E

A LBV LBV LBV

REV DESCRIPTION COMPILED CHECKED REVIEWED APPROVED DATE

BASIC DESIGN PHASE

CLIENT
SOUTH LUZON THERMAL ENERGY CORP.

EPC CONTRACTOR

PROJECT
1X135 MW CFB Power Plant Project, Phase 1

ISSUE TYPE:
DOCUMENT TITLE: 1x135MW I&C TOR for BTG
For Information
DOCUMENT NUMBER: SLTEC1-U-CSDD-001 REV. A

Date: 2012.10.27 Page 0/46

0
Table of Contents

1 GENERAL 3
1.1 LOCATION AND BRIEF DESCRIPTION OF THE PROJECT 3
1.2 SCOPE OF THIS DOCUMENT: 3
1.3 PREPARATION OF BID PROPOSAL 4
1.4 LANGUAGE 4
1.5 WORK ON SUNDAYS, HOLIDAYS AND NIGHTS 4
1.6 LIGHTS AND BARRIERS 4
2 SUBCONTRACTOR QUALIFICATION 4
3 RESPONSIBILITIES OF SUBCONTRACTOR 5
4 EXTENT OF THE CONTRACT 6
4.1 PRELIMINARIES 6
4.2 WORKS INCLUDE 7
4.2.1 Field Instruments Installation Boiler Area 7
4.2.2 Field Instruments Installation Turbine Area 8
4.2.3 Field Instruments Installation Generator System and Auxiliary 9
4.2.4 Field Instruments Installation in Auxiliary Equipment for Turbine 9
4.2.5 General Scope 10
4.3 WORKS EXCLUDED 14
4.4 RELATED WORKS 14
5 PURPOSE OF INSTRUMENTATION: 15
5.1 STANDARDS AND SPECIFICATIONS 15
5.1.1 Project Specifications: 15
5.1.2 Codes And Standards: 15
6 INSTRUMENTATION SYSTEM PHILOSOPHY 18
6.1 INSTRUMENT PHILOSOPHY 18
6.2 INSTRUMENT POWER SYSTEM PHILOSOPHY 19
6.2.1 Pneumatic Supply 19
6.2.2 Electric Power Supply 19
6.2.3 Instrument Earthing System Philosophy 20
6.2.4 Equipment Protection Philosophy 20
6.3 INSTRUMENT INSTALLATION PHILOSOPHY 21
6.4 INSTRUMENT INSPECTION & TESTING PHILOSOPHY 23
6.4.1 General 23
6.4.2 Flushing Of Lines 24
6.4.3 Instrument Supply Lines 24
7 OTHER REQUIREMENTS FOR INTERFACING/ WIRING TERMINATION 24
7.1 INSTRUMENT CABLES 24
7.1.1 Cable Types 24
7.1.2 Cable Sizes 25
7.1.3 Cable Shielding 25
7.1.4 Cable Runs 25
7.1.5 Cable Marking: 26
7.1.6 Cable Identification: 26
7.1.7 Cable Segregation: 26
7.1.8 Cable Installation: 27
7.1.9 Cable Termination: 27
7.1.10 Cable Junction Boxes: 28
7.1.11 Tubing Installation: 29
7.2 INSTRUMENT PROCESS CONNECTIONS: 30

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 8 EXECUTION METHODOLOGY 30
8.1 INSTRUMENTS IMPULSE PIPES 30
8.2 INSTALLATION OF CABLES TRAYS 31
8.3 EARTHING 34
8.4 PAINTING 34
8.5 TESTING 34
8.6 CALIBRATION 35
8.7 LOOP CHECKING 35
9 GENERAL REQUIREMENTS 36
9.1 TAGGING AND NAME PLATES 36
10 DOCUMENTATION 37
10.1 EQUIPMENT DOCUMENTATION 37
10.2 INSTRUMENT INDEX 38
10.3 INSTRUMENT DATA SHEET 39
10.4 INSTRUMENT CALCULATIONS (TO BE PROVIDED BY CNTIC) 39
10.5 DOCUMENTS/DRAWINGS AND DATA REQUIRED FROM CONTRACTOR 40
11 REVIEW AND APPROVAL 42
12 REFERENCE CHINESE STANDARDS 43
13 BATTERY LIMITS 45
14 WORK ITEMS, BILL OF MATERIALS AND DRAWINGS 46
15 TECHNICAL AND FINANCIAL PROPOSAL 46
16 PROJECT SCHEDULE 46

2
TECHNICAL TERMS OF REFERENCE INSTALLATION AND RELATED WORKS FOR
INSTRUMENTATION AND CONTROL 1X135MW SLTEC CFB POWER PLANT PROJECT
PHASE-1
_______________________________________________________________

1 GENERAL

1.1 LOCATION AND BRIEF DESCRIPTION OF THE PROJECT

The project referred to in this Terms of Reference (TOR) is situated in Barangay

Puting Bato, Calaca, Batangas, approximately 110 kilometers from the City of
Manila. The project title is 1 X 135 MW CFB Power Plant Project Phase 1. The
Owner is South Luzon Thermal Energy Corporation (SLTEC); the Engineering,
Procurement and Construction (EPC) contractor is D.M. Consunji, Inc. (DMCI);
and the Engineering and Procurement (EP) Sub-contractor is China National
Technical Import & Export Corporation (CNTIC). DMCI is also responsible for the
Construction (C) portion.

1.2 SCOPE OF THIS DOCUMENT:

This document defines the design criteria for the instrumentation and control
system envisaged on the new platforms and under this project.

Note: The scope of instrumentation activities pertaining to this project is

enlisted in the relevant section of Scope of Work.

The functional specifications of individual items shall be as given in scope of

work Instrumentation Engineering.

1.3 PREPARATION OF BID PROPOSAL

(1) Conditions Affecting the Works

Bidders must visit the site in accordance with the provisions of Sub-
Clause 1.3(3) and take such other steps as may be necessary to ascertain
the nature and location of the works, and the general and local
conditions which may affect the works or the cost thereof. Failure to do
so will not relieve the bidders from responsibility for estimating properly
the cost of successfully performing the works. DMCI will assume no
responsibility for any misunderstanding or representations concerning
conditions made by any of its personnel prior to the execution of the
contract.

(2) Pre-bid Conference

Pre-bid conference will be held at the place and time to be designated by

DMCI.

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 (3) Site Inspection
The Bidder is required to visit the location of the project and make his
own estimate of the facilities needed and those available including
familiarization with local conditions, availability of labor, transportation
facilities, uncertainties of weather, and other contingencies. DMCI will
extend reasonable assistance and cooperation in showing the proposed
site.

(4) Local Labor and Materials

The Bidder shall maximize utilization of locally available materials,
Philippine nationals for labor, skilled workers and supervisory services.
Preference in the hiring of local labor shall be given to residents within
the immediate vicinity of the project site.

1.4 LANGUAGE

The official language to be used shall be English. The bid proposal, contract
documents, reports, manuals, communication, correspondence between the
parties, order and work instructions and all safety notices shall be written in
English.

1.5 WORK ON SUNDAYS, HOLIDAYS AND NIGHTS

Work at site on Sundays, official holidays, and at nights shall be governed by

pertinent laws and regulations of the Philippines. DMCI will secure a permit
when necessary and requested so by the Subcontractor for overtime work and
work on Saturdays, Sundays, holidays, and nights for its own personnel and
those of the Subcontractor.

1.6 LIGHTS AND BARRIERS

The Subcontractor shall put up and maintain at the site such danger lights and
barriers as will effectively prevent accident in consequence of this works. If work
is done at night, the Subcontractor shall maintain from sunset to sunrise such
adequate flood lighting as DMCI may deem necessary for the safety of the
construction forces and for the proper observance and inspection of the
construction and erection activities.

2 SUBCONTRACTOR QUALIFICATION

2.1 The bidder (subcontractor) shall provide evidence of satisfactory

experience/proven track record in performing the job related to instrumentation
and control and experience in DCS installation for a power plant.

2.2 The bidder shall submit company profile reflecting financial stability, organization
and updated manpower complement, equipment and appropriate accreditation
registered to perform the required job related to the project implementation
(Instrumentation and Control of power plant project).

4
 2.3 A qualified welder to perform the welding job for cable tray and other related job
should submit a certificate of qualification.

2.4 The bidder shall be capable of providing insurance to its workers and its
temporary facilities (TEMFACIL) requirements such as office equipment, board
and lodging for its workers and needed computer and technology software as
needed for this project. Area for Temporary Facilities will provided by DMCI.

2.5 The Subcontractor shall have an effective quality, safety and environment
management system; must be ISO 9001, ISO 14001 and OSHA 18001 certified
and that the certifications are within their respective validity periods.

2.6 The Subcontractor shall have an established Quality Assurance Program subject
to DMCI approval. Subcontractors key personnel shall have the relevant
qualifications for project management to ensure that quality system is carried
out effectively during the entire duration of the contract.

2.7 The Subcontractor shall have an established Health, Safety and Environment
(HSE) Management System subject to DMCI approval. Subcontractors personnel
responsible for HSE aspects shall have relevant qualifications to ensure that HSE
Management System is carried out effectively during the entire duration of the
contract.

2.8 The Subcontractor shall provide methodology statement for erection of critical
components, heavy lifts etc. or as directed by DMCI.

