Inst. Technical

INSTRUMENTATION DEPARTMENT
SPEC. NO. STATUS PROJECT LOCATION CLIENT PURCHASER VENDOR W.O.NO. NAME OF WORK :
TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION 8122-14-TS-001

ENQUIRY
PAGE 1 OF 1
WORK ORDER
ON LINE LPG BLENDING FACILITIES MANGALORE M/s.HPCL M/s.HPCL
ERECTION TENDER SPECIFICATION - INSTRUMENTATION
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14FT603/94-R1
12.02.10 14.01.10 DATE
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REVISED ON CLIENTS COMMENTS ORIGINAL ISSUE

DESCRIPTION
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FACT ENGINEERING AND DESIGN ORGANISATION
INSTRUMENTATION DEPARTMENT Sl.

No. 1 8122-14-TS-001 SPL
CONTENTS TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION

Description
TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION
8122-14-TS-001
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ENGINEERING SPECIFICATION INSTRUMENT ERECTION INSTRUMENTATION WORKS - GENERAL SCOPE SCHEDULE OF ITEMS OF WORK-SUPPLY SCHEDULE OF ITEMS OF WORK-INSTALLATION INSTRUMENT SCHEDULE DATASHEETS 8122-14-DA-00006 Datasheet for Pressure Gauge 8122-14-DA-00007 Datasheet for Pressure Transmitter Datasheet for Pressure Switch 8122-14-DA-00008 Datasheet for Coriolis Mass flow meter 8122-14-DA-00010 Datasheet for Orifice 8122-14-DA-00011 8122-14-DA-00012 Datasheet for DP Transmitter Datasheet for Flow Computer 8122-14-DA-00013 Datasheet for Temperature Element 8122-14-DA-00015 Datasheet for Temperature Transmitter 8122-14-DA-00016 Datasheet for Hydrocarbon Detector 8122-14-DA-00020 8122-14-DA-00021 Datasheet for Analyzer Datasheet for Control Panel 8122-14-DA-00022 8122-14-DA-00023 Datasheet for Junction box Datasheet for Cable 8122-14-DA-00024 8122-14-TS-001 SV Subvendor List Spares List 8122-14-TS-001 SPR DRAWINGS Hook up Diagram 8122-14-HD-001 Index Sheet Process Hook up 8122-14-HD-003 to 009 ,011 8122-14-HD-012, 014 to 017 Electrical Hook up 8122-14-HD-010 Pneumatic Hook up Inst.Air supply Distribution diagram 8122-14-HD-018 8122-14-CL-001 toCL-005 Instrument Location and Cable routing Diagrams ( 5 sheets) 8122-14-AR-001 Instrument Location and Air routing Diagram 8122-14-JB-001 to JB 007 JB termination Connection drawings 8122-14-MD-001 to MD-016 Typical Installation Drawings 8122-14-CS-001 Cable Schedule Calibration Record Sheets (For Instrument loop)) 8122-11-PD-003 P&I Diagram for LPG Blending Facilities 25ES 401/94 25ES 403/98 8122-14-TS-001 SIW-S 8122-14-TS-001 SIW-I 8122-14-IS-001
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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
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14FT659/95
12.02.10 14.01.10
REVISED ON CLIENTS COMMENTS ORIGINAL ISSUE
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8122-14-TS-001
TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION
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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 Trusts (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 Purchasers 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.
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14FT606/94 REV. NO.
12.02.10 REVISED ON CLIENTS COMMENTS 15.01.10 ORIGINAL ISSUE

DATE DESCRIPTION
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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 1 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.
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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 vendors 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 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, manufacturers 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
14FT606/94
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
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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 contractors 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 contractors 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
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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 consultants (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.
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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
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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 0-25-50-75100-75-50-25-0 % 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 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
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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 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.
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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 1A 12A CS-347SS 12A 316SS-316SS 11H Welding Materials Coated electrodes No. 1 10 Material CS 18Cr 10Ni (347) Cb ASME SFA 5.1 5.4 Classification E7018 E347- 16 or 15 E316- 16 or 15 E316L- 16 or 15 E309- 16 or 15 ENi Cr. Fe-3 Bare wires ASME SFA 5.18 5.9 Classification ER70S-2 ER347 ER316 ER316L ER309 ER Ni Cr-3 316SS-347SS 10H 347SS-347SS 10H
11
18Cr 10Ni Mo 5.4 (316, 316L) 25Cr 12Ni (309) Inconel 5.4 5.11
5.9 5.9 5.14
12
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 A H Preheat Temp. (C) min 10 10 Postweld Heat Treatment Temp. (C) None 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.
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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 manufacturers 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 Finish Coats F-1 25 F-1 25 Final Finishing Color Aluminum Total 120 RAL Color Code No 9006
Surface temp. under 94 C T-1 (200 F) Paint thickness in microns 70
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 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
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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 manifoldequalizing 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 contractors 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.
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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.
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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 3.60 All instruments shall be provided with suitable rain guard/ canopy. 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. 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. 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. 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 Cable entry to control room shall be through Multi cable transit blocks. 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. The impulse tubes and pneumatic tubes shall be clamped to angles using Aluminium clamps at 1.5 Meter intervals. 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. 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. 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: Pressure gauges (Bourdon type& diaphragm seal) Electronic Transmitters ( Pressure & DP.) Temperature Transmitters, Thermowell-RTD
3.61
3.62
3.63 3.64 3.65
3.66 3.67
3.68 3.69
1. 2. 3.
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4. 5. 6. 7. B 1. 2. 3. 4. 5. 6. 7. 8.
Coriolis type mass flow meter with flow computer Pressure switches Gas detector Control valves, On-off trip valves Major fabrication works/laying works at field : Structurals, fabrication, laying, painting. Cable Tray laying, clamping/fixing. Junction box and transmitters fixing. Cable laying, dressing, routing, clamping, tagging, glanding and terminating. Installation of pipe lines mounted instruments-supervision and hookup Earthing , powering, interconnection inside control room. Cold loop check. Hot loop check line up commissioning integration.
14FT606/94
iso2.sty
ENGINEERING SPECIFICATION
INSTRUMENT ERECTION
NOTE:-
25ES401 / 94 PAGE 1 OF 22
CONTENTS
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 16.0.0 17.0.0 PART A - GENERAL SCOPE OF WORK CONTRACTORS OBLIGATIONS OWNERS SUPPLY PART B - TECHNICAL REQUIREMENTS INSTRUMENT INSTALLATION ON-LINE INSTRUMENTS FIELD MOUNTED PRIMARY MEASURING ELEMENTS FIELD MOUNTED TRANSMITTERS FIELD MOUNTED CONTROLLERS FIELD MOUNTED GAUGES FIELD MOUNTED SWITCHES ANALYSERS MISCELLANEOUS INSTRUMENTS JUNCTION BOXES,PDBs,MBs CONTROL PANELS FABRICATION WORK AND MOUNTING OF INTRUMENTS GENERAL NOTES FOR INSTRUMENT PIPING AND TUBING G EN ERA L NO TES O N TERM I N ATI O N, ELECTRICAL INSTALLATION AND GROUNDING GENERAL NOTES ON CABLE TRAY, DUCTS AND CONDUIT INSTALLATION CIVIL WORKS CALIBRATION AND FUNCTIONAL CHECK TESTING AND LOOP CHECKING PART C - JOB COMPLETION REQUIREMENTS COMPLETION OF ERECTION JOB COMMISSIONING AND START - UP BILL OF QUANTITIES AND MATERIALS PART D - PROCEDURES AND STANDARDS GENERAL REQUIREMENTS AND RECOMMENDATION FOR PIPE WELDING. SPECIFICATION FOR PAINTING WORK INSPECTION AND TEST PROCEDURE FOR INSTRUMENT INSTALLATION WORK. APPLICABLE STANDARDS PART E - ATTACHMENTS DRAWINGS - ANNEXURE I SCHEDULE OF WORK - ANNEXURE II ITEMS TO BE SUPPLIED BY CONTRACTOR ANNEXURE III
CHKD. BY:
The description under scope of supply will be general in nature and covers most of the prevalent types of instruments, some of which may not be required for this particular Project. Hence only the applicable items shall be referred to. For actual list of instruments, refer schedule of work.
PART A - GENERAL 1.0.0 SCOPE OF WORK

The scope of work shall include but not be limited to :Unpacking, checking, cleaning and withdrawal of instruments, instrument accessories and erection materials at owners stores and / or from places of storage any where within the boundary wall of project and existing factory. Return of left over materials to owners stores. Transportation and handling of instruments, instrument accessories and erection materials at owners stores and / or from places of storage any where within the boundary wall of project to work site and / or contractors stores. Installation of field mounted instruments such as pressure / vacuum gauges, dial thermometers, pressure switches, blind switches, manometers, differential pressure indicators, local flow indicators / recorders, local indicating controllers, flow transmitters, pressure transmit ters, differential pressure transmitters, temperature trans mitters, Rotameters etc. Installation of vessel mounted instruments such as level gauge glass, magnetic level gauges, bi-colour level gauges, torque tube level instruments, level switches, dial thermometers, pressure gauges etc. Installation of instruments on vendors equipments such as speed indicators, speed controllers, vibration / Axial displacement / Axial thrust monitoring systems, Ammeters, Antisurge controls etc. Supervision of installation of on line instrument (by other contractors) such as orifice flow elements, control valves ,PD / Turbine meters Rotameters,etc. Installation of Analytical instruments such as infrared Analysers, Paramagnetic Analysers, yT h e r m a l c o n d u c t i vi t y A n a ly s e r s , N OX Analysers, H2S Analysers, Silica Analysers, Density Analysers, PH Analysers, Electrical c o n d u c t i v i t y An a l y s e r s, D is s o l ve d O 2 Analysers, On line Gas Chromato graphs, Oxygen analysers etc. Installation of miscellaneous instruments such as Belt weighers, Flame safe guard instruments, pneumatic change over switches, Air sets, thermocouple assemblies, thermo resistance assemblies, purge type liquid level measuring systems, volume tanks for double action piston actuators etc. Installation of local panel mounted instruments such as receiver indicators, indicating controlISSUED ON: APRIL 94
1.1.0
1.2.0
1.3.0
18.0.0 19.0.0 20.0.0 21.0.0
1.4.0
1.5.0
22.0.0 23.0.0 24.0.0
1.6.0
25.0.0 26.0.0 27.0.0 28.0.0 29.0.0 30.0.0 31.0.0
1.7.0
1.8.0
PRPD. BY:
APPRD. BY:
INSTRUMENT ERECTION
25ES401 / 94 PAGE 2 OF 22
1.9.0 1.10.0 1.11.0 1.12.0
1.13.0
1.14.0 1.15.0 1.16.0 1.17.0 1.18.0
1.19.0
1.20.0
1.21.0
1.22.0 1.23.0
1.24.0 1.25.0
1.26.0 1.27.0
1.28.0
lers, pneumatic / electronic receiver recorders, manual loaders, ratio control stations, computing / selector relays, temperature indicators / recorders, receiver switches, alarm annunciators, timers, analyser recorders, etc. Interconnecting field & panel mounted instruments. Cutting gaskets of various materials to suitable sizes and fixing the same along with the fittings or flanged connections. Any modification jobs during installation of instru ments. Erection and interconnection of control panels, cubicle boards, control desks etc. locally and in the control rooms. 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. Fabrication and installation of instrument protective boxes. Laying and supporting of cable trays and ducts. Laying and supporting of instrument Air headers and distribution lines. Laying and supporting of multicore tubing and single run tubing on racks and their termination. Laying and supporting of multicore and single pair electrical cables, multicore and single pair compensating cables and any other special cables on racks / trays and their terminations. Fabrication, laying and supporting of impulse, piping and sample lines for the analysers and for Laboratory. Fixing in position electrical Junction Boxes, distribution boxes and relay boxes in the field and behind the control panels, conduit pipes, fittings and flame proof boxes. Any civil job involved in the installation of supports, mounting stands, control panels, Junction Boxes, and relay boxes air piping, tubes etc. Cleaning and blowing of main air header and distribution lines, pneumatic tubing, impulse piping and sample lines for analysers etc. Testing of main air header and distribution lines, pneumatic tubing etc.for any leakage and proper connections. Hydraulic / pneumatic testing of impulse piping and sample lines. Testing of electrical cables, compensating cables, and special cables for proper connections, continuity and insulation, together with DCS Contractor. Testing of complete instrument loops for proper connections and functioning, together with DCS Contractor. Steam tracing of impulse lines wherever necessary and final connections to steam jacketed instruments. Piping connections for internal washing of instruments and purging of instrument casing. Cleaning and painting of frames, supports, clamps, mounting stands and racks etc, as per
painting specifications. 1.29.0 Testing, calibration and functional checking of all the instruments and accessories. 1.30.0 TIG welding, stress relieving and dye penetrant tests wherever required. Welding of IBR impulse pipes (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
CONTRACTORS OBLIGATIONS
The contractors obligations shall include :2.1.0 Arrangement and supply of required tools and tackles such as electric welding sets, Gas welding sets, Gas cutting sets, Hydro testing pumps, trailer, Fork lifts, Crane, jumbo trucks, pipe and tube benders, Drilling equipments etc. and all other tools necessary for the installation of instru ments according to good international practice. 2.2.0 Arrangement and supply of consumables like welding electrodes, industrial gases, cleaning fluids such as kero sene, insulation tapes, sealing compounds, all clamping materials for cable / tube trays and racks, impulse piping and air header 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 ferrules etc. and all other consumables necessary for execution of the job. 2.3.0 Arrangement and supply of testing equipments and other instruments such as Dead weight tester (weight in kg/cm Sq.) manometer, portable pneumatic / electronic calibrator, standard test gauge, thermocouple test kit, D.C potentiometers, wheatstone bridge, decade resistance box, temperature baths with thermostatic control, oscilloscope, telephone sets, signal generator, megger, vacuum pump, hydraulic pump, avometer, digital multimeter, testing / calibrating facili ties for panel mounted indicators, recorders, controllers, computing relays, counters, turbine flow meters, transmit ters, electro-pneumatic convertors etc. 2.4.0 Planning and maintaining of all activities of the contract as per PERT network approved by owner. Arranging staff like supervisory staff, skilled and unskilled labour forces etc. as required for timely completion of the entire job. 2.5.0 Maintaining records on daily basis of all the works as per approved schedule, calibration and inspection reports as per the advice of OWNER. 2.6.0 Making arrangement for distribution of electricity and water from supply point to work spots. 2.7.0 Co-ordination with other contractors work as required by OWNER to complete the instrument erection work. 2.8.0 Security arrangement for contractors office and stores to ensure safety of all equipments and all free issue mate rials supplied by the OWNER. 2.9.0 Clearing of site after completion of work. 2.10.0 Return of OWNERS surplus and free supply materials and other excess material included in work order to OWNER after accounting.
ENGINEERING SPECIFICATION 3.0.0

3.1.0
INSTRUMENT ERECTION
5.0.0
25ES401 / 94 PAGE 3 OF 22
OWNERS SUPPLY
ON LINE INSTRUMENTS
Owners obligations shall include :Supply of all pipes, pipe fittings, cable trays and ducts, valves, flanges, junction boxes, control panels, gauge boards, two core and multicore control / power / shielded cables, three core and multicore resistance thermometer cables, single pair and multipair compensating cables, two core and multicore electrical / electronic cables etc (Except those included in the contractors scope.) 3.2.0 Supply of all pneumatic, electrical, electronic and analytical instruments, special sampling systems, resistance thermometers, dial thermometers, thermocouples, bi-metallic thermometers, thermowells, all the switches for alarm and shut down, Pressure and vacuum gauges, air filter regulators, solenoid valves, output gauges, analyzer cabinets etc. 3.3.0 Supply of water free of cost and electricity on chargeble basis. 3.4.0 Cranes, jumbo trucks, fork lifts etc.. will be speared by the owner on chargeable basis (only if available) other wise contractor has to make his own arrangements.
PART B - TECHNICAL REQUIREMENTS 4.0.0

4.1.0
INSTRUMENT INSTALLATION
The instrument contractor shall ensure that the instruments are received in good condition and shall report if any defects to engineer in charge. He will be responsible for the safety of all instruments thereafter till the commissioning of the plant. Any loss or damage of instruments while in his custodyshall be chargeable to the contractor. Contractor shall be responsible for supply and cost of all replacement material and labour necessary to rectify faults which occur during instrument installation testing period due to reasons such as falls or due to faulty work manship or faulty material in the contractors supply. All instruments are to be checked for their calibration prior to installation in the field and shall be corrected for any calibration misalignments that would have occurred during transportation or subsequent handling. All installation work shall be done as per released construction drawings, instrument installation drawings and manufacturers instruction manuals that will be supplied after the contract is finalised. If the area in which the installations are to be car ried out are partially Hazardous [As per area of classification] and partially general purpose then the instrument erection Contractor shall execute all the electrical works in accordance with applicable codes of Indian Standards for electrical installation and Owners safety regulations. Contractor is expected to handover all faulty instruments and any defects which may arise due to design omission or discrepancies found which would impede the proper functioning of instruments must be brought to the notice of engineer in charge without undue delay.
4.2.0
4.3.0
4.4.0
4.5.0
Instrument Contractor shall supervise and ensure correct installation of on-line instruments, by piping Contractor. It will be the responsibility of the instrument Contractor to see that the following are accomplished by the piping Contractor as per specifications and drawings. 5.1.0 FLOW TUBES (Venturi,Nozzle etc.) 5.1.1 The flow tube shall be installed in pipeline with arrow aligned in direction of flow. 5.1.2 The straight pipe lengths adjacent to flow tube shall conform to figures given by the vender drawings / standards. 5.1.3 Tapping & fittings shall be as specified in the instrument process piping drawings. 5.1.4 Measurement of I.D, lengths shall be done in order to ensure that correct unit is installed for each line. Change in I.D.if any, shall be reported to site Engineer. 5.1.5 Ensure that no weld deposit is projecting in the pipe line. 5.1.6 Gasket used shall be that specified for duty and shall not project inside the pipe beyond the limits specified by standards. 5.2.0 ORIFICE PLATE 5.2.1 Orientation of tapping & necessary straight length up stream and down stream of orifice. 5.2.2 Proper gasket (gasket shall not project inside the pipe and shall be within the limit specified in orifice plate specification. 5.2.3 Proper direction of orifice plate. 5.2.4 No weld material shall project Inside the pipe line near the orifice. 5.2.5 Location of tapping shall be at the proper distance from orifice plate. 5.2.6 Correct orifice plate / unit is installed for each line. 5.2.7 The drain / vent hole in the orifice plate shall be located 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-ordination with piping contractor with correct flow direction along with the straight pipe pieces adjacent to flow transmitter. Upstream and down stream lengths shall be checked. 5.3.2 In the case of pneumatic transmitter, connect receiver gauge and air set with proper air and signal tubing. Tubings wherever required shall be done with necessary slopes as stipulated in the installation standards 5.3.3 In the case of electronic transmitters twin core screened armored cable / cables as specified shall be glanded and terminated as per termination details. 5.4.0 R OTAM ETER , PURG E RO TAMETER & ROTAMETER TRANSMITTER Contractor shall supervise & ensure the following while piping is in progress.
5.4.1 5.4.2
INSTRUMENT ERECTION
25ES401 / 94 PAGE 4 OF 22
5.4.3 5.4.4
5.4.5
5.4.6 5.5.0
5.5.1 5.5.2
5.5.3 5.5.4
5.5.5
5.5.6 5.6.0
5.6.1 5.6.2 5.6.3 5.6.4
5.6.5
5.6.6
Verticality of the meter. The float which is removed for the purpose of transportation shall be kept in position before installation. Proper gaskets are used. Rotameter scale clearly visible from the operation platform. Reducer pairs supplied with meter to be installed by piping contractor shall be supervised by instrument contractor. For transmitters after installation, as above, proper air & Signal Connections shall be made through junction Box & to control room. [Tubing & tube - Connection are covered separately in section 16.0.0] Air set if supplied loose shall be installed as per instrument pneumatic diagrams. TURBINE FLOW METER / MAGNETIC / VORTEX / POSITIVE DISPLACEMENT FLOWMETERS The flowmeter is to be mounted, wired and tubed as mentioned below :Flowmeter shall be installed, in co-ordination with the piping Contractor, on pipeline with arrow aligned in the direction of flow. The straight pipe lengths adjacent to flowmeter shall be 10 x D upstream & 5 x D down stream or as recommended by the manufacturer. Care shall be taken to ensure correct alignment of the flowmeter with mating pipe work. Electrical connection from the flowmeter to the secondary instruments shall be made with twin core screened cable. Do not run the signal leads in the same conduit as that for supply. [Cable, wiring & conduit work are covered separately]. The complete installation shall be carried out in accordance with the instruction manual supplied by vendor & in co-ordination with the piping contractor. The flow meter shall not have any strain on its body from adjacent pipes. CONTROL VALVES, DAMPERS, PRESSURE REDUCING VALVES, DE-SUPERHEATERS Instrument Contractor shall ensure the following while the control valve is being installed by the piping Contractor. Control valve is installed in the correct direction. The control valve is not under mechanical strain after erection. Proper gaskets are used for the purpose. In the case of Butterfly control valves the vane shall not be obstructed by any piping parts and shall be free to rotate. The air supply to the control valve and the signal line from the respective controller to the valve positioner / valve shall be made by the instrument Contractor. Signal tubing, instrument piping etc. are covered separately For valves with air filter set and valve positioner, Contractor shall ensure that the valve positioner & the associated linkages are physically and
5.6.7
functionally in good condition. When solenoid valves are mounted on the valves, the air connections would be provided by the valve supplier. Contractor shall give all electrical connections through required fittings. Instrument Contractor shall ensure the proper installation of the pressure control valve by piping Contractor as regards direction and other aspects as for control valves. The back pressure tapping from the down stream piping shall be properly connected by the instrument Contractor. Calibration of control valve shall include all testing and calibration of all the accessories also. MOTOR OPERATED VALVES The instrument Contractor shall ensure proper installation of motor operated valve while it is being erected by piping Contractor. The electrical connection will be provided by the electrical Contractor. Instrument Contractor shall also ensure proper functioning of the limit switches. SOLENOID VALVES Work involves installation of solenoid valves on pneumatic signal lines to control valve / damper actuator, and termination of electrical cables. All necessary electric & pneu matic connections shall be done by instrument Contractor. [Tubing & wiring conduit work etc are covered separately under Sec. 16.0.0 & 17.0.0 ]
5.6.8
5.6.9 5.7.0
5.8.0
6.0.0
6.1.0 6.1.1
FIELD MOUNTED PRIMARY MEASURING ELEMENTS

