several kinds of weld-ing Procedure.

The contractor or subcontractor who will dothe actual welding work for piping shallselect the applicable welding procedure foreach kind of piping welding from Table. 1.

After that, the contractor or subcontractorshall pre pare the detailed WPS’s and pro-cedure Qualification Record (PQR’s) in ac-cordance with ASME CODE SECTION IXand the requirement of this specification,submit and obtain the written approval fromOwner prior to the commencement of anywelding work.

b. If the contractor or subcontractor wants touse other welding procedures not listed inTable.1, the contrac tor or subcontractorshall submit the detailed WPS’s and PQR’sto Owner and get the approval before use.

25.3.2 WELDING PROCEDURE FOR CARBONSTEEL

a. All pressure retaining welds and attachmentwelds to the pressure retaining parts shallbe made by SHIELDED METAL ARKWELDING (SMAW) using Low HydrogenType Elec trode AWS E 7018 except rootpass.

b. Root pass of girth butt weld and branchconnection weld, where the completepenetration in required shall be made byGAS TUNGSTEN ARC WELDING (GTAW)process or SMAW process. For GTAW, fillermetal shall comply with AWS ER70S - 2,3,6or ER70S - G (TGS-50, KOBE STEELLTD.). For SMAW, electrodes shall complywith ASW E6010.

c. For small diameter piping (2" & smaller), allGTAW process may be used for all passes.

d. End preparation and root gap shall be inaccordance wi th FIG.327.3.1 ofANSI/ASME B31.3.

e. In case of ASW E6010 for root pass, mini-mum.80 deg. C preheating is required forthe thickness 1/2" and over.

f. Weld progression for vertical position shallbe uphill.

g. When Post Weld Treatment (PWHT) isnecessary from the fluid service require-ment, PWHT conditions shall be as follows.

MATERIAL : carbon steel

HOLDING TEMPERATURE

: 625 +/- 25 deg. C

HOLDING TIME : min. 1 Hr

25.3.3 Welding Procedure For C-1/2MO Steel (pipingMaterial Service Class)

a. Root pass of girth butt weld and branchconnection weld where the completepenetration is required shall be made byGTAW process.

b. Filter pass and Cover pass shall be madeby GTAW or SMAW.

25ES401 / 94



PAGE 15 OF 22

c. GTAW filler metal shall comply with ASWER80S-D2 or ER80S-G (TGS - M, KOBESTEEL LTD.). For SMAW, electrode shallcomply with AWS E7016-Al,low hydrogentype elec trode. E7010-Al type (high cel-lulose type) shall not be used.

d. For small diameter piping ( 2" & under ), allGTAW process is preferable.

e. End preparation and root gap shall be inaccordance with FIG. 327.3.1 of ANSI /ASME B31.3.

f. Weld progression for vertical position shallbe uphill.

25.3.4 Welding Procedure For Austenitic StainlessSteel, S.S TP - 304, 304L, 316L,316SS.

a. Root pass of girth butt weld and branchconnection weld where the completepenetration is required shall be made byGTAW process Root pass by SMAWprocess shall be prohibited.

b. Filler pass and Cover pass shall be madeby GTAW or SMAW. For small diameterpiping (2" & under), all GTAW process ispreferable.

c. Acceptable filler metal and electrode shallbe as follows

Piping Material

Filler Metal(GTAW)

Electrode(SMAW)

TP304 AWS ER 308 AWS E 308-16

TP304L AWS ER 308L AWS E 308L-16

TP316L AWS ER 316L AWS E 316L-16

316SS AWS ER 316 AWSE316L-10

Notes:-

For welding electrodes AWS E308L-16,maxi-mum carbon content shall be 0.03% (Extra lowcarbon type). At the time of purchasing thesewelding materials, maximum carbon contentshall be specified, because maximum carboncontent of normal AWS E308l-16 and AWSE316L-16IS0.04%.

The following are the acceptable materialswhich comply with the above requirement.

AWS Class Trade Name & Manufacturer

E308L-16 NC38EL(K.S.L),WEL 308 ELC (N.W.R ( K.S.L — KOBE STEEL LTD )

E316L-16 NC36EL(K.S.L),WEL 316 ELC (N.W.R( N.W.R — NIPPON WELDING RODCO., LTD. )

d. End preparation and root gap shall be inaccordance wi th FIG.327.3.1 ofANSI/ASME B31.3.

e. Weld progression for vertical position shallbe uphill.

f. Internal back shielding with pure Argon gas(min.99.9%) shall be required during thewelding. Back shielding with Nitrogen gas

shall not be permitted.

g. Maximum interpass temperature duringwelding shall be 150 deg.C.

25.3.5 Welding Procedure For Dissimilar Metal

a. Root p[ass of girth butt weld and branchconnection weld where the completepenetration is required shall be made byGTAW process. Root pass by SMAWprocess shall be prohibited.

b. Filler pass and Cover pass shall be madeby GTAW or SMAW For small diameterpiping (2" & under), all GTAW process ispreferable.

c. Acceptable filler metals and electrodes forvarious combinations of base metal shall beas follows.

PIPINGMATERIAL C/S S.S

304S.S

304LS.S

316L

C/S — ER309E309-16

S.S 304 — ER308E308-16

S.S.304L —ER308LE308L-

16

S.S 316L —

Note: For E308L-16, max. C-content shall be0.03% (Extra low carbon). SEE Note2) of 3.3.3

d. End preparation and root gap shall be in accord-ance FIG. 327 3.1 of ANSI/ASME B31.3.

e. Weld progression for vertical position shall beuphill.

f. Internal back shielding with pure Argon gas(min. 99.9%) shall be required during the weld-ing. Back shielding with Nitrogen gas shall notbe permitted.

g. Maximum interpass temperature during weld-ing shall be 150deg.C.

h. Welding between galvanised carbon steel orZinc rich primer coated carbon steel and stain-less steel shall be prohibited to avoid the ZincEmbrittlement Crack on the weld and Heat Af-fected Zone (HAZ).

25.4.0 WELDING PROCEDURE QUALIFICATIONTEST

25.4.1 All welding procedures used for the instrumentpiping construction work shall be qualified orshall have been qualified by the contractor orsubcontractor at his responsibility in accordancewith ASME CODE SECTION IX and the require-ments herein before the commencement of anywelding work. If the contractor or subcontractordoes not have the Procedure QualificationRecords (PQR’s) for the applicable WeldingProcedure Specifica tions (WPS’s) according tothis specification require ments, he shall carryout the welding procedure quali fication test andshall submit the complete document as ’’WPS’s& PQR’s’’ to Owner for approval.

25.4.2 TABLE-2 ’’STANDARD PROCEDURE FORWELDING PROCEDURE QUALIFICATION

25ES401 / 94



PAGE 16 OF 22

TEST’’ are the sample of procedure quali fica-tion test for each welding procedure listed inTABLE-1

The contractor or subcontractor may modify thetest procedure as far as the requirements ofASME CODE SECTION IX and this specifica-tion are kept.

25.5.0 WELDER PERFORMANCE QUALIFICATIONTEST

25.5.1 All welders and welding operators engaged inthis job are required to pass the performancequalification test in accordance with ASMECODE SECTION IX. The contractor or sub-contractor shall be wholly responsible for qualifying each welder and welding operator to en-sure that the welder or welding operator hasenough skill to make the sound welds by usingthe welding procedure to be used for this job.

25.5.2 TABLE-3 ’’STANDARD PROCEDURE FORWELDER PERFORMANCE QUALIFICATIONTEST’’ are the sample of performance qualifica-tion test for each welding procedure listed inTABLE-1.

The contractor or subcontractor may modify thetest procedure as far as the requirements ofASME CODE SECTION IX and the specificationare kept.

25.5.3 Visual inspection during welding and after weld-ing is very important. Therefore the competentwelding inspec tor or welding supervisor whohas enough experiences for visual inspection ofweld shall witness the weld’s test and judge hiscapab i l i ty before guided bend test orradiographic examination.

25.5.4 GTAW welder who passed the carbon steel weldshall not be qualified for stainless TIG welding,even if the No. of ASME CODE SECTION IX issame, but not vise versa.

26.0.0 SPECIFICATION FOR PAINTING WORK :

26.1.0 SCOPE

This specification covers the general require-ments for painting of Instruments / accessories,steel structures and instrument piping.

26.2.0 REFERENCE

The requirements given in the followingspecification in the manner and to the extentindicated therein.

a. I.S. for surface preparation.

26.3.0 SURFACES TO BE PAINTED AND SURFACESNOT TO BE PAINTED

The following surfaces shall be painted in ac-cordance with the painting classes of thisspecification :-

26.3.1 Carbon steel instrument accessories.

26.3.2 Steel supporting structures.

26.3.3 Carbon steel instrument impulse piping.

26.3.4 Other surfaces which are required to be paintedfor any specific reason.

However, the following surfaces shall not bepainted :-

a. Non - ferrous metal, stainless steel or other

high alloy steel.

b. Name plates or identification tags.

c. Valve stems or other machined contact sur-faces.

d. Galvanized surfaces.

e. Insulation covers.

f. Plastic.

26.4.0 PAINTING CLASSES

The materials or paints specified in the CLAS-SES A to E are selected on the following basis:-

CLASS - A General use for surfaces with temp.upto 65 deg. C

CLASS - B Mild Acid/Alkaline and saline atmos-phere.

CLASS - C General use for surfaces above 65deg. C upto 120 deg. C strong AcidAlkali environment.

CLASS- D Highly corrosive areas, particularlyurea and abrasive environment, areassubject to wind, General use as forepoxy, chemical splashing areas includ-ing fluo rine, surfaces at sub - zerotemp.

CLASS - E : High temp. surfaces upto 400 deg. C

26.5.0 PREPARATION OF SURFACES

26.5.1 General Requirements

a. The surface shall be prepared to dry metalafter removing rust, oil, grease, dust, strain,or any other extraneous matter by manualor mechanical cleaning such as wire brush-ing, grinding, power brushing, etc.

b. Wet surfaces due to rain fall, dew - drop,frost, etc. shall be thoroughly wiped withrages and dried before each painting.

c. Cleaning of wet or soiled surfaces shall bedone immediately before application ofpaint in such a manner that adjacent wetpaint surfaces are not damaged by thecleaning operation.

d. Drying of wet surfaces may be expedited byblowing warm air.

e. The primed/painted surfaces shall be dryand clean before application of subsequentcoats. Deposits on the primed/painted sur-face must be cleaned before the applicationof the next coat.

f. If the painted surfaces are exposed to rainwhile painting is in progress, the affectedpaint shall be entirely removed and be re -painted after making the surface clean.

26.5..2 Cleaning of Surfaces

a. Cleaning of rolled steel surfaces shall becarried out in the manner that all crevices,corners, and edges of shape steel, joints ofsteel plates, especially around boltheads,weld beads etc. may be cleaned.

25ES401 / 94



PAGE 17 OF 22

b. Cleaned surfaces shall not be damaged byunnecessary tapping, etc.

c. Where sand blasting is required, the sameshall be carried out to SA 21/2 grade. Thesand blasted surfaces shall be paintedwithin 6 hours after sand blasting.

26.6.0 STORAGE OF PAINTING MATERIALS

26.6.1 Paints, varnishes, thinners or other volatile andinflammable painting materials shall be storedon a 150mm thick. layer of sand in well venti-lated and detached storage sheds.

26.6.2 Fire extinguishers or sufficient amount of sandshall be placed where readily accessible in caseof fire.

26.6.3 “No Smoking” and other suitable warning signs,such as “No Open Flames”, “Danger”,"Storageof inflammable Materials" etc. shall be postedaround storage sheds.

26.7.0 MIXING AND THINNING

Mixing and thinning shall be done only at wellventilated places where there are no openflames.

26.6.1 Mixing

Wherever mixing of base paint and additivesare involved, such mixing shall be done strictlyas per manufacture’s specifications/recommen-dations.

As far as practical, quantity of mixing shall besufficient to cover the given section or an entiresurface of the specific colour.

26.6.2 Thinning wherever required shall be strictly asper recommended ratio.

26.8.0 PAINTING

26.8.1 General Requirements

a. Painting on instrument equipment / acces-sories and piping shall be done at plant site,at shop as required.

b. Painting shall be performed only infavorable weather conditions. Painting shallnot be per formed in rainy, damp, windy,dusty, weather, or the day of such un-favorable weather is predicat ed.

c. During painting, adjacent surface shall beproperly protected from paint splashes,drips and other blemishes. If blemishes ordamages occur by accident, they shall bethoroughly cleaned, repaired or replaced.

d. Upon completion of painting work, all stag-ings, scaf foldings, paint containers, etc,shall be removed from the job site and thepremises shall be left clean.

e. Caution plates of ’’Wet Paint’’ shall beposted around the areas where readilyvisible, until the paint has completely dried.

26.8.2 Methods of Application

a. Painting shall be generally performed byhand brush method. Spray method may beadopted for surfaces like that of controlpanels for specific reasons.

b. Wherever hand brush method is employedfor painting, painting shall be done in alter-nate directions from vertical to horizontal,

or from horizontal to vertical and shall beapplied to all edges, corners, crevices,joints, intersections etc.

c. If brush marks, dags, runs, adhesions ofbrush bris tles, dust or blemishes occur, thesurfaces shall be lightly sandpaperedbefore successive coats are applied.

d. All surfaces that are inaccessible after in-stallation and assembly except for contactsurfaces shall be painted twice, that is afterfirst coat, the same is repeated again. Thesecond and final coats are also repeated insame manner.

