ADWEA I&C Installation

0 02-02-2002 Approved Issuerev. date Description/issued for prepared authorised

client: ADWEAproject: STANDARD SPECIFICATIONS FOR WATER WORKStitle: SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

tender: project: document: W-I-SS-008 rev: 0 sheet: 1 of: 32

SPECIFICATION FOR

INSTRUMENTATION & CONTROL

SYSTEMS INSTALLATIONS

Client ADWEAProject: STANDARD SPECIFICATIONS FOR WATER WORKSTitle: SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS


Table of Contents page

1. SCOPE...................................................................................................4

2. STANDARDS & CODES .......................................................................4

3. SITE CONDITIONS................................................................................4

4. DRAWINGS & DOCUMENTS................................................................54.1 Piping and Instrument Diagram ...................................................54.2 Instrument Index List ...................................................................54.3 Instrument Schedule....................................................................54.4 Panel Layouts..............................................................................64.5 Technical Submittals and Filled-in Data Sheets ..........................64.6 Loop Diagrams ............................................................................64.7 Logic Diagrams............................................................................64.8 Circuit Diagrams ..........................................................................64.9 Wiring Terminal Layout................................................................64.10 Instrument Process Connection & Hook-up Details.....................74.11 List of Instrument Setting.............................................................74.12 Drawing List.................................................................................74.13 Nameplate List.............................................................................74.14 Instrument Installation Drawings..................................................74.15 Instrument Cable Schedule .........................................................74.16 Instrument Location and Cable Layouts ......................................74.17 Instruction Manuals .....................................................................74.18 Maintenance Manual ...................................................................84.19 Cause & Effect Schedule.............................................................84.20 I/O Lists .......................................................................................84.21 Alarm and Trip List ......................................................................84.22 Screen Display Drawings.............................................................84.23 Functional Specification Document .............................................84.24 Spare Parts Lists .........................................................................84.25 Control Philosophy Documents ...................................................84.26 PLC Logic Software.....................................................................94.27 Method Statements and Test Procedures ...................................9

5. GENERAL REQUIREMENTS................................................................95.1 Workmanship...............................................................................95.2 Storage and Protection of Equipment..........................................95.3 Installation Instructions ..............................................................105.4 Coordination of Work.................................................................115.5 Clean Working Areas.................................................................11

6. CONSTRUCTION SPECIFICATION....................................................126.1 Field Instrumentation .................................................................126.2 Instrument Cabling ....................................................................166.3 Fiber Optic Cables.....................................................................19



7. INSTRUMENT CABINETS AND PANELS ..........................................247.1 System/Remote I/O Cabinets ....................................................257.2 Field Mounted Panels................................................................257.3 Remote Area Enclosures...........................................................26

8. IDENTIFICATIONS ..............................................................................268.1 Labelling and Name Plates........................................................268.2 Tag Numbers.............................................................................26

9. INSPECTION AND FUNCTIONAL TESTING......................................279.1 Quality Plan ...............................................................................279.2 Field Instrumentation .................................................................289.3 Instrument Calibration ...............................................................289.4 Calibration Guidelines ...............................................................289.5 Field Inspection .........................................................................299.6 Loop Testing..............................................................................31

10. COMMISSIONING AND START-UP....................................................32

11. SITE ACCEPTANCE TEST .................................................................32



1. SCOPE

This Specification covers the general requirements for the handling and installation of controlsystem and instrumentation equipment as laid down in the design, drawings, technicalspecification, bill of quantities and all the other related documents. Handling includes storing,protecting, transporting, etc. required for the installation of the equipment. Installationincludes the physical mounting, process connection, instrument air routing and connections,and cable routing and terminations, as required, to produce a complete functionalinstrumentation and control system as defined in the project drawings and documents.

2. STANDARDS & CODES

Equipment, materials and services provided for this project must comply with all applicablelocal and national codes, standards, regulations and the like. The CONTRACTOR shalldetermine what codes, standards etc. apply to items within the scope of this specification.

Specific applicable industry codes and standards to be used, are indicated in projectspecifications.

Compliance with the applicable portions of all project specifications shall be the responsibilityof the Contractor.

Any conflicts between the referenced documents shall be identified to ADWEA/ENGINEER inwriting for resolution.

CONTRACTOR shall refer to all project-related drawings and documents to carry out thestated activities.