ANNUBAR FLOW ELEMENTS / PITOT TUBE Elements shall be so installed that it can be inserted or withdrawn from the pressurized pipelines under flowing conditions without interruption of service. Annubar installation shall be as per instrument Process piping drawings and instruction manual supplied by the Vendor. All the process piping connections shall be given by the Contractor [Piping covered under 16.0.0]. TEMPERATURE ELEMENTS [T/C and RTD] T/C shall be installed at proper locations along with specified thermowell. T/W shall be screwed or flanged type and shall be adequately tightened with use of proper gasket , nuts & bolts which will be supplied by the owner. Each T/C shall be connected by proper signal / extension cable using proper glands from individual temperature element to junction boxes. From junction boxes, multi - core cables shall be used to connect the instruments to control room. [Cables are included separately under 18.0.0 ] MULTIPLE T/C ASSEMBLIES Work involved is same as above. RTD ELEMENTS [FOR BEARING TEMPERATURE] R.T.D. elements are already wired up to the local
6.1.2
6.1.3 6.2.0 6.2.1 6.2.2
6.2.3
6.3.0 6.4.0
INSTRUMENT ERECTION
25ES401 / 94 PAGE 5 OF 22
6.5.0
junction boxes by the equipment venders. Contractor shall connect these from junction boxes through the multicore leads with the corresponding instrument point. [The cabling is included separately under 18.0.0 ]. The RTD elements are already in stalled on machinery / equipment. In case these instruments are removed for shipment and are not installed by the vendor in the field, Instrument Contractor shall arrange to install these instruments as per 6.0.0. VIBRATION PROBES, AXIAL DISPLACEMENT PROBES & DRIVESPEED PROBES All the probes are already mounted on the machinery / equipment by the vender and wired upto junction box and terminated . Instrument Contractor shall provide the electrical connections from the junction box to control panel. In case these probes are removed for shipment and are not installed by the vendor in the field, instrument Contractor shall arrange to install these probes as per drawings.
7.4.3
7.4.4
7.4.5 7.4.6
7.0.0
7.1.0
FIELD MOUNTED TRANSMITTERS

PNEUMATIC D/P TRANSMITTERS FOR FLOW, LEVEL, DENSITY ETC. Mounting differential pressure transmitters, air filter regulator, locally fabricating suitable stands / supports, tubing them from the first isolation valves [at the orifice end] with the 3 valve manifold, giving necessary slopes as stipulated in the installation diagrams. Provide air supply using 6 mm OD SS tubes, connect 1/4" OD Copper tube [output], to a Receiver gauge or to the secondary local instrument or to junction box as the case may be. Install air filter set. [Tubing, process piping supports etc are covered separately under sec 16.0.0]. L EV EL TR AN SM I TTE RS - F L AN G E MOUNTED 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 tubing shall be installed as per item 7.1.0. FLUSH / EXTENDED DIAPHRAGM TYPE WITH REMOTE SEAL -FOR LEVEL AND DENSITY Work involved is identical to item 7.1.0 except that instead of impulse tubing, capillary tubing with flanged diaphragm to be mounted on to the vessel nozzle / isolation valves. The capillary tube shall be supported properly. GAUGE / ABSOLUTE PRESSURE TRANSMITTERS The work involved is identical to item 7.1.0 except that there will be only one impulse tapping. DISPLACEMENT TYPE LEVEL TRANSMITTERS WITH AIR SET The displacement type level transmitter with air set shall be fitted in such a way that it is subjected to minimum vibration. The installation shall be carried out using necessary pipes, isolation valves & other fittings as
7.5.0
7.6.0
7.7.0
7.2.0 7.2.1
7.8.0 7.8.1 7.8.2
7.2.2
7.8.3 7.8.4
specified in the instrument process piping drawings. Connection of Air lines that shall supply air, free of oil, water & dust at constant pressure of 1.4 kg/cm.sq. Calibration & checking should be carried out in Co- ordination with piping group. [Installation of valves, pipes & tubes are covered in sec tion 16.0.0] The air filter set shall be installed as specified in instrument pneumatic tubing diagram. The air filter set shall be installed as specified in instrument pneumatic tubing diagram. ELECTRONIC TRANSMITTERS The details in Item 7.1.0 to 7.4.0 under pneumatic transmitters will be applicable to electronic transmitters except that cabling is involved instead of tubing. ELECTROMECHANICAL LEVEL TRANSMITTERS Mounting the instrument on the vessel nozzle flange using proper gaskets, nut, bolts, and connecting the power / signal cables. RADIO-ACTIVE LEVEL TRANSMITTERS Installation of the radio-active source, line detector and 3 nos. point detectors as per the details provided by the manufacturer and strictly following the government regula tions. TANK LEVEL TRANSMITTERS (FLOAT AND TAPE TYPE) Installation of float and tape, guide wires, protector pipe with V-seal and mounting the transmitter on suitable supports. The protector pipe shall be properly supported and signal cable shall be terminated. TEMPERATURE TRANSMITTERS The installation shall be carried out as per instruction manuals of vendors. The thermowell with bulb shall be fixed [screwed or flanged] on the pipe line using proper thread sealant or nut, bolts, gaskets as the case may be as per 6.2.2]. Capillary shall be continuously supported. Air supply & signal connection shall be made. [Installation of tubes & pipes is covered separately under Sec. 16.0.0].
8.0.0
8.1.0
FIELD MOUNTED CONTROLLERS

INDICATING CONTROLLER FOR PRESSURE - WITH AIR SET The work involves mounting the transmitter / controller on proper support. Suitable piping connections, air supply connections, signal lines shall be provided as specified to correct final control element. The piping & tubing shall be as specified in the process piping diagrams. [The details for supports, tubing & piping are covered under 16.0.0]. DISPLACEMENT TYPE LEVEL TRANSMITTER + CONTROLLER WITH AIR SET
7.3.0
7.4.0 7.4.1
8.2.0
7.4.2
INSTRUMENT ERECTION
25ES401 / 94 PAGE 6 OF 22
Work involved is combination of 7.5.0 .
9.0.0
9.1.0
FIELD MOUNTED GAUGES

PRESSURE GAUGES Installing pressure gauge using suitable connecting tubes / vent / drain / valves etc. from the first isolation valves provided on ducts / pipes / vessels / pumps etc. MANOMETER Scope includes :The installation of instruments with proper supports. Filling with the proper manometer fluid. Connecting all the piping and valves as per the drawings. Providing final connection using a flexible hose. (The details for piping fitting and valves are covered separately.) LEVEL GAUGE [REFLEX TYPE] Each level gauge shall be fitted with a pair of gauge cocks. The piping connection & fitting shall be carried out as per the instruction given by the supplier and as per the instrument application diagram. MAGNETIC LEVEL GAUGES Work involved is same as item 9.3.0 except that care should be taken to handle it properly so that the magnetic float is not damaged. BOILER LEVEL GAUGES The high pressure level gauges shall be fitted with proper gaskets & weatherproof open end hood and suitable illuminator, operating on 220V, 50 HZ single phase supply. Process piping connections & complete installation shall be in accordance with Instruction manual supplied by ven dor. Supply using cables shall be connected to the illumina tor from the nearby switch provided by the electrical contractor. [The details for piping and fixing valves, conduit & wiring etc. shall be covered separately ]. BOILER LEVEL GAUGES WITH REMOTE INDICATION This shall include the erection of condensate chamber. Process connections & complete installation should be carried out in accordance with instruction manual supplied by the vender, while piping work is in progress. TANKAGE SYSTEMS Contractor shall ensure that the instrument is located in an easily accessible place. Location shall also be such that ambient temperature is within the specified limits as given by the vendor. Contractor shall install measuring tape, float, protector pipe, local indicator and supports as per the drawings of vendor / instruction manuals given by vendor. Contractor shall fix the channel steel or pipe vertically, which does not bend due to its weight,
9.2.0 9.2.1 9.2.2 9.2.3 9.2.4
9.3.0
under the side wall of tank, for accurate measurements. The float and tape shall not be subjected to sudden, abnormal vibrations due to a violent stream of feed fluid or while erecting the same. 9.8.0 DIAL TYPE INDICATING THERMOMETERS The work involves installing of thermometers and thermowells (threaded and flanged) on pipes, vessels using proper nuts, bolts & gaskets provided by piping group. The threaded thermowell shall be fitted using teflon tapes or pipe Dopes as the case may be. 9.9.0 TEST THERMOWELLS Mounting the thermowells on the pipes / vessels using proper nuts, bolts and gaskets. 9.10.0 DIFFERENTIAL PRESSURE INDICATOR Work involved is same as item - 9.1.0 except that there are two tapping. 9.11.0 THERMOMETERS - CAPILLARY TYPE Work involved is same as item - 9.7.0 except that the capillary tube shall be supported by tray / structural.
10.0.0 FIELD MOUNTED SWITCHES

10.1.0 R E CE I V ER PRE SSU RE SW I TCH (PNEUMATIC) The pressure switches shall be mounted on suitable supports. Necessary pneumatic tubing and electrical connections shall be made. The pneumatic signal shall come from corresponding transmitter. [Pneumatic tubing, electrical wiring are covered separately under 16.0.0 & 17.0.0] 10.2.0 DIRECT CONNECTED PRESSURE SWITCH Work involved is same as 10.1.0 but process S.S. tubing shall be connected from pipe lines / vessels using proper isolation valves instead of pneumatic copper tubing from transmitters. Pressure switches shall be installed rigidly to avoid vibration 10.3.0 DIRECT CONNECTED DIFFERENTIAL PRESSURE SWITCH Work involved is same as 10.2.0 except that two process S.S tubing shall be provided 10.4.0 DIRECT CONNECTED LEVEL SWITCH [INTERNAL / EXTERNAL /FLOAT TYPE] Scope includes the installation of level switches on the vessels, making necessary electrical connections using armoured cable. (Scope for wiring is covered separately under 16.0.0 & 17.0.0) 10.5.0 LEVEL SWITCH TUNING FORK TYPE , PADDLE TYPE, CAPACITANCE TYPE (WITH OR WITHOUT EXTERNAL CHAMBER) Scope of work is same as item 10.4.0] 10.6.0 TANK LEVEL SWITCHES (FLOAT AND TAPE TYPE) Installation of the float, tape and guide wires, mounting the switch on the vessel flange, con-
9.4.0
9.5.0 9.5.1
9.5.2
9.6.0 9.6.1 9.6.2
9.7.0
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necting the cable and terminating the cable. 10.7.0 TEMPERATURE SWITCH Mounting the temperature switch with thermowell on the vessel / pipe line, cabling and termination. 10.8.0 DIRECT CONNECTED FLOW SWITCHES Mounting the flow switch on the pipe line, cabling and termination. 10.9.0 LIMIT SWITCH Electrical connection to be made to the limit switches mounted on control valves, actuators etc.
11.0.0 ANALYSERS
Manufacturers instruction manuals shall be strictly fol lowed for the proper installation and functioning of the analyser. PH ANALYSERS IMMERSION TYPE Mounting the electrode with holder using the mounting hard ware provided, installing the analyser transmitter and JB on 2" pipe pedestal and termination. FLOW THROUGH TYPE Contractor shall supervise and ensure the proper installa tion of the electrode chamber on the pipe-line by piping group. Analyser transmitter and JB shall be mounted on 2" pipe pedestal and the air supply tubing, cabling and termi nation done. PH-ANALYSER, CABINET MOUNTED Installation of the analyser cabinet, air supply tubing, interconnecting cabling and termination. CONDUCTIVITY ANALYSERS Contractor shall supervise and ensure the proper installa tion of the electrode chamber on the pipeline by piping group. Analyser transmitter and JB shall be mounted on 2 pipe pedestal and the interconnecting cabling and termination done. CONDUCTIVITY ANALYSER WITH SAMPLING RACK Installation of the analyser sampling rack, impulse tubing for sample inlet and outlet / drain, cooling water inlet and outlet, interconnecting cabling and termination. DISSOLVED O2 ANALYSERS Mounting the electrode with holder using proper support, installing the analyser amplifier and JB on 2" pipe pedestal, mounting the power supply converter and interconnecting cabling and termination. PROCESS TITRATORS Installation of the process titrators inside the local control room and the connected cabling and tubing / piping, as per installation details provided by the manufacturer. DENSITY ANALYSERS (VIBRATION TYPE) Mounting the analyser sampling rack and doing the cabling and termination.
11.1.0 11.1.1
11.1.2
11.1.3
11.2.0
11.6.0 DENSITY ANALYSERS (FLOAT TYPE) Contractor shall supervise and ensure the proper installa tion of the density analyser on the pipe-line by piping group. Pneumatic to electronic converter shall be mounted on 2" pipe pedestal and the air supply / signal tubing, cabling and termination to be done. 11.7.0 MOISTURE ANALYSERS The analyser probe shall be mounted on the flange provided on the pipe line using proper gasket, nuts and bolts which will be supplied by the owner. The signal cable shall be connected to the probe and terminated. 11.8.0 OLEUM ANALYSERS Work involved is same as item 11.7.0 In addition to the above contractor shall mount the analyser transmitter and Junction box on suitable support in the field, and interconnecting cable to be terminated. 11.9.0 THERMAL CONDUCTIVITY ANALYSERS Installation of the sampling cabinet and analyser cabinet at locations shown in the layout drawings, connecting the sample tubing as per the drawings provided, and terminating the cables. Manufacturers instruction manuals shall be strictly followed for the installation and functioning 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. 11.12.0 NOX ANALYSERS Work involved is same as item 11.9.0. 11.13.0 SO2 ANALYSERS Work involved is same as item 11.9.0. 11.14.0 ZIRCONIA PROBE FOR O2 ANALYSERS Work involved is same as item 11.8.0. 11.15.0 ON LINE GAS CHROMATOGRAPHY Work involve is same as 11.9.0.
11.2.1
12.0.0 MISCELLANEOUS INSTRUMENTS

12.1.0 FLAME DETECTORS 12.1.1 Fixing the detecting element in such a way that direct flame and heat will not damage the same. 12.1.2 Mounting the preamplifier / relay units inside a dust tight metal enclosure or local panel supplied by others. 12.1.3 Interconnecting cabling between the detecting element and the relay. 12.2.0 VANE ACTUATORS 12.2.1 Supervision of installation of the vane actuator carried out by mechanical contractor and to ensure that the same is installed as per manufacturers recommendations. 12.2.2 Terminations of tubing and wiring on to the positioner, air set, I/P converter etc. of the actuator. 12.3.0 SUCTION PYROMETERS
11.3.0
11.4.0
11.5.0
INSTRUMENT ERECTION
25ES401 / 94 PAGE 8 OF 22
12.3.1 To install the suction pyrometer assembly on to the flanged nozzle of the furnace using proper gaskets, bolts and nuts, which will be supplied by 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 fittings for air connection to the ejector of the suction pyrometer. 12.3.4 Cabling for suction pyrometer will be similar to ther mocouple. 12.4.0 ACTUATOR OF CONTROLLED VOLUME PUMPS 12.4.1 The control volume pump will be installed by machinery contractor. Instrument contractor shall supervise the in stallation work and ensure that the same is installed as per manufacturers instructions / recommendations. 12.4.2 Provide the termination of signal cable (4 - 20 mA signal) and also tubing for all connection to the positioner unit and the actuator. 12.4.3 Generally, the scope of work will be similar to control valve. 12.5.0 OPERATION BOX This is required for the local operation of bagging machines etc.. This houses the push buttons and lamps required for the operation of bagging machine. Instrument erection contractor shall install the operation box properly on a suitable structure near by using brackets if required. Provide termination of all incoming and outgo ing cables to the operation box as per the wiring scheme of bagging machine supplier. 12.6.0 MOTION DETECTOR This is a small electronic instrument provided with mounting socket, similar to a relay. Contractor shall mount the motion detector inside a housing provided by purchaser and terminate all incoming and outgoing cables as per manufacturers wiring scheme. 12.7.0 I/P CONVERTERS + POSITIONERS & E/P POSITIONERS Mounting the I/P converters on seperate supports wherever necessary , making the electrical and pneumatic connections.
13.1.3
13.1.4
13.1.5
13.2.0 13.3.0
13.4.0
13.5.0
cess. If wiring is overhead, JBs/PDBs/Marshalling boxes shall be mounted a few feet above grade for easy access.Care shall be taken to ensure safe working conditions. Where wiring must enter the top of JBs / PDBs / Marshalling boxes,it shall be brought near the bottom of the box and then back up to terminals, forming a drip loop near the bottom of the JBs / PDBs / Marshalling boxes. JB s / PDB s / Marshalling boxes shall be mounted suitably such that they do not hinder works like movement of personnel around the plant,removal of equipments like heat exchanger shell tubes etc. RTD JUNCTION BOXES Work involved is same as item 13.1.0 THERMOCOUPLE JUNCTION BOXES Work involved is same as item 13.1.0, except that compensating cables are used instead of electrical cables. A.C POWER DISTRIBUTION BOXES Work involved is same as item 13.1.0, except that the distribution box houses isolation switches and fuse units for distributing 110 V A.C. power to field instrument. ENCLOSURES FOR INTRINSIC SAFE BARRIERS Work involved is same as item 13.1.0, except that the contrac tor shall mount I.S barriers inside the enclosure and the incoming & outgoing 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 the respective terminal blocks, and bulk heads respectively. Instrument contractor shall undertake the installation of panels, mounting the instruments on the panel and execute all the termination of wiring & tubing at the back of the panel. Instrument erection Contractors scope shall include but not be limited to the transportation, Calibration / testing, loop checking etc. of the panel mounted instruments. However if the contractor has to undertake some of wiring and tubing which are found necessary at a later stage for which they have to indicate the cost of the wiring / tubing per meter basis.The materials will be supplied by the purchaser. The local control panels shall be mounted as per the instru ment location and cable routing diagrams,IADs. All wires and tubes shall be terminated as per the instruction manual,IADs and as per termination procedure described under M elsewhere. Foundation for panels and racks shall meet the requirements of the equipment vendors specifications. Panels and racks shall be located to allow easy access and operation and to permit operator to survey the maximum panel area. Panels shall be arranged and located for easy reading,servicing and maintenance of equipments and panels / cubicles. Air purging shall be used
13.0.0 JUNCTION BOXES, PDBs, MBs

13.1.0 ELECTRICAL JUNCTION BOXES, PDB s, MBs AND TERMINATION BOXES 13.1.1 Fabrication of necessary supports and welding it on to the available structures or grouting on to the floor including the civil work connected with it. Mounting the junction box, connecting the individual cables and multicore cable using cable glands and terminating the wires. All the electrical wires shall be identified using the cable marking ferrules. For termination boxes only one cable entry and outlet is required. Blinding all other holes if required. 13.1.2 Where cable runs are underground, Junction Boxes,marshalling boxes shall be mounted above grade at convenient height for easy ac-
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wherever neces sary for environmental reasons as well as for electrical safety. Panels shall be removed from racks only when ready for installation. Hooks shall be used while lifting and moving the panels etc. Welding shall not be done on the panel at site for supports etc. Panels shall not be used as earth as it may damage the instruments,especially electron ic. Proper earthing for the panel shall be provided sepa rately,otherwise it shall be connected to the main earth of the plant.
(i) Pedestals shall be painted to protect from corrosive atmospheres and weather conditions.
16.0.0 GENERAL NOTES FOR INSTRUMENT PIPING AND TUBING

16.1.0 The sizes of the piping / tubing and also their materials of construction are decided by the designer of the instrumen tation and control system. 16.1.1 Instrument tubing [mainly S.S] shall be cut using only the standard cutter. Use only fine sand-paper for polishing the outer edge of the tubes 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 type couplings. After tightening, softly remove the joint and inspect for the uniform closure of the ferrule on the fitting 16.1.2 Where tubing are adjacent, clearance between them near the coupling portion shall be at least 10 cm for easy maintenance. 16.1.3 The pipes shall be supported on angles using proper U- clamps. 16.1.4 Pipe lines [for impulse lines ] shall be bent only after sandfilling and heating and using a bending machine. Otherwise, it will kink and become weak. 16.1.5 Always avoid sharp bends. Use only smooth bends wherever necessary. 16.1.6 Give proper support for the piping for drawing out purposes. 16.1.7 When using pipe connector or couplings, adequate space for spanner head shall be provided. 16.1.8 When brazing or welding two pipe ends, care shall be taken to see that the adjacent pipes / vessels are not affected by this heating. 16.1.9 For reference drawing list refer to Document Control Index. 16.1.10All instruments on instrument piping details and other instrument drawings are shown symbolically. For true picture and location of connections refer to vendors drawings. 16.1.11 Instrument connection block valves on lines, orifice flanges, vessels and equipment are to be in accordance with the specification of the line, vessels or equipment to which they connect and that are furnished by the piping division. 16.1.12 Field contractor shall relieve all connections of any strain by properly supporting all pots, leads and instru ments. Refer to Typical instrument support details and Standard Drawings attached. 16.1.13Instrument pressure leads and flowmeter leads are to be sloped 1 in 12 minimum in horizontal runs, except that long pressure instrument leads carried on racks through the yard may be run horizontally, but without pockets, together with pneumatic leads. 16.1.14When a pressure lead rises above the pressure connection and the instrument it serves, a minimum slope of approxi mately 1 in 12 from the high point of the lead toward the pressure connection and the instrument must be maintained,
15.0.0 FABRICATION WORK AND MOUNTING OF INTRUMENTS