26.9.0 PRECAUTIONS

26.9.1 Open flames, smoking, exposed elements orsources of ignition of any kind shall be strictlyprohibited in area where painting is being per-formed.

26.9.2 During painting operation and for a sufficienttime thereafter, welding or open flame work shallbe prohibited in the adjacent areas.

26.9.3 “"No smoking” and other warning panels to read“Caution” “No Open Flames” etc. shall beposted in all areas where and while painting isperformed. The signs shall remain posted for asufficient time after painting has been com-pleted.

26.9.4 Hand lamps, flashlights etc. which will cause afire shall be handled carefully.

26.9.5 Inflammable liquid with a flash point below 40deg. C shall not be used for cleaning purpose.

26.9.6 Where it is practicable, adequate ventilationshall be provided to reduce the concentration ofharmful vapours in the atmosphere. Otherwise,workmen shall wear vapour - proof masks, rub-ber gloves, etc. for protection when he has towork in a bad ventilated place.

26.10.0INSPECTION

26.10.1Finished surfaces shall be uniform and smooth,free from marks of drops, ridges, waves, laps,wrinkles, brush marks, and other defects.

26.10.2Finished surfaces shall be of uniform colour thatpresents good appearance, without spots,stains, and discolora tions.

26.10.3Inconspicuous parts, such as the corner of buil-dup members, around bolts, undersides andbacksides of pipelines, pipe bends and valvesetc., shall be closely checked so that they maynot be left unpainted.

26.10.4Paint colours for identification purposes ofpiping shall be checked for correct colour ap-plication, if required.

26.10.5Defective surfaces, if any, shall be cleaned andrepainted.

26.10.6Additional Requirements

a. Any imperfect or damaged layer shall be repaired before the next layer is applied.

b. The field welding for damaged layer shall berepaired before the next layer is applied.

c. Bolts and nuts shall be provided with therelevant priming coat immediately aftermounting.

25ES401 / 94



PAGE 18 OF 22

d. Places where field welds are to be provided,a section of 50 to 500mm shall remain un-painted, on both sides.

26.11.0 TABLES

Tables (Class - A to E) are given below.

CLASS - A

1. Scope of applications :-

Instrument accessories such as condensatepots, air headers, instrument pedestals, impulsepiping, steel structures etc.

2. Service conditions :-

Ambient - up to 65 deg. C

3. Surface preparation :-

Mechanical Power tool cleaning / wire brushing

4. Specification :-

Painting Process PaintNo.of

Coats

Filmthk. /Coat

Beforeshipmentat shop

PrimerRed oxide zinc

chromate primer toIS -2074

1 20

At field Primer - do - 1* / 2 20

Fistfinishcoat

Synthetic enamel toIS-2932 or

Aluminium paint toIS-2339

1 15

Secondfinsih coat - do - 1 15

( * ) — Where primer is applied before ship-ment, one coat instead of two coats shall beapplied.

CLASS- B

1. Scope of application :-

Instrument accessories such as condensatepots, air headers, instrument pedestals, impulsepiping, steel structure etc.

2. Service conditions :-

a. Chemical splashing area, mild acid /alkaline atmosphere.

b. Saline atmosphere.


Mechanical Power tool cleaning or wire brush-ing.

4. Specification :-


Coats

Filmthk. /Coat


PrimerRed oxide zinc

chromate primer-chlorinated rubber

based1 25


Fistfinishcoat

Chlorinated rubberfinish - unmodified 1 25


( * ) — Where primer is applied before ship-ment, one coat instead of two coats shall be ap-plied.

CLASS- C


Instrument accessories such as condensatepots, air headers, instrument pedestal, impulsepiping, steel structure etc.

2. Service condition :-

a. General use for surfaces 65 deg. C to 120deg.C.

b. Chemical splashing area particularly urea,acid/alkaline atmosphere

c. Highly corrosive area particularly urea andabrasive environment subject to wind/dripping etc.


Mechanical power tool cleaning/wire brushing.

4. Specification :-


Coats

Filmthk. /Coat


PrimerEpoxy Red oxideZinc Phosphate

primer1 25


Fistfinishcoat

Epoxy finish paint 1 40


( * ) — Where primer is applied before ship-ment, one coat instead of two coats shall be ap-plied.

CLASS-D


Instrument accessories such as condensatepots, air headers, instrument pedestal, impulsepiping, steel structure etc.


a. General use as for epoxy coatings

b. Highly corrosive and abrasive areas

c. Chemical splashing areas including fluorine

d. Surfaces at subzero temperatures

3. Surface Preparation :-

Mechanical power tool cleaning/wire brushing

4. Specification :-


Coats

Filmthk. /Coat

25ES401 / 94



PAGE 19 OF 22


Primer 2 pack polyurethane|primer 1 25


Fistfinishcoat

2 pack polyurethane|finish 1 40


CLASS-E


Instrument accessories such as condensatepots,air headers,instrument pedestal, impulsepiping, steel structure etc.


120 to 400 deg. C


Mechanical power tool cleaning/wire brushing

4. Specification :-


Coats

Filmthk. /Coat


PrimerHeat resistant

silicone| aluminiumpaint

1 25


Fistfinishcoat

- do - 1 20



27.0.0 INSPECTION AND TEST PROCEDUREFOR INSTRUMENT INSTALLATIONWORK

27.1.0 SCOPE

27.1.1 This specification covers the procedure for in-spection and test of instrument installation work.

27.2.0 REFERENCE

27.3.0 GENERAL

27.3.1 Inspections and tests shall be performed for thefollowing work items:

a. Instrument pressure piping

b. Instrument Electrical Wiring andTemperature Wiring

c. Instrument Signal Air Tubing

d. Instrument Supply Air Piping

27.3.2 Test reports shall be prepared for all tests andbe submitted to CONSULTANT / OWNER im-mediately after the tests are completed.

Typical report forms are shown in Appendices 1

through 4.

27.4.0 INSPECTION AND TEST - INSTRUMENTPRESSURE PIPING

27.4.1 Instrument pressure lead lines between theprocess isolating valves and the instruments towhich they are connected shall be tested. Priorto the test, the following items shall be in-spected visually:

a. Whether instruments are correctly installedac cording to the P & I Flow Diagram.

b. Whether the upstream and downstreamconnections of instrument pressure leadline for differential pressure type instrumentis correct.

c. Whether adequate slope is provided to in-strument pressure lead line.

d. Whether sufficient supports are provided toinstrument pressure lead line.

e. Whether correct materials of the correctrating are used for instrument pressure leadline.

27.4.2 Testing Description

Instruments with an operating pressure lessthan 40kgf/cm2G shall be pneumatically testedInstruments with an operating pressure equal toor more than 40kgf/cm2G shall be hydrostatical-ly and pneumati cally tested.

Unless otherwise specified, test shall beperformed with instrument connected to the line.

1.Hydrostatic Test

a. Test Fluid : Water

b. Test Pressure

Normally operating pressure x 1.5 or 90%of the maximum allowable pressure of in-strument (in the case of pressure instru-ment, it’s measuring range), whicheverlower.

c. Test Procedure ( see 14 FT 561 / 93 )

After closing the process isolating valvesand opening the equalizing valve, if in-stalled, fresh water shall be fed into thepressure lead line. Details are as follows:

Step 1.

close valves 1 , 2 , 8 .

Open valves 3 , 4 , 5 , 6 , 7 .

Pump enough water and pressurize systemup to test pressure.

Step 2.

Close valves 6 , 7 .

Open valve 8 .

Confirm that pressure gauge indicationdoes not decrease during 3 minutes.

Step 3.

Close valve 8 .

then open valves 1 , 6 , 7 .

Then pump enough water to confirm thatvalve 1 is not blocked

25ES401 / 94



PAGE 20 OF 22

Step 4.

Close valve 1 and open valve 2

Then pump enough water to confirm thatvalve 2 is not blocked.

Step 5.

Close valves 1 , 2 , 3 , 5 .

open valve 4 .

2.Pneumatic Test

a. Test Fluid : Air, N2 gas or inert gas.

b. Test Pressure

7 kgf/cm2G or 90% of the maximum allow-able pressure of instrument ( in the case ofpressure instrument, it’s measuring range),whichever lower, with a minimum test pres-sure of 1 kgf/cm2G. If instrument is notdurable to 1 kgf/cm2G, test shall be per-formed with instrument disconnected fromthe line.

c. Test Procedure.( see 14FT562/93 )

After closing the process isolating valvesand opening the equalizing valve, if in-stalled, test fluid shall be fed into the pres-sure lead line. Details are as follows:

Step 1.

Close valves 1 , 2 .

Open valves 3 , 4 , 5 , 6 .

Pressurize system up to the test pressure.

Step 2.

Close valve 6 .

Confirm that there is no leak by pouringsoap water on each connection.

Step 3.

Open valve 1 .

Confirm that valve 1 is not blocked.

Step 4.

Close valve 1 , pressurize system againand open valve 2 to confirm that valve 2is not blocked.

Step 5.

Close valves 1 , 2 , 3 , 5 .

Open valve 4 .

Notes:-

a. The analyzer pipeline shall be tested bydisconnecting the lead line from instrument.The test procedure shall be the same as thatwith process pipeline.

b. Test may be performed separately ortogether with the test for process piping orequip ment.

c. All instrument piping systems shall becleaned by blowing air or flushing waterbefore and/or after the test. All joints whichare defective shall be repaired immedi atelyand shall be re-tested by the original testmethod.

27.5.0 INSTRUMENT ELECTRICAL WIRING &

TEMPERATURE WIRING

27.5.1 GENERAL

Continuity, identification and cable insulationresistance tests shall be performed. Prior to thetest, the following shall be inspected visually:

(a) Whether instruments are correctly in-stalled according to the P & I FlowDiagrams.

(b) Whether wire marking and/or colorcoding at terminals are correct.

(c) Whether sealing compound or packing isprovided as specified at the entry of eachinstrument.

27.5.2. TEST PROCEDURE

Step.1. Continuity and identification of each wireand continuity of shield wire shall be in spectedbetween the field instrument termi nals and thecontrol panelboard terminals by using atelephone, a buzzer, or other suit able means.

Step 2.Insulation resistance test shall be per-formed by using a 500 V or 1000 V megger. Inthis case, the wire shall be disconnected fromthe terminal both at the field and in the controlpanel.

The minimum resistance value shall be as fol-lows:

a. Line to Line

min 10M ohmb. Line to ground

c. Line to shield

Step 3.The electricity charged in the wire by theinsulation resistance test shall be dis chargedby grounding the wire and then the wire shall beconnected firmly to its termi nal.

27.6.0 INSTRUMENT SIGNAL AIR TUBING

27.6.1 GENERAL

Continuity, identification and leak tests shallbe performed. Prior to the test, a visual inspec-tion shall be made as to whether instrumentsare correctly installed accord ing to the P & IDiagram.

27.6.2 TEST PROCEDURE.....(see 14 FT 563 / 93)

The following procedure applies only to the airtube between the field instrument and panelinstrument. Air tube between field instrumentsmay be tested by apply ing 1.0 kgf/cm2G air andswabbing solution to facili tate the detection ofleaks.

Step 1.For confirming continuity and identifica-tion, air tube connections both at field instrumentand control panel bulk header shall be dis con-nected. Then blow out the air tube 1.0 kgf/cm2Gair and check for correct line.

Step 2. The air tube shall be connected toinstrument which consumes no air such asreceiver gauge, pressure switch and field con-troller (set point, cut-off and process value line)and the air tube shall be plugged at instrumentwhich consumes air such as transmitter andcontroller output. In this case, the air tube maybe connected to control valve when it haspositioner, as its topwork has a large capacity,the air tube shall be discon nected and plugged.

25ES401 / 94



PAGE 21 OF 22

Namely, items 2 , 3 , 4 and 5 indi cated in fig.3shall be connected to instrument and items 1and 6 shall be plugged.

Step 3. Send 1.0 kgf/cm2G air to the field andclose valve A and open valve B .

Observe the pressure gauge C. The valuesgiven in table 1 are allowable maximum decreasing rate of the line pressure. If the rateexceeds the values, then all air tubes shall bechecked for leakage.

27.7.0 INSTRUMENT SUPPLY AIR PIPING

27.7.1 GENERAL

Pneumatic test and air blowing of the supply airpiping system shall be performed between thefirst take off valve on the main air header andinstruments. Prior to the test, visual inspectionshall be made as to whether instruments arecorrectly installed according to the P & IDiagram.

27.7.2 TEST FLUID AND PRESSURE

Test fluid shall be free of oil, dry air or N2 gas.

Test pressure for air supply pipe from mainheader first take-off valve to individual instru-ment air regulators shall be equal to main airheader operating pressure.

Short length of air tubes between instrumentand its air regulator shall be tested by the setpressure of the air regulator.

27.7.3 TEST PROCEDURE

Step 1. Air blowing of the system shall be performed bydisconnecting air tube at the inlet of the airregulator and opening the shutoff valve. Airblowing shall be done by opening and closingthe shutoff valve for a minimum of five times untilthe air system is confirmed to be clean.

Step 2. The air tube shall be connected again and theshutoff valve shall be opened to pressurize thesystem. All joints and connections shall beswabbed with soap solution to facilitate thedetection of leaks.

Note:

a. Test may be performed separately ortogether with the test of main air header.

b. All joints & connections found to be defec-tive shall be repaired immediately and shall

be re-tested by the original test method.