2.9 The Subcontractor shall provide sequence of work and program coordinated with
critical path.

3 RESPONSIBILITIES OF SUBCONTRACTOR

3.1 The Subcontractor shall be responsible for his organization and execution of the
works under the contract and the works shall be turned over to DMCI in
satisfactory and acceptable condition on the date stipulated on the contract.

3.2 From the commencement of works until the date the works are finally accepted
by DMCI as stipulated in the contract, the Subcontractor shall be fully
responsible for the care of the works and for the care of all materials and
equipment supplied by DMCI and CNTIC including all temporary works. Should
any damage, loss or injury happen to the works, materials or equipment or to
any part thereof from any cause whatsoever other than force majeure or other
circumstances beyond the control of concerned parties, the Subcontractor shall
at his own cost repair (or replace as deemed appropriate) and make good the
damage, loss or injury so that at completion, the works shall be in good order
and condition and in conformity with the requirements of the contract. In case of
material or equipment replacement, the Subcontractor shall provide guarantee
similar with the guarantee originally provided thereto.

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 3.3 The Subcontractor shall be responsible for his employees strict observance of
the laws of the Philippines relevant to the execution of the contract. He shall
conduct the works with due regard to safety against accidents to all project
personnel. He shall provide such machinery guards, safe walkways, ladders,
bridges and other safety devices as may be required by DMCI as requisite to the
prevention of accidents.

3.4 The Subcontractor shall keep all camps and the site of works in sanitary
condition in accordance with the laws of the Philippines and as directed by DMCI.
3.5 The Subcontractor shall employ only competent, skilled men to do the works,
and whenever DMCI formally informed the Subcontractor that any man,
including supervising personnel on the works is, in his opinion, incompetent,
unfaithful, subversive or disorderly, such man shall be discharged from the
works and not be rehired on this project.

3.6 The above principal feature of the work does not in any way limit the
responsibilities of the Subcontractor to general description of scope of
work but has to perform all works fully in compliance with the drawings,
specification and other related contract documents.

3.7 The Subcontractor shall be held responsible for the proper coordination of his
work in accordance with established and approved project schedule, programs
and priorities.

3.8 The Subcontractor shall provide all necessary shop drawings, CSDs, as-built
drawings and other drawings/documents as may be required by DMCI under the
contract.

3.9 The Subcontractor shall be responsible for the works specified in the erection
and installation quality standards and shall ensure that its works meet the
relevant requirements specified in such quality acceptance standards.

3.10 The Subcontractor shall bear full responsibility for the completeness, stability
and safety of all on-site operations, all construction methods and all engineering
notwithstanding whether DMCI have approved or agreed such construction
documents and/or other items provided by the Subcontractor.

4 EXTENT OF THE CONTRACT

4.1 PRELIMINARIES

The bidder shall include in the proposal the following requirements as

preliminaries:

(1) Mobilization and demobilization

(2) Standard tools and equipment for installation (other than heavy lifts)

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 (3) Domestic working visas, if applicable

(4) Physical examination of all workers

(5) Required uniforms and proper PPEs

(6) Travel expenses borne by the workers in going in and out of the site

(7) Office supplies, consumables and expenses

(8) Medical doctor at site for own workers

(9) Food allowances of all workers

(10)All safety paraphernalias, labor insurance, government insurance (as

applicable) and personal accident insurance of all workers

(11)Vehicle for workers and vehicle insurance

(12)Project supervision

(13)Value Added Tax (as applicable)

4.2 WORKS INCLUDE

The scope of work covered as detailed in this clause, shall include the assistance
during transportation and storage at site, handling from site warehouse/lay
down area to work area, material and equipment protection, fabrication,
erection, construction, painting, testing, commissioning, shop drawings, as-built
drawings, provision of services and workmanship warranty of the following:

4.2.1 Field Instruments Installation Boiler Area

Cable Pulling, Cable Tray and Conduits installation include Suitable

Fittings, Stanchions and Mounting Supports for Field Instruments,
Installation of Local and Remote Instruments and End-to-end Wiring
Termination and other related works to accomplish the project to the
following area:

a. Cyclone separators

b. Boiler pressure parts (furnace, heat recovery area, water

walls, headers, downcomers, feeders, risers, steam drum,
economizers, superheaters and reheaters)

c. Air Pre-heaters

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 d. Safety relief valves

e. Coal bunkers, coal feeders and coal feed pipe to furnace

f. Boiler Combustion and Ignition System

g. Sootblowing System

h. Main Steam System

i. Hot and Cold Reheat Steam System

j. Drain System

k. Condensate and Auxiliary System

l. Steam Turbine Bypass System (LP and HP Bypass)

m. Chemical Dosing, Feedwater and Steam Sampling Systems

n. Compressed Air System (Instrument and Service Air within

the boiler area)

o. Boiler Blowdown System

p. Air and Gas System (Primary Air Fans (PAFs), Secondary

Air Fans (SAFs), and High Pressure Fluidizing Fans
(HPFFs) including associated motor drives, silencers,
couplings, isolating dampers, inlet control vanes.

q. Air Ducting in the boiler area connected to PAF, SAF and

HPFF

r. Other items, whether specified or not, but necessary for

the operation of the complete boiler installation

s. Boiler Protection System

4.2.2 Field Instruments Installation Turbine Area

Cable Pulling, Cable Tray and Conduits installation include Suitable

Fittings, Stanchions and Mounting Supports for Field Instruments,
Installation of Local and Remote Instruments and End-to-end Wiring
Termination and other related works to accomplish the project to the
following area:

a. Steam Turbine and Auxiliaries (Governing System, Main

Steam and Reheat System, Safety Devices, Turning

8
 Device, Lube Oil/Control Oil Systems, Water Spray System,
etc.)

b. Instruments from TSI

c. Turbine Protection System

d. Other items, whether specified or not, but necessary for

the operation of the complete turbine installation

4.2.3 Field Instruments Installation Generator System and Auxiliary

Cable Pulling, Cable Tray and Conduits installation include Suitable

Fittings, Stanchions and Mounting Supports for Field Instruments,
Installation of Local and Remote Instruments and End-to-end Wiring
Termination and other related works to accomplish the project to the
following area:

a. Generator and Auxiliaries (Generator Stator, Generator

Rotor, Generator Cooling including Accessories.)

b. Excitation System (AVR, Power System Stabilizer,

Synchronizing System, Excitation Transformer.)

c. Generator Protection System (Various Relay Protections)

d. Generator Main Connections (Current and Potential

Transformers, Surge Arresters)

e. Other items, whether specified or not, but necessary for

the operation of the complete generator installation.

4.2.4 Field Instruments Installation in Auxiliary Equipment for Turbine

Cable Pulling, Cable Tray and Conduits installation including Suitable

Fittings, Stanchions and Mounting Supports for Field Instruments,
Installation of Local and Remote Instruments and End-to-end Wiring
Termination and other related works to accomplish the project to the
following area:

a. Condenser and Auxiliaries & Accessories

b. Condenser Vacuum System

c. Feedwater System (HP heaters and boiler feed pumps,

booster pumps, heater drain tanks and pumps.)

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 d. Condensate System (LP heaters, condensate pumps,
deaerator)

e. Gland Steam Condenser (Gland steam condenser exhaust

fans)

f. Closed Cooling Water System (expansion tank, Heat

Exchangers, Pumps)

4.2.5 General Scope

In addition, the following scope generally applies to Instrumentation and

Control works to be carried out by the Subcontractor:

The scope of work shall generally be as follows, however sub-contractor

to provide all necessary materials and accessories (as not mentioned to
the Division of Responsibility between DMCI and CNTIC) for installation &
commissioning and other documents/data provided in tender to complete
the work in all respects.

1. Loop checking, calibration, installation and commissioning of all

instruments (Control Valves, Indicators/Gauges, RTDs/TC, Transmitters,
Temperature Transmitters, etc. as per P&IDs, Data, sheets, technical/
standard specifications.

2. Installation, testing & commissioning of control panels (with all

accessories, instrumentation, microprocessor based indicators, signal
repeaters/isolators, push buttons/switches/lamps/relays, redundant power
supply regulators / converters etc.) in control room, as per tech specs.

3. Laying, termination, testing & commissioning of cables (single pair/multi

pair individual shielded / overall shielded, control / power cables, RS
232/RS485) from all field instruments/gas over oil actuator valves, gas
detectors, fire / smoke / heat detectors, horns / beacons etc. to junction
boxes/control room from junction boxes to control room, from control
panel to telemetry interface cabinet, from all types of electrical panels to
telemetry interface cabinet etc.

4. Laying, termination of cables from skid junction boxes to control rooms.

Calibration, loop checking of all instrumentation of metering / filtration /
letdown skids.

5. Laying termination and testing of Fiber Optic Cable of approved make in

trench as shown in specifications. The job to be done by contractor who
has experience of laying of FOC.

6. Making cut outs & termination of wires of loose supplied flow computers,
control unit, printer etc. in control panel being supplied by vendor

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7. Sealing of cables/tube entries into the control room after laying and
testing of all cables/ tubes either by filling with sealing compound or by
installing Multi-Cable Transit block (MCT) including fixing of MCT frame,
routing of cables through cable blocks, tightening of cable blocks.