15.1.0 FABRICATION WORK Instrument contractor shall fabricate different steel struc tures supplied to him as per drawings. Unit rates shall be applicable as shown in bid item. Minor civil works like chipping, grouting etc. shall form part of fabrication job like welding rods and gas shall be included in the fabrica tion cost. 15.2.0 INSTRUMENT AIR LINES 15.2.1 Piping contractor will terminate main instrument air header lines on the pipe bride with first isolation valve for branch lines for instrument air distribution. The fittings will be of welded type and pipes will be of galvanised carbon steel type. Contractors scope includes installing, testing and commissioning of these lines. 15.2.2 316L PIPES / 316 SS PIPES, CARBON STEEL PIPES Welding of instrument impulse lines using pipes shall be done by qualified welders as per the stamdard welding procedure. 15.2.3 NOTES ON MOUNTING OF INSTRUMENTS (a) Mounting of all accessories of field mounted instruments such as manifolds, air sets, condensate pots etc.. wherever applicable, are included in the installation of the instru ments and no extra shall be paid for there accessories. (b) No field mounted instrument shall be installed with support from impulse piping / signal lines. (c) Hand rails shall never be used for mounting or support ing instruments. (d) Instruments shall be mounted on pedestals fabricated using base plate and 2" pipe of about 1.5 mt. height. (e) All field mounted instruments shall be mounted at grade or on platform. (f) If pedestal is installed at grade,it shall be fixed to the concrete paving with anchor bolts. (g) If ground is un-paved,a concrete base shall be provided for the pedestal. Pedestals mounted on top of platforms or process piping shall be removable. (h) The instruments shall be mounted on pedestals using U clamps,nuts and bolts or as per installation drawings given by engineering dept. or vendor.
INSTRUMENT ERECTION
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except as specified in note m above. 16.1.15 Field contractor shall provide sufficient flexibility for pressure leads and pneumatic leads to allow for thermal expansion of vessels, lines or equipment to which they connect. 16.1.16 Use bends in all pressure leads and keep threaded joints to a minimum. 16.1.17 Bends in tubing for pneumatic leads are to be kept to the absolute minimum required. 16.1.18 All pressure leads and pneumatic leads to and from instruments are to be thoroughly cleaned of burrs and foreign matter before being put into operation. 16.1.19 All pressure instruments in wet service are to be cor rected for liquid head pressure. 16.1.20 Instruments, instrument pressure leads, flow meter leads and pneumatic leads shall not be mounted on, nor supported from platforms, railings, steel supports, equipment and process or utility lines that are subject to abnormal vibra tions, part icularly vibrations caused by reciprocating machines, unless absolutely necessary. Additional bracing and / or supports shall be provided for instruments and instrument leads to assure rigidity under such abnormal conditions. 16.1.21 Where rack is not provided, pneumatic leads [generally 3 or less ] shall be strapped to air headers or branches. 16.1.22 Elevations shown in instrument locations and air supply header drawings are to bottom of piping unless otherwise noted. 16.1.23 The quantities given in the bill of material for pipes and tubes are for straight pieces only. Installation of fittings like elbows, tees, valves condensate pots etc. shall be included in the cost of erection and no separate charges will be applicable for these items. 16.1.24 Locations and facing of instruments shall be adhered to as closely as possible. 16.1.25 Air supply piping will be supported on existing steel. Field contractor shall provide additional steel wherever required. 16.1.26 Field contractor shall provide all materials required for mounting and supporting instruments, instrument pots, piping etc. Refer to Typical Instrument support details drawings. 16.1.27 Unless otherwise noted, pedestal type mounted transmitters, indicators, recorders and controllers shall be located with the center line of the instrument, 1.3 M above grade or platform. 16.1.28 All elevations given are based on the grade elevation indicated on the lay out drawings. 16.1.29 All tube fittings shall be used as specified in instrument hook up & layout drawings. The Contractor shall ensure material, dimension and physical condition of all items before putting them to service. 16.1.30 For D/P transmitters with capillary extension, the capillary tube shall be insulated using glasswool with aluminum cladding as indicated in the instrument application diagrams. 16.1.31 Welding as per the standard procedure / specifications shall be followed. Any preheating
/ postweld heat treatment shall be done wherever required as per standards. 16.1.32All pipes shall be thoroughly checked for cleanliness and moisture before and after installation. 16.1.33After testing, all C.S. pipes shall be epoxy painted. 16.1.34The take off points shall be from top of the header. 16.1.35While brazing or welding two pipe ends,care shall be taken to see that adjacent pipes / vessels do not get affected due to heating. 16.1.36Even when dryers are supplied to keep the air dry,a drain or drains shall be installed at low point(s) in the system to provide drainage. 16.1.37No hicks or cuts shall be made on any of the enclosed tubes as these will be points of potential failure.
17.0.0 GENERAL NOTES ON TERMINATION, E L E CT RI CAL I NS TALL ATIO N AND GROUNDING

17.1.0 TERMINATION 17.1.1 Wires of the cable shall be cut as it comes off the reel at a location free from sharp objects. 17.1.2 Jacket and shield material shall be terminated without nicking insulation underneath.If no pair jacket is used and pairs are individually shielded then insulating tape or sleeving shall be applied to exposed shielding in order to protect accidental grounds. 17.1.3 All cable ends shall be protected against moisture entry prior to connecting the cable to its permanent terminations. 17.1.4 Stripping of insulations from wires shall be done without nicking the conductor.Standard stripping tools of proper design shall be used. 17.1.5 Screws shall be torqued adequately to get good contact with wires inserted under the screw. 17.1.6 Proper compression of the terminal screws shall be done to prevent corrosion which may later cause poor continuity,galvanic, or rectification action.High quality terminal strips and insulating materials shall be used. 17.1.7 All wires or leads terminated at connection shall have sufficient slack to reduce the effect of vibrations. 17.1.8 Necessary cable supports shall be provided to avoid having cable weight supported from wire terminations. 17.2.0 ELECTRICAL INSTALLATION 17.2.1 The equipment erection and their installation shall conform to the latest Indian Electricity Rules and Indian Factories Act, as regards safety, earthing and other essen tial provisions specified therein for installation and operation of the electrical part of the instrumentation loop. 17.2.2 Fittings, switches, distribution boards, junction boxes etc. for electrical lines shall be installed at places as indicated in drawings. 17.2.3 The cable termination shall be done using solderless crimping type closed eyelet connectors [Contractors supply].
INSTRUMENT ERECTION
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17.2.4 Cables carrying 110 volts or above shall not run in the same conduit, metal or PVC ducting, trunking or trays as cables carrying lower voltage. 17.2.5 Cables carrying alternating current shall not be run in the same conduit, metal or PVC ducting, trunking or trays, as cables carrying direct current. 17.2.6 Laying of earth conductors, fixing on cable duct / tray structural, clamping / jointing by brazing wherever necessary, testing and commissioning including supply of earth conductors, crimping lugs, bolts, nuts, washers etc. and supply and installation of earth pits as per drawing. 17.2.7 Where cables are run through pipes, the entry to and exit from pipes shall be smooth and free from burrs. Cables shall be pulled into such pipes in such a way that there is no damage to the cable. 17.2.8 Where space is left in pipes for cables to be pulled in at a later date, a galvanised draw wire of adequate size shall be left in the pipes. 17.2.9 There shall be no intermediate joints in any cable. Joints shall be made only at terminals in instruments or approved equipment. 17.2.10 Temperature compensating cables, alarm and trip system wires shall be run in conduit or on cable tray as specified on drawings. 17.2.11 Elevations shown for horizontal conduit / tray runs are the elevations of the platforms, steel or piping from which these are to be supported. Contractor shall provide any additional supports if required. 17.2.12 Vertical conduit / tray runs at structures shall be supported from ladders unless otherwise noted. 17.2.13 Location and elevation of conduit / cable tray run may be changed when necessary to avoid interference. 17.2.14 Cables shall be located at a minimum distance of 300 mm from hot piping or equipment. 17.2.15 Vents and drains shall be furnished at high and low points in conduit runs. Conduit shall be sloped toward drain fittings. 17.2.16 All sealing fittings shall be dammed with fiber and filled with sealing compound after wiring is completed. 17.2.17 The 24 V / 110 V alarm, control and instrument power wiring shall be run in conduit from local instruments to centrally located terminal boxes. Wire shall be copper, single conductor, PVC insulated rated 600 volt. 17.2.18 Conduits in main runs shall be supported on a suitable steel rack. 17.2.19 Minimum size of conduit shall be 20 mm. 17.2.20 All spare wires shall be tagged and placed in convenient place or terminated suitably. 17.2.21 All cables shall be tagged with aluminiumtag plates. 17.3.0 GROUNDING 17.3.1 All exposed non-current metallic parts that could become energised with hazardous potentials shall be reliably connected to the equipment grounding circuits.
17.3.2 On complex interconnected instrumentation networks caution shall be exercised when en grounding the circuits to ensure that multiple grounds are not established. 17.3.3 Shielded type instrument wiring shall be grounded at only one end. 17.3.4 All instrument grounds shall be checked for same potential if tying between instrument circuit grounds to the same earth electrode beds that are used for power grounding is done. 17.3.5 All spare conductors in a multicore cable shall be grounded to avoid induction of large voltage surges on signal circuits when nearby lightning strikes occur. 17.3.6 Shields or signal wires shall never be left unconnected,grounded indiscriminately, connected to their signal pair at two or more points, or tied to other signal leads. 17.3.7 Instruments, junction boxes , cable gland plates shall 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 ducts shall be achieved by use of cable tray bends and tee pieces or by efficient clamping. For cable trays, generally available supports will be used for routing. But wherever it is not available, Contractor shall make necessary supports for routing the cable trays / cable ducts. 18.2.0 Main cables shall be laid through cable ducts. Contractor shall provide proper covers after installation of all the cables inside the duct. All pneumatic tubing and electrical cables shall be clamped on the cable tray at intervals of not more than 500 mm. 18.3.0 Grease shall be applied to all machine bolts before tightening. Necessary quantity of grease shall be supplied by Contractor. Cable trays & Cable ducts shall be fixed on structural supports fabricated at site by Contractor. 18.4.0 Contractor shall fabricate at site the bends, tees, crossings, suitable and required clamps from sheets / strips etc. for the trays and ducts wherever required according to the routing requirement. The cables taken along trays / angles alone will have to be clamped. The cable inside the duct shall be neatly arranged. This shall also include laying under ground cable through the trench wherever re quired. 18.5.0 The quantities given in the bill of material for cable trays, cable conduits and cable ducts are for straight pieces only. Installation of fittings like bends, tees, reducers etc. shall be included in the cost of erection and no separate charges will be applicable for these fittings. Asbestos covering shall be provided for cable ducts at locations where fire proofing is required. 18.6.0 Trays are not designed as walk ways or hoisting beams and persons shall be advised not to use them as such. 18.7.0 All runs of ducting and conduits shall be mechanically and electrically continuous.Running threads shall be secured by lock nuts. 18.8.0 Under ground conduit banks which cross
INSTRUMENT ERECTION
25ES401 / 94 PAGE 12 OF 22
beneath roadways,railways or other areas subject to heavy loading or having poor soil conditions shall be adequately supported or the envelope reinforced using concrete cover slabs to pre vent shearing,crushing or damage from uneven settlement. 18.9.0 All underground runs in process plants shall be clearly marked for run location and identified,using pointer and service identification signs as per the installation stand ards. 18.10.0 Cable conduits shall be supported at least every 1.5 mtrs.Supports shall never be tag welded to conduits. 18.11.0 Conduits shall not be supported from piping that may have to be replaced or removed for inspection nor supported from high temperature piping. 18.12.0 Conduit runs shall be solidly connected to assure conti nuity for their entire length.Ground jumpers shall be installed where physical conditions cast any doubt as to the required electrical continuity. 18.13.0 All underground conduits shall be arranged in banks and should have protection and identifying concrete envelope. 18.14.0 Conduit banks shall be installed about 2 feet below grade,12"below drainage ditches in process areas,or below the frost line,whichever is greater. 18.15.0 The ends of cables shall be properly sealed before pulling in to prevent moisture and damaging substances from entering. 18.16.0 Cables normally shall be pulled directly from a shipping reel into position in the tray. Small cables (2" and smaller in diameter), can be laid with a basket grip. The pulling tension shall not exceed the cable manufacturers recommenda tions. Pulleys,rollers etc. shall be used to guide the cables into positions in a tray. 18.17.0 Specific care shall be taken while installing Special cables like co-axial cables,as electrical characteristics may change due to improper handling. 18.18.0 Care shall be taken to see that there are no kinks or loops that may scrape the edges of conduit fittings,cover plate surfaces and edges etc. and result in damaged insula tion and even broken wire. 18.19.0 Covers on trays shall be used to prevent accumulation of dirt,debris,snow,ice etc. 18.20.0 A minimum of 5 feet clearance shall be present between noise generating equipments and cable tray on which signal cables will be laid. 18.21.0 Cable trays shall be run with the breadth of the tray in a vertical plane.Where FEDOs site engineer agrees that a vertical run is not possible,a short horizontal section shall be used but the run shall revert to the vertical plane at the nearest point. 18.22.0 The contractors scope shall include cable laying harnessing / dressing, clamping on trays, making aluminium tags with cable numbers punched on it [as per cable schedule] and fixing them on either end of the cables before entering the instruments, junction boxes or control room. The tags may be tied to the cable using G.I.
wires. PVC marking ferrules [ Contractors scope of supply ] shall be used at the termination end of the cables. All single / multicore tubing / cables connecting the field instruments / junction boxes with bulk heads / junction boxes of control panel are to be laid on cable trays and properly clamped at intervals not exceeding 1000 mm on horizontal runs and 300 mm on vertical runs.
19.0.0 CIVIL WORKS

All civil works such as grouting, chipping of the wall / concrete floor as required for some fixtures of instruments, cable racks, instrument pedestals, etc. will have to be undertaken by the Contractor. All the chipped areas shall be replastered to attain the same finish as before. For opening up the walls at any place prior permission shall be obtained & the same shall be closed neatly after completion of said work to the same specification & finish as before such a work was undertaken.
20.0.0 CALIBRATION AND FUNCTIONAL CHECK

The instrument Contractor shall possess all relevant test instruments and shall test the installation in the following manner in the presence of site engineer. 20.1.0 All pneumatic signal lines shall be disconnected and blown through with instrument air. 20.2.0 The signal lines shall be blanked off and pressurised pneumatically using bubble bottle to 1.5 Kg/cm2. The bubble rate after pressurising shall be less than 1 bubble in ten minutes. 20.3.0 All instrument air mains shall be isolated from the instrument and pressurised pneumatically 1.5 times maximum working pressure and isolated from the source of pressure. The pressure shall not fall by more than 0.1 Kg/cm2 in ten minutes. 20.4.0 All impulse lines shall be isolated from the instrument, and hydraulically tested to 1.5 times the working pressure and isolated from the source of pressure. The pressure shall not fall by more than 0.1 Kg/cm2 in ten minutes. 20.5.0 All the installations will have to be checked and tested by the method of simulation for working of entire instru mentation loop and its circuit to include the relevant primary, secondary and control elements. 20.6.0 All RTD electric and electronic instrument wiring shall be tested for resistance between conductors and earth and for 500 DC. These tests shall be carried out with all con ductors disconnected except from the test instruments. The insulation resistance shall not be less than 10 mega ohms. 20.7.0 Transmitter connections to the correct receivers and polarity shall be checked. 20.8.0 Controller connections to the correct control devices shall be checked. 20.9.0 Correct connection of pneumatic and electric switches shall be checked. 20.10.0 Correct operation of all alarms and functioning of inter locks shall be checked. This testing shall be coordinated with site engineer.
INSTRUMENT ERECTION
8. Dial thermometer & Temp. Transmitter Temperature Switches
25ES401 / 94 PAGE 13 OF 22
Temp. bath Checked at various Temperastandard ther- ture mometer Multivolt source or Resistance source Bently Nevada testing equipment Checked increasing & decreasing the valve This is to be calibrated as per manufacturers instruction.If contractor does not have the inster. he shall do this on subcontractor under his responsibility by BN Indian Agent. Calibration shall be checked using zero & span gases & noting the output meter. Using these std solution & output meter calibration to be checked. Lubricated stoped & checked for smooth operation & Hystersis I/P SOV, Limit switch, valve opening & closing time etc. to be checked. Manufacturers instruction manuals.
20.11.0 The written results / certificates of all tests (loop tests and group tests) shall be approved by site engineer in writing. 20.12.0 Reasonable evidence of the satisfactory condition of the test equipment shall be provided, if required. 20.13.0 All errors of faulty workmanship regarding the installation discovered during the testing shall be corrected. 20.14.0 All pneumatic, electro-pneumatic and electronic transmit ters, indicators and recorders shall be calibrated taking eight check points throughout the instrument range. Four each shall be taken on the upscale run and downscale run. 20.15.0 Contractor shall have signal sources and other precision calibration equipments for all pneumatic and electronic instruments as per the instrument list given. The ranges of the instrument shall be set as per the specifications. The instruments shall have required characteristics throughout their range as per the specifications, within the tolerance. Any deviations shall be brought to the notice of Engineer-in-charge. Contractor shall undertake any minor repairs of instruments found necessary, as part of calibra tion work. However such work may be undertaken only with the consent of the Engineer-incharge. 20.16.0 Precaution shall be taken to see that no instrument is subject to overloading or unwanted signal is supplied to the instrument. 20.17.0 Calibration work shall be undertaken only after studying the instruction manuals and other special instructions from manufacturers regarding each instrument. NOTE: (a) All the hydraulic test fluid shall be drained off from the impulse line when hydraulic test is over. (b) All impulse line shall be blown off using instrument air before testing. (c) For float type level instrument the test pressure shall be the rated pressure. 20.18.0 Procedure for testing and checking of instruments.
1. Pressure / Vaccum gauge Dead weight test and vacuum gauge test Pressure Pneumatic gauge rig Receiving Using test Instrument rigs with ac(Pneumatic) curate gauge Receiving Instrument (Electr.) Receiving Pressure switch Receiver Switches Electronic Switch By comparing with master gauge By comparing with Hg manometer - do -
9.
10. Vibration / Axial displacement system
ANALYSER
1. 2. 3. 02,H2,CO2 Zero / Span etc. gas & output meter PH, ConSolution & ductivity output meter disolved 02 Control Pneumatic / valve Electric test rig. Controller
4. 5.
6.
7.
Electronic & Pneumatic rigs. TemperaPotenCalibration to be checked give ture intiometer/Decadknown input of T/C or resisdicator e resistance tance and comparing output box. with std. curves. Differential Hydraulic or Out put shall be measured pressure & pneumatic rig using master output gauge. Pr.transmit- output meter ters Hg (Elect or manometer Pneumatic ) E/P Field Checking shall be done by transducer calibrator feeding input field calibrate & standard out- noting the output reading reput gauge for quired the output. Hg manometer.
20.19.0 To identify the stage of inspection done the different colour of the small label shall be attached 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 be done after installation to verify freedom from grounds. 21.1.2 After all connections are given the complete loop shall be checked for satisfactory performance. 21.1.3 Where meggers are used,care shall be taken not to use a voltage in excess of the insulations rated voltage. 21.1.4 While testing the wires, all the instruments shall be disconnected to avoid damage to the instruments. 21.1.5 Wire to wire and wire to ground resistance shall normally not exceed 10 M.ohms in most applica-
2. 3.
4.
5. 6. 7.
Using Electronic - do calibrator & test rig. Hydrolic / Check the operation & setPneumatic ting using multimeter tester Pneumatic - do test rig. Signal gener- do ator
INSTRUMENT ERECTION
25ES401 / 94 PAGE 14 OF 22
tions. 21.1.6 The shield drain shall also be tested for accidental shorts or grounds as just another conductor requiring high resistance to ground. 21.1.7 Grounding circuits shall be tested for resistance low enough to operate overcurrent devices should a ground fault occur within the instrument. 21.1.8 This is part of the instrument installation work(see item 22.0.0) Instrument erection will be considered 100% complete only after all the checks as indicated below are complete. 21.1.9 All instrument loops are to be checked for compliance of the installation drawings. Wherever possible signals are to be simulated at the transmitter end and shall be followed at the indicator / controller / alarm / interlock components upto the final control element. Loop check shall be carried out by simulation of signal from transmitter end at minimum four points, 25%, 50%, 75% and 100%. All defects such as leaks at the instrument process piping / tubing, instrument air lines / fittings etc, insulation / connection faults at the electrical wiring shall be rectified to the satisfaction of the Owner. All the calibration variations, misalignment of linkages of final control elements are to be rectified. 21.1.10 All the joints in the air lines and the signal lines are to be tested for leaks using soap solution. All checking shall be done as per the general notes on wiring & tubing.
statement for the material supplied to him. The work will be deemed incomplete without submis sion of proper material reconciliation report. The responsi bility of submitting Material Reconciliation report with out any delay towards the end of the job lies solely with the contractor. The statement prepared by the contractor with proper references of receipts dates etc. should be submitted which will be verified for the total quantum of job carried out and material / items installed. After checking all the three statements with due allowance for wastage / scrap, material s t a t e m e n t s ca n b e a c c e p t e d b y FEDO/OWNER/CLIENT. This marks the completion of the job and final payment will be made only after this activity is completed. Allowance f or un ac cou nt ab le wasta ge fo r vario us categories of material will be as given below :-
Item
Length of S.S.pipes,tubes alloy steel pipes. Electrical cables.(3 meter per length of cable or which ever is less) C.S.pipes, aluminium trays Structural material Valves, pipe fittings, compression fittings cable glands etc. Nut, Bolt, gasket material
%allowance 0.5% 2% 1% 2% NIL 2%
PART C - JOB COMPLETION REQUIREMENTS 22.0.0 COMPLETION OF ERECTION JOB