28.0.0 APPLICABLE STANDARDS

API-RP-550 Installation of refinery Instru-ments & control system

ISA Standard Standard & practices for in-stallation.

28.1.0 OTHER STANDARDS

Inspection & test procedure for instrument in-stallation work.

General requirement and recommendation forpiping welding.

Installation standards for instrumentation.

PART E - ATTACHMENTS

29.0.0 DRAWINGS - ANNEXURE I

The drawings supplied for Instrument erectionare attached in Annexure I.The drawingsprovided are only typical and covers almost alltype of instruments.All the required drawing willbe supplied before or progressively duringerection.If any modification / deviation in thedrawings shall be informed to engg. departmentfor approval.

30.0.0 SCHEDULE OF WORK - ANNEXURE II

The schedule of work in detail attached in An-nexure - II.The instrument contractor shall followstandard erection procedure and maintain goodquality of work.The wastage of material shall belimited to minimum as possible.

31.0.0 ITEMS TO BE SUPPLIED BY CONTRAC-TOR - ANNEXURE III

The list of items to be supplied by the contractoris attached in Annexure - III.The instrumentcontractor shall supply the specified items pur-chased from standard suppliers/subvendorsapproved by FEDO / OWNER .The items sup-plied shall be inspected for damages and com-pliance with specification s given by the engg.department. Any damage and unacceptablevariation s shall be recorded (Refer 25 FT 403)and brought to the notice of concerned Engineer- in- charge.

25ES401 / 94



PAGE 22 OF 22

———————————————————————————————

1.0.0 These specifications establish and define theMaterial and Construction requirements for In-strumentation works.

2.0.0 Providing and operating necessary Measuringand Testing Devices and Materials including allconsumables are included in the Scope of Work.No separate measurement or payment for test-ing the WORK and Materials shall be made butrates quoted for various items shall be deemedto include the cost of such tests which arerequired to ensure achievement of specifiedquality.

3.0.0 All materials supplied by the Contractor shallbe as per FEDO specifications / of standardquality manufactured by renowned concernsconforming to Indian Standards or equivalentand shall have ’IS’ mark as far as possibleunless otherwise approved by Engineer-in-charge. The CONTRACTOR shall furnishmanufacturer’s certificates for the materialssupplied by him when asked for. Further, heshall get the materials tested by an approvedtest house, if asked for by the Engineer-in-Charge. The cost for all the tests and testcertificates shall be borne by the CONTRAC-TOR. No separate payment shall be made forthe testing. The Engineer-in-Charge shall havethe right to determine whether all or any of thematerials are suitable. Any material procured orbrought to SITE and not conforming to specifica-tions and satisfaction of the Engineer-in-chargeshall be rejected and the CONTRACTOR shallremove the same immediately from SITE at hisown expense and without any claim for compen-sation due to such rejection.

4.0.0 Wherever referred to in this document, only therevi sion which shall be in force till completion ofthe WORK of specification, CODES of Practiceand other publications of the Bureau of IndianStandards shall be applicable.

5.0.0 In case of conflict amongst the provisions ofSchedule of Rates, specifications and drawings,all of them shall be read in conjunction with eachother and clari fication shall be obtained from theEngineer-in-Charge whose decision shall befinal and binding. Following procedure maygenerally be followed.

5.1.0 Description of items in Schedule of Rates shallbe followed when provisions therein are dif-ferent from those in specifications.

5.2.0 Where the description of item does not call forsome specific requirements but the same isgiven in specifications, the specifications shallbe followed, in addition to the requirementsgiven in description of item.

5.3.0 Where drawings call for requirements differentfrom or additional to those given in item descrip-tion and specifications, the decision of the En-gineer-in-Charge shall be obtained as to whatshall be followed.

6.0.0 Method of measurement

6.1.0 The method of measurements for all worksshall be as indicated elsewhere in the WorkOrder and where not specified, latest revision ofthe relevant IS code for the concerned job shallbe followed.

6.2.0 In the absence of stipulations in any of the abovedocuments, the following guidelines shallgenerally be followed.

1. Installation work of all online instrumentsshall be measured in ‘numbers’

2. Field mounted transmitters, local instru-ments/ analysers, PH/Conductivity trans-mitters, gas analysers, field mountedswitches,Junction Boxes of different type,etc. shall be measured in numbers.

3. For PH/conductivity transmitters and gasanalysers work, installation, calibration andinter connections shall also be included.

4. For toxic gas mounting system calibration,installation and loop checking shall be in-cluded.

5. Measurements for fabrication and paintingof structural steel shall be in metric tonnecorrected to nearest kilogram.

6. Tubes & pipes shall be measured in metrescorrected to nearest centimeter.

7. Tube/pipe fittings, valves, etc. shall bemeasured separately in ‘numbers’.

8. Measurement of cables and conduits shallbe in meters, corrected to nearest cen-timeter.

9. Cable transit blocks shall be measuredseparately in numbers.

10. Cable ducts and cable trays shall bemeasured in length in metres corrected tonearest centimetre according to their sizes,material of construction and other speci fica-tions respectively. Expanders, bends,Tees, etc. shall not be measured separately.

11. All instrument accessories viz. dip tube in-strument air header, air filter regulator,purge rotameter, condensate pot etc. shallbe measured in ‘numbers’.

12. Heat tracing of impulse lines or whereeverrequired shall be measured in metres cor-rected to nearest centimetre of the linestraced.

13. Insulation of pipes shall be measured inlength in metres corrected to nearest cen-timetre.

14. Erection of instrument panels, etc. shall bemeasured in numbers, which includecalibration of all panel indicators, etc. andall the required wiring.

15. Configuration/calibration of instrumentsshall be measured in ‘numbers’.

16. No separate measurements shall be takenfor painting site fabricated items like instru-ment supports, stanchions, structurals,etc.

17. Aluminium sheets/MS sheets for makingshelter for instruments shall be measured insquare metres (corrected to nearest squarecentimetre) according to their respectivegauge/thickness.

18. Items required for the completion of erectionjobs, such as clamps with nuts and lock

25ES403 / 98 - R1


ENGINEERINGSPECIFICATIONS

INSTRUMENTATION WORKSGENERAL SCOPE PAGE 1 OF 2

iso2.sty

PRPD. BY: RECOM. BY: ISSUED BY: ISSUED ON: 26 - 3 - 99

washers, for pipes, clamps for cable trays,strips with bolts for clamping cables ontrays, tag plates, anchor bolts, Al/SS tagsfor cables, cable marking ferrules(Al-phabets & numbers) Aluminium crimpinglugs, GI bolts (hexagonal), machine bolts, Jbolts, U bolts ,other installation materialssuch as teflon tape, pipe dope for threads,sealing compound, cotton waste, kerosene,three in one oil, PVC sleeve,etc. charges forwe lding accessories such asoxygen/acetylene, Argon cylinders/weldingelectrodes etc. shall not be measuredseparately.

19. Copper cable/aluminium strips for earthingshall be measured in length in metres cor-rected to nearest centimetre.

20. Cable ties shall be measured in numbersaccording to their respective sizes.

21. Installation of instruments like control val-ves. flow elements, etc. shall normally beunder the scope of piping contractor butcalibration, hydrotest and loop check are tobe done by instrument contractor. Butequipment and vessel mounted equipmentsshall be in stalled/tested and commissionedby the instrument contractor. Credit formeasurements for such items shall be givenaccordingly. But no separate measurements shall be considered for heavy/lightequipments required for transporting/liftingand installing the equipments.

22. Installation of analysers shall include instal-lation of local sampling system, secondary

sampling system, cabinet and power supplybox, etc. for ca l ibrat ion acces-sories/manifold etc. and for calibration gasno separate measurements shall be con-sidered.

23. No separate charges shall be payable forcalibration equipments, hardware andsoftware work, etc. required for installationand commissioning.

24. Unless specified otherwise, the followingscrap allowances shall be permitted. Thepercentage allowance shall be accountedon the basis of erected weights / length ofcable.

Salvageable Unaccountable

Structural steel 3% .05%

Power cable 2.5% 1%

Control cable 3% 1%

25. For the purpose of accounting departmentalmaterials, all pieces measuring less thanthe following shall be treated as scrap.

-Structural steel - 2M

-Power cable - 3M

-Control cable - 3M

25ES403 / 98 - R1


ENGINEERINGSPECIFICATIONS

INSTRUMENTATION WORKSGENERAL SCOPE PAGE 2 OF 2

*****************************************

INSTRUMENTATION 8122-14-IS-001DEPARTMENT PAGE OF 8 R0

AI AO DI DO

1 PT 101 8122-11-PD-0003 PRESSURE TRANSMITTER Local 1 0 - 25 KG/CM2G

PI 101 8122-11-PD-0003 PRESSURE INDICATOR DCS

2 TT 101 8122-11-PD-0003 TEMPERATURE TRANSMITTER Local 1

TI 101 8122-11-PD-0003 TEMP. INDICATOR DCS

3 PSHH 101 8122-11-PD-0003 PRESSURE SWITCH HIGH HIGH Local 1CONNECTED TO SHIPS SHORE ESD





6 PSHH 201 8122-11-PD-0003 PRESSURE SWITCH HIGH HIGH Local 1CONNECTED TO SHIPS SHORE ESD

7 MOV 101 8122-11-PD-0003 MOTOR OPERATED VALVE Local


9 FT 101 8122-11-PD-0003CORIOLIS TYPE MASS

FLOWMETERLocal 1 0 - 250000 KG/H

FI 101 8122-11-PD-0003 FLOW COMPUTER Local

FI101 8122-11-PD-0003 FLOW INDICATOR DCS

FIC 101 8122-11-PD-0003 FLOW INDICATING CONTROLLER DCS 0 - 250000 KG/H

FCV 101 8122-11-PD-0003 CONTROL VALVE Local 1

10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET


8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET



8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET

8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET

TEMPERATURE COMPENSATON

RemarksRANGE ENGG UNIT

INSTRUMENT SCHEDULE

INSTRUMENT TYPECONNECTIVITY

(LocaL/DCS)CONTROL

PANEL

DCSSlNo. SERVICE/LOCATIONTag No. P&ID No./Ref dwg.