8. Arranging all necessary test and calibration equipment.

9. Following tests shall generally be included at factory &site (contractor to

provide QA/QC document and get approval for all critical items of
instrumentation);

i. Material test certificates, hydraulic test certificate.

ii. Calibration certificate for all instruments.

iii. Valve related testing certificate.

iv. Test certificates for all cables.

v. Calibration/loop checking at site of all instruments.

10. Acceptance of instrumentation / materials, exemption of inspection at any

stage does not absolve vendor of his responsibility for handing over all
instrumentation in perfect working condition to owner while handing over
the site.

11. Installation of junction boxes & cable glands in field for all
instrumentation.

12. Installation of Metering panels supplied by vendor in control rooms,

including installation, testing, calibration, loop checking, and connection /
termination of loose supplied instruments & accessories for metering
panels.

13. Fabrication of pipe nipples as necessary including threading as per

installation standards.

14. Drilling of holes in blind flanges including cutting threads as per

installation standards.

15. Drilling holes for providing glands/grommets on panels shut down

cabinets, power supply cabinets, local control panels, pneumatic
enclosures, junction boxes etc., wherever required for cables entry.

16. Installation, of all steel structure (Angles, Pipe stanchions, canopies,

channels, plates, anchor bolts, nuts etc.)

11
17. Installation, of perforated GI cable trays, Road crossing sleeve pipes,
MCTS for control room entry, GI strips, Earthing wires etc.

18. Fabrication/ installation of pipe stanchion as per Instrument support

standards including casting of concrete pedestal, grouting, welding etc. as
necessary.

19. Installation, testing & commissioning of all instruments piping, tubing,

instrument valves & manifolds for field

20. Installation of all consumables required for instrumentation job, like

welding, welding materials, welding gases, studs, nuts, washers, bolts,
clamps, clips, gaskets, Teflon tape, Lugs, ferrules etc.

21. Installation of all materials including but not limited to structure steel,
cable trays, cables, junction boxes & cable glands(for loose supplied
meters/valves ,which are assembled at site by contractor) to complete the
job in all respects. The job also includes installation, and termination of
cables from field to control room as per drawings/specs of vendor.

22. Writing tags details for all instruments with suitable markers or electronic
printing machine.

23. Installation of loose supplied instruments, cables, junction boxes, tubing,

valve/manifolds, fittings etc., of metering skids / filtration skids / letdown
skids as per vendors drawings.

24. Construction of cable trench in field for all locations/stations as per

approved drawing (if applicable)

25. Minor civil works like chipping of pavement, grouting of instrument

panels/supports/ stanchions on the pavement, laying of conduits below
pavement after chipping and refinishing of pavement as necessary. Civil
works including the casting of foundation as required for instrument
supports where paved surfaces do not exist.

26. Installation, testing & commissioning of all items specifically listed in the
Schedule of Rates with specifications attached elsewhere in the tender
document.

27. Painting of all structural supports for trays, pipes, junction boxes,
instruments, ducts as per painting specification or as instructed by
Engineer-in-Charge.

28. All paints, primers as per painting specifications given intender.

12
29. Grounding of shields of shielded cables to respective instrument earth bus
provided in the control room/local panel/thermocouple head etc. as
required and instructed by Engineer-in- Charge.

30. Incorporation of all information in owners drawings/document, as per the

actual execution of work at site including preparation and submission of
as-built drawings.

31. Submission of final material appropriation statements for all the materials
issued by the Owner.

32. As-built construction drawings and documents.

33. Furnishing all drawings, documents for review/approval as per tender

document

34. Start-up and commissioning assistance as required and agreed upon with
Engineer-in-Charge.

35. Participate in the inspection activities before handover of foundation to

confirm its correctness

36. Secure third party certification of hoisting facilities and pressure vessels
within the scope of work

37. Provide the required equipment, tools and instruments necessary for
installation and acceptance.

38. On-site calibration of all instruments necessary for permanent works (e.g.
pressure gage, thermometer, thermoelectric couple, relay, density gauge,
vibration measurement elements, revolving speed, axial displacement and
safety valve, etc.)

39. Supply of temporary test facilities and materials necessary for all on-site
erection and installation works until acceptance, as well as the facilities
and materials installation, operation, maintenance and removal.

40. Implementation of erection and installation works arising from design

changes.

41. Assistance and participation during the conduct of pre-commissioning and

commissioning activities, including debugging of all devices within the
scope of work; coordinating starting and debugging of sub-system and
entire system.

42. The Subcontractor shall likewise assist in the commissioning of sub-

systems, provide temporary measures during starting & commissioning
period of entire system as well as recovery, perfection and defect-

13
 elimination of system. He shall be responsible for coordination of
performance test and installations necessary for performance test.

43. Provide free on-site training for production staffs of the Owner and
necessary technical information before handover of system if the Owner
deemed it necessary. The training method shall be a combination of
classroom lectures and on-site training as approved by DMCI.

44. Record all erection and installation work processes and ensure the
accuracy and correctness of these records, so as to ensure traceability

All works not specifically mentioned above but are related to installation of
the complete equipment shall be carried out by the Subcontractor in
accordance with the construction drawings and manufacturers drawings
provided by DMCI.

4.3 WORKS EXCLUDED

a. BOP System Instrumentation and Control

4.4 RELATED WORKS

The following related works are to be considered as reference, guide and

reminders that whatever procedures to be executed shall be planned with
respect to these works:

The Subcontractor shall provide and keep an up-to-date As-Built drawings of

structures constructed and all equipment and accessories erected or installed.
These drawings shall show all changes and revisions from the latest approved
drawings and specifications, including the exact as-built locations, sizes, and
kinds of equipment and accessories, miscellaneous metalworks, embedded
piping and electrical systems and other concealed items of work.

These drawings shall be kept in the Subcontractors field office but shall be made
available at all times for review of DMCI. At the end of every work, all entries,
changes or revisions made in the drawings shall be checked and approved by
DMCI.

5 PURPOSE OF INSTRUMENTATION:

The purpose of instrumentation is to provide a system such that all the required
information / data / signal in the desired form and place are available and they
work for safe monitoring, controlling and operation of the process and
associated systems and to make the required information available at local
control centers and Remote Telemetry Unit (RTU) interface in required form,
following the Basic Bid Work, the Instrumentation Design Criteria and the
Functional Specifications of the tender document.

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5.1 STANDARDS AND SPECIFICATIONS

5.1.1 Project Specifications:

SLTEC1-C-ISD-001 GENERAL SCHEME OF THE PLANT

AUTOMATION CONTROL AND
SUPERVISION SYSTEM DIAGRAM
SLTEC1-CKN-ESL-001 CONFIGURATION DIAGRAM OF
MICROCOMPUTER MONITORED SYSTEM
FOR NETWORK
SLTEC1-C-INS-001 I&C LEGEND
SLTEC1-C-IDD-001 DESIGN DESCRIPTION OF I&C PART
SLTEC1-CMA-IEM-001 MAIN EQUIPMENT AND MATERIAL LIST
SLTEC1-CWQ-IEL-001 CENTRALIZED CONTROL ROOM
AND ELECTRIC EQUIPMENT ROOM LAY-
OUT
SLTEC1-C-IEL-001 SCHEMATIC DIAGRAM OF MAIN
BUILDING CABLE ROUTE

5.1.2 Codes And Standards:

The instrumentation erection, calibration and testing shall be carried out

in accordance with various related national, international and other
recognized Standards in instrumentation but not limited to the following:
The Standards referred herein and mentioned below shall be of the latest
edition

American Petroleum Institute

API RP 554 Process Instruments and Control

API RP 555 Process Analyzers

API RP 551 Process Measurement Instrumentation

API RP 7.1 Pneumatic Control Circuit Pressure Test

American National Standards Institute (ANSI)

ANSI C 96.1 Temperature Measurement Thermocouples

American society of Mechanical Engineers (ASME)

ASME PTC 19.3 Performance Test Code Temperature Measurement

British Standards

15
 BS 1904 Specification for industrial platinum resistance
thermometer sensors

BS 4937 International Thermocouple Reference Tables

BS EN 60529 Specification for degrees of protection provided by

enclosures (IP) codes

BS-6739 Instrumentation in process control systems:

Installation design and practice.

IEC 60331 Fire resisting characteristics of electric cables

IEC 61508-1-7 Functional safety on electrical / electronic

programmable electronic safety-related
systems

IEC 61131-3 1993 Programmable Controllers Part 3: Programming

Languages

Institute of Electrical and Electronic Engineers (IEEE)

IEEE 828 Standard for Software Configuration of

Management Plans

IEEE 1042 Guide to Software Configuration management

IEEE Computer Society Document

IEC 332 Test on bunched wires or cables.

IEC 529 Degree of protection provided for enclosures.

IEC 534-2 Industrial process control valves-flow capacity.