The completion of the entire erection job on Instrumentation will be considered in following three major stages and the payment will be accordingly made subject to the other commercial terms. a. 60% of the job will be considered complete when erection of the instrument material is mechanically completed. b. 20% of the job will be considered completed on completion of checking and calibration of individual instruments. c. 20% of the job will be considered complete after loop checking of instruments. 22.1.0 MATERIAL RECONCILIATION / WASTAGE ALLOWANCE The contractor shall plan and execute the work in such a manner that wastage of material shall be limited to minimum. The contractor should take precaution to ascertain the actual route and lengths required before laying of cables and tubes so that the lengths of cut pieces are kept to the minimum possible, and not exceed 0.5% of total Qty., for cables and SS tubes as far as possible. Total wastage / scrap which cannot be accounted for in receipt, consumption return statement should not exceed following % allowance itemwise. Items supplied by owner as free issue shall be returned to store with proper return notes. He shall also furnish reconciliation
NOTE :For wastage over and above the figures indicated, contractor will be charged at the cost of price+over heads+taxes. 22.2.0 QUANTITY VARIATION Quantities indicated in the bill of quantities are tentative and are likely to vary subsequently. The unit rates shall remain firm for any variation in the scope of work to the extent + or - 25% of total contract value.
23.0.0 COMMISSIONING AND START-UP

For commissioning and start up contractor shall deploy qualified skilled, semi-skilled and unskilled personnel at the rates quoted under schedule of labour rates. The approximate number of personnel that would be required are also indicated in the schedule of labour rates. The owner will have option to engage partially, fully or additional personnel as required by him and the contractor shall provide the personnel at the rate indicated. Actual requirement will be intimated to the contractor at least 15 days in advance. These rates shall be applicable for any additional work done on labour supply basis.
24.0.0 BILL OF QUANTITIES AND MATERIALS

24.1.0 RATES The rates for installation of instrumentation shall
INSTRUMENT ERECTION
25ES401 / 94 PAGE 15 OF 22
24.1.1
24.1.2 24.1.3
24.1.4 24.1.5 24.1.6
24.1.7 24.1.8 24.2.0 24.2.1
24.2.2
include for :Handling, transportation, care and protection of owner issued equipment and materials from owners stores to con tractors store or point of installation. All installation works, fixing and testing. Maintaining proper inventory of owner supplied equipments and materials and returning all surplus equipments and materials to stores of owner, after completion of work. Provision of adequate and proper storage for owners equipment and materials. Provision of complete Instrument workshop with testing and calibration equipments. Provision of all installation equipment, tools, scaffold ing, workshops and offices and any other equipment and / or appliances necessary to complete the installation, in ac cordance with the specifications. All consumable materials, other than those separately enumerated in the bid items. Removal, re-calibration and re-installation of instru ments as required during pre-commissioning. MEASUREMENT As far as possible, all measurements for payment shall be taken from Good for construction drawings released for construction and schedules provided by owner. Only the items listed in the schedule shall be measured for payment. All other labours and activities necessary to complete the installation shall be deemed included in the items in the schedule. Note: For measurement & billing refer formats 25 FT 407 & 25 FT 408.
a. TABLE-1 includes the several kinds of welding Procedure. The contractor or subcontractor who will do the actual welding work for piping shall select the applicable welding procedure for each kind of piping welding from Table. 1. After that, the contractor or subcontractor shall pre pare the detailed WPSs and procedure Qualification Record (PQRs) in accordance with ASME CODE SECTION IX and the requirement of this specification, submit and obtain the written approval from Owner prior to the commencement of any welding work. b. If the contractor or subcontractor wants to use other welding procedures not listed in Table.1, the contrac tor or subcontractor shall submit the detailed WPSs and PQRs to Owner and get the approval before use. 25.3.2 WELDING PROCEDURE FOR CARBON STEEL a. All pressure retaining welds and attachment welds to the pressure retaining parts shall be made by SHIELDED METAL ARK WELDING (SMAW) using Low Hydrogen Type Elec trode AWS E 7018 except root pass. b. Root pass of girth butt weld and branch connection weld, where the complete penetration in required shall be made by GAS TUNGSTEN ARC WELDING (GTAW) process or SMAW process. For GTAW, filler metal shall comply with AWS ER70S - 2,3,6 or ER70S - G (TGS-50, KOBE STEEL LTD.). For SMAW, electrodes shall comply with ASW E6010. c. For small diameter piping (2" & smaller), all GTAW process may be used for all passes. d. End preparation and root gap shall be in a c c o r d a n c e wi t h F I G . 3 2 7 . 3 . 1 o f ANSI/ASME B31.3. e. In case of ASW E6010 for root pass, minimum.80 deg. C preheating is required for the thickness 1/2" and over. f. Weld progression for vertical position shall be uphill. g. When Post Weld Treatment (PWHT) is necessary from the fluid service requirement, PWHT conditions shall be as follows.
MATERIAL HOLDING TEMPERATURE HOLDING TIME : carbon steel : 625 +/- 25 deg. C : min. 1 Hr
PART D - PROCEDURES AND STANDARDS 25.0.0 GENERAL REQUIREMENTS AND RECOMMENDATION FOR PIPE WELDING
25.1.0. SCOPE 25.1.1 This specification covers the requirements and recommendations for welding procedure qualification test and welder s performance qualification test of piping / instrumentation structural work. 25.2.0. REFERENCES 25.2.1 The following codes, standards and specifications in the latest editions as of November 1984 shall form a part of this specification unless otherwise specified herein. a. ANSI/ASME B31.3 b. ASME CODE SECTION IX c. SPECIFICATION FOR FABRICATION AND INSTALLATION OF STEEL PIPING. d. PIPING MATERIAL CLASSIFICATION 25.3.0 WELDING PROCEDURE 25.3.1 GENERAL
25.3.3 Welding Procedure For C-1/2MO Steel (piping Material Service Class) a. Root pass of girth butt weld and branch connection weld where the complete penetration is required shall be made by GTAW process. b. Filter pass and Cover pass shall be made by GTAW or SMAW.
c.
INSTRUMENT ERECTION
25ES401 / 94 PAGE 16 OF 22
GTAW filler metal shall comply with ASW ER80S-D2 or ER80S-G (TGS - M, KOBE STEEL LTD.). For SMAW, electrode shall comply with AWS E7016-Al,low hydrogen type elec trode. E7010-Al type (high cellulose type) shall not be used. d. For small diameter piping ( 2" & under ), all GTAW process is preferable. e. End preparation and root gap shall be in accordance with FIG. 327.3.1 of ANSI / ASME B31.3. f. Weld progression for vertical position shall be uphill. 25.3.4 Welding Procedure For Austenitic Stainless Steel, S.S TP - 304, 304L, 316L,316SS. a. Root pass of girth butt weld and branch connection weld where the complete penetration is required shall be made by GTAW process Root pass by SMAW process shall be prohibited. b. Filler pass and Cover pass shall be made by GTAW or SMAW. For small diameter piping (2" & under), all GTAW process is preferable. c. Acceptable filler metal and electrode shall be as follows
Piping Material TP304 TP304L TP316L 316SS Filler Metal (GTAW) AWS ER 308 AWS ER 308L AWS ER 316L AWS ER 316 Electrode (SMAW) AWS E 308-16 AWS E 308L-16 AWS E 316L-16 AWSE316L-10
shall not be permitted. g. Maximum interpass temperature during welding shall be 150 deg.C. 25.3.5 Welding Procedure For Dissimilar Metal a. Root p[ass of girth butt weld and branch connection weld where the complete penetration is required shall be made by GTAW process. Root pass by SMAW process shall be prohibited. b. Filler pass and Cover pass shall be made by GTAW or SMAW For small diameter piping (2" & under), all GTAW process is preferable. c. Acceptable filler metals and electrodes for various combinations of base metal shall be as follows.
PIPING MATERIAL C/S S.S 304 S.S.304L S.S 316L C/S S.S 304 S.S 304L ER309 E309-16 ER308 E308-16 ER308L E308L16 S.S 316L
Notes:For welding electrodes AWS E308L-16,maximum carbon content shall be 0.03% (Extra low carbon type). At the time of purchasing these welding materials, maximum carbon content shall be specified, because maximum carbon content of normal AWS E308l-16 and AWS E316L-16IS0.04%. The following are the acceptable materials which comply with the above requirement.
AWS Class Trade Name & Manufacturer E308L-16 E316L-16 NC38EL(K.S.L),WEL 308 ELC (N.W.R ( K.S.L KOBE STEEL LTD ) NC36EL(K.S.L),WEL 316 ELC (N.W.R ( N.W.R NIPPON WELDING ROD CO., LTD. )
d. End preparation and root gap shall be in a c c o r d a n c e w i t h F I G. 3 2 7 . 3 . 1 o f ANSI/ASME B31.3. e. Weld progression for vertical position shall be uphill. f. Internal back shielding with pure Argon gas (min.99.9%) shall be required during the welding. Back shielding with Nitrogen gas
Note: For E308L-16, max. C-content shall be 0.03% (Extra low carbon). SEE Note2) of 3.3.3 d. End preparation and root gap shall be in accordance FIG. 327 3.1 of ANSI/ASME B31.3. e. Weld progression for vertical position shall be uphill. f. Internal back shielding with pure Argon gas (min. 99.9%) shall be required during the welding. Back shielding with Nitrogen gas shall not be permitted. g. Maximum interpass temperature during welding shall be 150deg.C. h. Welding between galvanised carbon steel or Zinc rich primer coated carbon steel and stainless steel shall be prohibited to avoid the Zinc Embrittlement Crack on the weld and Heat Affected Zone (HAZ). 25.4.0 WELDING PROCEDURE QUALIFICATION TEST 25.4.1 All welding procedures used for the instrument piping construction work shall be qualified or shall have been qualified by the contractor or subcontractor at his responsibility in accordance with ASME CODE SECTION IX and the requirements herein before the commencement of any welding work. If the contractor or subcontractor does not have the Procedure Qualification Records (PQRs) for the applicable Welding Procedure Specifica tions (WPSs) according to this specification require ments, he shall carry out the welding procedure quali fication test and shall submit the complete document as WPSs & PQRs to Owner for approval. 25.4.2 TABLE-2 STANDARD PROCEDURE FOR WELDING PROCEDURE QUALIFICATION
INSTRUMENT ERECTION
25ES401 / 94 PAGE 17 OF 22
25.5.0 25.5.1
25.5.2
25.5.3
25.5.4
TEST are the sample of procedure quali fication test for each welding procedure listed in TABLE-1 The contractor or subcontractor may modify the test procedure as far as the requirements of ASME CODE SECTION IX and this specification are kept. WELDER PERFORMANCE QUALIFICATION TEST All welders and welding operators engaged in this job are required to pass the performance qualification test in accordance with ASME CODE SECTION IX. The contractor or subcontractor shall be wholly responsible for quali fying each welder and welding operator to ensure that the welder or welding operator has enough skill to make the sound welds by using the welding procedure to be used for this job. TABLE-3 STANDARD PROCEDURE FOR WELDER PERFORMANCE QUALIFICATION TEST are the sample of performance qualification test for each welding procedure listed in TABLE-1. The contractor or subcontractor may modify the test procedure as far as the requirements of ASME CODE SECTION IX and the specification are kept. Visual inspection during welding and after welding is very important. Therefore the competent welding inspec tor or welding supervisor who has enough experiences for visual inspection of weld shall witness the welds test and judge his c a p a b i l i t y b e f o re g u i d e d b e n d t e s t o r radiographic examination. GTAW welder who passed the carbon steel weld shall not be qualified for stainless TIG welding, even if the No. of ASME CODE SECTION IX is same, but not vise versa.
high alloy steel. b. Name plates or identification tags. c. Valve stems or other machined contact surfaces. d. Galvanized surfaces. e. Insulation covers. f. Plastic. 26.4.0 PAINTING CLASSES The materials or paints specified in the CLASSES A to E are selected on the following basis :CLASS - A CLASS - B CLASS - C General use for surfaces with temp. upto 65 deg. C Mild Acid/Alkaline and saline atmosphere. General use for surfaces above 65 deg. C upto 120 deg. C strong Acid Alkali environment. Highly corrosive areas, particularly urea and abrasive environment, areas subject to wind, General use as for epoxy, chemical splashing areas including fluo rine, surfaces at sub - zero temp.
CLASS- D
CLASS - E : High temp. surfaces upto 400 deg. C
26.0.0 SPECIFICATION FOR PAINTING WORK :

26.1.0 SCOPE This specification covers the general requirements for painting of Instruments / accessories, steel structures and instrument piping. 26.2.0 REFERENCE The requirements given in the following specification in the manner and to the extent indicated therein. a. I.S. for surface preparation. 26.3.0 SURFACES TO BE PAINTED AND SURFACES NOT TO BE PAINTED The following surfaces shall be painted in accordance with the painting classes of this specification :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 painted for any specific reason. However, the following surfaces shall not be painted :a. Non - ferrous metal, stainless steel or other
26.5.0 PREPARATION OF SURFACES 26.5.1 General Requirements a. The surface shall be prepared to dry metal after removing rust, oil, grease, dust, strain, or any other extraneous matter by manual or mechanical cleaning such as wire brushing, grinding, power brushing, etc. b. Wet surfaces due to rain fall, dew - drop, frost, etc. shall be thoroughly wiped with rages and dried before each painting. c. Cleaning of wet or soiled surfaces shall be done immediately before application of paint in such a manner that adjacent wet paint surfaces are not damaged by the cleaning operation. d. Drying of wet surfaces may be expedited by blowing warm air. e. The primed/painted surfaces shall be dry and clean before application of subsequent coats. Deposits on the primed/painted surface must be cleaned before the application of the next coat. f. If the painted surfaces are exposed to rain while painting is in progress, the affected paint 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 be carried out in the manner that all crevices, corners, and edges of shape steel, joints of st eel pla tes, e specially a roun d bolt heads,weld beads etc. may be cleaned.
INSTRUMENT ERECTION
25ES401 / 94 PAGE 18 OF 22
26.6.0 26.6.1
26.6.2
26.6.3
26.7.0
26.6.1
26.6.2 26.8.0 26.8.1
26.8.2
b. Cleaned surfaces shall not be damaged by unnecessary tapping, etc. c. Where sand blasting is required, the same shall be carried out to SA 21/2 grade. The sand blasted surfaces shall be painted within 6 hours after sand blasting. STORAGE OF PAINTING MATERIALS Paints, varnishes, thinners or other volatile and inflammable painting materials shall be stored on a 150mm thick. layer of sand in well ventilated and detached storage sheds. Fire extinguishers or sufficient amount of sand shall be placed where readily accessible in case of fire. No Smoking and other suitable warning signs, such as No Open Flames, Danger,"Storage of inflammable Materials" etc. shall be posted around storage sheds. MIXING AND THINNING Mixing and thinning shall be done only at well ventilated places where there are no open flames. Mixing Wherever mixing of base paint and additives are involved, such mixing shall be done strictly as per manufactures specifications/recommendations. As far as practical, quantity of mixing shall be sufficient to cover the given section or an entire surface of the specific colour. Thinning wherever required shall be strictly as per recommended ratio. PAINTING General Requirements a. Painting on instrument equipment / accessories and piping shall be done at plant site, at shop as required. b. Painting shall be performed only in favorable weather conditions. Painting shall not be per formed in rainy, damp, windy, dusty, weather, or the day of such unfavorable weather is predicat ed. c. During painting, adjacent surface shall be properly protected from paint splashes, drips and other blemishes. If blemishes or damages occur by accident, they shall be thoroughly cleaned, repaired or replaced. d. Upon completion of painting work, all stagings, scaf foldings, paint containers, etc, shall be removed from the job site and the premises shall be left clean. e. Caution plates of Wet Paint shall be posted around the areas where readily visible, until the paint has completely dried. Methods of Application a. Painting shall be generally performed by hand brush method. Spray method may be adopted for surfaces like that of control panels for specific reasons. b. Wherever hand brush method is employed for painting, painting shall be done in alternate directions from vertical to horizontal,
or from horizontal to vertical and shall be applied to all edges, corners, crevices, joints, intersections etc. c. If brush marks, dags, runs, adhesions of brush bris tles, dust or blemishes occur, the surfaces shall be lightly sandpapered before successive coats are applied. d. All surfaces that are inaccessible after installation and assembly except for contact surfaces shall be painted twice, that is after first coat, the same is repeated again. The second and final coats are also repeated in same manner. 26.9.0 PRECAUTIONS 26.9.1 Open flames, smoking, exposed elements or sources of ignition of any kind shall be strictly prohibited in area where painting is being performed. 26.9.2 During painting operation and for a sufficient time thereafter, welding or open flame work shall be prohibited in the adjacent areas. 26.9.3 "No smoking and other warning panels to read Caution No Open Flames etc. shall be posted in all areas where and while painting is performed. The signs shall remain posted for a sufficient time after painting has been completed. 26.9.4 Hand lamps, flashlights etc. which will cause a fire shall be handled carefully. 26.9.5 Inflammable liquid with a flash point below 40 deg. C shall not be used for cleaning purpose. 26.9.6 Where it is practicable, adequate ventilation shall be provided to reduce the concentration of harmful vapours in the atmosphere. Otherwise, workmen shall wear vapour - proof masks, rubber gloves, etc. for protection when he has to work in a bad ventilated place. 26.10.0 INSPECTION 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 that presents good appearance, without spots, stains, and discolora tions. 26.10.3Inconspicuous parts, such as the corner of buildup members, around bolts, undersides and backsides of pipelines, pipe bends and valves etc., shall be closely checked so that they may not be left unpainted. 26.10.4Paint colours for identification purposes of piping shall be checked for correct colour application, if required. 26.10.5Defective surfaces, if any, shall be cleaned and repainted. 26.10.6Additional Requirements a. Any imperfect or damaged layer shall be re paired before the next layer is applied. b. The field welding for damaged layer shall be repaired before the next layer is applied. c. Bolts and nuts shall be provided with the relevant priming coat immediately after mounting.
INSTRUMENT ERECTION
Second finsih coat
25ES401 / 94 PAGE 19 OF 22
- do 1 25
d. Places where field welds are to be provided, a section of 50 to 500mm shall remain unpainted, on both sides. 26.11.0 TABLES Tables (Class - A to E) are given below.
( * ) Where primer is applied before shipment, one coat instead of two coats shall be applied.
CLASS - A
1. Scope of applications :Instrument accessories such as condensate pots, air headers, instrument pedestals, impulse piping, steel structures etc. Service conditions :Ambient - up to 65 deg. C Surface preparation :Mechanical Power tool cleaning / wire brushing Specification :Process Paint Red oxide zinc chromate primer to IS -2074 - do Synthetic enamel to IS-2932 or Aluminium paint to IS-2339 - do No. Film of thk. / Coats Coat 1 1* / 2 1 20 20 15
CLASS- C
1. Scope of application :Instrument accessories such as condensate pots, air headers, instrument pedestal, impulse piping, steel structure etc. Service condition :a. General use for surfaces 65 deg. C to 120 deg.C. b. Chemical splashing area particularly urea, acid/alkaline atmosphere c. Highly corrosive area particularly urea and abrasive environment subject to wind/drip ping etc. Surface preparation :Mechanical power tool cleaning/wire brushing. Specification :Process Paint Epoxy Red oxide Zinc Phosphate primer - do Epoxy finish paint - do No. Film of thk. / Coats Coat 1 1* / 2 1 1 25 25 40 40
2. 3. 4.
2.
Painting Before shipment at shop At field
3. 4.
Primer Primer Fist finish coat Second finsih coat
15
CLASS- B
1. Scope of application :Instrument accessories such as condensate pots, air headers, instrument pedestals, impulse piping, steel structure etc. Service conditions :a. Chemical splashing area, mild acid / alkaline atmosphere. b. Saline atmosphere. Surface preparation :Mechanical Power tool cleaning or wire brushing. Specification :Process Paint Red oxide zinc chromate primerchlorinated rubber based - do Chlorinated rubber finish - unmodified No. Film of thk. / Coats Coat 1 1* / 2 1 25 25 25
2.
CLASS-D
1. Scope of application :Instrument accessories such as condensate pots, air headers, instrument pedestal, impulse piping, steel structure etc. Service condition :a. General use as for epoxy coatings b. Highly corrosive and abrasive areas c. Chemical splashing areas including fluorine d. Surfaces at subzero temperatures Surface Preparation :Mechanical power tool cleaning/wire brushing Specification :Process Paint No. Film of thk. / Coats Coat
3.
2.
4.
3. 4.
Primer Primer Fist finish coat
Painting
Before shipment at shop At field
INSTRUMENT ERECTION
25ES401 / 94 PAGE 20 OF 22
Primer Primer Fist finish coat
2 pack polyurethane| primer - do 2 pack polyurethane| finish
1 1* / 2 1
25 25 40
CLASS-E
1. Scope of application :Instrument accessories such as condensate pots,air headers,instrument pedestal, impulse piping, steel structure etc. Service condition :120 to 400 deg. C Surface preparation :Mechanical power tool cleaning/wire brushing Specification :Process Paint Heat resistant silicone| aluminium paint - do - do - do No. Film of thk. / Coats Coat 1 1* / 2 1 1 25 25 20 20
2. 3. 4.
27.0.0 INSPECTION AND TEST PROCEDURE FOR I NST RUME NT INSTALLATION WORK
27.1.0 SCOPE 27.1.1 This specification covers the procedure for inspection and test of instrument installation work. 27.2.0 REFERENCE 27.3.0 GENERAL 27.3.1 Inspections and tests shall be performed for the following work items: a. Instrument pressure piping b. In strument Elect rical Wiring a nd Temperature Wiring c. Instrument Signal Air Tubing d. Instrument Supply Air Piping 27.3.2 Test reports shall be prepared for all tests and be submitted to CONSULTANT / OWNER immediately after the tests are completed. Typical report forms are shown in Appendices 1
through 4. 27.4.0 INSPECTION AND TEST - INSTRUMENT PRESSURE PIPING 27.4.1 Instrument pressure lead lines between the process isolating valves and the instruments to which they are connected shall be tested. Prior to the test, the following items shall be inspected visually: a. Whether instruments are correctly installed ac cording to the P & I Flow Diagram. b. Whether the upstream and downstream connections of instrument pressure lead line for differential pressure type instrument is correct. c. Whether adequate slope is provided to instrument pressure lead line. d. Whether sufficient supports are provided to instrument pressure lead line. e. Whether correct materials of the correct rating are used for instrument pressure lead line. 27.4.2 Testing Description Instruments with an operating pressure less than 40kgf/cm2G shall be pneumatically tested Instruments with an operating pressure equal to or more than 40kgf/cm2G shall be hydrostatically and pneumati cally tested. Unless otherwise specified, test shall be performed 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 instrument (in the case of pressure instrument, its measuring range), whichever lower. c. Test Procedure ( see 14 FT 561 / 93 ) After closing the process isolating valves and opening the equalizing valve, if installed, fresh water shall be fed into the pressure 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 system up to test pressure. Step 2. Close valves 6 , 7 . Open valve 8 . Confirm that pressure gauge indication does not decrease during 3 minutes. Step 3. Close valve 8 . then open valves 1 , 6 , 7 . Then pump enough water to confirm that valve 1 is not blocked
INSTRUMENT ERECTION
25ES401 / 94 PAGE 21 OF 22
Step 4. Close valve 1 and open valve 2 Then pump enough water to confirm that valve 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 allowable pressure of instrument ( in the case of pressure instrument, its measuring range), whichever lower, with a minimum test pressure of 1 kgf/cm2G. If instrument is not durable to 1 kgf/cm2G, test shall be performed with instrument disconnected from the line. c. Test Procedure.( see 14FT562/93 ) After closing the process isolating valves and opening the equalizing valve, if installed, test fluid shall be fed into the pressure 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 pouring soap water on each connection. Step 3. Open valve 1 . Confirm that valve 1 is not blocked. Step 4. Close valve 1 , pressurize system again and open valve 2 to confirm that valve 2 is not blocked. Step 5. Close valves 1 , 2 , 3 , 5 . Open valve 4 . Notes:a. The analyzer pipeline shall be tested by disconnecting the lead line from instrument. The test procedure shall be the same as that with process pipeline. b. Test may be performed separately or together with the test for process piping or equip ment. c. All instrument piping systems shall be cleaned by blowing air or flushing water before and/or after the test. All joints which are defective shall be repaired immedi ately and shall be re-tested by the original test method. 27.5.0 INSTRUMENT ELECTRICAL WIRING &
TEMPERATURE WIRING 27.5.1 GENERAL Continuity, identification and cable insulation resistance tests shall be performed. Prior to the test, the following shall be inspected visually: (a) Whether instruments are correctly installed according to the P & I Flow Diagrams. (b) Whether wire marking and/or color coding at terminals are correct. (c) Whether sealing compound or packing is provided as specified at the entry of each instrument. 27.5.2. TEST PROCEDURE Step.1. Continuity and identification of each wire and continuity of shield wire shall be in spected between the field instrument termi nals and the control panelboard terminals by using a telephone, a buzzer, or other suit able means. Step 2.Insulation resistance test shall be performed by using a 500 V or 1000 V megger. In this case, the wire shall be disconnected from the terminal both at the field and in the control panel. The minimum resistance value shall be as follows:
a. b. c. Line to Line Line to ground Line to shield min 10M ohm
Step 3.The electricity charged in the wire by the insulation resistance test shall be dis charged by grounding the wire and then the wire shall be connected firmly to its termi nal. 27.6.0 INSTRUMENT SIGNAL AIR TUBING 27.6.1 GENERAL Continuity, identification and leak tests shall be performed. Prior to the test, a visual inspection shall be made as to whether instruments are correctly installed accord ing to the P & I Diagram. 27.6.2 TEST PROCEDURE.....(see 14 FT 563 / 93) The following procedure applies only to the air tube between the field instrument and panel instrument. Air tube between field instruments may be tested by apply ing 1.0 kgf/cm2G air and swabbing solution to facili tate the detection of leaks. Step 1.For confirming continuity and identification, air tube connections both at field instrument and control panel bulk header shall be dis connected. Then blow out the air tube 1.0 kgf/cm2G air and check for correct line. Step 2. The air tube shall be connected to instrument which consumes no air such as receiver gauge, pressure switch and field controller (set point, cut-off and process value line) and the air tube shall be plugged at instrument which consumes air such as transmitter and controller output. In this case, the air tube may be connected to control valve when it has positioner, as its topwork has a large capacity, the air tube shall be discon nected and plugged.
INSTRUMENT ERECTION
25ES401 / 94 PAGE 22 OF 22
be re-tested by the original test method.
Namely, items 2 , 3 , 4 and 5 indi cated in fig.3 shall be connected to instrument and items 1 and 6 shall be plugged. Step 3. Send 1.0 kgf/cm2G air to the field and close valve A and open valve B . Observe the pressure gauge C. The values given in table 1 are allowable maximum de creasing rate of the line pressure. If the rate exceeds the values, then all air tubes shall be checked for leakage. 27.7.0 INSTRUMENT SUPPLY AIR PIPING 27.7.1 GENERAL Pneumatic test and air blowing of the supply air piping system shall be performed between the first take off valve on the main air header and instruments. Prior to the test, visual inspection shall be made as to whether instruments are correctly installed according to the P & I Diagram. 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 main header first take-off valve to individual instrument air regulators shall be equal to main air header operating pressure. Short length of air tubes between instrument and its air regulator shall be tested by the set pressure of the air regulator. 27.7.3 TEST PROCEDURE Step 1. Air blowing of the system shall be performed by disconnecting air tube at the inlet of the air regulator and opening the shutoff valve. Air blowing shall be done by opening and closing the shutoff valve for a minimum of five times until the air system is confirmed to be clean. Step 2. The air tube shall be connected again and the shutoff valve shall be opened to pressurize the system. All joints and connections shall be swabbed with soap solution to facilitate the detection of leaks. Note: a. Test may be performed separately or together with the test of main air header. b. All joints & connections found to be defective shall be repaired immediately and shall
28.0.0 APPLICABLE STANDARDS