10 TE 101 8122-11-PD-0003 TEMPERATURE ELEMENT Local

11 FFC 101 8122-11-PD-0003 RATIO CONTROLLER DCS

12 FT 201 8122-11-PD-0003CORIOLIS TYPE MASS

FLOWMETERLocal 1 0 - 175000 KG/H

FI 201 8122-11-PD-0003 FLOW COMPUTER Local

FI201 8122-11-PD-0003 FLOW INDICATOR DCS

FIC 201 8122-11-PD-0003 FLOW INDICATING CONTROLLER DCS 0 - 175000 KG/H

FCV 201 8122-11-PD-0003 CONTROL VALVE Local 1

TE 201 8122-11-PD-0003 TEMPERATURE ELEMENT Local


321 CLIENT0 09.09.09 MJ MS SG P.O.NO.

REV DATE PRPD CHKD APPD VENDOR

TEMPERATURE COMPENSATON FOR FT 101


TEMPERATURE COMPENSATON FOR FT 201

12"-LPG-303-3A3S-IC60 LPG TO E 301 INLET

14F

T 6

09 /

05


LPG BLENDING FACILITIES

HPCL, MANGALORE

PROJECT


AI AO DI DORemarksRANGE ENGG UNIT

INSTRUMENT SCHEDULE


(LocaL/DCS)CONTROL

PANEL


14 XEV 101 8122-11-PD-0003 SOLENOID VALVE Local 1

15 PSV 101 8122-11-PD-0003 SAFETY RELIEF VALVE Local


TIC 102 8122-11-PD-0003 TEMP. INDICATING CONTROLLER DCS

TCV 102 8122-11-PD-0003 CONTROL VALVE Local 1





PIAL 401 8122-11-PD-0003 ALARM LOW DCS



23 PG 402 8122-11-PD-0003 PRESSURE GAUGE Local 0 - 6 KG/CM2G


25 PSV 401 8122-11-PD-0003 SAFETY RELIEF VALVE Local

1"-LPG-314-B1A LPG FROM E 301 OUTLET12"-LPG-304-B1A-IC60 LPG FROM E 301 OUTLET

12"-LPG-304-B1A-IC60 LPG FROM E 301 OUTLET

16"-SW-403-(GRP) HEATING SEA WATER I/L TO E301

16"-SW-401-(GRP) SEA WATER TO E 301

1"-SW-410-GRP SEAWATER TO E 301




12"-LPG-302-3A3S-IC60 LPG FROM SM 301 OUTLET


26 FE 401 8122-11-PD-0003 FLOW ELEMENT Local 1

FT 401 8122-11-PD-0003 DP FLOW TRANSMITTER Local 1 0 - 1300000 KG/H

FI 401 8122-11-PD-0003 FLOW INDICATOR DCS





30 AT 401 8122-11-PD-0003 LPG ANALYZER Local 1

AI 402 8122-11-PD-0003 LPG ANALYZER INDICATOR DCS





16"-SW-403-(GRP) SEAWATER TO E 301

12"-LPG-305-B1A-IC60 LPG TO BOOSTER PUMP P 301 A/B


HPCL, MANGALORE

16"-SW-404-(GRP) SEAWATER TO SU 401



14F

T 6

09 /

05

PROJECT



AI AO DI DORemarksRANGE ENGG UNIT

INSTRUMENT SCHEDULE


(LocaL/DCS)CONTROL

PANEL







PAL 1201 8122-11-PD-0003 LOW ALARM DCS

PIC 1201 8122-11-PD-0003PRESSURE INDICATING

CONTROLLERDCS 0 - 30 KG/CM2G

PCV 1201 8122-11-PD-0003 CONTROL VALVE Local 1


37 PG 301A 8122-11-PD-0003 PRESSURE GAUGE Local 0 - 25 KG/CM2G

38 PG 301B 8122-11-PD-0003 PRESSURE GAUGE Local 0 - 25 KG/CM2G



40 TT 404 8122-11-PD-0003 TEMPERATURE TRANSMITTER Local 1 0 - 40 DEG.C


41 TT 102A 8122-11-PD-0003 TEMPERATURE TRANSMITTER Local 1 -50 - 25 DEG.C

12"-LPG-308-B1A-IC60 LPG

MOUNTED ON TOP OF SU 401

12"-LPG-303-3A3S-IC60 E301 INLET

12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 B DISCHARGE

12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 A DISCHARGE

12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 A/B SUCTION



RECEIPT PIPELINE AT MLIF TERMINAL

6"-LPG-301A-3A3S-IC60 UNLOADING ARM OUTLET

TI 102A 8122-11-PD-0003 TEMP. INDICATOR DCS

42 TT 301 8122-11-PD-0003 TEMPERATURE TRANSMITTER Local 1 0 - 40 DEG.C




4"-LPG-310-B1A-IC60 P301A/B DISCHARGE

14F

T 6

09 /

05



HPCL, MANGALORE

PROJECT


AI AO DI DO1 MOV 101 8122-11-PD-0003 MOTOR OPERATED VALVE Local

PB 101 OPEN DCS 1PB 101 CLOSE DCS 1ZSL 101 LOW LIMIT SWITCH Local 1ZLL 101 LOW LOW DCS

ZSH 101 HIGH LIMIT SWITCH Local 1ZLH 101 HIGH HIGH DCS

XSL 101 REMOTE/LOCAL INDICATION Local

XRL 101 REMOTE/LOCAL INDICATION DCS 1






SlNo. SERVICE/LOCATIONTag No. P&ID No./Ref dwg. RemarksRANGE ENGG UNIT

INSTRUMENT SCHEDULE


(LocaL/DCS)CONTROL PANEL

DCS










14F

T 6

09 /

05



HPCL, MANGALORE

PROJECT



AI AO DI DOSlNo. SERVICE/LOCATIONTag No. P&ID No./Ref dwg. RemarksRANGE ENGG UNIT

INSTRUMENT SCHEDULE



DCS











12"-LPG-302-3A3S-IC60 LPG FROM SM 301 OUTLET

6"-LPG-301A-3A3S-IC60






14F

T 6

09 /

05

PROJECT



HPCL, MANGALORE

12"-LPG-304-B1A-IC60



INSTRUMENT SCHEDULE



DCS










ZSH 306 HIGH LIMIT SWITCH Local 1

12"-LPG-313-B1A-IC60

12"-LPG-312-B1A-IC60






14F

T 6

09 /

05



HPCL, MANGALORE

PROJECT



INSTRUMENT SCHEDULE



DCS











12"-LPG-305-B1A-IC60 LPG TO BOOSTER PUMP P 301 A/B



11 P 301A 8122-11-PD-0003 PUMP Local

ML 301A RUNNING INDICATION DCS 1YL 301A TRIP INDICATION DCS 1PB 301A CLOSE/TRIP DCS 1



PROJECT LPG BLENDING FACILITIES

HPCL, MANGALORE


14F

T 6

09 /

05

LPG BOOSTER PUMP A



INSTRUMENT SCHEDULE



DCS

12 P 301B 8122-11-PD-0003 PUMP Local

ML 301B RUNNING INDICATION DCS 1YL 301B TRIP INDICATION DCS 1PB 301B CLOSE/TRIP DCS 1

13 P 401A 8122-11-PD-0003 PUMP Local

ML 401A RUNNING INDICATION DCS 1YL 401A TRIP INDICATION DCS 1PB 401A CLOSE/TRIP DCS 1

14 P 401B 8122-11-PD-0003 PUMP Local

ML 401B RUNNING INDICATION DCS 1YL 401B TRIP INDICATION DCS 1PB 401B CLOSE/TRIP DCS 1

15 P 401C 8122-11-PD-0003 PUMP Local

ML 401C RUNNING INDICATION DCS 1YL 401C TRIP INDICATION DCS 1PB 401C CLOSE/TRIP DCS 1

LPG BOOSTER PUMP B

SEA WATER PUMP A

SEA WATER PUMP C

SEA WATER PUMP B



14F

T 6

09 /

05



HPCL, MANGALORE

R0dial size 150mm 100mm dial material aluminium 304SS 1movement material 304SS 316SS pointer anod. Al. Knife edged 2gauge connection 1/2" NPTM 1/4" NPTM micrometer zero adj. yes no. 3connection type rad. bottom low back tag no. on dial yes no 4case material die cast Al. 304SS case ring type screwed slip 5socket material 316 SS case tightness/gasket vapour tight / neoprene 6accuracy < + 1%fsd < + 0.5% fsd blow out vent yes no 7standard IS3624-1979 window material shatter proof 3mm glass 8max. over pressure 125% high temp. acrylic 9damping no oil filled extra detachable tag 2mm Alu. 2mm 304SS 10dial back ground / marking white/black protection class IP65 IP55 11solid front yes no test & calibration certificate yes no 12

1314

1 2 3 4 5 6 7 8 9 151 11.5 / - 10 / - 0 - 25 A D Y 16

171 18 / - 10 / - 0 - 40 A D Y 18

191 18 / - 10 / - 0 - 40 A D Y 20

211 3.5 / - 25 / - 0 - 6 A D N 22

231 3.5 / - 25 / - 0 - 6 A D N 24

252627282930

1 sensing element type (A) bourdon (B) diaphragm (C) capsule 312 lining material (T) teflon 323 sensing element material (D) 316SS (E) 304SS (F) monel (G) phos. bronze 33

(L) 3/4"NPTF (M) 15 NB 150# (N) 25NB 150# (O) 50 NB 150# 34flange material 316SS PTFE coated SS316 35(P) 1.5mtrs (Q) 2mtrs (R)………… matl. 316 SS 36fluid mercury 37

NPTM sch 80 sch 160 38size 1/2" material 316SS 39end conn. NPTM size 1/2" 40material 316SS 41

8 (W) over range protection device end conn. NPTF size 1/2" 429 (Y) pulsation dampner end conn. NPTM material 316SS 43

Notes:-1 2-Valve manifold shall be provided in SS316.2 The Pressure gauges in sea water line shall be with diaphragm seal.

3210

REV

Note-1

PG 301



12"-LPG-305-B1A-IC60

P 301 A/B Discharge

Note-1

Note-1

14F

T35

2/06


PRPD CHKDDATEMS

CLIENT

sens

ordi

a. s

eal

PG 301A

PG 403

PG 301B

PG 402

VENDORP.O.NO.

HPCL, MANGALORE

4

SGMJ

PROJECT

capillary length

6

(K) gauge connector

(S) syphon

12"-LPG-305-B1A-IC60 P 301 A/B Discharge


APPRD

acce

ssor

ies

5

7

15.01.10

gene

ral

Service temp.

nor./max. oC

range kg/cm2

Sensor

diaphragm seal conn.type

P 301 A/B Suction12"-LPG-305-B1A-IC60

PAGE 1 OF 1

tag no. qty. nos.

press. nor/max kg/cm2

DATA SHEET

LOCAL PRESSURE GAUGE8122-14-DA-00006

dia. seal

accessories remarks

DATA SHEET PAGE 1 OF 3 R0

Integral flush diaphragm seal Integral extended diaphragm seal 1 Remote seal flush diaphragm Remote seal extended diaphragm 2 Standard 1/2" NPT connection 3 Standard analog Smart HART Transmitter, 2 wire 4Local indi.plug in type Analog (or) Digital None 5Enclosure W/P IP65 E/P Non incendive I.S (as per note 2) 6Sensor type Piezo electric Capacitance Mfr. std. 7Accuracy ± 0.25% ± 0.10% ±0.075% Compensation Amb.temp. Pr. 8Output Digital 4-20 mA (HART Protocol) Supply 24V DC 9External zero adjustment Required Cable entry 1/2" NPTF 10Span adjustment Required Drain / vent plugs Yes No 11Zero supr / elev Required Hydraulic test pr. 1.5 time wor.pr 12Calibration Manual By calibrator Painting Epoxy MFRstd 13Damping Adjustable Mtg.bracket with bolts/nuts Reqd. Note 3 14Sensor diagnostics Required Rangeability Min 1:100 1:5 15Tag no. 16Quantity (nos.) 17Service 18

19Fluid 20Wor.pr-nor / max Kg/cm2g 15 21 15 21 21Temp. nor/max. OC -4 - -44 - 22Density at condition kg/ m3 23Sp. gravity/ mole.wt 24Calibrated range Kg/cm2g 25Line size / material 26Type - hp / lp Flanged NPT(F) Flanged NPT(F) Flanged NPT(F) 27Size / rating- hp / lp 28

(ELECTRONIC)

Pro

cess

dat

aT

ype

Gen

eral

8122-14-DA-00007PRESSURE TRANSMITTER

PT 201

1/2" 50 NB 300 #

PT 302ONE ONEONE

PT 101

Propane Line to SM 301 inletButane Line to SM 301 inlet

1/2" 50 NB 300 #

Con

nect

ion

556 - 5900.601/58 0.59 / 52

5830.583/44

0-25250 NB / A333 Gr 1/6 smls

10 -

300 NB/ A106 GR.B PE,smls0-25

200 NB / A333 Gr 1/6 smls

1/2" 50 NB 300 #

0-25

LPG Line

18 -LPG

601

Butane Propane

.

Size / rating- hp / lp 28Ref. Sketch 29Capillary length m 30Exte. Diap. Length mm 31Process flange ANSI 304L SS 32Bolts and nuts ANSI304 SS 33Isolating diaphragm 34Wetted parts 35Capillary 36`O' ring PTFE 37Accessories 38

39Make / model no. 40

41Notes: 1 Additional cable entry shall be plugged with 1/2" NPT 316SS plug. 42

2 Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification. 433 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 444 Built in lightning protection shall be provided 45

464748

321 CLIENT0 13.10.09 MJ MS SG P.O. NO

REV DATE PRPD CHKD APPRD VENDOR

-

PROJECT

HPCL, MANGALORE

PR

. XT

TR

Mat

eria

l

-

2-Valve manifold, Double Compression SS Cable Gland PTFE

- 1/2" 50 NB 300 #

ANSI304 SS

-

14F

T35

1/94



PTFE

1/2" 50 NB 300 #

Con

nect

ion

-

-

ANSI 316 SS ANSI 304L SS

ANSI316 SS ANSI 304L SS ANSI 304L SS

ANSI 316 SS ANSI304 SS

- 1/2" 50 NB 300 #

- ANSI304L SS ANSI 304L SS

-



19Fluid 20Wor.pr-nor / max Kg/cm2g 12 30 21Temp. nor/max. OC 10 - 22Density at condition kg/ m3 23Sp. gravity/ mole.wt 24Calibrated range Kg/cm2g 25Line size / material 26Type - hp / lp Flanged NPT(F) 27Size / rating- hp / lp 1/2" 50 NB 300# 28

Con

nect

ion

0.556 / 552

300 NB / A106 GR.B PE,smls

ONE


PT 1201

(ELECTRONIC)

Pro

cess

dat

aT

ype

Gen

eral

LPG line at MLIF Terminal

0 - 30

556

Propane

.

Size / rating- hp / lp 1/2" 50 NB 300# 28Ref. Sketch 29Capillary length m 30Exte. Diap. Length mm 31Process flange ANSI 304L SS 32Bolts and nuts ANSI304 SS 33Isolating diaphragm ANSI 316 SS 34Wetted parts ANSI 304L SS 35Capillary 36`O' ring PTFE 37Accessories 38



2 Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification. 433 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 44

45464748



Con

nect

ion

2-valve manifold, Double compression SS Cable gland

14F

T35

1/94


LPG BLENDING FACILITIESPROJECT

HPCL, MANGALORE

-

PR

. XT

TR

Mat

eria

l

--



19Fluid 20Wor.pr-nor / max Kg/cm2g 3.5 - 21Temp. nor/max. OC 25 - 22Density at condition kg/ m3 23Sp. gravity/ mole.wt 24Calibrated range Kg/cm2g 25Line size / material 26Type - hp / lp Flanged NPT(F) 27Size / rating- hp / lp 28

(ELECTRONIC)

Pro

cess

dat

aT

ype

Gen

eral

Sea Water to E301 inlet


PT 401ONE

0 - 6

997

Sea Water

Con

nect

ion

0.997 / 18

400 NB / GRP

1/2" 25 NB 150 #

.