IEC 751 Platinum resistance temperature sensors

EC 801 Electromagnetic compatibility for

industrial process measurement and control
equipment

BS-6739 Instrumentation in process control systems:

Installation design and practice

Instrumentation Systems and Automation Society (ISA)

16
 ISA 5.1 Instrumentation Symbols and Identification

S 7.0.01 Quality Standard for Instrument Air

ISA/ANSI-S 84.01 Application of Safety Instrumented Systems for the

Process Industry

ISA 912.13 Parts I: Performance Requirements,

Combustible Gas Detectors
Part II: Installation, Operation and Maintenance of
Combustible Gas Detectors

ISA S 71.01 Environmental Conditions for Process

Measurement and Control Systems: Temperature
and Humidity

ISA S 71.04 Environmental Conditions for Process

Measurement and Control Systems: Airborne
contaminants

ISA S 75.01.01 Flow equations for sizing control valves

S 75.03 Face to Face Dimensions for Flanged Globe

Style Control valves

ISO 5167 Measurement of Fluid Flow by means of

Orifice Plates

National Electrical Manufacturers Association (NEMA)

NEMA 250 Enclosures for electrical Equipment (1000

Volts maximum)

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code

NFPA 1 Fire Protection Code

NFPA 72 E Automatic Fire Detectors

NFPA 496 Standard for Purged and Pressurized

Enclosures for Electrical Equipment

6 INSTRUMENTATION SYSTEM PHILOSOPHY

6.1 INSTRUMENT PHILOSOPHY

17
All the offered instruments / equipment or equipment of similar design
manufactured by the same supplier shall have been:
a) Type tested by the authority approved by the Company.
b) In continuous satisfactory service on offshore for a minimum
period of two years.

i. Field Instruments:

All field instruments connected with well monitoring and

control, and all facilities that are not to be operated from a
central control room, shall be pneumatic except those that
are connected to RTU, which shall be electronic, SMART
type.

All instruments connected to control room and remote unit

control panels of related systems shall be electronic,
SMART type. (The instruments that are to be connected to
the Control System in Central Control Room or otherwise
shall be governed by the Basic Bid Work.)

For remote control application, remote telemetry,

telecontrol and data gathering, electronic instruments shall
be used.

All final actuation / control device, controlled from

remote / Central Control Room (CCR) shall in general be
pneumatically actuated or motor controlled if applicable.

Hand-held Intrinsically Safe calibration / configuration

units shall be supplied to enable online diagnostics,
configuration or calibration of electronic instruments from
any point in the loop. The number of such calibration /
configuration units shall be as per the Basic Bid Work.

ii. Pneumatic Field Instruments:

The instrument air supply shall conform to ISA S7.3

Quality Standard for Instrument Air.

Each pneumatic instrument supply shall be provided with

independent filter regulator. For pneumatic instruments,
dry instrument gas / air supply shall be as follows:
5.5 Kg/cm2 (min.)
7.5 Kg/cm2 (nor.)
10.5 Kg/cm2 (max.)

All related equipment shall be suitable for operating in the

above-specified range.

18
 For pneumatic analog control applications, the actuating
signal range shall be 0.2 to 1 Kg/cm 2g. For pneumatic on-
off applications, the actuating signal shall be 0 or 6.5
Kg/cm2g.

iii. Electronic Field Instruments:

All electronic transmitters shall be 24 V DC loop-powered

types with 4 20 mA Smart analog output signal.
Electronic Transmitters shall have integral LCD display.
Where this is not possible, a suitable separate local loop
indicator shall be provided.
Local electrical control and alarm switches shall be
hermetically sealed DPDT Micro Switch activated. The
switches shall be rated for 110 V AC 10 Amps.

iv. Control Room Instrumentation:

All signals to and from the Central Control Room shall be

electric / electronic.
The standard signal shall be analogue 4-20 mA using 2-
wire system, standard thermocouple, RTD output, and / or
suitable pulse signal.

Instruments located on control panels and central control

room (CCR) shall be microprocessor based.

On platforms with processing facilities, a Distributed

Control System (DCS) shall be provided for monitoring and
controlling the process, and for generating alarms in case
of process upsets.

6.2 INSTRUMENT POWER SYSTEM PHILOSOPHY

6.2.1 Pneumatic Supply:

For pneumatic instruments, dry instrument gas / air supply shall be as

follows:

a) 5.5 Kg/cm2 (min.)

b) 7.5 Kg/cm2 (nor.)

c) 10.5 Kg/cm2 (max.)

6.2.2 Electric Power Supply:

Components of power supply system shall be of highest available quality

for reliability and long service life.

19
 Power supplies for all transmitters, controllers, signal converters, electric
system and components in shutdown system shall be supplied from
uninterruptible power supplies.

Power distribution to each consumer shall be through proper,

independent switch and fuse. Protective fuses shall be of indicating
cartridge type mounted in fuse holders.

In general, the following Power Supplies shall be used for

instrumentation and Control:

a) For Process Platforms: 220V AC + 5%, 60HZ + 1% (UPS) for all

instruments control. However, all components / instruments /
system shall be suitable for 220 V + 10% AC, 60 Hz + 3%

b) For Process & Well Platforms: 24V DC + 5% Battery Negative

earthed for Platform interlock system, solenoid valves, and alarm
status lamp.

6.2.3 Instrument Earthing System Philosophy

Two separate earthing systems shall be provided:

a) Electrical Safety Earth Bonded to the site structure and utilized

for electrical safety of metal enclosures and chassis on all
instruments and electrical components.

b) Instrument Clean Earth Insulated from the site structure and

other metal work utilized for instrument cable screens and bonded
to the main electrical earthing system at a single point.

6.2.4 Equipment Protection Philosophy

a) Environmental Protection:

All instruments / equipment and installation material shall be

suitable for the overall climatic conditions, the position within the
installation and the local environment, with particular attention to
site ambient conditions. The conditions will include exposure to
moist salt laden atmosphere, sea spray, sunlight, monsoon
rainfall, temperature, humidity, wind, fungal growth, vibration and
shock, EMI and RFI.

Instrumentation shall withstand not only the quoted

environmental conditions, but also the periodic testing of the
Deluge or Fire Hose System.

20
 All field instruments shall be provided with necessary weathering
and anticorrosion protection. All field instruments shall be
provided with suitable stretchable plastic to protect them during
handling, installation and commissioning and should be protected
against damage caused by welding during construction work.
Labels and tags that may be exposed to paint spray shall be
temporarily masked with a transparent material during
construction activities, which shall be removed at the time of hand
over of the work. Plastic plugs shall be fitted to all instrument
tubing and air, process and cable entry ports until final
connections are made.

b) Ingress Protection:

i. All field instruments shall have ingress protection to

NEMA 4X or IP 66.

ii. All instruments installed inside pressurized equipment /

control rooms shall have Ingress Protection to IP 42 as a
minimum.

6.3 INSTRUMENT INSTALLATION PHILOSOPHY

All work shall be of the highest quality craftsmanship and shall conform to the
best applicable engineering practices, and, relevant codes referred in the bid
document.

All instruments shall be installed in a neat workmanlike manner ensuring ease of

operation and maintenance.

The Contractor shall prepare hook-up and installation detail drawings regarding
each type of instrument for the Companys approval, and shall carry out the
installation in accordance with these approved drawings.

The Contractor shall install instruments and equipment with due consideration of
the following:

a) No instrument with the exception of pressure gauges and

temperature indicators shall be installed in such a way that it
depends on its impulse piping or electrical connections for its
support.

b) Positioning of equipment shall not constitute a safety hazard.

Where possible, instruments shall be mounted so that they are
protected from the effects of rain and sun, while maintaining the
requirements for access and visibility. Where this is not possible,
the Contractor shall provide a fixed cover or hood to protect
instruments, without impairing access or visibility.

21
 c) Visibility and accessibility for both maintenance and operations
purpose.

d) Ease of access for lifting heavy items of equipment such as

valves.

e) All instruments and valves shall be free from vibration.

f) Instruments shall be mounted / connected so as not to stress

vessel nozzles or pipe tapping.
g) All local process-connected instruments shall be located as close
as possible to the point of measurement while still being
accessible from the deck, ladder or a platform.

h) Instruments requiring frequent routine access (including hand-

valves, manual resets, manual switches, etc.) shall be mounted
approximately

i) 1.4m above the deck or platform for ease of accessibility,

j) Instruments shall be properly supported on brackets or mounted

on sub-plates, or placed on a suitable pedestal, pipe stand or
structural support.

k) Pipe or structural stands may be welded directly onto platform

plate, with a suitable penetration in the grating, where applicable.

l) Instruments, tubing, cables and cable ladder shall not be fixed to

gratings or handrails.

m) Instruments (other than pressure instruments) shall not be

mounted directly on process piping without the Companys written
approval.

n) Instruments or instrument lines shall not be supported on

handrails unless approved by the Company.

o) Fittings such as instrument isolating valves and instrument air or

gas regulators shall be supported either on the instrument stand
or close coupled to the instrument in a manner that no undue
stress is imposed of the tubing or instrument.

Instrument stands or panels shall be in accordance with the approved drawings,

with consideration for:

a) The most direct routes for tubing and piping to and from the
stand, using common tubing runs and avoiding crossovers.

22
 b) Ease of inter-connections between instruments.

c) Ease of access for on-site calibration and / or removal of

instruments.

d) Minimum interference between tubing, piping and cabling to

instruments.

A 316 SS filter regulator with gauge shall be provided for each instrument
requiring regulated gas or air supply.

All open ports (vents / drains) on field instruments shall be made to face
downwards if it is already not so and fitted with bug screens.