API-RP-550 ISA Standard Installation of refinery Instruments & control system Standard & practices for installation.
28.1.0 OTHER STANDARDS Inspection & test procedure for instrument installation work. General requirement and recommendation for piping welding. Installation standards for instrumentation.
PART E - ATTACHMENTS 29.0.0 DRAWINGS - ANNEXURE I

The drawings supplied for Instrument erection are attached in Annexure I.The drawings provided are only typical and covers almost all type of instruments.All the required drawing will be supplied before or progressively during erection.If any modification / deviation in the drawings shall be informed to engg. department for approval.
30.0.0 SCHEDULE OF WORK - ANNEXURE II

The schedule of work in detail attached in Annexure - II.The instrument contractor shall follow standard erection procedure and maintain good quality of work.The wastage of material shall be limited to minimum as possible.
31.0.0 ITEMS TO BE SUPPLIED BY CONTRACTOR - ANNEXURE III

The list of items to be supplied by the contractor is attached in Annexure - III.The instrument contractor shall supply the specified items purchased from standard suppliers/subvendors approved by FEDO / OWNER .The items supplied shall be inspected for damages and compliance with specification s given by the engg. department. Any damage and unacceptable variation s shall be recorded (Refer 25 FT 403) and brought to the notice of concerned Engineer - incharge.
iso2.sty
ENGINEERING SPECIFICATIONS
1.0.0
INSTRUMENTATION WORKS GENERAL SCOPE