Size / rating- hp / lp 28Ref. Sketch 29Capillary length 30Exte. Diap. Length mm 31Process flange 32Bolts and nuts 33Isolating diaphragm 34Wetted parts 35Capillary 36`O' ring 37Accessories 38



2 Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification. 433 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 444 Built in lightning protection shall be provided 45

464748



PROJECT

HPCL, MANGALORE

Double compression SS Cable gland

-

PR

. XT

TR

Mat

eria

l

PTFE

-

14F

T35

1/94



1.5 m

Con

nect

ion

1/2" 25 NB 150 #

Hastelloy C ANSI 304L SS

Hastelloy C Hastelloy C

ANSI304 SS

Type Direct Receiver Case Aluminium 1Switch form Snap acting micro switch Enclosure Ex. Proof I.S. (Note 2) 2Switch type SPDT DPDT Weather proof IP65 3Contact rating 24 V DC 0.5A Area classification 4No. of switches One Two Connection 1/2" NPTF 1/4" NPTF 5

O / R protection 150% of Design pressure 6Differential Adjustable Fixed Repeatability ' + 1% of span 7

Internal External Cable entry 1/2" NPTF 3/4" NPTF 3/4" ET 8Tag no. 9Quantity(nos.) 10Service 11Location 13Fluid 14

Pr. Nor / max. kg/cm2g 15 21 15 21 15

Temp. nor / max. OC -4 -44 16

Sp. gravity / density kg / m3 0.601 601 0.583 583 17Viscocity cP 18% Solids 19Element type ref. 20Element material 21Conn. Size / type 22Range 23Min. differential 24Set points Single Double Single Double 25

High Low High Low 26Alarm set value in kg/cm2g 27Accessories 28

2930

Over range protection 31Make 32 model no. 33

** Manufacturer to specifyNotes:-1. Connected to Ship's Shore Emergency Shutdown System.2. Area classification is Zone 2, Gr.IIA,IIB.Switches shall be with EExia certification for area classification.

3



PROJECT



HPCL, MANGALORE

316SS1/2" NPTM/Threaded

0 - 25 kg/cm2g

150% of Design pressure

PSHH 101ONE

Butane line

0.192

**

Propane

0 - 25 kg/cm2g

21

Gen

eral

Pro

cess

dat

a

Ele

men

t / C

onne

ctio

n

TO SM 301 INLETButane

0.204

14F

T35

3/94

**316SS

21

1/2" NPTM/Threaded

150% of Design pressure

R0

ONE

IEC Zone 2 Gr II A, II B, T4

PSHH 201

Propane lineTO SM 301 INLET

8122-14-DA- 00008DATASHEET

PRESSURE SWITCH PAGE 1 OF 1

JOB :

R0measurement massflow density both WP IP 65 E/P Exia 1sensor type coriolis thermistor intrinsic safe non-incendive 2mounting in line horizontal insertion type vertical 3transmitter remote integral output 4-20 mA + HART Protocol 4transmitter type elect(analog) m.P based no.of outputs one two 5probe length (thermistor) 800 mm cable entry 1/2" NPT 6power supply 24 VDC 110V AC 230V AC painting epoxy mfr.std 7accuracy ± 0.25 % local indicator reqd. not reqd. 8display type alpha nume. LCD type interconn. Cable reqd. not reqd 9temp. correction reqd. not reqd. press. Correction reqd not reqd 10tag no.& quantity (nos.) FT/FIC 101 FT/FIC 201 11

1213

fluid liquid gas liquid gas 14gas composition 15pressure kg/cm2g 15 15 16temperature (oC) 17

density (nor.) kg/m3 601 583 18

density range (kg/m3) 19viscosity cP 0.204 0.192 20flow normal/max/min. Kg/h 210000 / 250000 / - 21flow range Kg/h 22line size / class 250 NB/ 300# SCH 40 200 NB/ 300# SCH 40 23allowable press.drop mmWC 5000 5000 24type flanged flanged 25size /rating /material 26pipe ID 27probe matl. (thermistor type) AISI 316 SS AISI 316 SS 28sensor matl.(thermistor type) glass encapsulated glass encapsulated 29measuring tube 316 LSS hastalloy-C SS 304L 316 LSS hastalloy-C SS 304L 30housing AISI 304SS AISI 316 SS AISI 304SS AISI 316 SS 31terminal box Die cast Alu AISI 316 SS Die cast Alu AISI 316 SS 32cable length - m 300 mfr to specify 300 mfr to specify 33sensors & transducers pressure temp. (Note 5) pressure temp. (Note 5) 34staightener-provide if reqd. required not required required not required 35

purge conn. moisture trap purge conn. moisture trap 36 cooling / heating fins cooling / heating fins 37

make / model 38

Notes : 1. Sizing of the meter shall be done by the vendor for the following conditions. Meter size shall be selected accordingly.2. Reducer-expanders, materials same as line material with flanges, bolts and nuts shall be provided.3. Sizing calculations shall be submitted for review.4. Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification.5. Temperature elements shall be provided externally to provide temperature compensation.

CLIENTP.O. NO

15.01.10 MJ MSDATE PRPD CHKD


acce

ssor

ies

mat

eria

l

others

140000 / 175000 / -

conn

ecti

on * / 300# / SS304L (Note 1) * / 300# / SS304L (Note 1)

enclosure

Propane line

-4

0 - 250000 0 - 175000

Butane line

14F

T16

2 / 0

6

REV

21


0 SG

HPCL, MANGALORE

VENDORAPPRD

43

PAGE 1 OF 1

8122-14-DA-00010MASS FLOW METER

service

DATA SHEET

gene

ral

proc

ess

data

-44

R 0tag no. 1

qty. (nos.) 2

3

4

location 5

fluid:wet gas / dry gas 6

steam / gas ratio of wet gas 7

wor. pr./ design pr. kg/ cm2g 8

wor.temp./ design temp. 0 C 9

density at wkg. condn. kg/m3 10

molecular weight 11

compressibility factor 12

gas law deviation constant 13

viscosity at condn. (cSt) 14

flow min / nor. / max. at condn. / unit, Kg/hr 15

flow at max. instrument range Kg/hr 16

allowable pressure drop. mmWG 17

d/p at max. flow `h' mmWG 18

line size / material / schedule 19

pipe ID (mm) 20

slip plate carrier unit 21

sq. edged int. orice 22

conical entrance 23

24

bore location concentric 25

tapping type flg corner D & D/2 26

flange size / rating 27

flage std. / material 28

element material / thickness note 1 29

throat dia. `d'/ ratio (approximate) 30

drain / vent hole size mm. 31

drain / vent hole location from c/l of orifice 32

impulse tapping size 1/2" NPT(F) 33

calculation standard BS 1042,1989,92 ISO 5167 34

ref. std. no. 35

adjacent piping yes no 36

orifice flange yes no 37

isolation valves yes no 38

pipe unit yes no 39

recommended str. length - up / downstream mm. 40

IBR certificate Required 41Notes : * Vendor to furnish.1. Thickness of the element to ISA RP 3.22. See DP Flow transmitter datasheet no: 8122-14-DA-00012

CLIENTMJ MS P.O.NO.

PRPD CHKD VENDOR

PROJECT

FLOW ELEMENT ORIFICE PLATE

5000

Monel

SEA WATER TO E 301

FE 401co

nnec

tion

DATE APPRD15.01.10 SG

acce

ssor

y / m

ater

ial

DATA SHEET

14F

T15

5/03

8122-14-DA-00011 PAGE 1 OF 1

proc

ess

data

-

service

3

elem

ent d

etai

ls


210

REV


HPCL, MANGALORE

element type

16"-SW-403-(GRP) Sea Water

-

400NB / GRP / -

3.5 / -25 / -

0.89- / 1110000 / 1300000

ONE

997

1300000

181

-

-

*

396.87

0.66*

OF 1 R0 Integral flush diaphragm seal Integral extended diaphragm seal 1 Remote seal flush diaphragm Remote seal extended diaphragm 2 Standard 1/2" NPT connection 3 Standard analog Smart Transmitter, 2 wire HART Protocol 4Local indi.plug in type Analog Digital None 5Enclosure W/P IP65 E/P NEC Cl Div Gr Non incendive I.S.(Note 1) 6Sensor type Piezo electric DP Mfr. std. 7Accuracy (cal.range) ± 0.25% ± 0.10% Amb.temp. Pr. 8Output Digital 4-20mA 9External zero adjustment (Local) Required 10Span adjustment (Local) Required Yes No 11Zero supr / elev Required 12

Calibration Manual By calibrator 13Damping Adjustable Mtg.bracket with bolts/nuts Reqd 14Sensor diagnostics Required 1:100 15Tag no. 16Quantity (nos.) 17Service 18Type of measurement 20Fluid 21

kg/hr 22Wor.pr-nor / max kg/cm2 g 23Wor. temp.OC Nor/ Max 24Density at condition kg/ m3 25Sp. gravity / mole.wt 26Viscosity- cP 27Calibrated span mmWC 28d / p at 0% / 100% mmWC 29Line size / material 30Type - hp / lp Flanged NPT(F) 31Size / rating- hp / lp 32Ref. Sketch 33Capillary / ext.diaph.length 34Process flange 35Bolts and nuts 36Isolating diaphragm 37Wetted parts 38Capillary 39Body Material 40'O' ring PTFE 41Accessories 42Make / model no. 43

1. Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification. 442. 2" Pipe Mounting Bracket and mounting kit shall be provided.3. Additional cable entry shall be plugged with 1/2" NPT 316SS plug.4. Buit-in lightning protection required.5. Pressure drop at max. flow to be used for sizing. See flow element datasheet no: 8122-14-DA-00011

3 PROJECT21 CLIENT0 15.01.10 MJ MS SG P.O. NO


1.5 time wor.prEpoxy

24V DC1/2" NPTF Cable entry

Drain/vent plugs Hydraulic test pr. Painting

by mfr.

SS 316D

P.X

TT

R

HPCL, MANGALORE


Double Compression SS Cable Gland

Flow

ONESea water

TRANSMITTER (ELECTRONIC)DIFFERENTIAL PRESSURE

FT/FI 401

8122-14-DA-00012

1:50 Rangeability

Compensation Supply

Typ

eG

ener

alP

roce

ss d

ata

Con

nect

ion

5m x 2 Nos

Flow normal/max

- / 5000 (Note 5)400 NB/ GRP

14F

T40

1/99


Mat

eria

l

3.5/- 25/-997

0.997/180.89

0 - 5000

1110000 / 1300000

Notes:

DATASHEET

Hastelloy C ANSI304 SS Hastelloy C Hastelloy C

1/2" 25 NB 150#

Sea water

8122-14-DA-00013

Page 1 OF 1 R01

1 Tag Nos. FFC 101 2

2 Quantity 1 No. 3

3 Enclosure Protection Exia for area classification Zone II Gr II A, II B. / WP IP65 4

4 Cable Entry 1/2" NPT(F) 5

5 Cable Glands Required 6

6 Mounting Field/ Panel Field 7

7 Case Material ** 8

8 Input Types Temperature RTD 9

Pressure -- 10

Flow Analog, 4-20 mA 11

9 No of Inputs 3 12

10 Display type Backlit LCD, Alphanumeric display 13

11 Keyboard Required 14

12 Alarm Contacts Required, 2 Nos 15

13 No of Outputs 2 ** 16

14 Output Range 4 - 20 mA 17

15 Communications Serial Comm. With selectable baud rate and parity. 18

16 Sensitivity ** 19

17 Accuracy ** 20

18 Power Supply V/I/Hz 24 VDC 21

19 Power consumption in W ** 22

20 Operating Temperature Deg.C 17 Deg.C - 40 Deg.C 23

24

25

** Manufacturer to specify 26

27

28

DATASHEET

FLOW COMPUTER

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

4 PROJECT32 CLIENT HPCL, MANGALORE1 P.O. NO0 15.01.10 VENDOR

REV DATE PRPD CHKD APPRD

14F

T63

6A/9

4

MJ


MS


SG

DATA 8122-14-DA-00015SHEET PAGE 1 OF 1 R0

Type Thermocouple grounded RTD 1

Element material Pt - 100 Reference standard ANSI-MC-96.12 DIN 43760 2

Sheathed yes no Sheath material Inconel 600 SS 316 SS 304 3

Mineral insulation MgO Ref. Sketch 4

sheath OD 6 mm Thermocouple wire size 18 SWGfor single 5

Thermowell yes no 22 SWGfor duplex 6

No. of leads 2 3 4 34 SWG for type-R 7

Construction bar stock drilled Fabricated Vibration proof Req. Not req. 8

Connection type Flange Note 2 Screwed Welded 9

Hydraulic test 100 Kg/Cm2 or 1.5 times max. working pr., Whichever is greater 10

Radiographic test (both planes) Required for 10% of total no of thermowells 11

Details to be punched on flange Tag no., flange size, rating & material of thermowell 12

Enclosure Weather proof IP 65 Explosion proof IEC Zone 1 Gr II A, II B, T4 Safe 13

Material Die cast Aluminium No of cable entries 1 2 14

Cover Screwed Cap Chain for head cover Required 15

Spring loaded type Required Corrosion proof tag plate Required 16

Cable entry 1/2" NPT(F) 3/4"NPT S-single D-duplex L-immersion length 17

Connection to thermowell 1/2" NPT(M) M- Multi assembly 18

Qty press. Temp. Range T/W conn. Size/ 'L' Line S/D 19

Tag no nos. nor/max nor/max deg C rating/material mm size IBR /M 20

kg/Cm2g deg C /matl 21

1 15 -4 / - -50 - 25 300 250 NB Not req. D 22

1 15 10 / - 0 - 40 300 200 NB Not req. D 23

1 15 -4 / - -50 to 25 300 250 NB Not req. D 24

1 13.2 10 / - -25 to 25 300 300 NB Not req. D 25

1 18 10 / - 0 to 40 250 100 NB Not req. D 26

1 15 -44 / - -50 to 25 300 200 NB Not req. D 27

1 3.5 25 / - 0 to 40 300 400 NB Not req. D 28

1 3.5 20 / - 0 to 40 300 400 NB Not req. D 29

1 ATM 20 / - 0 to 40 400 Tank Not req. D 30

1 13.2 -20 / - -50 to 25 300 300 NB Not req. D 31

32

33

34

35

36

37

38

39

40

41

42

Notes:1. Thermowell Flanges shall be as per ANSI B16.5.