3. SITE CONDITIONS

a) The site location of this project has a dust laden atmosphere. The temperature at nightdrops considerably, resulting in condensation. These conditions attack instrumentationelectric terminals, contacts, etc. for which the CONTRACTOR must design protectivemeasures. Any instrumentation not in an air conditioned atmosphere shall be suppliedwith waterproof, dust tight enclosures. In addition, local instrument cabinets shall also beweatherproof and equipped with space heaters.

b) It is the CONTRACTOR's responsibility to design, furnish and install the instruments andcontrol equipment to withstand and operate properly under the prevailing ambientconditions described in the project General Technical Requirements of this Contract.This Specification serves as a guideline to the CONTRACTOR. The CONTRACTORshall make recommendations and include all the necessary equipment or protectingdevices based on his previous experience on similar installations.

c) All transmitters, electric/pneumatic converters, switches and other electrical deviceswhich provide input signals to control systems must be housed in waterproof, insulated,dust-tight and heated (as required) local instrument cabinets to protect against corrosion,humidity and condensation. Sun shades shall also be provided and designed to protectcabinets from direct rays of the sun.



d) Special precautions shall be taken in the selection of materials and the design ofenclosures to prevent failure and deterioration of mechanical and electrical componentsdue to the prevailing humidity, high temperature and very corrosive atmosphere. As aminimum, all equipment mounted in control rooms shall be suitable for operation at 45ºC.Field mounted equipment shall be suitable for operation upto 52ºC and shall be providedwith sun shields.

e) The CONTRACTOR shall furnish, design and install all equipment in accordance withthe requirements of the National Electrical Code. Special care shall be taken in areasclassified as hazardous, such as areas near the flammables.

4. DRAWINGS & DOCUMENTS

The CONTRACTOR shall prepare and submit all the required drawings and documents forthe instruments and control systems in hard copies and in soft copies (if required byADWEA/ENGINEER).

All drawings and documents shall be subject to approval of the ADWEA/ENGINEER, andshall be appropriately detailed and properly described in the English language.

The set of instrumentation drawings and documents as well as instrumentation of packageunits shall include, but not be limited to the following:

4.1 Piping and Instrument Diagram

All instrumentation systems for measurement and control required for the project shall beshown on the Piping and Instrument Diagram (P&ID). All the basic functions of theinstrumentation and control systems shall be shown.

The symbols and identification numbers to be used for the graphical representation andidentification of instruments shall be in accordance with ISA S5.1, or the latest standard.

4.2 Instrument Index List

This list shall show all instrument tag numbers, description, location, service and remarks.

4.3 Instrument Schedule

This list shall show all instrument tag numbers, drawing number on which the instrument isshown, location, description of the instrument, manufacturer name, model type, power supplytype, adjusted range, set point operate range, material wetted parts. Process connection,field hook-up drawing and references of specification of instrument.



4.4 Panel Layouts

These drawings shall show the inside and outside layout (to scale) of panels with instrumentsin outline dimensions, the indication of the tag numbers for each instrument, the numberingand main dimensions of panel sections and complete panel.

The same requirements apply for the drawings of any auxiliary panel.

4.5 Technical Submittals and Filled-in Data Sheets

Technical Submittals shall be prepared for all components of instrumentation systems.Separate data sheets shall be filled-in for different type of instrument. All relevant process,construction and engineering data materials shall be incorporated on these data sheets.

The technical submittals shall be provided with an index. The CONTRACTOR shall issuedocumentation of the selected equipment with the respective specifications to theADWEA/ENGINEER in the approval stage in accordance with the requirements indicated inthe General Technical Requirements.

4.6 Loop Diagrams

For each instrumentation system a loop diagram shall be prepared. This diagram shall showall components in one loop with their tag numbers, terminal strip numbers, cable numbers,relevant engineering data and connection to the instrument electrical supply system. Thedrawings shall clearly show the function of the various components.

The location of components shall be clearly indicated, e.g. in areas for panel, back of panel,field, etc.

4.7 Logic Diagrams

For systems, such as interlocking systems, shutdown systems, emergency systems, etc.,logic diagrams shall be prepared.

The logic diagram symbols shall be in accordance with IEC 60117-15.

4.8 Circuit Diagrams

Circuit diagrams shall be made of electrical circuits and shall be in accordance with IEC60117 and IEC 60113. All components such as switches, relays, timers, lamps etc. shall beprovided with a tag number. The location of components shall be clearly indicated, e.g. forelectrical panel, instrument panel, field, etc.