6.2.0
25ES403 / 98 - R1 PAGE 1 OF 2
2.0.0
3.0.0
4.0.0
5.0.0
5.1.0
5.2.0
5.3.0
6.0.0 6.1.0
These specifications establish and define the Material and Construction requirements for Instrumentation works. Providing and operating necessary Measuring and Testing Devices and Materials including all consumables are included in the Scope of Work. No separate measurement or payment for testing the WORK and Materials shall be made but rates quoted for various items shall be deemed to include the cost of such tests which are required to ensure achievement of specified quality. All materials supplied by the Contractor shall be as per FEDO specifications / of standard quality manufactured by renowned concerns conforming to Indian Standards or equivalent and shall have IS mark as far as possible unless otherwise approved by Engineer-incharge. The CONTRACTOR shall furnish manufacturers certificates for the materials supplied by him when asked for. Further, he shall get the materials tested by an approved test house, if asked for by the Engineer-inCharge. The cost for all the tests and test certificates shall be borne by the CONTRACTOR. No separate payment shall be made for the testing. The Engineer-in-Charge shall have the right to determine whether all or any of the materials are suitable. Any material procured or brought to SITE and not conforming to specifications and satisfaction of the Engineer-in-charge shall be rejected and the CONTRACTOR shall remove the same immediately from SITE at his own expense and without any claim for compensation due to such rejection. Wherever referred to in this document, only the revi sion which shall be in force till completion of the WORK of specification, CODES of Practice and other publications of the Bureau of Indian Standards shall be applicable. In case of conflict amongst the provisions of Schedule of Rates, specifications and drawings, all of them shall be read in conjunction with each other and clari fication shall be obtained from the Engineer-in-Charge whose decision shall be final and binding. Following procedure may generally be followed. Description of items in Schedule of Rates shall be followed when provisions therein are different from those in specifications. Where the description of item does not call for some specific requirements but the same is given in specifications, the specifications shall be followed, in addition to the requirements given in description of item. Where drawings call for requirements different from or additional to those given in item description and specifications, the decision of the Engineer-in-Charge shall be obtained as to what shall be followed. Method of measurement The method of measurements for all works shall be as indicated elsewhere in the Work Order and where not specified, latest revision of the relevant IS code for the concerned job shall be followed.
RECOM. BY:
In the absence of stipulations in any of the above documents, the following guidelines shall generally be followed. 1. Installation work of all online instruments shall be measured in numbers 2. Field mounted transmitters, local instruments/ analysers, PH/Conductivity transmitters, gas analysers, field mounted switches,Junction Boxes of different type, etc. shall be measured in numbers. 3. For PH/conductivity transmitters and gas analysers work, installation, calibration and inter connections shall also be included. 4. For toxic gas mounting system calibration, installation and loop checking shall be included. 5. Measurements for fabrication and painting of structural steel shall be in metric tonne corrected to nearest kilogram. 6. Tubes & pipes shall be measured in metres corrected to nearest centimeter. 7. Tube/pipe fittings, valves, etc. shall be measured separately in numbers. 8. Measurement of cables and conduits shall be in meters, corrected to nearest centimeter. 9. Cable transit blocks shall be measured separately in numbers. 10. Cable ducts and cable trays shall be measured in length in metres corrected to nearest centimetre according to their sizes, material of construction and other speci fications respectively. Expanders, bends, Tees, etc. shall not be measured separately. 11. All instrument accessories viz. dip tube instrument air header, air filter regulator, purge rotameter, condensate pot etc. shall be measured in numbers. 12. Heat tracing of impulse lines or whereever required shall be measured in metres corrected to nearest centimetre of the lines traced. 13. Insulation of pipes shall be measured in length in metres corrected to nearest centimetre. 14. Erection of instrument panels, etc. shall be measured in numbers, which include calibration of all panel indicators, etc. and all the required wiring. 15. Configuration/calibration of instruments shall be measured in numbers. 16. No separate measurements shall be taken for painting site fabricated items like instrument supports, stanchions, structurals,etc. 17. Aluminium sheets/MS sheets for making shelter for instruments shall be measured in square metres (corrected to nearest square centimetre) according to their respective gauge/thickness. 18. Items required for the completion of erection jobs, such as clamps with nuts and lock
ISSUED ON: 26 - 3 - 99
PRPD. BY:
ISSUED BY:
ENGINEERING SPECIFICATIONS
INSTRUMENTATION WORKS GENERAL SCOPE
25ES403 / 98 - R1 PAGE 2 OF 2
19.
20. 21.
22.
washers, for pipes, clamps for cable trays, strips with bolts for clamping cables on trays, tag plates, anchor bolts, Al/SS tags for cables, cable marking ferrules(Alphabets & numbers) Aluminium crimping lugs, GI bolts (hexagonal), machine bolts, J bolts, U bolts ,other installation materials such as teflon tape, pipe dope for threads, sealing compound, cotton waste, kerosene, three in one oil, PVC sleeve,etc. charges for we l d i n g a cc e s s o rie s such as oxygen/acetylene, Argon cylinders/welding electrodes etc. shall not be measured separately. Copper cable/aluminium strips for earthing shall be measured in length in metres corrected to nearest centimetre. Cable ties shall be measured in numbers according to their respective sizes. Installation of instruments like control valves. flow elements, etc. shall normally be under the scope of piping contractor but calibration, hydrotest and loop check are to be done by instrument contractor. But equipment and vessel mounted equipments shall be in stalled/tested and commissioned by the instrument contractor. Credit for measurements for such items shall be given accordingly. But no separate measure ments shall be considered for heavy/light equipments required for transporting/lifting and installing the equipments. Installation of analysers shall include installation of local sampling system, secondary
sampling system, cabinet and power supply b o x , e t c . f o r c a l i b ra t i o n a c c e ssories/manifold etc. and for calibration gas no separate measurements shall be considered. 23. No separate charges shall be payable for calibration equipments, hardware and software work, etc. required for installation and commissioning. 24. Unless specified otherwise, the following scrap allowances shall be permitted. The percentage allowance shall be accounted on the basis of erected weights / length of cable.
Salvageable Structural steel Power cable Control cable
3% 2.5% 3%
Unaccountable
.05% 1% 1%
25. For the purpose of accounting departmental materials, all pieces measuring less than the following shall be treated as scrap. -Structural steel - 2M -Power cable - 3M -Control cable - 3M
*****************************************
SlNo. Tag No. P&ID No./Ref dwg. SERVICE/LOCATION
INSTRUMENT SCHEDULE
CONTROL PANEL CONNECTIVITY (LocaL/DCS) Local DCS Local DCS Local Local DCS Local DCS Local Local Local Local Local DCS DCS Local Local DCS Local Local DCS DCS Local Local Local 1 1 1 1 1 1 1 1 1 DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE
RANGE ENGG UNIT
AI AO DI DO 1 0 - 25 KG/CM2G
1
2
PT 101 PI 101 TT 101 TI 101
8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003
10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET 10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET 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 INLET 8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET 10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET 8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET 10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET
PRESSURE TRANSMITTER PRESSURE INDICATOR TEMPERATURE TRANSMITTER TEMP. INDICATOR PRESSURE SWITCH HIGH HIGH PRESSURE TRANSMITTER PRESSURE INDICATOR TEMPERATURE TRANSMITTER TEMP. INDICATOR PRESSURE SWITCH HIGH HIGH MOTOR OPERATED VALVE MOTOR OPERATED VALVE CORIOLIS TYPE MASS FLOWMETER FLOW COMPUTER FLOW INDICATOR FLOW INDICATING CONTROLLER CONTROL VALVE
3 4
PSHH 101 PT 201 PI 201
CONNECTED TO SHIPS SHORE ESD 0 - 25 KG/CM2G
TT 201 TI 201
6 7 8 9
PSHH 201 MOV 101 MOV 201 FT 101 FI 101 FI101 FIC 101 FCV 101
CONNECTED TO SHIPS SHORE ESD
0 - 250000
KG/H
0 - 250000
KG/H
10 11 12
TE 101 FFC 101 FT 201 FI 201 FI201 FIC 201 FCV 201 TE 201
TEMPERATURE COMPENSATON FOR FT 101 8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET
TEMPERATURE ELEMENT RATIO CONTROLLER CORIOLIS TYPE MASS FLOWMETER FLOW COMPUTER FLOW INDICATOR FLOW INDICATING CONTROLLER CONTROL VALVE
0 - 175000
KG/H
0 - 175000
KG/H
TEMPERATURE COMPENSATON FOR FT 201 12"-LPG-303-3A3S-IC60 LPG TO E 301 INLET
TEMPERATURE ELEMENT MOTOR OPERATED VALVE PROJECT CLIENT P.O.NO. VENDOR
13
MOV 301
14FT 609 / 05
3 2 1 0
REV
LPG BLENDING FACILITIES HPCL, MANGALORE
09.09.09
MJ
MS
SG
DATE
PRPD
CHKD
APPD
INSTRUMENT SCHEDULE
CONTROL PANEL CONNECTIVITY (LocaL/DCS) Local Local Local DCS Local Local Local 1 1 DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE
RANGE ENGG UNIT
AI AO DI DO 1
14 15 16
XEV 101 PSV 101 TT 102 TIC 102 TCV 102
8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003
12"-LPG-303-3A3S-IC60 LPG TO E 301 INLET 1"-LPG-314-B1A 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 12"-LPG-304-B1A-IC60 LPG FROM E 301 OUTLET 12"-LPG-302-3A3S-IC60 LPG FROM SM 301 OUTLET
SOLENOID VALVE SAFETY RELIEF VALVE TEMPERATURE TRANSMITTER TEMP. INDICATING CONTROLLER CONTROL VALVE MOTOR OPERATED VALVE MOTOR OPERATED VALVE
17 18
MOV 302 MOV 103
21
PT 401 PI 401 PIAL 401
8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003
16"-SW-401-(GRP) SEA WATER TO E 301
PRESSURE TRANSMITTER PRESSURE INDICATOR ALARM LOW
Local DCS DCS Local DCS Local Local Local Local Local DCS Local Local Local DCS Local DCS Local
0-6
KG/CM2G
22
TT 401 TI 401
16"-SW-401-(GRP) SEA WATER TO E 301 16"-SW-401-(GRP) SEA WATER TO E 301 16"-SW-403-(GRP) SEA WATER TO E 301 1"-SW-410-GRP SEAWATER TO E 301 16"-SW-403-(GRP) SEA WATER TO E 301
TEMPERATURE TRANSMITTER TEMP. INDICATOR PRESSURE GAUGE PRESSURE GAUGE SAFETY RELIEF VALVE FLOW ELEMENT DP FLOW TRANSMITTER FLOW INDICATOR
23 24 25 26
PG 402 PG 403 PSV 401 FE 401 FT 401 FI 401
0-6 0-6
KG/CM2G KG/CM2G
1 1 0 - 1300000 KG/H
27 28 29
XEV 102 XEV 103 TT 402 TI 402
16"-SW-403-(GRP) SEAWATER TO E 301 16"-SW-404-(GRP) SEAWATER TO SU 401 16"-SW-404-(GRP) SEAWATER TO SU 401 16"-SW-404-(GRP) SEAWATER TO SU 401 12"-LPG-305-B1A-IC60 LPG TO BOOSTER PUMP P 301 A/B
SOLENOID VALVE SOLENOID VALVE TEMPERATURE TRANSMITTER TEMP. INDICATOR LPG ANALYZER LPG ANALYZER INDICATOR MOTOR OPERATED VALVE
1 1 1
30
AT 401 AI 402
31
MOV 304
14FT 609 / 05
3 2 1 0
REV
PROJECT CLIENT P.O.NO. VENDOR
09.09.09
MJ
MS
SG
DATE
PRPD
CHKD
APPD
INSTRUMENT SCHEDULE
CONTROL PANEL CONNECTIVITY (LocaL/DCS) Local Local Local Local DCS DCS DCS Local Local Local Local Local DCS Local DCS Local DCS Local DCS 1 1 1 1 1 1 DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE
RANGE ENGG UNIT
AI AO DI DO 0 - 25 KG/CM2G
32 33 34 35
PG 301 MOV 305 MOV 307 PT 1201 PI 1201 PAL 1201 PIC 1201 PCV 1201
8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003 8122-11-PD-0003
12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 A/B SUCTION 12"-LPG-308-B1A-IC60 LPG 12"-LPG-313-B1A-IC60 LPG RECEIPT PIPELINE AT MLIF TERMINAL
PRESSURE GAUGE MOTOR OPERATED VALVE MOTOR OPERATED VALVE PRESSURE TRANSMITTER PRESSURE INDICATOR LOW ALARM PRESSURE INDICATING CONTROLLER CONTROL VALVE
0 - 30
KG/CM2G
0 - 30
KG/CM2G
36 37 38 39
MOV 307 PG 301A PG 301B PT 302 PI 302
6"-LPG-301A-3A3S-IC60 UNLOADING ARM OUTLET 12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 A DISCHARGE 12"-LPG-305-B1A-IC60 BOOSTER PUMP P 301 B DISCHARGE 12"-LPG-308-B1A-IC60 LPG
MOTOR OPERATED VALVE PRESSURE GAUGE PRESSURE GAUGE PRESSURE TRANSMITTER PRESSURE INDICATOR
0 - 25 0 - 25 0 - 25
KG/CM2G KG/CM2G KG/CM2G
40
TT 404 TI 404
MOUNTED ON TOP OF SU 401
TEMPERATURE TRANSMITTER TEMP. INDICATOR
0 - 40
DEG.C
41
TT 102A TI 102A
12"-LPG-303-3A3S-IC60 E301 INLET
-50 - 25
DEG.C
42
TT 301 TI 301
4"-LPG-310-B1A-IC60 P301A/B DISCHARGE
0 - 40
DEG.C
14FT 609 / 05
3 2 1 0
REV
09.09.09
MJ
MS
SG
DATE
PRPD
CHKD
APPD
SlNo. 1 Tag No. MOV 101 PB 101 PB 101 ZSL 101 ZLL 101 ZSH 101 ZLH 101 XSL 101 XRL 101 2 MOV 201 PB 101 PB 101 ZSL 101 ZLL 101 ZSH 101 ZLH 101 XSL 101 XRL 101 3 MOV 301 PB 301 PB 301 ZSL 301 ZLL 301 ZSH 301 ZLH 301 XSL 301 XRL 301 8122-11-PD-0003 8122-11-PD-0003 P&ID No./Ref dwg. 8122-11-PD-0003 SERVICE/LOCATION
INSTRUMENT SCHEDULE
DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE MOTOR OPERATED VALVE OPEN CLOSE LOW LIMIT SWITCH LOW LOW HIGH LIMIT SWITCH HIGH HIGH REMOTE/LOCAL INDICATION REMOTE/LOCAL INDICATION
CONTROL PANEL
CONNECTIVITY (LocaL/DCS) Local DCS DCS Local DCS Local DCS Local DCS Local DCS DCS Local DCS Local DCS Local DCS Local DCS DCS Local DCS Local DCS Local DCS
RANGE ENGG UNIT
AI AO DI DO 1 1 1 1
10"-BL-101-3A3S-IC60 BUTANE TO SM 301 INLET
8"-PL-201-3A3S-IC90 PROPANE TO SM 301 INLET
MOTOR OPERATED VALVE OPEN CLOSE LOW LIMIT SWITCH LOW LOW HIGH LIMIT SWITCH HIGH HIGH REMOTE/LOCAL INDICATION REMOTE/LOCAL INDICATION
1 1 1 1
12"-LPG-303-3A3S-IC60 LPG TO E 301 INLET
1 1 1 1
14FT 609 / 05
3 2 1 0 09.09.09
REV
MJ
MS
SG
DATE
PRPD
CHKD
APPD
INSTRUMENT SCHEDULE
DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE
CONNECTIVITY CONTROL PANEL (LocaL/DCS) Local DCS DCS Local DCS Local DCS Local DCS
RANGE ENGG UNIT
AI AO DI DO
MOV 103 PB 103 PB 103 ZSL 103 ZLL 103 ZSH 103 ZLH 103 XSL 103 XRL 103
8122-11-PD-0003
12"-LPG-302-3A3S-IC60 LPG FROM SM 301 OUTLET
1 1 1 1
8122-11-PD-0003
6"-LPG-301A-3A3S-IC60
Local DCS DCS Local DCS Local DCS Local DCS 1 1 1 1 1
MOV 302 PB 302 PB 302 ZSL 302 ZLL 302 ZSH 302 ZLH 302
8122-11-PD-0003
12"-LPG-304-B1A-IC60
MOTOR OPERATED VALVE OPEN CLOSE LOW LIMIT SWITCH LOW LOW HIGH LIMIT SWITCH HIGH HIGH
Local DCS DCS Local DCS Local DCS 1 1 1 1
14FT 609 / 05
3 2 1 0 09.09.09
REV
MJ
MS
SG
DATE
PRPD
CHKD
APPD
SlNo. Tag No. XSL 302 XRL 302 12"-LPG-313-B1A-IC60 P&ID No./Ref dwg. SERVICE/LOCATION
INSTRUMENT SCHEDULE
DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE REMOTE/LOCAL INDICATION REMOTE/LOCAL INDICATION
CONNECTIVITY CONTROL PANEL (LocaL/DCS) Local DCS
RANGE ENGG UNIT
AI AO DI DO 1
8122-11-PD-0003
8122-11-PD-0003
12"-LPG-312-B1A-IC60
14FT 609 / 05
3 2 1 0 09.09.09
REV
MJ
MS
SG
DATE
PRPD
CHKD
APPD
INSTRUMENT SCHEDULE
DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE
CONNECTIVITY CONTROL PANEL (LocaL/DCS) Local DCS DCS Local DCS Local DCS Local DCS
RANGE ENGG UNIT
AI AO DI DO
8122-11-PD-0003
12"-LPG-305-B1A-IC60 LPG TO BOOSTER PUMP P 301 A/B
1 1 1 1
10
8122-11-PD-0003
12"-LPG-308-B1A-IC60 LPG
Local DCS DCS Local DCS Local DCS Local DCS Local DCS DCS DCS 1 1 1 1 1 1 1 1
11
P 301A ML 301A YL 301A PB 301A
8122-11-PD-0003
LPG BOOSTER PUMP A
PUMP RUNNING INDICATION TRIP INDICATION CLOSE/TRIP
14FT 609 / 05
3 2 1 0 09.09.09
REV
MJ
MS
SG
DATE
PRPD
CHKD
APPD
SlNo. 12 Tag No. P 301B ML 301B YL 301B PB 301B 13 P 401A ML 401A YL 401A PB 401A 14 P 401B ML 401B YL 401B PB 401B 15 P 401C ML 401C YL 401C PB 401C 8122-11-PD-0003 SEA WATER PUMP C 8122-11-PD-0003 SEA WATER PUMP B 8122-11-PD-0003 SEA WATER PUMP A P&ID No./Ref dwg. 8122-11-PD-0003 SERVICE/LOCATION
INSTRUMENT SCHEDULE
DCS
8122-14-IS-001
PAGE OF 8
R0
Remarks
INSTRUMENT TYPE PUMP RUNNING INDICATION TRIP INDICATION CLOSE/TRIP PUMP RUNNING INDICATION TRIP INDICATION CLOSE/TRIP PUMP RUNNING INDICATION TRIP INDICATION CLOSE/TRIP PUMP RUNNING INDICATION TRIP INDICATION CLOSE/TRIP
CONNECTIVITY CONTROL PANEL (LocaL/DCS) Local DCS DCS DCS Local DCS DCS DCS Local DCS DCS DCS Local DCS DCS DCS
RANGE ENGG UNIT
AI AO DI DO 1 1 1
LPG BOOSTER PUMP B
1 1 1
1 1 1
1 1 1
14FT 609 / 05
3 2 1 0 09.09.09
REV
MJ
MS
SG
DATE
PRPD
CHKD
APPD
8122-14-DA-00006 DATA LOCAL PRESSURE GAUGE PAGE 1 OF 1 R0 SHEET dial size 150mm 100mm dial material aluminium 304SS movement material 304SS 316SS pointer anod. Al. Knife edged gauge connection 1/2" NPTM 1/4" NPTM micrometer zero adj. yes no. connection type rad. bottom low back tag no. on dial yes no case material die cast Al. 304SS case ring type screwed slip socket material 316 SS case tightness/gasket vapour tight / neoprene accuracy < + 1%fsd < + 0.5% fsd blow out vent yes no standard IS3624-1979 window material shatter proof 3mm glass max. over pressure 125% high temp. acrylic damping no oil filled extra detachable tag 2mm Alu. 2mm 304SS dial back ground / marking white/black protection class IP65 IP55 solid front yes no test & calibration certificate yes no press. temp. dia. range qty. Sensor accessories remarks tag no. Service nor/max nor./max. seal 2 nos. kg/cm o 1 2 3 4 5 6 7 8 9 kg/cm2 C
general
PG 301 PG 301A PG 301B PG 402 PG 403 1 1 1 1 1 12"-LPG-305-B1A-IC60 P 301 A/B Suction 12"-LPG-305-B1A-IC60 P 301 A/B Discharge 12"-LPG-305-B1A-IC60 P 301 A/B Discharge 16"-SW-401-(GRP) SEA WATER TO E 301 16"-SW-403-(GRP) SEA WATER TO E 301 11.5 / 18 / 18 / 3.5 / 3.5 / 10 / 10 / 10 / 25 / 25 / 0 - 25 0 - 40 0 - 40 0-6 0-6 A A A A A D D D D D N N Y Y Y Note-1 Note-1 Note-1
1 2 3 4 5 6 7 8 9
sensing element type lining material sensing element material diaphragm seal conn.type capillary length
(S) syphon (K) gauge connector (W) over range protection device (Y) pulsation dampner
dia. seal
(A) bourdon (T) teflon (D) 316SS (L) 3/4"NPTF
sensor
(B) diaphragm (E) 304SS (M) 15 NB 150# 316SS (Q) 2 mtrs (F) monel (N) 25NB 150#
(C) capsule (G) phos. bronze (O) 50 NB 150# 316 SS
flange material (P) 1.5 mtrs fluid size end conn. material end conn. end conn.
PTFE coated SS316 (R) matl. sch 80 material size 1/2" size material
1/2"
mercury
NPTM 1/2" NPTM
accessories
sch 160 316SS
316SS
NPTF NPTM 316SS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Notes:1 2-Valve manifold shall be provided in SS316. 2 The Pressure gauges in sea water line shall be with diaphragm seal.
14FT352/06
3 2 1 0 15.01.10 REV DATE
PROJECT
MJ MS SG
PRPD
CHKD
APPRD
CLIENT P.O.NO. VENDOR
DATA SHEET
Integral flush diaphragm seal Remote seal flush diaphragm Standard 1/2" NPT connection Standard analog Local indi.plug in type Enclosure Sensor type Accuracy 0.25% Output Digital External zero adjustment Span adjustment Zero supr / elev Calibration Manual Damping Sensor diagnostics Tag no. Quantity (nos.) Service Type
PRESSURE TRANSMITTER (ELECTRONIC)
8122-14-DA-00007
PAGE 1 OF 3 R0
1 2 3 Smart HART Transmitter, 2 wire 4 Analog (or) Digital None 5 W/P IP65 E/P Non incendive I.S (as per note 2) 6 Piezo electric Capacitance Mfr. std. 7 0.10% 0.075% Compensation Amb.temp. Pr. 8 4-20 mA (HART Protocol) Supply 24V DC 9 Required Cable entry 1/2" NPTF 10 Required Drain / vent plugs Yes No 11 Required Hydraulic test pr. 1.5 time wor.pr 12 By calibrator Painting Epoxy MFRstd 13 Adjustable Mtg.bracket with bolts/nuts Reqd. Note 3 14 Required Rangeability Min 1:100 1:5 15 PT 101 PT 201 PT 302 16 ONE ONE ONE 17 Butane Line to SM 301 inlet Propane Line to SM 301 inlet LPG Line 18 19 Fluid 20 Butane Propane LPG Wor.pr-nor / max Kg/cm2g 18 15 21 15 21 21 O Temp. nor/max. C -4 -44 10 22 Density at condition kg/ m3 601 583 556 - 590 23 Sp. gravity/ mole.wt 0.601/58 0.583/44 0.59 / 52 24 Calibrated range Kg/cm2g 0-25 0-25 0-25 25 Line size / material 250 NB / A333 Gr 1/6 smls 200 NB / A333 Gr 1/6 smls 300 NB/ A106 GR.B PE,smls 26 Type - hp / lp Flanged NPT(F) Flanged NPT(F) Flanged NPT(F) 27 Size / rating- hp / lp 1/2" 50 NB 300 # 1/2" 50 NB 300 # 1/2" 50 NB 300 # 28 Ref. Sketch 29 Capillary length m 30 Exte. Diap. Length mm 31 Process flange ANSI 304L SS ANSI 304L SS ANSI304L SS 32 Bolts and nuts ANSI304 SS ANSI304 SS ANSI304 SS 33 Isolating diaphragm ANSI 316 SS ANSI 316 SS ANSI316 SS 34 Wetted parts ANSI 304L SS ANSI 304L SS ANSI 304L SS 35 Capillary 36 Ò' ring PTFE PTFE 37 PTFE Accessories 2-Valve manifold, Double Compression SS Cable Gland 38 39 Make / model no. 40 41 Notes: 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. 43 3 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 44 4 Built in lightning protection shall be provided 45 46 47 48
Integral extended diaphragm seal . Remote seal extended diaphragm
14FT351/94
PR. XTTR
3 2 1 0 REV
Material
Connection
Process data
General
PROJECT 13.10.09 DATE MJ PRPD MS CHKD SG APPRD CLIENT P.O. NO VENDOR
DATA SHEET
8122-14-DA-00007
PAGE 2 OF 3
Integral extended diaphragm seal Remote seal extended diaphragm
R0
1 2 3 Smart HART Transmitter, 2 wire 4 Analog (or) Digital None 5 W/P IP65 E/P Non incendive I.S (as per note 2) 6 Piezo electric Capacitance Mfr. std. 7 0.10% 0.075% Compensation Amb.temp. Pr. 8 4-20 mA (HART Protocol) Supply 24V DC 9 Required Cable entry 1/2" NPTF 10 Required Drain / vent plugs Yes No 11 Required Hydraulic test pr. 1.5 time wor.pr 12 By calibrator Painting Epoxy MFRstd 13 Adjustable Mtg.bracket with bolts/nuts Reqd. Note 3 14 Required Rangeability Min 1:100 1:5 15 PT 1201 16 ONE 17 LPG line at MLIF Terminal 18 19 Fluid 20 Propane Wor.pr-nor / max Kg/cm2g 12 30 21 O Temp. nor/max. C 10 22 Density at condition kg/ m3 556 23 Sp. gravity/ mole.wt 0.556 / 552 24 Calibrated range Kg/cm2g 25 0 - 30 300 NB / A106 GR.B PE,smls Line size / material 26 Type - hp / lp Flanged NPT(F) 27 Size / rating- hp / lp 1/2" 50 NB 300# 28 Ref. Sketch 29 Capillary length m 30 Exte. Diap. Length mm 31 Process flange ANSI 304L SS 32 Bolts and nuts ANSI304 SS 33 Isolating diaphragm ANSI 316 SS 34 Wetted parts ANSI 304L SS 35 Capillary 36 Ò' ring PTFE 37 2-valve manifold, Double compression SS Cable gland Accessories 38 39 Make / model no. 40 41 Notes: 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. 43 3 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 44 45 46 47 48
14FT351/94
PR. XTTR
3 2 1 0 REV
Material
Connection
Process data
General
DATA SHEET
8122-14-DA-00007
PAGE 3 OF 3 R0
1 2 3 Smart HART Transmitter, 2 wire 4 Analog (or) Digital None 5 W/P IP65 E/P Non incendive I.S (as per note 2) 6 Piezo electric Capacitance Mfr. std. 7 0.10% 0.075% Compensation Amb.temp. Pr. 8 4-20 mA (HART Protocol) Supply 24V DC 9 Required Cable entry 1/2" NPTF 10 Required Drain / vent plugs Yes No 11 Required Hydraulic test pr. 1.5 time wor.pr 12 By calibrator Painting Epoxy MFRstd 13 Adjustable Mtg.bracket with bolts/nuts Reqd. Note 3 14 Required Rangeability Min 1:100 1:50 15 PT 401 16 ONE 17 Sea Water to E301 inlet 18 19 Fluid 20 Sea Water Wor.pr-nor / max Kg/cm2g 3.5 21 O Temp. nor/max. C 25 22 Density at condition kg/ m3 997 23 Sp. gravity/ mole.wt 0.997 / 18 24 Calibrated range Kg/cm2g 0-6 25 400 NB / GRP Line size / material 26 Type - hp / lp Flanged NPT(F) 27 Size / rating- hp / lp 1/2" 25 NB 150 # 28 Ref. Sketch 29 Capillary length 1.5 m 30 Exte. Diap. Length mm 31 Hastelloy C ANSI 304L SS Process flange 32 Bolts and nuts ANSI304 SS 33 Isolating diaphragm Hastelloy C 34 Wetted parts Hastelloy C 35 Capillary 36 Ò' ring PTFE 37 Double compression SS Cable gland Accessories 38 39 Make / model no. 40 41 Notes: 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. 43 3 Mounting kit for 2" pipe mounting shall be offered.MOC shall be SS316 44 4 Built in lightning protection shall be provided 45 46 47 48
Integral extended diaphragm seal . Remote seal extended diaphragm
14FT351/94
PR. XTTR
3 2 1 0 REV
Material
Connection
Process data
General
DATA SHEET
Type Switch form Switch type Contact rating No. of switches Differential Tag no. Quantity(nos.) Service Location Fluid Pr. Nor / max. kg/cm2g Temp. nor / max. OC Sp. gravity / density kg / m3 Viscocity cP % Solids Element type ref. Element material Conn. Size / type Range Min. differential Set points Alarm set value Accessories in kg/cm2g General
PRESSURE SWITCH
Direct Receiver Snap acting micro switch SPDT DPDT 24 V DC 0.5A One Two Adjustable Internal Case Enclosure
8122-14-DA- 00008
PAGE 1 OF 1 R0
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Aluminium Ex. Proof I.S. (Note 2) Weather proof IP65 IEC Zone 2 Gr II A, II B, T4 Area classification Connection 1/2" NPTF 1/4" NPTF O / R protection 150% of Design pressure Fixed Repeatability ' + 1% of span External Cable entry 1/2" NPTF 3/4" NPTF PSHH 101 PSHH 201 ONE ONE Butane line Propane line TO SM 301 INLET TO SM 301 INLET Propane Butane 15 21 15 21 -4 -44 0.601 601 0.583 583 0.204 0.192
3/4" ET
Process data
Element / Connection
**
316SS 1/2" NPTM/Threaded 0 - 25 kg/cm2g Single High 21 Double Low
**
316SS 1/2" NPTM/Threaded 0 - 25 kg/cm2g Single High 21 Double Low
Over range protection Make model no.
150% of Design pressure
150% of Design pressure
** Manufacturer to specify
Notes: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 14FT353/94 2 1 0 REV
PROJECT LPG BLENDING FACILITIES

15.01.10 MJ MS SG CLIENT P.O.NO. HPCL, MANGALORE
DATE
PRPD
CHKD
APPRD VENDOR
JOB : FACT ENGINEERING AND DESIGN ORGANISATION
DATA SHEET measurement massflow sensor type mounting transmitter transmitter type probe length (thermistor) power supply 24 VDC accuracy display type temp. correction tag no.& quantity (nos.) service fluid gas composition pressure kg/cm2g
temperature (oC) density (nor.) kg/m3
MASS FLOW METER density coriolis in line remote elect(analog) 800 mm

110V AC 0.25 %
8122-14-DA-00010 enclosure
PAGE 1 OF 1 WP IP 65 E/P R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
both
alpha nume. reqd.
thermistor horizontal insertion type integral output m.P based no.of outputs cable entry 230V AC painting local indicator LCD type interconn. Cable not reqd. press. Correction
FT/FIC 101
general
intrinsic safe vertical 4-20 mA + HART Protocol one two

1/2" NPT
Exia non-incendive
epoxy reqd. reqd. reqd

FT/FIC 201
mfr.std not reqd. not reqd not reqd
Butane line liquid gas

15 -4
Propane line liquid gas

15 -44 583 0.192
process data
601
0.204 210000 / 250000 / -
accessories
density range (kg/m3) viscosity cP flow normal/max/min. Kg/h flow range Kg/h line size / class allowable press.drop mmWC type size /rating /material pipe ID probe matl. (thermistor type) sensor matl.(thermistor type) measuring tube housing terminal box cable length - m sensors & transducers staightener-provide if reqd. others make / model
0 - 250000
250 NB/ 300# SCH 40 5000
140000 / 175000 / 0 - 175000

200 NB/ 300# SCH 40 5000
connecti on
flanged * / 300# / SS304L (Note 1)

AISI 316 SS
flanged * / 300# / SS304L (Note 1)

AISI 316 SS
material
glass encapsulated 316 LSS hastalloy-C

AISI 304SS Die cast Alu AISI 316 SS AISI 316 SS
glass encapsulated SS 304L

316 LSS AISI 304SS Die cast Alu
hastalloy-C
AISI 316 SS AISI 316 SS
SS 304L
300 mfr to specify pressure temp. (Note 5) required not required purge conn. moisture trap cooling / heating fins
300 mfr to specify pressure temp. (Note 5) required not required purge conn. moisture trap cooling / heating fins
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. 4 3 2 1 0 15.01.10 REV DATE
PROJECT CLIENT P.O. NO
14FT162 / 06
MJ PRPD
MS CHKD
SG APPRD
VENDOR
DATA SHEET tag no. qty. (nos.) service
FLOW ELEMENT ORIFICE PLATE