2. For the Temperature elements with asscociated transmitters see attached datasheet no. 8122-14-DA-00016

CLIENTP.O. NO

MJ MS SGPRPD CHKD APPRDDATE

LPG line

Propane line

Butane line

Propane line

Butane line

TEFACT ENGINEERING AND DESIGN ORGANISATION

HPCL, MANGALORE

REV

4321

15.01.10

TE/TT 401

TE/TT 402

TE/TT 404 Sea Water (SU 401)

LPG line

40NB / 300# / HastelloyC


TEMPERATURE ELEMENT

0

40NB / 300# / SS304

40NB /300#/ SS304

40NB / 150# / Monel400

TE/TT 101

TE/TT 102

TE/TT 301

VENDOR

E

LEM

EN

TT

HE

RM

OW

ELL

H

EA

D

PROJECT

Service

TE 101

TE 201


14F

T40

1/94

TE/TT 201

TE/TT 102A

Sea Water

Sea Water

Propane line


40NB / 300# / SS304

40NB / - / Monel400

40NB / - / Monel400


DATA 8122-14-DA-00016SHEET PAGE 1 OF 1 R0Input to Transmitter RTD Pt 100 T/C type 1Output 4 to 20 mA 2 wire system Smart with HART protocol 2Supply voltage 24 V DC 3Enclosure weather proof IP 65 EExia as per IEC Zone 2 Gr II A, II B. Safe 4Local indication required Not required 5Painting epoxy 2 coats 6Cable entry 1/2" NPT (F) 3/4" NPT 2 nos 7Accuracy +/- 0.2 % +/- 0.5 % 8Accessories mounting brackets, bolts & nuts suitable for 2" pipe mounting Double comp.SS CG, SS316 Plug 9

1011

Sl. No Qty. Range 1213

1 -50 to 25 14

1 -25 to 25 15

1 0 to 40 16

1 -50 to 25 17

1 0 to 40 18

1 0 to 40 19

1 0 to 40 20

1 -50 to 25 14

15

23

24

25

26

27

28

29

3031323334

35

36

37

383940

Notes:

1 Vendor shall include all fittings and accessories as required for mounting as Integral head mounted transmitter.

2 2 nos of cable entries shall be provided for the transmitter. One number shall be plugged with SS316

and the other shall be provided with SS cable gland.

3 Each instrument shall be marked with the following

Instrument tag No.,Instrument Sr. No., Manufacturer’s name, Instrument range and engineering units.

Sizes of cable entry and element entry to thermowell shall also be marked.

CLIENTP.O. NO

MJ MS SGPRPD CHKD APPRD

TT

0DATE

15.01.10

TEMPERATURE TRANSMITTER

14F

T40

3/94

VENDOR

PROJECT


REV

4321

Remarks


TT/TI 101

LPG lineTT/TIC 102

TT/TI 301

TT/TI 201

TT/TI 401

Butane line

LPG line

Sea water

Sea water (SU 401)

LPG line

Tag no Service

Propane line

Sea water

1

2

3

4

HPCL, MANGALORE

TT/TI 402

TT/TI 404

TT/TIC 102A

5

6

7

8

8122-14-DA- 00020Page 1 OF 1 R0

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

9 9

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 18

19 19

20 20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

4 PROJECT32 CLIENT1 P.O. NO0 15.01.10 VENDOR

REV DATE

3. Commissioning and calibration of instruments shall be in vendors scope. Vendor shall supply all the materials required for this.

Notes:

1. Vendor shall specify the current consumption required for the Instrument.2. Vendor shall specify and supply all the accessories required for the sensor.

LPG BLENDING FACILITIESHPCL, MANGALORE

HYDROCARBON DETECTORS

Ingress Protection IP65Sensitivity 1% LELAccuracy

FACT ENGINEERING AND DESIGN ORGANISATION14F

T63

6A/9

4

APPRDCHKDPRPDMS SG

DATA SHEET

Above 0% LELSensor Case Stainless Steel 316

+/-3% LEL PropaneResponse timeSelf Test RequiredRelative humidity 0 to 99% (without condensation)Output signal 4 - 20 mA

MJ

Tag No. GM 101, GM 102, GM 103, GM 104Detection Principle Infrared absorptionGases detected Hydrocarbons (LPG)Range

T90<30sec

Power supply 24 VDCOperating temperature 17 Deg.C - 40 Deg.C // 20 Deg.CEnclosure Exproof Exd for area classification Zone II Gr II A, II B.Cable entry 1/2" NPT (F)

Quantity 4 nos.

Cable glands Required, MOC shall be SSElectro magnetic compatibility Protection against RFI/EMI and lightning strike required

To be provided in gas cylinder with known ppm of LPG along with calibration kit

Calibration gas

8122-14-DA- 00021Page 1 OF 1 R1

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 9

9 10

10 11

11 12

12 14

13 15

16

17

18

19

20

21

22

23

24

25

26

27

1 Vendor shall specify the current consumption required for the Instrument arrangement. 28

2 29

3 30

31

4 32

33

5 34

35

36

37

38

4 PROJECT32 CLIENT1 12.02.10 P.O. NO0 13.10.09 VENDOR

REV DATE

Sensor Case

FACT ENGINEERING AND DESIGN ORGANISATION14FT

636A

/94

APPRDCHKDPRPDMS SG

SG

3.5Kg/cm2

Notes:

Vendor shall specify and supply all the accessories required for the sensor arrangement.

DATA SHEET

Gases detectedProcess Fluid

Analyser (LPG)Sea water 100%

ANALYSER

Output signal

RangeStainless Steel 316

Sea water line Pressure

LPG, Above 0%

Tag No. AT 401Location/Line no. 16"-SW-404-(GRP)Service

MJMS

Sea water outlet of E301

Power supply 24 VDCOperating temperature 20 0C

4 - 20 mA


MJ

Commissioning and calibration of instruments shall be in vendors scope. Vendor shall supply all the materials required for this.

Cable entry for instruments 1/2" NPT (F)

M/S.HPCL, MANGALORE

Cable glands Required, MOC shall be SS

A typical schematic of analyser is given vide 8122-14-MD-016. The arrangement shall be in a purged panel with adequate ingress protection. The scheme proposed by the contractor shall be submitted and got approved before proceeding with procurement.

1

DATA SHEET

CONTROL PANEL (RTU)

8122-14-DA-00022

Page 1 of 3 R0

4 PROJECT ON LINE LPG BLENDING FACILITIES 3

2 CLIENT M/s HPCL 1 P.O. NO 0 15.01.10 MJ MS SG

VENDOR FEDO

REV DATE PRPD CHKD APPRD


14FT

106/

94

gene

ral

Type Self standing Wall mounted Open Explosion proof W/P 65

Desk Enclosed cubicle Back open Air purged Dust proof

Location Indoor Outdoor

Front arrangement Ordinary Semigraphic Graphic

Atmosphere Air conditioned Air purged Explosive gas Corrosive gas Non A/C room

size

Length 800 mm No. of sections One

Height 2000 mm in total (with out channel base) 100 mm for channel base

Depth 800 mm

Semigraphic board Height mm Length of each sections mm No. of sections

cons

truc

tion

Material Cold rolled carbon steel sheets for panel HRS For semigraphic board

Thickness of steel sheets Front board 3 mm Semigraphic board mm

Side board 2 mm Back board 1 mm

Celling board 2 mm Bottom 2 mm

Gland plate 3 mm

Type of semigraphic Fibre glass Rear engraved Screen printing

Stiffener 40 x 40 x 6 t angle

Channel base 100 x 50 x 6 t channel One unit for panels

Parts mounting 45 x45 x 2 t univer. channel 45 x 22.5 x 2 t univer. channel

Joint of front board Tight flush type Bent type Welded

Door Required Not required Seal packing Handle with key

Location Rear Right side Left side Both sides

Front RTU Panel- split door

Illumination Inside Outside-front Fluorescent 60 W AC 230V

Door switch Hand lamp lamp nos./ sect.

Cable entry Bottom (gland plate) Side Top

pain

ting

Colour Out side surface Grey Inside surface White Tubing

Channel base Black Graphic symbol see attached sheet Air supply

Finish Glazed with two coats of lacquer Semi matt with three coats of paint

Powder Coated Matt finish Silk screen for semigraphic

Painting process Standard * Manufacture’s standard

tubi

ng Tubing material / size

Bulk head size / material

Position of bulk head Front Back Bottom Upper $

*- powder coated after required chemical processing. $ - Side - Top

DATA SHEET

CONTROL PANEL (RTU)

8122-14-DA-00022

Page 2 of 3 R0


wiri

ng

Wiring method PVC duct Conduit pipe

Wire size Signal 0.5 sq. mm Control cables1.5 sq. mm Main source 2.5 sq. mm

Colour identification as per IS 375 Yellow for AC control circuit interlock Blue for DC control circuit

Green for earthing circuit Grey for alarm circuit

Red for phase, black for neutral AC Red & blue for DC lines supply

power

Wire marker Required

Terminal Open stack type Phoenix type/Elmex/wago *

Terminal board With tag no. plate With insulation cover

Terminal board pos. Side Front Back Bottom Upper

el

ectr

ic s

ourc

e

Source AC100V AC 110V AC 230V 50 Hz 60 Hz

Transformer KVA x V Dry type sets

Main switch NFB one per each phase x one sets

Switch for instruments Snap switch Separate for each instrument Isolator for

Fuse main supply

DC source Yes No See attached sheet

Voltage stabiliser Yes No. See attached sheet

Earthing With earthing terminals

Inte

rlock

sys

tem

&

oth

ers

Alarm annunciator Required Not required Specification

Interlock system Required Not required Spec . No. Drg. No.

Ammeter Required Not required Accuracy Size Sets

Qty. as required Ind. lamps Selector switches Push button switches

nam

e pl

ate Material / size Acrylic resin formica 50mm X 30 mm X 1mm thick

Colour Letters White Black Size

Back ground White Black

Letters Engraved Painted

acce

ssor

ies

Clock Yes No. Electric type Digital Mechanical

Anchor bolt & nut Required

Eye bolt Required

Plug & socket AC120V class AC 220V class DC 24V class Sets

Exhaust fan AC 100V AC 110V 2sets

Tool box Wooden Steel mm(W) X mm(H) X mm(D)

Floor plate mm X mm X sets

Communication unit Hand lamp with cable

Cable gland Nickel plated brass, double compression type (As required)

Notes: - * - Terminal blocks shall be grouped as follows:- 1) TB1- for power supply;

2) TB2 –Analog Inputs /Outputs 3) TB3- Digital inputs 3) TB4 – Digital Outputs to SOV

DATA SHEET

CONTROL PANEL (RTU)

8122-14-DA-00022

Page 3 of 3 R0


mou

nted

spa

re c

ards

Stop valve 10% 20%

Bulk head 10% 20%

NFB 10% 20%

Switch for instrument 10% 20%

Terminal board 10% 20%

Cable glands 10% 20%

Lamp 10% 20%

Fuse unit 10% 20%

Pressure switch 1 no.

Annunciator card 10% 20%

com

mis

sion

ing

spar

e pa

rts

Relay 10% nos.

Lamp 10% nos.

Fuse 10% nos.

Lamp holder 10% nos.

Board union % nos.

Copper ring % nos.

Terminal 10% nos.

Paint for repairing 10% nos.

Push button switch 10% nos.

Snap switch 10% nos.

Notes: Relay : OMRON Make

Coil voltage : 24 VDC,

Contact rating : 110 VAC, 5A

Mounting : Din Rail

Necessary channel & hold on clips must be included

DATA 8122-14-DA-00023SHEET PAGE 1 OF 2 R01 Type Termination box Junction box2 Purpose Connecting the electrical / signal cables from individual instruments

with transmitters located at distant places From individual instruments with the multicore going to the C / R

3 Enclosure Weather proof as per IP 65 Increased safety Explosion proof as per NEC Class Div Gr note 4

4 Dimension mm (W) X mm(H) X mm(D)mm diameter Note 1

5 Material of construction Sheet steel of thickness 2.5 mm Cast iron LM6 Al Alloy6 Type of lever Bolted& Hinged ( lift off type robust in construction capable of

supporting the door when opened) Screwed7 Gasket / O-ring Non - deteriorating sealing strip gasket O - ring of material8 Mounting Wall mounting Bracket mounting Pedestal mounting

Pipe mounting Note 39 Cable gland material Nickel plated brass 304 SS Aluminium10 Type of cable gland Explosion proof W/P single compression double compression

Check nut for ET cable glands11 Finish Painted with 2 coats of grey colour outside and white inside over

2 coats of primer for sheet steel Painted with grey colour outside and white inside Damp proof and vermin proof Mfr. std.