6.4 INSTRUMENT INSPECTION & TESTING PHILOSOPHY

6.4.1 General

The Contractors quality plan shall include a comprehensive fully

documented inspection and testing plan specific to the project.

The procedures shall include inspection specifically for compliance with

hazardous areas requirements, including current certificate, without
which no circuit or loop shall be energized.

All testing, calibration and pre-commissioning shall be done by the

Contractor. The Contractor shall also provide assistance as required
during commissioning activities.

The Contractor shall provide suitable workshop facilities and shall provide
all necessary test and calibration instruments and equipment.

The Company reserves the right to reject any or all test and calibration
work if found not complying with the Specification requirement. The
Contractor shall complete and submit documentation for all calibration,
testing and pre-commissioning. Company Representative prior to
shipment shall check out panels, consoles, and packaged instrument
assemblies for their compliance with specification requirements.

The Contractor shall in the presence of the Company Representative,

verify by inspection, calibration and loop testing, that, all instrumentation
in field and control room including local and remote/central control
panels, are complete and operable as per specification requirement. All
testing and calibration shall be subject to approval of the Company.

In addition to calibration/testing, loop checking, setting for safety devices

like process switches, safety valves etc. and simulation testing of all

23
 interlock and shutdown systems, done at fabrication yards, the same
shall also be carried out at offshore site as well.

In general, the pipes and tubes shall be cleaned before testing. They
shall then be subject to hydro-test (or other applicable tests) and then
blow dried.

6.4.2 Flushing Of Lines

The Contractor shall remove in line instruments like flow meter, control
valves/safety valves, if necessary, and provide spool pieces/flanges prior
to flushing of lines.

6.4.3 Instrument Supply Lines

Instrument air/gas piping and tubing shall be disconnected upstream of

all filter/regulators before testing, the piping and tubing shall then be
hydro-tested as explained below and then shall be blown down to remove
hydro-test water, slag and mill scale from lines.

Instrument air supply lines shall be blown with instrument air prior to
connecting to instruments. Instrument air/gas mains shall be isolated from
the instrument and pressurized to 11/2 times maximum working pressure
with instrument air, they shall be isolated from the pressure source and the
pressure reading on a test gauge shall not fall by more than one psig in ten
minutes.

7 OTHER REQUIREMENTS FOR INTERFACING/ WIRING TERMINATION

7.1 INSTRUMENT CABLES

7.1.1 Cable Types

The specification of the cables will be provided by CNTIC during the detailed
design.
The material of conductor is copper, flame retardant power and control
cables shall be applied to flammable and explosive areas like fuel oil area;
Cable with copper shield will be used for control cable of computer system.
Cables for binary input signals will be overall shielded and cables for analog
signals will be individual pair shielded+ total shielded. Multi-conductor cables
will be used for compensating cable.

The cables used shall in general be of the following types:

a) Fire Resistant
b) Fire Retardant Cables

24
 The properties of fire retardant cables to be used for
different applications shall in general be as follows:

i. Signal Cables:

ii. Multi-pair cables shall have following additional

features:

iii. Control / Alarm

iv. Compensating Cables for Thermocouples

v. Power Cables

vi. Special Cables

7.1.2 Cable Sizes

Cables with individually screened pairs shall be used for very low-level
signals such as thermocouple wiring or similar, or for pulsed signals.

7.1.3 Cable Shielding

All instrument signal cables shall be continuously shielded with the shield
grounded at the same point as the signal circuit, generally at the control
instrument (panel) end.

7.1.4 Cable Runs

All instrumentation cables shall be supported / layed in trays. Power

cables shall not be run in trays carrying signal cables. The physical
separation of power and signal cables shall be as per API-550 Part I
SECTION VII. Cable in intrinsically safe circuits shall preferably be not
run in the tray for cables in non-intrinsically safe circuits. If run in the
same tray a metallic earthed separator shall be provided.

Where cables are run through conduit, the entry and exit shall be smooth
and free from burrs. The use of conduits shall be kept to a minimum, as
far as possible.

Cables must be pulled into conduit in a way that ensures there is not
damage to the cable.

Splices shall be made only at terminals, in instruments or approved

equipment/junction boxes in any cable path shall be limited to one only.

7.1.5 Cable Marking:

25
 All cables shall be identified with stainless steel cable markers securely
fixed to the cable with cable tie wraps at the following locations:

All cable glands

Entering and leaving cable ladders, ducts and supports

Cable markers shall be fitted during or immediately after

cable installation.

7.1.6 Cable Identification:

All wiring, cables, tubes, multi-tube bundles, junction boxes and auxiliary
equipment shall be suitably identified as per applicable codes and
practices.
Plastic adhesive tapes shall not be used for identification. Identification
and details of all such equipment and wiring/tubing shall also be clearly
marked on appropriate drawings. All wiring shall be tagged with slip on
or clip-on wire marker at both ends with the wire number specified on
the drawings.
Terminals for electrical connections including thermocouple extension
wires shall be numbered and identified to indicate polarity, ground
Connections, test connections, and any other pertinent information.

7.1.7 Cable Segregation:

The Contractor shall ensure that there is no interference between cables

having different voltage or signal types.

Instrument cables shall be segregated from antenna cables and others

carrying RF signals so as to avoid interference.

Very low-level signals, such as thermocouple wiring, or of pulsed signals

or any other signal types, which may be liable to affect or be affected by
any other cables, shall have individual and overall screens and shall be
installed on a separate tray or ladder adequately separated from other
cable systems.

Intrinsically safe signal cables may be run on the same tray as non-IS
signal cables if they are segregated by metal barrier.

7.1.8 Cable Installation:

All instrument signal cables shall be continuously screened, with screens

grounded at the equipment room end only and securely insulated at the
field end. All cables exiting equipment rooms shall be armoured,
including serial link and data highway cables.

26
 For ease of instrument disconnection, an adjustable elbow or union shall
be provided between the terminating gland and the instrument.

A neat loop of cable 250 mm diameter shall be left immediately adjacent

to all instrument devices in the field.

Cabling to locally mounted instruments shall not be routed across normal

or emergency walkways nor interfere with access to equipment.

Cable transits shall be used to provide gas-tight cable penetrations

through decks or firewalls.

7.1.9 Cable Termination:

All cables shall be terminated using double compression type glands on

explosion proof equipment. These glands shall be explosion proof,
certified. All cable glands in outdoor service and on equipment subjected
to salt water spray shall be weather proof also. All terminations shall be
screw clamp type terminals for 2.5-mm2 conductors minimum (no flying
leads) and correctly certified where necessary. Insulated crimp lugs shall
be used for all cable core connections, with only one conductor per
terminal side.

No wire shall be terminated/left with mechanical strain on it in any

conduit or trunking.
Cables shall be terminated in 316 SS glands, suitably certified where
necessary. The inner sheath shall be left on the cable after the gland,
and removed at the point of entry into wiring duct.

Cable cores shall not be pig tail finish.

Cable screens and drain wires shall be securely insulated at the final field
termination.
The communications conductor of a cable shall be terminated in the
bottom terminal(s) of a row of terminals.

Printed sleeve-type ferrules shall be fitted to all cable cores on both sides
of every core. C type and adhesive type shall not be used.

All cables shall be individually loomed at maximum fixing centers of 60

mm and where cores leave the loom.

Only one conductor shall be used per terminal side.

Cable entry to control room/other rooms shall be through listed

multicable transits.

Terminal blocks shall be non-hygroscopic, Vibration proof, stack on type

and shall use captive screws for terminals. Terminals shall be tinned or

27
 Silver plated. All terminations shall be through use of wire lugs. Terminal
blocks shall be flame retardant type.

Cable Termination for Skid Items:

Manufacturer or fabricator supplying skid mounted equipment or vessels

with instrumentation which provides or utilizes off skid alarms /
shutdowns / control functions, shall terminate signals on a central
junction box, near skid boundary, available for hook-up by Contractor.
The location of this junction box shall be noted on vendor drawings.

7.1.10 Cable Junction Boxes:

Separate junction boxes shall be used for intrinsically safe wiring.

Junction boxes in any cable path from field to control room shall be
limited to one only. Instrument junction boxes shall not be used for
electrical power cables.

Field junction boxes shall be certified for use in hazardous area in which
they are installed.

Cables shall not enter through the top or sides of outdoor enclosures. For
indoor enclosures, bottom entry is preferred.

Entries shall be suitably spaced to enable ease of installation of cable

glands.

Tapped cable entries shall be of good quality, without stripped or

damaged threads. The thread shall be continuous and shall permit the
cable gland to fit squarely against the gland plate (or enclosure).

Where the gland plate is not thick enough for tapping, cable glands shall
be fitted with double locknuts.

All junction boxes shall be effectively sealed, once uncrated or fitted into
position. All lids shall be replaced during any break in work. Where this is
impractical, e.g. large multi-cable junction boxes, a heavy PVC sheet shall
be used to cover the junction box to exclude rain and dust

All terminals (including unused terminals) shall be tightened down. For

communing of terminals, feed through cross connection bar shall be
used. Comb connectors shall not be used.

7.1.11 Tubing Installation:

The primary instrument block valves for all instruments shall be as per
piping specifications.

28
 All impulse lines shall be run with a slope not less than 1 in 12 except
where otherwise specified. Direction of slope is to be downward from the
process for liquid service and upward from the process for gas service.