FE 401 ONE SEA WATER TO E 301 16"-SW-403-(GRP) Sea Water 3.5 / 25 / 997 18 1 0.89 - / 1110000 / 1300000 1300000 5000 400NB / GRP / 396.87 slip plate carrier unit sq. edged int. orice conical entrance concentric flg corner Monel
8122-14-DA-00011
PAGE 1 OF 1 R 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 D & D/2 26 27 28
location fluid:wet gas / dry gas steam / gas ratio of wet gas wor. pr./ design pr. kg/ cm2g wor.temp./ design temp. 0 C density at wkg. condn. kg/m3 molecular weight compressibility factor gas law deviation constant viscosity at condn. (cSt) flow min / nor. / max. at condn. / unit, Kg/hr flow at max. instrument range Kg/hr allowable pressure drop. mmWG d/p at max. flow `h' mmWG line size / material / schedule pipe ID (mm) element type
connection element details
process data
bore location tapping type flange size / rating flage std. / material element material / thickness throat dia. `d'/ ratio (approximate) drain / vent hole size mm. drain / vent hole location from c/l of orifice impulse tapping size calculation standard ref. std. no. adjacent piping orifice flange isolation valves pipe unit recommended str. length - up / downstream mm. IBR certificate
note 1
29 30 31 32 33
0.66 * *
1/2" NPT(F)
BS 1042,1989,92 ISO 5167
34 35 36 37 38 39 40 41
accessory / material
yes yes yes yes Required
no no no no
Notes : 1. Thickness of the element to ISA RP 3.2 2. See DP Flow transmitter datasheet no: 8122-14-DA-00012
* Vendor to furnish.
14FT155/03
3 2 1 0 REV
PROJECT
15.01.10 MJ MS SG
DATE
PRPD
CHKD
APPRD
CLIENT P.O.NO. VENDOR
DATA SHEET
Type
DIFFERENTIAL PRESSURE TRANSMITTER (ELECTRONIC)
8122-14-DA-00012
PAGE 1 OF 1 R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Process data
Integral flush diaphragm seal Remote seal flush diaphragm Standard 1/2" NPT connection Standard analog Local indi.plug in type Enclosure Sensor type Accuracy (cal.range) 0.25% Output Digital External zero adjustment (Local) Span adjustment (Local) Zero supr / elev Calibration Manual Damping Sensor diagnostics Tag no. Quantity (nos.) Service Type of measurement Fluid kg/hr Flow normal/max Wor.pr-nor / max kg/cm2 g Wor. temp.OC Nor/ Max Density at condition kg/ m3
Integral extended diaphragm seal Remote seal extended diaphragm Smart Analog W/P IP65 Piezo electric 0.10% 4-20mA Required Required Required By calibrator Adjustable Required Transmitter, 2 wire HART Protocol Digital None NEC Cl Div Gr Non incendive DP Mfr. std. Amb.temp. Compensation 24V DC Supply 1/2" NPTF Cable entry Yes Drain/vent plugs Hydraulic test pr. 1.5 time wor.pr Painting Epoxy Mtg.bracket with bolts/nuts Rangeability 1:50
E/P
I.S.(Note 1) Pr.
General
No
Reqd 1:100
FT/FI 401 ONE Sea water Flow

Sea water
Sp. gravity / mole.wt Viscosity- cP Calibrated span mmWC d / p at 0% / 100% mmWC Line size / material Type - hp / lp Flanged NPT(F) 1/2" 25 NB 150# Size / rating- hp / lp Ref. Sketch Capillary / ext.diaph.length 5m x 2 Nos Hastelloy C Process flange ANSI304 SS Bolts and nuts Hastelloy C Isolating diaphragm Hastelloy C Wetted parts Capillary Body Material SS 316 'O' ring PTFE Accessories Double Compression SS Cable Gland Make / model no. by mfr. Notes: 1. Area classification is Zone 2, Gr.IIA,IIB.Transmitters shall be with EExia certification for area classification. 2. 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
1110000 / 1300000 3.5/25/997 0.997/18 0.89 0 - 5000 - / 5000 (Note 5) 400 NB/ GRP
14FT401/99
DP.XTTR
3 2 1 0 REV
Material
Connection
PROJECT CLIENT SG P.O. NO APPRD VENDOR
15.01.10 DATE
MJ PRPD
MS CHKD
DATA SHEET
1 2 3 4 5 6 7 8
FLOW COMPUTER
8122-14-DA-00013 Page 1 OF 1 R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
9 10 11 12 13 14 15 16 17 18 19 20
Tag Nos. Quantity Enclosure Protection Cable Entry Cable Glands Mounting Field/ Panel Case Material Input Types Temperature Pressure Flow No of Inputs Display type Keyboard Alarm Contacts No of Outputs Output Range Communications Sensitivity Accuracy Power Supply V/I/Hz Power consumption in W Operating Temperature Deg.C
FFC 101 1 No. Exia for area classification Zone II Gr II A, II B. / WP IP65 1/2" NPT(F) Required Field ** RTD -Analog, 4-20 mA 3 Backlit LCD, Alphanumeric display Required Required, 2 Nos 2 ** 4 - 20 mA Serial Comm. With selectable baud rate and parity. ** ** 24 VDC ** 17 Deg.C - 40 Deg.C
** Manufacturer to specify
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
14FT636A/94
4 3 2 1 0 REV
PROJECT LPG BLENDING FACILITIES CLIENT HPCL, MANGALORE P.O. NO VENDOR
15.01.10
DATE
MJ PRPD
MS CHKD
SG APPRD
DATA SHEET
Type Element material ELEMENT Sheathed Mineral insulation sheath OD Thermowell No. of leads THERMOWELL Construction Connection type Hydraulic test Radiographic test (both planes) Details to be punched on flange Enclosure Material HEAD Cover Spring loaded type Cable entry Connection to thermowell Qty Tag no nos. Service Thermocouple grounded Pt - 100 yes MgO 6 mm yes 2 3 4
TEMPERATURE ELEMENT
RTD Reference standard no Sheath material Ref. Sketch Thermocouple wire size no
8122-14-DA-00015
PAGE 1 OF 1
ANSI-MC-96.12 Inconel 600 SS 316 DIN 43760 SS 304
R0
1 2 3 4
18 SWGfor single 22 SWGfor duplex 34 SWG for type-R
5 6 7 Req. Not req. 8 9 10 11 12 Safe 1 Required Required 2 13 14 15 16 17 18 'L' mm Line size /matl IBR S/D /M 19 20 21
bar stock drilled Flange Note 2
Fabricated Screwed
Vibration proof Welded
100 Kg/Cm2 or 1.5 times max. working pr., Whichever is greater Required for 10% of total no of thermowells Tag no., flange size, rating & material of thermowell Weather proof IP 65 Die cast Aluminium Screwed Required 1/2" NPT(F) 1/2" NPT(M) press. nor/max kg/Cm2g Temp. nor/max deg C 3/4"NPT Cap Explosion proof IEC Zone 1 Gr II A, II B, T4 No of cable entries Chain for head cover Corrosion proof tag plate S-single D-duplex L-immersion length
M- Multi assembly Range deg C T/W conn. Size/ rating/material
TE 101 TE 201 TE/TT 101 TE/TT 102 TE/TT 301 TE/TT 201 TE/TT 401 TE/TT 402 TE/TT 404
1 1 1 1 1 1 1 1 1
Butane line Propane line Butane line Propane line LPG line Propane line Sea Water Sea Water Sea Water (SU 401) LPG line
15 15 15 13.2 18 15 3.5 3.5 ATM 13.2
-4 / 10 / -4 / 10 / 10 / -44 / 25 / 20 / 20 / -20 / -
-50 - 25 0 - 40 -50 to 25 -25 to 25 0 to 40 -50 to 25 0 to 40 0 to 40 0 to 40 -50 to 25
40NB / 300# / HastelloyC 40NB / 300# / SS304 40NB / 300# / HastelloyC 40NB / 300# / HastelloyC 40NB /300#/ SS304 40NB / 300# / SS304 40NB / 150# / Monel400 40NB / - / Monel400 40NB / - / Monel400 40NB / 300# / HastelloyC
300 300 300 300 250 300 300 300 400 300
250 NB Not req. 200 NB Not req. 250 NB Not req. 300 NB Not req. 100 NB Not req. 200 NB Not req. 400 NB Not req. 400 NB Not req. Tank
Not req.
D D D D D D D D D D
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
TE/TT 102A 1
300 NB Not req.
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
14FT401/94
4 3 2 1 0 REV
PROJECT CLIENT P.O. NO 15.01.10 DATE MJ PRPD MS CHKD SG APPRD VENDOR
LPG BLENDING FACILITIES
HPCL, MANGALORE
TE
DATA SHEET
TEMPERATURE TRANSMITTER
8122-14-DA-00016
PAGE 1 OF 1 R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 14 15 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Input to Transmitter Output Supply voltage Enclosure Local indication Painting Cable entry Accuracy Accessories
RTD Pt 100 T/C type 4 to 20 mA 2 wire system Smart with HART protocol 24 V DC weather proof IP 65 EExia as per IEC Zone 2 Gr II A, II B. Safe required Not required epoxy 2 coats 1/2" NPT (F) 3/4" NPT 2 nos +/- 0.2 % +/- 0.5 % mounting brackets, bolts & nuts suitable for 2" pipe mounting Double comp.SS CG, SS316 Plug
Sl. No 1 2 3 4 5 6 7 8
Tag no TT/TI 101 TT/TIC 102 TT/TI 301 TT/TI 201 TT/TI 401 TT/TI 402 TT/TI 404 TT/TIC 102A
Qty.
1 1 1 1 1 1 1 1 Butane line LPG line LPG line Propane line Sea water Sea water Sea water (SU 401) LPG line
Service
Range
-50 to 25 -25 to 25 0 to 40 -50 to 25 0 to 40 0 to 40 0 to 40 -50 to 25
Remarks
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., Manufacturers name, Instrument range and engineering units. Sizes of cable entry and element entry to thermowell shall also be marked.
14FT403/94
4 3 2 1 0 REV
PROJECT CLIENT P.O. NO 15.01.10 DATE MJ PRPD MS CHKD SG APPRD VENDOR
TT
DATA SHEET
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
HYDROCARBON DETECTORS
8122-14-DA- 00020 Page 1 OF 1 R0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Tag No. Detection Principle Gases detected Range Sensor Case Ingress Protection Sensitivity Accuracy Response time Self Test Relative humidity Output signal Power supply Operating temperature Enclosure Cable entry Cable glands Electro magnetic compatibility Quantity Calibration gas
GM 101, GM 102, GM 103, GM 104 Infrared absorption Hydrocarbons (LPG) Above 0% LEL Stainless Steel 316 IP65 1% LEL +/-3% LEL Propane T90<30sec Required 0 to 99% (without condensation) 4 - 20 mA 24 VDC 17 Deg.C - 40 Deg.C // 20 Deg.C Exproof Exd for area classification Zone II Gr II A, II B. 1/2" NPT (F) Required, MOC shall be SS Protection against RFI/EMI and lightning strike required 4 nos. To be provided in gas cylinder with known ppm of LPG along with calibration kit
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. 3. Commissioning and calibration of instruments shall be in vendors scope. Vendor shall supply all the materials required for this.
33 34 35 36 37 38 39 40 41 42
14FT636A/94
4 3 2 1 0 REV
PROJECT CLIENT P.O. NO VENDOR LPG BLENDING FACILITIES HPCL, MANGALORE
15.01.10
DATE
MJ PRPD
MS CHKD
SG APPRD
DATA SHEET
1 2 3 4 5 6 7 8 9 10 11 12 13 Tag No. Location/Line no. Service Gases detected Process Fluid Range Sensor Case Output signal Power supply Operating temperature Sea water line Pressure Cable entry for instruments Cable glands
ANALYSER
AT 401 16"-SW-404-(GRP) Sea water outlet of E301 Analyser (LPG) Sea water 100% LPG, Above 0% Stainless Steel 316 4 - 20 mA 24 VDC 0 20 C 2 3.5Kg/cm 1/2" NPT (F) Required, MOC shall be SS
8122-14-DA- 00021 Page 1 OF 1 R1

1 2 3 4 5 6 7 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26
Notes: 1 Vendor shall specify the current consumption required for the Instrument arrangement. 2 Vendor shall specify and supply all the accessories required for the sensor arrangement. 3 Commissioning and calibration of instruments shall be in vendors scope. Vendor shall supply all the materials required for this. 4 A typical schematic of analyser is given vide 8122-14-MD-016. The arrangement shall be in a purged panel with adequate ingress protection. 5 The scheme proposed by the contractor shall be submitted and got approved before proceeding with procurement.
27 28 29 30 31 32
33 34 35 36 37 38
14FT636A/94
4 3 2 1 0 REV
PROJECT
LPG BLENDING FACILITIES
12.02.10
13.10.09
DATE
MJ MJ PRPD
MS MS CHKD
SG SG APPRD
CLIENT M/S.HPCL, MANGALORE P.O. NO VENDOR
DATA SHEET
CONTROL PANEL (RTU)
8122-14-DA-00022 Page 1 of 3 R0
W/P 65 Dust proof
Type general
Self standing Desk
Wall mounted Enclosed cubicle
Open Back open Outdoor
Explosion proof Air purged
Location Front arrangement Atmosphere Length
Indoor Ordinary Air conditioned 800 mm 2000 mm in total (with out channel base) 800 mm Height mm Semigraphic Air purged
Graphic Explosive gas No. of sections One 100 mm for channel base Corrosive gas Non A/C room
size
Height Depth Semigraphic board Material Thickness of steel sheets
Length of each sections HRS
mm
No. of sections For semigraphic board Semigraphic board Back board 1 mm Bottom 2 mm mm
Cold rolled carbon steel sheets for panel Front board 3 mm Side board 2 mm Celling board 2 mm Gland plate 3 mm
Type of semigraphic construction Stiffener Channel base Parts mounting Joint of front board Door
Fibre glass 40 x 40 x 6 t angle 100 x 50 x 6 t channel 45 x45 x 2 t univer. channel Tight flush type Required Location Not required Rear Front
Rear engraved
Screen printing
One unit for
panels
45 x 22.5 x 2 t univer. channel Bent type Seal packing Right side RTU Panel- split door Fluorescent lamp Side Inside surface White Graphic symbol see attached sheet 60 W nos./ sect. Top Tubing Air supply AC 230V Handle with key Left side Both sides Welded
Illumination
Inside Door switch
Outside-front Hand lamp
Cable entry Colour painting
Bottom (gland plate) Out side surface Grey Channel base Black
Finish
Glazed with two coats of lacquer Powder Coated Matt finish
Semi matt with three coats of paint Silk screen for semigraphic Manufactures standard
Painting process Tubing material / size tubing Bulk head size / material Position of bulk head
Standard *
Front
Back $ - Side - Top
Bottom
Upper $
*- powder coated after required chemical processing.
14FT106/94
4 3 2 1 0
REV
PROJECT CLIENT P.O. NO

15.01.10
ON LINE LPG BLENDING FACILITIES

M/s HPCL FEDO
MJ
PRPD
MS
CHKD
DATE
SG APPRD
VENDOR
DATA SHEET
Wiring method
CONTROL PANEL (RTU)
8122-14-DA-00022 Page 2 of 3 R0
PVC duct Control cables1.5 sq. mm Yellow for AC control circuit interlock Green for earthing circuit
Conduit pipe Main source 2.5 sq. mm Blue for DC control circuit Grey for alarm circuit Red & blue for DC lines supply
Signal 0.5 sq. Wire size mm Colour identification as per IS 375 wiring
Red for phase, black for neutral AC power Wire marker Terminal Terminal board Terminal board pos. Source Transformer Side AC100V KVA x Required Open stack type With tag no. plate Front AC 110V V Back AC 230V Dry type
Phoenix type/Elmex/wago * With insulation cover Bottom 50 Hz sets Upper 60 Hz
electric source
Main switch Switch for instruments
NFB one per each phase x one sets Snap switch Fuse Separate for each instrument Isolator for main supply See attached sheet See attached sheet
DC source Voltage stabiliser Earthing
Yes Yes
No No.
With earthing terminals Required Required Required Ind. lamps Acrylic resin formica Letters Back ground White White Painted No. Electric type Digital Mechanical Not required Not required Not required Selector switches
Specification
Interlock system & others
Alarm annunciator Interlock system Ammeter Qty. as required Material / size Colour
Spec . No. Accuracy
Drg. No. Size Sets
Push button switches 50mm X 30 mm X 1mm thick Black Black Size
name plate
Letters Clock Anchor bolt & nut Eye bolt
Engraved Yes Required Required AC120V class AC 100V Wooden mm X AC 220V class AC 110V Steel mm X sets
accessories
Plug & socket Exhaust fan Tool box Floor plate Communication unit Cable gland
DC 24V class 2sets mm(W) X mm(H) X
Sets
mm(D)
Hand lamp with cable 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
Stop valve Bulk head mounted spare cards NFB Switch for instrument Terminal board Cable glands Lamp Fuse unit Pressure switch Annunciator card Relay Lamp commissioning spare parts Fuse Lamp holder Board union Copper ring Terminal Paint for repairing Push button switch Snap switch Notes:
CONTROL PANEL (RTU)
8122-14-DA-00022 Page 3 of 3 R0
10% 10% 10% 10% 10% 10% 10% 10% 1 no. 10% 10% 10% 10% 10% % % 10% 10% 10% 10%
20% 20% 20% 20% 20% 20% 20% 20%
20% nos. nos. nos. nos. nos. nos. nos. nos. nos. nos.
Relay
Coil voltage Contact rating Mounting
: OMRON Make : 24 VDC, : 110 VAC, 5A : Din Rail
Necessary channel & hold on clips must be included
DATA SHEET 1 Type

2 Purpose
ELECTRICAL JUNCTION BOXES - FOR SIGNAL /CONTROL
8122-14-DA-00023
PAGE 1 OF 2 R0
Termination box Junction box Thermocouple junction box Connecting the electrical / signal cables from individual instruments with transmitters located at distant places
3 Enclosure 4 Dimension
5 Material of construction
From individual instruments with the multicore going to the C / R Weather proof as per IP 65 Increased safety Explosion proof as per NEC Class Div Gr note 4 mm (W) X mm(H) X mm(D) mm diameter Note 1
Sheet steel of thickness 2.5 mm Cast iron LM6 Al Alloy
6 Type of lever 7 Gasket / O-ring 8 Mounting 9 Cable gland material

10 Type of cable gland 11 Finish
Hinged ( lift off type robust in construction capable of Bolted& supporting the door when opened) Screwed Non - deteriorating sealing strip gasket O - ring of material Wall mounting Bracket mounting Pedestal mounting Pipe mounting Note 3 Nickel plated brass 304 SS Aluminium
Explosion proof W/P single compression double compression Check nut for ET cable glands 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. White plastic tag plate Non-corrosive SS tag plate. Ref.note (2) Size drain hole at bottom with plug Drain fittings Breather For connecting the shield drain wires Connecting telephone wires from multicore cables Provided outside the box Outdoor operation subjected to direct sun & rain without further protection from weather For explosion proof from CMRS, Dhanbad
12 13 14 15 16 17 18 19 20 21
Name plate Junction box to be provided with One terminal block Two terminals provided for Earthing terminal Junction boxes shall be suitable for Certificates Reference drawing no. Quantity (nos.) Make / model no.
8122-14-MD- 006 7 Mfr to specify
Notes:1) Manufacture to provide exact dimensions 2) Tag Nos. JBS 001,JBS 002,JBS 003, JBS 004, JBS 005, JBS 006, & JBC 001 3) JB's shall be suitable for pedestal / frame mounting 4) Junction boxes shall be exproof Exd to area classification, Zone 2, Gr II A/IIB.
14FT203/94
3 2 1 0 REV
PROJECT ON LINE LPG BLENDING FACILITIES 14.01.10 DATE MJ PRPD MS CHKD CLIENT SG APPRD VENDOR
M/s. HPCL, Mangalore
DATA SHEET
ELECTRICAL JUNCTION BOXES - FOR SIGNAL/CONTROL

22.Cable entry with cable glands Size Nos. Side (C/D) Location Bottom(B)
8122-14-DA-00023
PAGE 2 OF 2 R0
1 2 Top 3 4
1/2" NPT 1 1/4" NPT
6 1
5 6 7
23.Terminals Size Nos. Type of terminal Material of terminal
8 9 10 11 12 13 14 15
24 min.
Antivibration springs loaded terminals.
Terminals shall be of Phoenix/ Equivalent type of SS 304 in poly amide for mounting on DIN standard Ts-35
Note:
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 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
DATA SHEET
Item number Standard
CABLE - SIGNAL / CONTROL / POWER

A IS 1554 / IS 694 300V COPPER STRANDED - 7 16AWG PVC / Type C 850C EXTRUDED 1.1mm * 1 PAIR TWISTED ALU. BACKED MILAR 0.075mm * 25% HELICAL TINNED COPPER 7 ' STRANDS 20 AWG
NON HYGROSCOPIC
8122-14-DA-00024
PAGE 1 OF 2 R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 C IS 1554 / IS 694 300V AT COPPER STRANDED - 7 16AWG PVC / Type C 800C EXTRUDED 1.1mm * 3 CORE TWISTED ALU. BACKED MILAR 0.075mm * 25% HELICAL TINNED COPPER 7 ' STRANDS 20 AWG NON HYGROSCOPIC HELICAL 50%
AA IS 1554 / IS 694 300V COPPER STRANDED - 7 20AWG PVC / Type C 800C EXTRUDED 0.8mm * 6 PAIR TWISTED ALU. BACKED MILAR 0.075mm * 0.25 HELICAL TINNED COPPER 7 ' STRANDS 20 AWG NON HYGROSCOPIC HELICAL 50%
Voltage class(Insul. Class) Conductor Insulation Core Drain wire Shielding Binder Material Type solid/stranded Size Material Type Size No. of cores Core arrangement Material Thickness/size Overlap Wrapping style Material Type Size Material Wraping style Overlap Material Tickness/size Material Thickness Material Armour Type Thickness/size Material Overall sheath Thickness Type (Min.)
HELICAL 50%
PVC extruded type C 850C
Sheath Filler
PVC extruded type C 850C PVC extruded type C 850C As per core dia. As per core dia.
As per core dia.