12 Name plate White plastic tag plate Non-corrosive SS tag plate. Ref.note (2) 13 Junction box to be provided with Size drain hole at bottom with plug Drain fittings Breather14 One terminal block For connecting the shield drain wires15 Two terminals provided for Connecting telephone wires from multicore cables16 Earthing terminal Provided outside the box17 Junction boxes shall be suitable for Outdoor operation subjected to direct sun & rain without further

protection from weather18 Certificates For explosion proof from CMRS, Dhanbad19 Reference drawing no. 8122-14-MD- 00620 Quantity (nos.) 721 Make / model no. Mfr to specify

Notes:-1) Manufacture to provide exact dimensions2) Tag Nos. JBS 001,JBS 002,JBS 003, JBS 004, JBS 005, JBS 006, & JBC 0013) JB's shall be suitable for pedestal / frame mounting4) Junction boxes shall be exproof Exd to area classification, Zone 2, Gr II A/IIB.

321 CLIENT M/s. HPCL, Mangalore0 14.01.10 MJ MS SG



PROJECT ON LINE LPG BLENDING FACILITIES

14F

T20

3/94

ELECTRICAL JUNCTION BOXES - FOR SIGNAL /CONTROL

Thermocouple junction box


1

Nos. 2

3

4

1 5

6

7

8

Nos. 9

24 min. 10

11

12

13

14

15

Terminals shall be suitable for 1.5 sq.mm.wires.

Cable size - 1 PAIR 16AWG screened armoured signal cable

Multicore: 6 pair 20AWG individual & overall screened armoured signal cable

A

C D

B

Side (C/D) Bottom(B) Top

ELECTRICAL JUNCTION BOXES - FOR SIGNAL/CONTROL

22.Cable entry with cable glands

Size Location

8122-14-DA-00023

Note:


Antivibration springs loaded terminals.

on DIN standard Ts-35

Earth strip shall be insulated from other metallic parts. Each terminal strip/terminal box shall be foreseen with space for terminating all shield earth wires for individual cables and 1multicore cable (totally 7 Nos.).

Terminals shall be of Phoenix/Equivalent type of SS 304 in poly

amide for mounting

Type of terminal Material of terminal

1/2" NPT 6

23.Terminals

1 1/4" NPT

Size

DATA 8122-14-DA-00024SHEET

Item number 1

Standard 2

Voltage class(Insul. Class) 3

Material 4

Type solid/stranded 5

Size 6

Material 7

Type 8

Size 9

No. of cores 10

Core arrangement 11

Material 12

13

Overlap 14

Wrapping style 15

Material 16

Type 17

Size 18

Material 19

Wraping style 20

Overlap 21

Material 22

Tickness/size 23

Material 24

25

Material 26

As per core dia.

GAL. STEEL

PVC extruded type ST2,FRLS

PAGE 1 OF 2 R0

C

IS 1554 / IS 694

300V

AT COPPER

PVC extruded type C 850C PVC extruded type C 850C

20 AWG

NON HYGROSCOPIC

HELICAL

50%50%

HELICAL

3 CORE

TWISTED

STRANDED - 7

16AWG

PVC / Type C 800C

TINNED COPPER

7 ' STRANDS

0.3mm *

A

As per core dia.


0.3mm *

20 AWG

NON HYGROSCOPIC

HELICAL

TINNED COPPER

7 ' STRANDS

25%

HELICAL

EXTRUDED

ALU. BACKED MILAR

0.25

0.075mm *0.075mm *

ALU. BACKED MILAR

PVC / Type C 800C

1.1mm *

ALU. BACKED MILAR

EXTRUDED EXTRUDED

0.8mm *

TWISTED

6 PAIR

1.1mm *

TWISTED

1 PAIR

20AWG

Shi

eldi

ngD

rain

wire

Bin

der

Fill

er

As per core dia.

50%

PVC extruded type C 850C

20 AWG

CABLE - SIGNAL / CONTROL / POWERC

ondu

ctor

Insu

latio

nC

ore

AA

IS 1554 / IS 694

300V

COPPER

STRANDED - 7

GAL. STEEL

She

ath

IS 1554 / IS 694

COPPER

300V

STRANDED - 7

16AWG

PVC / Type C 850C

Thickness/size

Thickness (Min.)

0.075mm *

25%

HELICAL

GAL. STEEL


0.3mm *

TINNED COPPER

7 ' STRANDS

NON HYGROSCOPIC

HELICAL

Material 26

Type 27

28

Material 29

30

Type 31

Drum length 32

Cutting length 33

Drum length tolerance 34

Communication wire 35

Colour coding 36

Core 1 37

Core 2 38

Core 3 39

Outer sheath 40

Note 1) Drum length shall be finalised based on cutting length at site

CLIENT15.01.10 MJ MS SG PO.NO



BLACK

50 M

GAL. STEEL

ROUND WIRE

1.4mm *

PVC type ST2,FRLS

1.24mm

EXTRUDED

+5%

RED

-

+5%

RED

300 M

GAL. STEEL

1.4mm *

PVC type ST2,FRLS

1.4mm

EXTRUDED

2000M (Note 1)

14F

T20

2 / 9

4

Arm

our

Ove

rall

shea

th

* thickness shall be selected as per IS standard

Thickness/size

Thickness

+5%

1.4mm *

RED

BLACK

GAL. STEEL

1.24mm

01


M/s HPCL

ROUND WIRE

EXTRUDED

ROUND WIRE

PVC type ST2,FRLS

-

-

REQUIRED

BLACK

DATA 8122-14-DA-00024SHEET PAGE 2 OF 2 R0

Item number 1

Standard 2

Voltage class 3

Material 4

Type solid/stranded 5

Size 6

Material 7

Type 8

Size 9

No. of cores 10

Core arrangement 11

Material 12

Thickness/size 13

Overlap 14

Wrapping style 15

Material 16

Type 17

Size 18

Material 19

Wraping style 20

Overlap 21

Material 22

Tickness/size 23

Material 24

Thickness 25

Material 26

Type 27

Thickness/size 28

Material 29

Thickness 30

Type 31

Drum length 32

Cutting length 33

Drum length tolerance 34

Communication wire 35

Colour coding 36

Core 1 37

Core 2 38

Outer sheath 39

CLIENT15.01.10 MJ MS SG P.O.NO.



PVC / Type C 850C

STRANDED-7

As per core dia.

1.2mm *

2 CORE

TWISTED

NON HYGROSCOPIC

2.5mm2

0.5

PIS 1554 / IS 694

650V

COPPER

PVC type ST2,FRLS

+5%

BLACK

EXTRUDED

PROJECT

M/s. HPCL


RED

1.4 mm *

HELICAL


0.3mm *

GAL. STEEL

ROUND WIRE

1.4 mm *

Shi

eldi

ngD

rain

wire

Bin

der

Fill

erC

ondu

ctor

Insu

latio

nC

ore

PVC

Extruded type C 850C

CABLE - SIGNAL / CONTROL / POWER14

FT

202

/ 94

She

ath

Arm

our

Ove

rall

shea

th

0

* thickness shall be selected as per IS standard

570 M

TECHNICALPROCUREMENTSPECIFICATION

PRESSURE GAUGES

1. H-Guru Instruments2. Bells Controls Ltd.3. Waree Instruments Ltd.4. Switzer Instruments Pvt. Ltd.5. General Instruments Consortium6. Wika instruments (I) pvt ltd.7. Odin (I)pvt ltd.8. Manometer (India) Pvt Ltd. Bombay.9. Forbes Marshall Hybd Ltd.10. Pyro Electric Instruments Goa Pvt Ltd.

ELECTRONIC TRANSMITTERS( PRESSURE & TEMPERATURE) – SMART TYPE

1. Siemens Ltd2. Yokogawa India Ltd.3. Emerson Process Management (India) Pvt. Ltd.4. Asian Brown Brovery.5. Honeywell Automation India Ltd6. Thermax Fuji Electronic Ltd.

MASS FLOWMETERS

1. Yokogawa India Ltd.2. Emerson Process Management (India) Pvt. Ltd.3. Asian Brown Brovery.4 Krohne Marshall Ltd

ORIFICE PLATES

1 Instrumentation Ltd., Palakkad2 Baliga Lighting Equipments Pvt. Ltd, Chennai3 Hydropneumatics, Mumbai4 Chemtrols Samil (India) Pvt Ltd., Mumbai5 IA Flow Elements pvt. Ltd., Chennai6 General Instruments Consortium

8122-14-TS-001 SVSUB VENDOR LIST

00F

T02

4 /9

4


ORIGINAL ISSUE


PAGE 1 OF 2 R0

SGMJ MSREV.NO. DATE

0 14.01.10

TECHNICALPROCUREMENTSPECIFICATION

CABLES1. Delton Cables Ltd.2. Brooks cable Works Ltd 3.KEI Industries Ltd4. Associated Cables, Mumbai5. Reliance Engineers Ltd.6. General Instruments Consortium7. Universal Cables Ltd.8. Toshniwal Cables Kolkata9. Associated Flexibles & Wires Pvt Ltd.

GRP/ FRP CABLE TRAYS1. General Composite Pvt Ltd.2. Ercon Composites

PRESSURE SWITCH 1. Wika Instruments Pvt Ltd.2. Chemtrols Engineering Ltd.3 Pyro electric Instruments Goa Pvt ltd.4. General Instruments ConsortiumSwitzer Instruments Pvt Ltd.5 Indfoss (Bombay) Ltd.

JUNCTION BOXES (EX PROOF & W/P)1. Baliga Lighting Equipment Pvt Ltd2. Flexpro Electricals, Bombay.3. CEAG Flame proof controls4. Flameproof Control Gears

HYDROCARBON DETECTOR / LPG ANALYSER

1. Detection Instruments (India) Pvt. Ltd.2. Tritech 3. Honeywell Automation India Ltd

REV.NO. DATE

0 14.01.10

R0

SGMJ MS

8122-14-TS-001 SVSUB VENDOR LIST

00F

T02

4 /9

4


ORIGINAL ISSUE


PAGE 2 OF 2

TECHNICALPROCUREMENTSPECIFICATION R 0

TE insert for immerson length (L) of

REV.

1 No.

4

400 mm

MS SG

APPROVEDCHECKED

1 No.

1 No.

0 - 25 kg/cm2 1No.

300 mm

DP TRANSMITTER/ PRESSURE TRANSMITTER

1 No.

TEMPERATURE GAUGE

00F

T02

2/00 DATE

MJ1

ORIGINAL ISSUE

PREPARED

2

DESCRIPTION


Sl. No.Description

0 14.01.10

1

3

SPARES

Quantity

PRESSURE GAUGE

Pressure Range - 0 - 6 kg/cm2 ( Diaphragm seal type)

0 - 40 kg/cm2

8122-14-TS-001 SPRPAGE 1 OF 1

Total priceUnit price

2 PRESSURE SWITCH 1 No.

3

5 HYDROCARBON DETECTOR 1No.

6 TEMPERATURE TRANSMITTER 1No.

Notes: * To be verified at site before cutting.

CHKD

SPARE SPAREFT 201 FCV 201

82

5, 10, 5, 5, 20

10,10,5,8JBS 0046 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE

FT 101 FCV 101

PSHH 101 PSHH 201SPARE

SPARE

JBC 0016 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG

SCRE. ARMO. SIGNAL CABLE

SPARE

GM 104 SPARE

SPARE

300 5,5,5JBS 0066 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG


PT 1201 PCV 1201SPARE SPARE

GM 103 SPARE

800 25,42,30JBS 0056 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE

TT 301 PT 302SPARE SPARE

TT 201 PT 201

160 5,5,20,20JBS 0016 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG


TT 101 PT 101SPARE SPARE

TT 404

110 10,10,13,13, 15

GM 101

JBS 0026 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG


TT 401AT 401 SPAREPT 401

CLIENT

SG8122M/s.HPCL, MANGALORE

JOB NO.1

PROJECT

23.11.09 MJ MSSG

MANGALORE LPG BLENDING FACILITIES


0 VENDORRev Date PRPD APPRD

3

INSTRUMENTATION DEPARTMENT

CABLE SCHEDULE

cable / JB no.

Cable spec.-(multi core/individual cables)

Contents

5,8117

R1

Remarks/(Drum No.)

lengthmulti.core

(mtr)*

lengthindiv.core

(mtr)*

Page 1 of 2

8122-14-CS-001

14F

T60

8A/9

4-R

1

15.01.10 MJ MS

4

2

JBS 0036 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG


FT 401 TT 102TT 402 SPARE

TCV 102 GM 102

100

0 15.01.10Rev Date APPRD

VENDORSGPRPD CHKD

MS1

MJJOB NO.

PROJECT

CLIENT

14F

T60

8B/9

8

8127

ONLINE LPG BLENDING FACILITIES

8127-14-CS-001

R0CABLE SCHEDULE

MARSHALLING CABINET IN CONTROL ROOM XEV 102

MARSHALLING CABINET IN CONTROL ROOM

Remarks/(Drum No.)

Length*(metre)

XEV 101


3 CORE 2.5mm2 UNSCREENED ARMOURED CABLE

XEV 103

To

Page 2 of 2

Cable spec. From

XEV 102

MARSHALLING CABINET IN CONTROL ROOM

175


XEV 103 170


INSTRUMENTATION DEPARTMENT

Cable No.

XEV 101

M/s. HPCL-MANGALORE

PAGE DOC. GRP.