Tubing shall be joined by compression fittings.

Instrument lines shall be run in the vertical plane as far as possible and
shall be run with the minimum number of changes of directions
consistent with good practice and neat appearance. All pipe and tubing
shall be run in horizontal and vertical planes only.

Tubing shall be bent with correct size tubing bender where required to
avoid the use of fittings. Tubing cutter shall always be used to cut tubing.
The use of short lengths of tubing in long runs shall be avoided, to avoid
the use of fittings.

All tubing shall be run in such a manner as to give the maximum

protection against mechanical damage. Tubing runs shall be grouped
together and clamped where possible. Tubing shall be arranged so that
couplings can be tightened without distorting lines. Instrument tubing
shall not run on trays intended for cables and shall not share the same
transit with cables.

Tubing run in permanent enclosures shall not have joints, except at

special junction boxes provided for this purpose.

Where tubing is run in permanent enclosures, the Contractor shall ensure

that entry and exit of such enclosures is clean and smooth.

Pipes or tubes installed but not connected, shall have the ends closed in
approved fashion to prevent the entry of foreign material by suitable caps
or plugs.

All reasonable precautions shall be taken to prevent foreign material

entering tubing / pipelines before and during erection.

Where permanent enclosures are left with space for instrument tubing to
be pulled in at some future date, a galvanized pull wire of adequate size
shall be left in the tray.

On tubing to pipe connections and in making of screwed pipe joints,

Teflon tape shall be applied to make thread in a manner to insure tape is
not over the end of the male fittings.

7.2 INSTRUMENT PROCESS CONNECTIONS:

Instrument process connections shall be as per relevant piping

specifications.

29
 The nozzle length on vessels for temperature instruments on piping will
be 200 mm (8"). For Thermowell installation, minimum pipe size shall be
4". All threaded connections of the instruments shall be tapered.

Connection for air or gas supply, transmission and control signals shall
normally be internally threaded NPT. Instruments process
measurement connections shall be threaded minimum.

Instrument isolation valves shall be installed as per the P & IDs and as
detailed in the approved hook-up drawings.

Take-offs from lines or vessels for all direct connected pressure

instruments shall meet or exceed the line or vessel specification. All
pressure instruments shall have an individual piping block valve and a 2,
3 or 5-valve manifold as appropriate, providing block, bleed and bypass.
The only exception to this is for DP level transmitters with filled leg,
which shall have block and bleed but no bypass capability.

A maximum of two (2) pressure instruments may be connected to the

same pressure tapping, so long as their function is not safety-related.
Instruments for ESD or F&G systems shall each have their own individual
tapping. Each pressure instrument shall have individual block.

Each pressure transmitter shall be supplemented with a direct connected

process pressure gauge on the same tapping.

8 EXECUTION METHODOLOGY

8.1 INSTRUMENTS IMPULSE PIPES

8.1.1 All impulse lines shall be installed in the best workman like manner and
shall follow installation standards in each case. Where there is no
installation standard, the instruction of the Engineer-in-Charge shall be
followed.

8.1.2 Horizontal and vertical lines shall be installed using levels and plumb
bobs.

8.1.3 All welding shall be carried out as per welding procedures and codes with
electrodes approved by Engineer-in-Charge. Only qualified welders
approved by Engineer-in-Charge shall carry out welding works. Any
materials like electrode, equipment, testing charges for various tests etc.,
required for initial qualification of the welder/ welders shall be borne by
the contractor. Wherever welding of dissimilar materials are envisaged
for any process hook-up, the contractor's scope includes these welding
along with supply of weld materials.

30
 8.1.4 Impulse pipes shall be bent using pipe benders only; hot bending will be
totally rejected. Pipes shall be cut using pipe cutting device. Hot cutting
will not be allowed.

8.1.5 All threaded joints shall be jointed with PTFE tape only. No other pipe
jointing compound shall be used.

8.1.6 All impulse lines shall be properly supported at regular intervals of 1

meter. Wherever insert plates are not available, supports on concrete
structures or on ceilings shall be fixed with a minimum of 10 mm
expansion bolts. A suitable support will be provided.

8.2 INSTALLATION OF CABLES TRAYS

8.2.1 Multicore cables shall always be installed on trays/inside trenches and

shall be properly clamped. At every vertical drop to junction boxes, they
shall be clamped at more frequent intervals (maximum of 400 mm). They
shall be connected inside junction boxes strictly according to the number
system as mentioned in cable schedule. At bends minimum radius shall
be maintained as per manufacturer's standard. The angle tray supports
shall be fabricated from 40 mm x 40 mm x 5 mm angles, as a minimum.

8.2.2 Identification tags shall be provided on either end of multicore cables as

per Cable schedules. Engraved tag plates or PVC ferrules shall be used
for identification of cables.

8.2.3 All Multicore cables shall be cut after the exact site measurements are
taken between ends. The cable drums shall be selected before cutting the
lengths so as to avoid any wastage.

8.2.4 All multi-cables laid in trenches/trays shall be properly dressed and will
tied with suitable ties.

8.2.5 In the field, the cables shall be laid in trenches and trays as per layout
drawings.

8.2.6 Inside control room all cables shall be laid in trenches or in the ceiling.
When laid in the ceiling the cables shall be properly dressed and tied as
per instructions of Engineer-in-Charge.

8.2.7 The cable trays/angle trays shall be properly supported at a regular

interval of maximum of 1 meter from insert plates or steel structures.
Wherever insert plates are not available supports on concrete structures
and ceilings shall be fixed with minimum 10 mm diameter expansion
bolts. Angle supports for cable trays/angle trays shall be fabricated from
40 mm x 40 mm x 5 mm MS angles as a minimum.

8.2.8 All supports shall be cut with hacksaw only. Any work executed by gas
cutting for making holes or cutting pieces will be totally rejected. Free

31
 ends of angle support shall not have sharp edges and shall be properly
rounded off.

8.2.9 Cable trays/angle trays shall be used for branch cables from main trays.
Width of trays shall be selected according to number of cables. Trays
shall be laid generally as per site conditions with the approval of
Engineer-in-Charge.

8.2.10 No welding on galvanised trays/angles/cable trays shall be allowed in

general. In specific cases where welding is unavoidable, this shall be
carried out as per instructions from Engineer-in-Charge. For welding, if
required, following procedure shall be followed as a minimum:

8.2.11 Remove galvanization thoroughly from the portion to be welded.

8.2.12 After welding, clean the welded portion for any slug and sharp edge.

8.2.13 Welded portion shall be painted.

8.2.14 Laying of Cables

8.2.15 All cables shall be laid in accordance with installation drawings and cable
schedules. Before laying, cable / multi-cable on drums shall be tested to
ascertain the transit damages.

8.2.16 All cable routes shall be carefully measured and cables cut to the
required lengths, leaving sufficient amount for the final connection of the
cable to the terminals on either end. Sufficient extra length of cable shall
be kept at the termination points.

8.2.17 All cables shall be indicated close to their termination point by cable
number as per cable schedules / junction boxes schedules. PVC
ferrule/tag plate shall be used and these identification tags shall be
securely fastened to the cables.

8.2.18 Once a cable has been cut, cables shall be taped with an approved PVC
or rubber insulating tape to protect against dirt and moisture.

8.2.19 The bending radius of cables shall be maintained as per manufacturers'

recommendation. Cables installed shall run parallel or at right angles with
beams, walls or columns.

8.2.20 Cables shall be rigidly supported on structural steel and masonry

individually or in groups as required using PVC covered galvanized clips,
multiple cable supports or cable trays. Cable shall be supported at every
500 mm on vertical runs and every 100 mm on horizontal runs.

8.2.21 Compensating cable etc. is separated from other power supply cables.

32
8.2.22 Trenches shall have sufficient depth and width to accommodate all cables
correctly spaced. A proper segregation of control and signal cables shall
be observed.

8.2.23 After lying of all the cables, the cable entry to control room shall be
suitably filled and sealed.

8.2.24 Cables shall be laid strictly in line with cable schedule.

8.2.25 All cable entries to equipment located outdoors and Control Room
Cabinets should be from below. Top entry is not allowed and side entry
shall be provided with drip nose.

8.2.26 Sufficient cable spare length shall be provided for equipment that needs
future adjustments or where equipment has to be dismounted for
maintenance and calibration without disconnecting the cable.
8.2.27
8.2.28 Cable tray numbering and marking shall be provided at every 10m and at
each end of cable way & branch connection.

8.2.29 Joints run of cable shall not be permitted.

8.2.30 At least 300 mm clearance shall be provided between - HT power & LT

power cables, - LT power & LT control/instrumentation cables.

8.2.31 Segregation (physical isolation to prevent fire jumping)

8.2.32 All cable associated with the unit shall be segregated from cables of other
Units.

8.2.33 Interplant cables of station auxiliaries and unit critical drives shall be
segregated in such a way that not more than half of the drives are lost in
case of single incident of fire.

8.2.34 Contractor shall furnish sets of cable termination kits like Crimping tools,
etc., which are required for maintenance of the system as per the type of
termination used.

8.2.35 No splices shall be made in conductors for instrument.

8.2.36 Proper termination of cable shields shall be verified and the grounding of
the same shall be coordinated so as to achieve grounding of all data and
voice cable shields at same potential. This shall be completed prior to
system tests.