PVC extruded type ST2,FRLS
PVC extruded type ST2,FRLS PVC extruded type ST2,FRLS
0.3mm * GAL. STEEL ROUND WIRE 1.4mm * PVC type ST2,FRLS 1.24mm EXTRUDED 300 M +5% RED BLACK
0.3mm * GAL. STEEL ROUND WIRE 1.4mm * PVC type ST2,FRLS 1.4mm EXTRUDED 2000M (Note 1) +5% REQUIRED
0.3mm * GAL. STEEL ROUND WIRE 1.4mm * PVC type ST2,FRLS 1.24mm EXTRUDED 50 M +5% -
Drum length Cutting length Drum length tolerance Communication wire Colour coding Core 1 Core 2 Core 3 Outer sheath
34 35 36
RED BLACK
RED BLACK
37 38 39 40
* thickness shall be selected as per IS standard Note 1) Drum length shall be finalised based on cutting length at site
14FT202 / 94
1 0 REV
15.01.10 DATE
MJ PRPD
MS CHKD
SG APPRD
LPG BLENDING FACILITIES PROJECT CLIENT M/s HPCL PO.NO VENDOR
DATA SHEET
Item number Standard Voltage class Conductor Material Type solid/stranded Size Material Type Size No. of cores Core arrangement Material Drain wire Shielding Thickness/size Overlap Wrapping style Material Type Size Material Binder Wraping style Overlap Material Tickness/size Material Thickness Material Armour Type Thickness/size Material Overall sheath Thickness Type
CABLE - SIGNAL / CONTROL / POWER
8122-14-DA-00024
PAGE 2 OF 2 R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
P
IS 1554 / IS 694 650V COPPER STRANDED-7 2.5mm PVC Extruded type C 850C 1.2mm * 2 CORE TWISTED
2
Core
Insulation
NON HYGROSCOPIC HELICAL 0.5 PVC / Type C 850C As per core dia. PVC extruded type ST2,FRLS 0.3mm * GAL. STEEL ROUND WIRE 1.4 mm * PVC type ST2,FRLS 1.4 mm * EXTRUDED 570 M +5%
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Drum length Cutting length Drum length tolerance Communication wire Colour coding Core 1 Core 2 Outer sheath
Sheath Filler
RED BLACK
37 38 39
* thickness shall be selected as per IS standard
PROJECT LPG BLENDING FACILITIES

14FT202 / 94
0 REV
15.01.10 DATE
MJ PRPD
MS CHKD
SG APPRD
CLIENT M/s. HPCL P.O.NO. VENDOR
TECHNICAL PROCUREMENT SPECIFICATION
SUB VENDOR LIST
8122-14-TS-001 SV
PAGE 1 OF 2 R0
PRESSURE GAUGES 1. H-Guru Instruments 2. Bells Controls Ltd. 3. Waree Instruments Ltd. 4. Switzer Instruments Pvt. Ltd. 5. General Instruments Consortium 6. 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 Ltd 2. Yokogawa India Ltd. 3. Emerson Process Management (India) Pvt. Ltd. 4. Asian Brown Brovery. 5. Honeywell Automation India Ltd 6. 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 2 3 4 5 6 Instrumentation Ltd., Palakkad Baliga Lighting Equipments Pvt. Ltd, Chennai Hydropneumatics, Mumbai Chemtrols Samil (India) Pvt Ltd., Mumbai IA Flow Elements pvt. Ltd., Chennai General Instruments Consortium
00FT024 /94
0
REV.NO.
14.01.10
DATE
ORIGINAL ISSUE
DESCRIPTION
MJ
PREPARED
MS
CHECKED
SG
APPROVED
TECHNICAL PROCUREMENT SPECIFICATION
SUB VENDOR LIST
8122-14-TS-001 SV
PAGE 2 OF 2 R0
CABLES 1. Delton Cables Ltd. 2. Brooks cable Works Ltd 3.KEI Industries Ltd 4. Associated Cables, Mumbai 5. Reliance Engineers Ltd. 6. General Instruments Consortium 7. Universal Cables Ltd. 8. Toshniwal Cables Kolkata 9. Associated Flexibles & Wires Pvt Ltd. GRP/ FRP CABLE TRAYS 1. 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. Switzer GeneralInstruments InstrumentsPvt Consortium Ltd. 5 Indfoss (Bombay) Ltd.
JUNCTION BOXES (EX PROOF & W/P) 1. Baliga Lighting Equipment Pvt Ltd 2. Flexpro Electricals, Bombay. 3. CEAG Flame proof controls 4. Flameproof Control Gears
HYDROCARBON DETECTOR / LPG ANALYSER 1. Detection Instruments (India) Pvt. Ltd. 2. Tritech 3. Honeywell Automation India Ltd
00FT024 /94
0
REV.NO.
14.01.10
DATE
ORIGINAL ISSUE
DESCRIPTION
MJ
PREPARED
MS
CHECKED
SG
APPROVED
TECHNICAL PROCUREMENT SPECIFICATION Description Sl. No. 1 PRESSURE GAUGE Pressure Range 0-6
SPARES
8122-14-TS-001 SPR
PAGE 1 OF 1 Quantity Unit price R 0
Total price
kg/cm2 ( Diaphragm seal type)
1 No. 1 No.
0 - 40 kg/cm2
PRESSURE SWITCH
1 No.
TEMPERATURE GAUGE TE insert for immerson length (L) of 300 mm 400 mm DP TRANSMITTER/ PRESSURE TRANSMITTER 0 - 25 kg/cm2
1 No. 1 No.
1No. 1No.
HYDROCARBON DETECTOR
TEMPERATURE TRANSMITTER
1No.
3 2 1 0
00FT022/00
14.01.10
ORIGINAL ISSUE DESCRIPTION
MJ
PREPARED
MS
CHECKED
SG
APPROVED
REV.
DATE
cable / JB no. Cable spec.-(multi core/ individual cables) 6 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE 6 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE 6 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE
CABLE SCHEDULE
length multi. core (mtr)* 160 PT 401 AT 401 TT 401 SPARE GM 101 TT 404 110 FT 401 TT 402 TT 102 SPARE TCV 102 GM 102 100 FT 101 SPARE FCV 101 SPARE FT 201 FCV 201 82 TT 301 SPARE PT 302 SPARE GM 103 SPARE 800 PT 1201 SPARE PCV 1201 SPARE GM 104 SPARE 300 PSHH 101 SPARE PSHH 201 SPARE SPARE SPARE 117
8122-14-CS-001
Page 1 of 2 R1
Remarks/ (Drum No.) length indiv. core (mtr)* 5,5,20,20
Contents TT 101 SPARE PT 101 SPARE TT 201 PT 201
JBS 001
JBS 002
10,10,13,13, 15
JBS 003
5, 10, 5, 5, 20
6 PAIR 16 AWG OVERALL SCRE. JBS 004 ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE 6 PAIR 16 AWG OVERALL SCRE. JBS 005 ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE 6 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE 6 PAIR 16 AWG OVERALL SCRE. ARMO.CABLE/ 2 CORE 16 AWG SCRE. ARMO. SIGNAL CABLE
10,10,5,8
25,42,30
JBS 006
5,5,5
JBC 001
5,8
Notes:
* To be verified at site before cutting.
14FT608A/94-R1
4 3 2 1 0 Rev
PROJECT MANGALORE LPG BLENDING FACILITIES 15.01.10 23.11.09 Date MJ MJ PRPD MS SG MS SG CHKD APPRD CLIENT JOB NO. VENDOR
M/s.HPCL, MANGALORE
8122
Cable No. XEV 101 XEV 102 XEV 103 Cable spec.
3 CORE 2.5mm2 UNSCREENED ARMOURED CABLE 3 CORE 2.5mm UNSCREENED ARMOURED CABLE 3 CORE 2.5mm UNSCREENED ARMOURED CABLE
2 2
CABLE SCHEDULE
From
MARSHALLING CABINET IN CONTROL ROOM MARSHALLING CABINET IN CONTROL ROOM MARSHALLING CABINET IN CONTROL ROOM
8127-14-CS-001 Page 2 of 2
To XEV 101 XEV 102 XEV 103 Length* (metre) 175 170 170
R0
Remarks/ (Drum No.)
14FT608B/98
PROJECT ONLINE LPG BLENDING FACILITIES 1 0 Rev CLIENT M/s. HPCL-MANGALORE JOB NO. 8127 VENDOR
15.01.10 Date
MJ PRPD
MS CHKD
SG APPRD
No.
CALIBRATION RECORD SHEET

Guages PLANT: LPG BLENDING FACILITIES, M/s.HPCL PAGE
DOC. GRP.
JOB No.8122
Tag number Manufacturer / type no Serial No Range (span) Accuracy Master Calibration Instrument & serial no. Master Calibration Instrument Certificate validity Date
Initial Setting (Input) % Actual 0 25 50 75 100 Reading % Actual Error Setting (Input) % Actual 0 25 50 75 100
Final Reading % Actual Error
Remarks:
Test performed by HPCL FEDO Contractor
Witnessed by HPCL FEDO Contractor Signature Date
No.

TRANSMITTER PLANT: LPG BLENDING FACILITIES, M/s.HPCL PAGE
DOC. GRP.
JOB No.8122
Tag number Manufacturer / type no Serial No Range (span) Accuracy Master Calibration Instrument & serial no. Master Calibration Instrument Certificate validity Date
Initial Setting (Input) % Actual 0 25 50 75 100 Reading % Actual Accuracy Setting (Input) % Actual 0 25 50 75 100
Final Reading % Actual Accuracy
Remarks:
No.

TEMPERATURE ELEMENTS PAGE
DOC. GRP.
JOB No. 8122
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 Required /mV Actual /mV
Error ( C)
One measurement shall be normal operating temperature
Remarks:
No.

CONTROL VALVES AND ACCESSORIES PAGE
DOC. GRP.
JOB No. 8122
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 Setting (Input) % Actual 0 25 50 75 100 75 50 25 0 Valve Position % Actual Accuracy Setting (Input) % Actual 0 25 50 75 100 75 50 25 0 Final Valve Position % Actual Accuracy
Pressure test: Stroke time: Open:
Leak test: Close:
Leakage class: Failure position:
Accessories function check:
Remarks:
SCHEDULE OF ITEMS OF WORK

BID ITEMS - SUPPLY REF.CL. NO.OF QUANTITY UNIT ENGG. SPEC.
BID ITEMS - INSTRUMENT INSTALLATION ITEM . NO DESCRIPTION
2 3
Modification of Existing Control system a) Control Panel with I/O cards, terminals, cable glands etc. b) HMI Online Instruments a) Coriolis type Mass Flow meter i) FT 101 ii) FT 201 iii) Flow computer b) Orifice Plate 1) FE 401 Field Mounted Transmitter 1) LPG Analyzer ( AT 401) 2) Pressure Transmitter ( PT 101, PT 201, PT 302,PT 1201 ) 3) Pressure Transmitter - Diaphragm seal type PT 401 4) DP Transmitter (FT 401) 5) Temp.Transmitter ( TT 101, TT 102, TT 201, TT 401, TT 402,TT 404, TT 301, TT102A ) Gauges a) Pressure Gauge - bourdon type 1) PG 301 2) PG 301A 3) PG 301B b) Pressure Gauge -Bourdon type with diaphragm seal 1) PG 402 2) PG 403 Switches a) Pressure Switch (PSHH 101,PSSH 201) Hydrocarbon Detectors (GM 101,GM 102, GM 103, GM 104)
PROJECT CLIENT JOB NO. LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
1 1
EA EA
4 5 6 7 8 9 10 11 12
1 1 1 1 1 4 1 1 8
EA EA EA EA EA EA EA EA EA
13 14 15 16 17 18 19 Note:
3 2 1 0 REV
1 1 1 1 1 2 4
EA EA EA EA EA EA EA
15.01.10 MJ
DATE PREPD
MS
CHKD
SG
APPRD
INSTRUMENTATION DEPARTMENT BID ITEMS - INSTRUMENT INSTALLATION ITEM . NO

DESCRIPTION
20 21
Spares - ( Refer. 8122-14-TS -001 SPR) MULTI CABLE TRANSIT Block for cable entry
Lot EA
22
EARTH PIT (NOTE 1)
EA
23
Supply of 6 sq.mm Arm.copper cable, sand, charcoal, electrode,CU accessories/busbar,eyelets lugs, etc as reqd INSTRUMENT AIR HEADER CABLES
EA
24 25 26 27
a) 1 Pair 16AWG screened armoured signal / Control cable(Copper), FRLS PVC inner & outer sheathed b) 6 Pair 20AWG overall & ind. screened armoured cable(Copper), FRLS PVC inner & outer sheathed c) 3core 2.5mm2 unscreened armoured cable (Power Cable), FRLS PVC inner & outer sheathed d) 3 core 16AWG Screened armoured cable For Hydrocarbon detector JUNCTION BOX a) 6 Pair Signal/ Control Junction Box CABLE TRAY (Including Bends, Expanders,Tee etc) 50mm perforated FRP 100mm perforated FRP 200mm perforated FRP
300 8250 3200 50
M M M M
28 29 30 31
7 2425 215 10
EA M M M
TUBE 32 Seamless tube 6 mm OD / 4mm ID-A 269 TP 316 70 M 33 Seamless tube 12 mm OD / 1.5 mm thick -A 269 TP 316 55 M 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) JBS 006 Location is near the Receipt pipe line at MLIF terminal LPG Storage tank area, 12 km away from the Booster pump
3 2 1 0 REV PROJECT CLIENT LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
11.02.10 MJ 15.01.10 MJ
DATE PREPD
MS MS
CHKD
SG SG
APPRD
JOB NO.
INSTRUMENTATION DEPARTMENT BID ITEMS - INSTRUMENT INSTALLATION ITEM . NO DESCRIPTION

BID ITEMS - SUPPLY BID ITEMS - INSTRUMENT DISMANTLING REF.CL. NO.OF ENGG. SPEC. QUANTITY UNIT
34
Seamless Pipe 1/2" plain A312TP316 Sch 80
TUBE FITTINGS:
35 36 37 38 39 40 41 42 43 UNION CONNECTOR : 1/2"NPTF / 1/2" NPTF A182TP316 UNION CONNECTOR : 6MM /6MM OD MALE CONNECTOR : 1/2"NPTM / 12MM OD,A182F 316 MALE CONNECTOR : 1/2"NPTM / 6MM OD,A182F 317 UNION TEE : 12 MM / 12 MM A182TP316 FEMALE CONNECTOR : 1/2 " NPTF / 12MM, A182F 316 REDUCING COUPLING :3/4 " NPTFx 1/2 "SW ISOLATION VALVE :1/2" NPTF/1/2" NPTF, A182F 316, 800# Sch.40 NIPPLE BET :1/2" NPTM / 1/2"NPTM ,SS 316 9 4 EA EA EA EA EA EA EA EA EA
22
8 5 5 10 9 10
Structural steel
44 45 46 50 x 50 x 5 mm angle 35 x 35 x 5 mm angle 25 x 5 mm flat 0.17 7.3 0.2 METRIC TONS METRIC TONS METRIC TONS
Structurals
47 48 Canopy for instruments & JB Stanchions for instruments, JB 2" CS Sch 40 pipe ( for fabrication work of stanchion) 37 28 EA EA
Notes: 3 2 1 0 REV PROJECT CLIENT LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
11.02.10 MJ 15.01.10 MJ
DATE PREPD
MS MS
CHKD
SG SG
APPRD
JOB NO.

BID ITEMS - INSTRUMENT INSTALLATION ITEM . NO DESCRIPTION
Control room Modification woks (Existing Control system)

50 a) Installation of the control panel with required base frame, glanding and termination of cables including Installation of cable glands, termination lugs, ferrules,cable ties,lables, permanent markers, bolts/nuts/washers,spare fused connectors. DIN rails,MCB,Fuse,flexible & prefab cable With end connectors etc. b) Installation of HMI c) Configuration of new I/O with existing control system including hot loop checking, configuration of the the new I/O in the control system, trend/ graphic configuration etc. Online Instruments a) Coriolis type Mass Flow meter 53 54 55 56 i) FT 101 ii) FT 201 iii) Flow computer b) Orifice Plate 1) FE 401 b) Control Valve 1) FCV 101 2) FCV 201 3) TCV 102 4) PCV 1204
LOT
51 52
1 1
EA Lot
1 1 1 1
EA EA EA EA
57 58 59 60
1 1 1 1
EA EA EA EA
c) On-off Valve 61 1) XEV 101 With SOV 62 2) XEV 102 With SOV 63 3) XEV 103 With SOV Note:
3 2 1 0 REV PROJECT CLIENT JOB NO.
1 1 1
EA EA EA
LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
15.01.10 MJ
DATE PREPD
MS
CHKD
SG
APPRD

BID ITEMS - SUPPLY REF.CL. NO.OF QUANTITY ENGG. SPEC. UNIT
64 65 66 67 68
Field Mounted Transmitter 1) LPG Analyzer ( AT 401) 2) Pressure Transmitter ( PT 101, PT 201, PT 302,PT 1201 ) 3) Pressure Transmitter - Diaphragm seal type PT 401 4) DP Transmitter (FT 401) 5) Temp.Transmitter ( TT 101, TT 102, TT 201, TT 401, TT 402,TT 404, TT 301, TT102A ) Gauges a) Pressure Gauge , bourdon type 1) PG 301 2) PG 301A 3) PG 301B b) Pressure Gauge , bourdon type with diaphragm seal 1) PG 402 2) PG 403 a) Pressure Switch (PSHH 101,PSSH 201) Hydrocarbon Detectors (GM 101,GM 102, GM 103, GM 104)
1 4 1 1 8
EA EA EA EA EA
69 70 71 72 73 74
1 1 1 1 1 2
EA EA EA EA EA EA
75
EA
76 77 78
MULTI CABLE TRANSIT Block for cable entry

EARTH PIT (NOTE 1)
1 1 2
EA EA EA
INSTRUMENT AIR HEADER
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.
3 2 1 0 REV PROJECT CLIENT LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
11.02.10 MJ 15.01.10 MJ
DATE PREPD
MS MS
CHKD
SG SG
APPRD
JOB NO.

BID ITEMS - SUPPLY BID ITEMS - INSTRUMENT DISMANTLING UNIT
REF.CL. NO.OF QUANTITY ENGG. SPEC.
CABLES 79 80 81 82 a) 1 Pair 16AWG screened armoured signal / Control cable(Copper), FRLS PVC inner & outer sheathed b) 6 Pair 20AWG overall & ind. screened armoured cable(Copper), FRLS PVC inner & outer sheathed c) 3core 2.5mm2 unscreened armoured cable (Power Cable), FRLS PVC inner & outer sheathed d) 3 core 16AWG Screened armoured cable For Hydrocarbon detector JUNCTION BOX a) 6 Pair Signal Junction Box CABLE TRAY (Including Bends, Expanders,Tee etc) 50mm perforated FRP 100mm perforated FRP 200mm perforated FRP TUBE Seamless tube 6 mm OD / 4mm ID-A 269 TP 316 Seamless tube 12 mm OD / 1.5 mm thick -A 269 TP 316 Seamless Pipe a) 1/2" plain A312TP316 Sch 80 300 8250 3200 50 M M M M
83
EA
84 85 86 87 88 89 90 91 92
2425 215 10 70 55 3 0.17 7.3 0.2
M M M M M M METRIC TON METRIC TON METRIC TON
Structural steel
50 x 50 x 5 mm angle 35 x 35 x 5 mm angle 25 x 5 mm flat
Structural work
93 94 Canopy for instruments & JB Stanchions for instruments, JB 37 28 EA EA
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 3 2 1 0 REV PROJECT CLIENT LPG BLENDING FACILITIES M/s. HPCL, MANGALORE 8122
MJ 15.01.10 MJ
11.02.10 DATE PREPD
MS MS
CHKD
SG SG
APPRD
JOB NO.

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INSTRUMENTATION DEPARTMENT

TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION 8122-14-TS-001

ON LINE LPG BLENDING FACILITIES MANGALORE M/s.HPCL M/s.HPCL

ERECTION TENDER SPECIFICATION - INSTRUMENTATION

12.02.10 14.01.10 DATE

REVISED ON CLIENTS COMMENTS ORIGINAL ISSUE

FACT ENGINEERING AND DESIGN ORGANISATION

INSTRUMENTATION DEPARTMENT Sl.

CONTENTS TECHNICAL SPECIFICATION FOR INSTRUMENT INSTALLATION

REVISED ON CLIENTS COMMENTS ORIGINAL ISSUE

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

12.02.10 REVISED ON CLIENTS COMMENTS 15.01.10 ORIGINAL ISSUE

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

5.9 5.9 5.14

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

Surface temp. under 94 C T-1 (200 F) Paint thickness in microns 70

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

3.63 3.64 3.65

FACT ENGINEERING AND DESIGN ORGANISATION

TECHNICAL SPECIFICATION FOR INSTRUMENTS INSTALLATION

FACT ENGINEERING AND DESIGN ORGANISATION

PART A - GENERAL 1.0.0 SCOPE OF WORK

18.0.0 19.0.0 20.0.0 21.0.0

22.0.0 23.0.0 24.0.0

25.0.0 26.0.0 27.0.0 28.0.0 29.0.0 30.0.0 31.0.0

FACT ENGINEERING AND DESIGN ORGANISATION

1.9.0 1.10.0 1.11.0 1.12.0

1.14.0 1.15.0 1.16.0 1.17.0 1.18.0

FACT ENGINEERING AND DESIGN ORGANISATION

ENGINEERING SPECIFICATION 3.0.0

PART B - TECHNICAL REQUIREMENTS 4.0.0

FACT ENGINEERING AND DESIGN ORGANISATION

5.6.1 5.6.2 5.6.3 5.6.4

FIELD MOUNTED PRIMARY MEASURING ELEMENTS

6.1.3 6.2.0 6.2.1 6.2.2

FACT ENGINEERING AND DESIGN ORGANISATION

FIELD MOUNTED TRANSMITTERS

7.8.0 7.8.1 7.8.2

FIELD MOUNTED CONTROLLERS

FACT ENGINEERING AND DESIGN ORGANISATION

Work involved is combination of 7.5.0 .

FIELD MOUNTED GAUGES