No. INSTRUMENTATION DEPARTMENT

JOB No.8122

CALIBRATION RECORD SHEET

Guages PLANT: LPG BLENDING FACILITIES, M/s.HPCL

Tag number Manufacturer / type no Serial No Range (span) Accuracy Master Calibration Instrument & serial no. Master Calibration Instrument Certificate validity Date

Initial Final Setting (Input) Reading % Setting (Input) Reading %

% Actual Actual Error % Actual Actual Error 0 0

25 25 50 50 75 75 100 100

Remarks: Test performed by Witnessed by

HPCL HPCL

FEDO

Contractor

FEDO Contractor Signature Date

PAGE DOC. GRP.


JOB No.8122


TRANSMITTER PLANT: LPG BLENDING FACILITIES, M/s.HPCL

Tag number Manufacturer / type no Serial No Range (span) Accuracy Master Calibration Instrument & serial no. Master Calibration Instrument Certificate validity Date

Initial Final Setting (Input) Reading % Setting (Input) Reading %

% Actual Actual Accuracy % Actual Actual Accuracy 0 0

25 25 50 50 75 75 100 100

Remarks: Test performed by Witnessed by

HPCL HPCL

FEDO

Contractor


PAGE DOC. GRP.


JOB No. 8122


TEMPERATURE ELEMENTS PLANT: LPG BLENDING FACILITIES, M/s.HPCL

Tag number Manufacture / type No. Serial No. Accuracy Calibration instruction Calibration standard & serial No. Master Calibration Instrument Certificate validity Date

Temperature ( °C) Resistance / mV Output

Error ( °C)

Required Ω/mV Actual Ω/mV

One measurement shall be normal operating temperature Remarks: Test performed by Witnessed by HPCL HPCL

FEDO

Contractor


PAGE DOC. GRP.


JOB No. 8122


CONTROL VALVES AND ACCESSORIES PLANT: LPG BLENDING FACILITIES, M/s.HPCL

Tag number Manufacturer / type Serial No Calibration instruction Calibration standard & serial no Flow characteristic Actuator supply pressure

Stroke test:

Initial Final Setting (Input) Valve Position % Setting (Input) Valve Position %

% Actual Actual Accuracy % Actual Actual Accuracy 0 0

25 25 50 50 75 75 100 100 75 75 50 50 25 25 0 0

Pressure test: Leak test: Leakage class: Stroke time: Open: Close: Failure position: Accessories function check: Remarks: Test performed by Witnessed by HPCL HPCL

FEDO

Contractor


INSTRUMENTATION

BID ITEMS - INSTRUMENT INSTALLATION BID ITEMS - SUPPLY

2 a) Control Panel with I/O cards, terminals, cable glands etc.3 b) HMI

4 i) FT 101

5 ii) FT 201

6 iii) Flow computer

7Field Mounted Transmitter

8 1) LPG Analyzer ( AT 401)9 2) Pressure Transmitter ( PT 101, PT 201, PT 302,PT 1201 )

10 3) Pressure Transmitter - Diaphragm seal type PT 40111 4) DP Transmitter (FT 401)

UNIT

1

ENGG. SPEC.

Gauges

DESCRIPTION

Modification of Existing Control system

REF.CL. NO.OFITEM .NO

EA1 EA

5) Temp.Transmitter ( TT 101, TT 102, TT 201, TT 401,

SCHEDULE OF ITEMS OF WORKDEPARTMENT

a) Pressure Gauge - bourdon type

QUANTITY

12

EA

TT 402,TT 404, TT 301, TT102A )

1) FE 401 1

81

41

EA

1 EA

EAEA

1 EAEA

EA

Online Instruments

b) Orifice Plate

a) Coriolis type Mass Flow meter

1 EA

1

b) Pressure Gauge -Bourdon type with diaphragm seal

Switches18 a) Pressure Switch

Note:

11

EA

3) PG 301B EA

(GM 101,GM 102, GM 103, GM 104)

1

4 EA

8122


M/s. HPCL, MANGALORECLIENT

MJ

(PSHH 101,PSSH 201)

01 JOB NO.


Hydrocarbon Detectors

a) Pressure Gauge - bourdon type

REV APPRD15.01.10

CHKDMS

19

13

16 2) PG 403

2) PG 301A 1) PG 301

SGDATE PREPD

2

3

EA

17

1415

1) PG 402 EA

2

11

EA

EA

INSTRUMENTATION


EARTH PIT (NOTE 1)

electrode,CU accessories/busbar,eyelets lugs, etc as reqd

27 M

20 Spares - ( Refer. 8122-14-TS -001 SPR)

SCHEDULE OF ITEMS OF WORK

ITEM .NO

DESCRIPTIONREF.CL. NO.OFENGG. SPEC.

DEPARTMENT

UNIT

M

M

2 EA

CABLE TRAY (Including Bends, Expanders,Tee etc)28

300

detector

3200

CABLES

50

b) 6 Pair 20AWG overall & ind. screened armoured cable(Copper), FRLS PVC inner & outer sheathed

a) 6 Pair Signal/ Control Junction Box

23

Supply of 6 sq.mm Arm.copper cable, sand, charcoal,

INSTRUMENT AIR HEADER

QUANTITY

EA

25

24 a) 1 Pair 16AWG screened armoured signal / Control cable(Copper), FRLS PVC inner & outer sheathed

c) 3core 2.5mm2 unscreened armoured cable (Power Cable), FRLS PVC inner & outer sheathed

26

d) 3 core 16AWG Screened armoured cable For Hydrocarbon

M

8250

1 Lot

21 MULTI CABLE TRANSIT Block for cable entry 1

122

JUNCTION BOX

EA

EA7

M30 M31 M

TUBE

Note: 1) Earth pit locations shall be noted from 8122-14-CL-003, R1. For system Earth, the existing earth pit shall be made use of.2)

SGDATE PREPD

M32

CABLE TRAY (Including Bends, Expanders,Tee etc)

100mm perforated FRP2425215

33

MJ

2

3

Seamless tube 12 mm OD / 1.5 mm thick -A 269 TP 316

29 50mm perforated FRP


01 JOB NO.

FACT ENGINEERING AND DESIGN ORGANISATIONREV

MJ15.01.10

CHKD

SGCLIENT

MS

M/s. HPCL, MANGALORE

APPRD

812211.02.10

Seamless tube 6 mm OD / 4mm ID-A 269 TP 316

MS

PROJECT

JBS 006 Location is near the Receipt pipe line at MLIF terminal LPG Storage tank area, 12 km away from the Booster pump

70M55

10200mm perforated FRP

INSTRUMENTATION

BID ITEMS - INSTRUMENT INSTALLATION BID ITEMS - SUPPLY BID ITEMS - INSTRUMENT DISMANTLING

1/2" plain A312TP316 Sch 80

36

444546

8

10

EA

9 EA

5

0.177.30.2

38

UNION CONNECTOR : 1/2"NPTF / 1/2" NPTF A182TP316

UNION TEE : 12 MM / 12 MM A182TP316 FEMALE CONNECTOR : 1/2 " NPTF / 12MM, A182F 316

ISOLATION VALVE :1/2" NPTF/1/2" NPTF, A182F 316, 800# Sch.40

UNION CONNECTOR : 6MM /6MM ODEA

9 EAEA4

5

MALE CONNECTOR : 1/2"NPTM / 12MM OD,A182F 316 2237

REDUCING COUPLING :3/4 " NPTFx 1/2 "SW

MALE CONNECTOR : 1/2"NPTM / 6MM OD,A182F 317

34

Structural steel

42

25 x 5 mm flat

Structurals

MSeamless Pipe

EA

EAEA

METRIC TONS

EA

50 x 50 x 5 mm angle METRIC TONS

METRIC TONS

10

ITEM .UNIT

TUBE FITTINGS:

35 x 35 x 5 mm angle

REF.CL. NO.OF

3

DEPARTMENT

35

39

NODESCRIPTION

SCHEDULE OF ITEMS OF WORK

ENGG. SPEC.QUANTITY

40

43

41

NIPPLE BET :1/2" NPTM / 1/2"NPTM ,SS 316

4748

2" CS Sch 40 pipe ( for fabrication work of stanchion)

Notes:

EA

01

Canopy for instruments & JB

2 CLIENT

Stanchions for instruments, JB

MS

37

PROJECT

28



EA

3

MJ SG JOB NO.

15.01.10 MS FACT ENGINEERING AND DESIGN ORGANISATIONDATE PREPD APPRD

SG8122

MJREV

11.02.10

CHKD

INSTRUMENTATION


DIN rails,MCB,Fuse,flexible & prefab cable With end connectors etc.

including hot loop checking, configuration of the the new I/O in the control system, trend/ graphic configuration etc.

53 i) FT 101 54 ii) FT 20155 iii) Flow computer

56

b) Control Valve5758

LOT

markers, bolts/nuts/washers,spare fused connectors.

1glanding and termination of cables including Installation of cable

50 a) Installation of the control panel with required base frame,

EAEA

1) FE 401

1) FCV 101

1

12) FCV 201 1

b) Orifice PlateEA

Lot52 c) Configuration of new I/O with existing control system 151

UNIT

b) Installation of HMI 1 EA

glands, termination lugs, ferrules,cable ties,lables, permanent

Control room Modification woks (Existing Control system)

DEPARTMENT SCHEDULE OF ITEMS OF WORK

ITEM .DESCRIPTION

REF.CL. NO.OFQUANTITY

NO ENGG. SPEC.

EA

Online Instruments

1 EA

1 EA

a) Coriolis type Mass Flow meter

1

585960

616263Note:


EAEAEA


JOB NO.

PREPD CHKD APPRDMJ

8122

SGMSREV DATE

10 15.01.10

PROJECT LPG BLENDING FACILITIES3

CLIENT2

c) On-off Valve

3) XEV 103 With SOV

1) XEV 101 With SOV

11

2) FCV 2013) TCV 1024) PCV 1204

1

1 EA12) XEV 102 With SOV

EAEA

1

INSTRUMENTATION


Field Mounted Transmitter64 1) LPG Analyzer ( AT 401)65 2) Pressure Transmitter ( PT 101, PT 201,

PT 302,PT 1201 )66 3) Pressure Transmitter - Diaphragm seal type PT 40167 4) DP Transmitter (FT 401)

a) Pressure Switch

EA75 4Hydrocarbon Detectors

EA

(PSHH 101,PSSH 201)74

71 3) PG 301B

2 EA

73 2) PG 403 172 1) PG 402 1

1

EA

EAb) Pressure Gauge , bourdon type with diaphragm seal

1EA70 2) PG 301A 1EA69 1) PG 301

a) Pressure Gauge , bourdon typeGauges

1

NO ENGG. SPEC.UNIT

EA

EA1


ITEM .DESCRIPTION


EA4

68 5) Temp.Transmitter ( TT 101, TT 102, TT 201, TT 401, 8 EAEA1

TT 402,TT 404, TT 301, TT102A )

EARTH PIT (NOTE 1)

Note: 1) Earth pit locations shall be noted from 8122-14-CL-003, R1. For system Earth, the existing earth pit shall be made use of.

(GM 101,GM 102, GM 103, GM 104)

78

77

INSTRUMENT AIR HEADER

76

SG FACT ENGINEERING AND DESIGN ORGANISATION0 15.01.10 MJ

8122

2

MSREV DATE PREPD CHKD APPRD

1 11.02.10 MJ MS SG JOB NO.

3

CLIENT



2 EA

1

EA

1 EAEA

75 4

MULTI CABLE TRANSIT Block for cable entry

Hydrocarbon Detectors

INSTRUMENTATION

BID ITEMS - INSTRUMENT INSTALLATION BID ITEMS - SUPPLY BID ITEMS - INSTRUMENT DISMANTLING

82

8586

TUBE

Seamless Pipea) 1/2" plain A312TP316 Sch 80

90

M88 Seamless tube 12 mm OD / 1.5 mm thick -A 269 TP 316 55 M

89

200mm perforated FRP 10

87 Seamless tube 6 mm OD / 4mm ID-A 269 TP 316 70

84 50mm perforated FRP 2425CABLE TRAY (Including Bends, Expanders,Tee etc)

83 a) 6 Pair Signal Junction Box 7 EA

300

80 b) 6 Pair 20AWG overall & ind. screened armoured cable(Copper), FRLS PVC inner & outer sheathed

M79 a) 1 Pair 16AWG screened armoured signal / Control cable(Copper), FRLS PVC inner & outer sheathed

81 c) 3core 2.5mm2 unscreened armoured cable (Power Cable), FRLS PVC inner & outer sheathed

8250 M

3200 M


ITEM .DESCRIPTION


NO ENGG. SPEC.

50

JUNCTION BOX

CABLES

UNIT

Structural steel

M

M

d) 3 core 16AWG Screened armoured cable For Hydrocarbon detector

50 x 50 x 5 mm angle 0.17 METRIC TON

100mm perforated FRP

3

MMM

215

909192

9394

Note: 1 . JBS 006 Location is near the Receipt pipe line at MLIF terminal LPG Storage tank area, 12 km away from The Booster Pump

JOB NO. 81221 11.02.10 MJ MS0 15.01.10 MJ MS SG FACT ENGINEERING AND DESIGN ORGANISATION

REV PREPD CHKD

2 M/s. HPCL, MANGALORECLIENT

3 PROJECT LPG BLENDING FACILITIES

DATE

SG

APPRD

Stanchions for instruments, JB 28 EA

Structural workCanopy for instruments & JB 37 EA

25 x 5 mm flat 0.2 METRIC TON35 x 35 x 5 mm angle 7.3 METRIC TON50 x 50 x 5 mm angle 0.17 METRIC TON

instrumentation technical specification...

Documents