8.2.37 The Contractor shall take full care while laying / installing cables as
recommended by cable manufacturers regarding pulling tensions and
cable bends. Cables damaged in any way during installation shall be
replaced at the expense of the bidder.

33
8.3 EARTHING

Earthing of junction boxes, local panels / cabinets, as required shall be carried

out as per the documents and instruction from Engineer-in-Charge.

8.4 PAINTING

8.4.1 This part of the specification is applicable to cable ducts, angle trays.
Instrument supports and cable trays, all structural supports for the above
items, etc.

8.4.2 The surface to be painted shall be thoroughly cleaned with wire brush,
sand paper to remove all scales. After cleaning, the surface is painted
with one coat of red oxide zinc chromate primer.

8.4.3 Final second coating shall be subject with the approval of Engineer-in-
Charge.

8.4.4 It shall be noted that final second coating on external surfaces not
covered by cables, etc. shall be applied just before handing over the plant
or commissioning of the plant whichever is earlier.

8.5 TESTING

8.5.1 All signal cables shall be checked for megger values and continuity before
final termination and ferruling.

8.5.2 Testing shall be carried out after the Installation of instrument with
primary piping complete in all respects and approved by Engineer-in-
Charge.

8.5.3 Primary piping shall be tested hydraulically to 1.5 times the operating
pressure after isolating the instruments. Flushing of piping shall be
carried out as per instructions of Engineer-in-Charge. Lines shall be
blown after hydro-testing.

8.6 CALIBRATION

All instruments shall be calibrated as per instructions given in manufacturers

manuals/engineer -in-charge. Standard test instruments shall be used for
calibration of instruments.

8.7 LOOP CHECKING

8.7.1 Loop checking shall be performed after calibration; interconnection of

signal lines is carried out for all instruments. Loops tests are conducted
to check the functional performance of all elements comprising the loop,
thereby ensuring proper interconnections and operations.

34
 8.7.2 Before proceeding for loop checking, the calibration results of individual
elements shall be documented and shall be approved by Engineer In
Charge for correctness of installations, measurements and calibration
results.

8.7.3 Loop testing for all control loops shall be simulating process conditions
for at least 0%, 25%, 50%, and 100% of full scale inputs. Detailed
procedure shall be admitted by Engineer In Charge for approval
before proceeding for loop checking.

8.7.4 In case of shutdown systems, field/receiver switches are simulated for

abnormality by disconnecting the wires at terminals. Function of all
associated systems are checked including performance of solenoid
valves, On/Off type control/shutdown valves including proper functioning
of limit switches and other accessories. Adjustment of limit switches
wherever necessary also form part of checking of loop performance.

8.7.5 Performance of individual loops shall be accepted for an overall accuracy

of 1.5%. Where deviation is found to exist more than specified limit,
contractor shall recalibrate the instruments which shall also form part of
loop testing, at no extra cost.

8.7.6 After the loop test is complete, the contractor shall connect back any
terminations and connections removed for loop checking.

8.7.7 A loop shall be considered as handed over only after measurements in

that particular loop are completed and certified by Engineer-in-Charge, in
addition to loop sheets being duly filled in all respects, approved and
accepted by Engineer-in-Charge and Client. In case of loops in which
certain instruments of the loops are calibrated by other agency, loop
checking shall be performed in coordination with the agency involved. If
a defect in the calibration of the instruments in contractors scope is
observed, same shall be rectified to the satisfaction of the Engineer-in-
Charge. However, if detect is detected in the calibration of the
instruments in the scope of other agency, same shall be rectified by the
agency involved. After the calibration has been rechecked by other
agency/agencies, the loop checking would be performed to the
satisfaction of Engineer-in-Charge. This is part of the contractor scope of
work.

8.7.8 Final certified loop sheets shall be submitted in 5 copies.

9 GENERAL REQUIREMENTS

9.1 TAGGING AND NAME PLATES

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 The Contractor shall assign individual tag numbers in accordance with the
Companys established system to all instruments. The tag numbers shall include
the following information and other related parameters for identification:

Last 2 digits of reference P&ID

Instrumentation Identification Number
Name of the Instrument
Name of the Platform

The tag number of every instrument shall appear on all relevant drawings and
documents that pertain to the specific instrument.

Nameplates and identification tags shall be provided to properly identify each

piece of instrumentation / equipment including instruments, Junction boxes,
bulkhead connections, cables, wiring, etc.

All instruments shall have SS tag or nameplate of a permanent type with

identification number and service description.

All panel instrument nameplates shall be constructed of white laminated plastic

plates with black engraved lettering and securely fastened with 316 SS screws.

All front panel mounted equipment shall also be identified with a metal or plastic
nameplate attached to the rear of the device, and easily visible via the rear
access doors.

All wiring, cables, tubes, multi-tube bundles, junction boxes and auxiliary
equipment shall be suitably identified as per applicable codes and practices.
Plastic adhesive tapes shall not be used for identification. All wiring shall be
tagged with slip on or clip-on wire marker at both ends, with the wire number
specified on the drawing.

All site-mounted instruments, junction boxes, air/gas headers, tubing and wiring
terminations shall be labelled or tagged in manner approved by the Company.
Instruments shall be furnished with stainless steel nametags containing tag
number, manufacturers name, model number and serial number. This tag shall
be approximately 3 x 1 and shall be attached to the instrument with 16 gauge
stainless steel wire.

Labels shall be positioned directly on the equipment or immediately adjacent for

best visibility. Positioning the label to one side shall be done only when other
preferred positions are unavailable. Where label positioning is difficult, the
Companys representative shall determine the final position. Junction box labels
shall be fitted on the lid in a central position.

10 DOCUMENTATION:

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 The contractor shall provide hard copies plus electronic copies for all the
documents.

10.1 Equipment Documentation:

a) The Contractor shall provide the following documents as a

minimum:

i. Operating philosophy of the system

ii. Proposed maintenance schedule of all major components,
for the design life of the system, and their replacement
requirements.
iii. Equipment specifications
iv. Catalogues
v. Data sheets
vi. Test certificates
vii. Deviation schedule
viii. System layout drawings
ix. Functional schematic
x. Bill of material / material take off
xi. Instrument layout & cable tray routing drawings
xii. Instrument calibration procedures
xiii. Cable schedule
xiv. Level Sketches
xv. Instrument & Junction box location plans / layouts
xvi. Loop schematics
xvii. Interconnection diagrams
xviii. Cable termination details
xix. Installation standards / drawings
xx. Pneumatic ESD loop and pneumatic FSD (Fusible Plug)
layouts
xxi. Servo / air supply header and distribution drawings
xxii. Redundant cables list
xxiii. Junction box wiring scheme
xxiv. Field calibration and loop checking report
xxv. MCT block sizing and arrangement drawing
xxvi. As-built drawings

b) Minimum 4 (four) sets of Dossier shall be provided to the

Company.
c) The contractor shall be responsible for the authenticity of the
drawings & data provided by the vendor as sell as sub-vendor(s).
d) Each vendor data items requested above must be identified by the
Purchase Order number and equipment tag number located on
the cover sheet or first page of said item and in the case of
engineering drawings on each and every drawing.
e) Any additional data/drawings required as a result of issuing
supplements to a purchase order or during detailed engineering

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 shall be furnished by Vendor and handled in the same manner as
the original order.
f) All drawings and literatures shall be in English language and in
the Metric Measurement System.
g) The reproducible drawings, 279mm X 432mm (11" x 17") size and
full size are to be of such quality that clears legible prints.

10.2 Instrument Index

The contractor shall provide an Instrument Index.

The index shall include the information listed below:

Instrument Tag Number
Service Description
Vessel / Line details
Process fluid
Operating pressure / temperature / flow / level parameters
Manufacturer / Model
Range / Calibrated Range
Reference Piping And Instrument Diagram Drawing Number
Data Sheet Number, With Latest Revision
Location Of Instrument (i.e. Field, Control Panel)
Remarks Column

The instrument index shall form the basis for documenting all instrumentation
and shall be listed in alphanumeric order of instrument tag number and shall
contain all relevant information for each instrument. The index shall be based on
Microsoft Access.

10.3 Instrument Data Sheet:

A duly filled data sheet shall be provided for every item of instrumentation
equipment, including those which are part of equipment packages, except those
items which form part of the bulk material take-off. These specification sheets
shall contain all information pertaining to a particular instrument including:

Manufacturer

Model

Mechanical Details

Electrical Details

Materials

Process Data (where required)

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 Range

Hazardous area classification and certificate details (type of protection,

certifying authority)

Line or Vessel Number

When a number of items are identical in their requirements, these can be

covered by a single specification sheet, provided all tag numbers are clearly
listed.

The Contractor shall submit his proposed data sheet for Company approval.

Data sheets shall be generated using Microsoft Excel.

10.4 INSTRUMENT CALCULATIONS: (to be provided by CNTIC)

The Contractor shall provide certified calculations for instruments, including

those listed below:

Control valve sizing

Regulator sizing

Relief valve and rupture disc sizing

Shutdown valve stroking time

Flow element sizing

Restriction orifice sizing and stress analysis

Thermowell wade frequency

DP level transmitter ranging

Intrinsically safe loop calculations, including cable, isolator and

field device parameters

Cable voltage drop

Diaphragm seal selection

Analyzer fast loop time

These shall form part of the relevant Purchase Specification to be submitted

during Detailed Engineering.

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10.5 DOCUMENTS/DRAWINGS AND DATA REQUIRED FROM CONTRACTOR

Following drawings and documents are to be generated by contractor and

submitted for review/approval/records. Signed & stamped Tech. specs of each
item to be submitted along with other documents of the item. (All documents
related to particular item to be submitted in one lot).QA/QP document of each
item/system to be submitted.

10.5.1 Purchase order, data sheets, model no. details, catalogues, and
manuals, vendor drawings documents:-For review/approval.

10.5.2 Control panel/Telemetry interface cabinet GA drawings, Detailed wiring

drawing, catalogues, model no. details of various items, Functional
schematics etc.;:-For review/approval.

10.5.3 Fire detection system, details of each item with catalogues/model no.
details, fire alarm panel GA, wiring drawing, Functional schematics, Zone
layout drawing, Location drawing of each item.:-For review /approval.

10.5.4 Gas detection system, details of each item, catalogues, Panel GA, wiring
drawing, functional schematic, location drawings of each item.:-For
review/approval.

10.5.5 Instrument location drawing, trench layout, control room entry drawing
and other drawings/docum;ents in tender to complete the work in all
respects :-For review/approval.

10.5.6 Junction box, cable schedule:-For review/approval.

10.5.7 Control room equipment layout drawing:-For review/approval.

10.5.8 Manufacturers test reports, certificates, statutory certificates:-For

review/records.

10.5.9 Hydraulic test, calibration, loop check reports:-For records.

10.5.10 Sizing calculations of pressure relief valves:-For review/approval.

10.5.11 The Subcontractor shall prepare and submit to DMCI for approval
or reference the main group of drawings and technical data/documents
including but not limited to the following:

(a) Codes and Standards which shall govern the Subcontractors scope
of works under the contract

(b) Quality Assurance Program and Procedure Manual to be used in

the project implementation

40
 (c) Working Plan which shall include the Subcontractors organization,
working system, construction methods, overall project schedule,
list of equipment and instruments to be used, etc.

(d) Reports and test results shall be submitted upon the completion
of the tests carried out in accordance with the approved
procedures and specifications.

(e) As built drawings:-For records.

(f) Test procedures:-For review/approval.

(g) Instrument location drawing, trench layout, control room entry

drawing and other drawings/documents in tender to complete the
work in all respects :-For review/approval.

(h) Junction box, cable schedule:-For review/approval.

(i) Control room equipment layout drawing:-For review/approval.

(j) Manufacturers test reports, certificates, statutory certificates:-For

review/records.

(k) The Subcontractor shall submit complete consolidated and

coordinated layout drawings for all systems. The drawings shall
include plan views, elevations and sections of all systems and
shall be on a scale of not less than 1:32 (3/8-inch equal to one
foot). Clearly identify and dimension the proposed locations of the
principal items of equipment. The drawings shall clearly show the
proposed location and adequate clearance for all equipment,
piping, pumps, valves and other items. Show the access means
for all items requiring access for operations and maintenance. Do
not install equipment, piping or cabling/wiring until layout
drawings have been approved.

10.5.12 AS-BUILT DRAWINGS and TEST RESULTS

(a) Provide Five (5) bound copies. Deliver to DMCI not less than 30
days prior to completion of a phase or final inspection.

(b) Include all new and temporary equipment and all elements of
each assembly.

(c) Schematic diagrams and wiring diagrams of all control systems

corrected to include all field modifications.

(d) All drawings and writings shall also have computer file to be
submitted to DMCI.

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 (e) All drawing sheet format shall be submitted first to DMCI for
approval prior to accomplishing all drawings.

(f) All test results sheet format shall be submitted first to DMCI for
approval prior to accomplishing all test results.

13 REVIEW AND APPROVAL

13.1 The Contractor shall thoroughly review and approve vendor drawings for all
instruments including sub-package items, DCS, ESD system, local pneumatic
SDP, pneumatic ESD / FSD loop charging panel, etc., as applicable, before
forwarding to Company for further review and / approval. Only the approved
drawings duly stamped and signed by a competent engineer of the Contractor
shall be sent to the Company.

13.2 All purchase specifications along with list of deviations, calculation sheets, offers
of the vendor and all relevant correspondence shall be furnished for Companys
approval. Contractor shall not place the order without obtaining prior approval
from the company.

13.3 Contractor shall prepare and furnish the list of all drawings / documents as
enlisted in the bid document for Companys review. The category of drawings /
documents (i.e. whether to be reviewed / approved by the Company) shall be
decided after award of Contract.

13.4 All vendors drawing shall be submitted for companys review after the
contractors engineering consultant approves them.

14 REFERENCE CHINESE STANDARDS

14.1 Products provided by CNTIC shall be manufactured according to relevant

Chinese standards and other products shall be determined by mutual negotiation
of two parties according to on-site requirements.

14.2 Products provided by CNTIC or building installation of engineering projects

designed by CNTIC shall be carried out according to relevant Chinese standards
and other items shall be determined by mutual negotiation of two parties
according to on-site requirements.

14.3 The publications/standards listed below form a part of this specification to the
extent referenced.

(a) Technical code for designing fossil fuel power plants

DL5000-2000

(b) Code for designing insulation and painting of fossil fuel power plant
DL/T5072-1997

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(c) Code for design of thermal power plant steam/water piping
DL/T5054-1996

(d) Technical code for design of thermal power plant air & flue gas ducts/raw
coal & pulverized coal piping
DL/T5121-2000

(e) Technical rule for designing auxiliary power system of fossil fuel power
plant
DL/T5153-2002

(f) Code for design of industrial television systems engineering

GB J115-87

(g) For hydraulic design of fossil fuel power plants DL/T

5339-2006

(h) Technical codes for chemical design of thermal power plant

DL/T 5068-2006

(i) Code of safety operation in power engineering construction. (Part of

steam power plants) DL5009.1
2002

(j) Supervision code for boiler and pressure vessel of the power industry
DL612-1996

(k) Inspection code for boiler and pressure vessel of the power industry
DL647-1998

(l) The Code of Erection and Acceptance of Electric Power Construction -

Section of thermal automation
DLT5190.5-2004

(m) Standard for Quality Inspection and Evaluation of Thermal Power

Construction -Section of thermal automation; etc.

(n) DL 5004-1991 Standard for design of thermal process automation

laboratory of fossil fuel power plants

(o) DL/T 1012-2006 Code for acceptance test of TSI & ETS in fossil fuel
power plant

(p) DL/T 1056-2007 Technical supervision guide for instrument and control
in power plant

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 (q) DL/T 1083-2008 Specification of distributed control system for fossil fuel
power plant

(r) DL/T 5004-2004 Design Standard of I&C Laboratory for Fossil Power
Plant

(s) DL/T 589-96 Directives of thermal instrumentation and control for coal
fired boiler in power plant

(t) DL/T 655-1998 Code for on-line acceptance test of furnace safeguard
supervisory system in fossil fuel power plant

(u) DL/T 655-2006 Code for acceptance test of furnace safeguard

supervisory system in fossil fuel power plant

(v) DL/T 656-1998 Code for on-line acceptance test of turbine control
system in fossil fuel power plant

(w) DL/T 656-2006 Code for acceptance test of turbine control system in
fossil fuel power plant

(x) DL/T 657-2006 Code for acceptance test of modulating control system in
fossil fuel power plant

(y) DL/T 657-1998 Code for on-line acceptance test of modulating control
system in fossil fuel power plant

(z) DL/T 659-1998 Code for on-line acceptance test of distributed control
system in fossil fuel power plant

(aa) DL/T 658-1998 Code for on-line acceptance test of sequence control
system in fossil fuel power plant

15 BATTERY LIMITS

15.1 BTG equipment installation are not covered in I&C scope of works

15.2 The BOP stand-alone systems are not covered in the scope of works, such as
follows:

a) Coal Handling System

b) Ash Handling System
c) DM Plant System
d) Electro-Chlorinator System
e) Sewage Waste Water Treatment System

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 f) Chemical Dosing System
g) Water and sampling System
h) Soot Blower System
i) Circulating Water Pump System

15.3 For BTG instruments and its BOP (non-stand-alone system), the boundary is
from the installation of devices or equipments to the designated terminal panel
in any location.

15.4 All works related to DCS System is not covered in these scope of work:
a) DCS Panel erection
b) DCS Power Supply
c) Termination of I/Os (assistance only if needed by DCS contractor)
15.5 Turbine Control System

15.6 Boiler Control System

15.7 Generator and Auxiliary System

16 WORK ITEMS, BILL OF MATERIALS AND DRAWINGS

For work items and Bill of Materials (, refer to table attached as Annex 1 and drawings
attached as Annex 2.

Note: Annexes are not yet final and to be determined (Bill of Materials for the
I&C Works shall come from CNTIC).

17 TECHNICAL AND FINANCIAL PROPOSAL

The bidder shall submit its technical proposal with respect to this Terms of Reference
and its financial proposal using the format used in Annex 3.

18 PROJECT SCHEDULE

The bidder shall submit its proposal in reference to the Project Schedule attached as
Annex 4.

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