4.9 Wiring Terminal Layout

CONTRACTOR shall supply wiring terminal layout blocks with their tag nos. wire numberswith their incoming and outgoing destinations.



4.10 Instrument Process Connection & Hook-up Details

Instrument process connections and hook-up material, take-off, thread, rating, standards etc.shall be shown on typical drawings common for particular type of instrument and shall beused at site by the CONTRACTOR. These typicals shall be accompanied by the list ofauxiliary materials such as tubing for instrument piping, connectors, unions, valves, etc. Bothdrawings and material specifications are subject of ADWEA/ENGINEER approval.

4.11 List of Instrument Setting

This list shall show tag number, instrument range, switch point at required conditions, theequivalent setting of the relevant instrument, etc. This list shall be made before start-up of theinstallation subject to ADWEA/ENGINEER approval.

4.12 Drawing List

The CONTRACTOR shall prepare a drawing list, on which each drawing sheet is separatelymentioned. The drawing list shall be combined with the drawing status report (monthlydrawing schedule).

4.13 Nameplate List

This list shall show all nameplate inscriptions and dimensions including type of fixing,location, letter size, format, etc.

4.14 Instrument Installation Drawings

These drawings shall show, the instruments fixing brackets, stands, enclosures, shades, etc.materials, details of fixing, location etc.

4.15 Instrument Cable Schedule

This schedule shall show cable No., from, to, cores, sizes, type of cable, type of installationremarks etc.

4.16 Instrument Location and Cable Layouts

These drawings shall show approximately location of instruments, cable routing and cablenumbers in detail.

4.17 Instruction Manuals

CONTRACTOR shall furnish all Instruction Manual covering all instruments and controlsystems as shipped. Revised manual pages shall be provided to show all changes made inthe field by CONTRACTOR's Service engineer. The Instruction Manuals shall be furnished inaccordance with the Project General Technical Requirements.



4.18 Maintenance Manual

CONTRACTOR shall supply a complete set of maintenance manual covering allinstrumentation and control systems.

4.19 Cause & Effect Schedule

Contractor shall submit a complete sets of all pumping station systems, protections andcontrol function in a form of cause and effect schedule.

4.20 I/O Lists

Contractor shall submit a complete sets of input/output signals, digital and analogue whichshall be used by the control system showing tag numbers, description, type of signal, racknumber, addresses, panel numbers, slot, card, channel … etc.

4.21 Alarm and Trip List

This list shall show all instruments tag numbers, description and type of indication(Alarm/Trip), stet point operation. ON/OFF delay time (if required).

4.22 Screen Display Drawings

These drawing shall show, the format of all the required HMI screens as per contractspecification.

The symbols and colours shall be as ADWEA standard and requirement.

4.23 Functional Specification Document

This document shall cover the explanations of all subject related to HMI screens includingequipment status, system control, display items, alarming, real time and historical trending,system security, mimics, reports etc.

4.24 Spare Parts Lists

These documents shall cover all spare parts in relation to the instrumentation and the controlsystems.

4.25 Control Philosophy Documents

These documents shall explain the control/protection and operation philosophy of all mainand sub-systems, stating clearly if there are any deviations from the Contract Documents.

The Contractor shall also explain his fall back strategy in case of SCADA Control Systemfailure.



4.26 PLC Logic Software

The PLC Logic Software shall be submitted in ladder language program in hard copy and softcopy format. The Contractor shall provide the PLC programming software toADWEA/ENGINEER for easy checking of the submitted program.

4.27 Method Statements and Test Procedures

The Contractor shall furnish all method statements and test procedures, subject toADWEA/ENGINEER approval, before installation and testing of all project devices andequipment of the project, according to the Contract Specifications.

5. GENERAL REQUIREMENTS

5.1 Workmanship

Instrumentation and control systems installation work (the work) shall be performed incompliance with all contract documents, project specifications and drawings, and goodconstruction practices.

The work shall be performed, with good workmanship, by qualified personnel in compliancewith established safety regulations. All work shall be performed using only the correct toolsfor the purpose.

The work shall be performed so that the safety, integrity and quality of all systems areassured, including overall appearance and aesthetics.

Defective work or works which does not conform to the contract documents, shall becorrected at the CONTRACTOR'S expense.

Work in hazardous areas shall be carried out in accordance with the applicable regulationsand safety procedures.

Tie-ins to the existing facilities will be thoroughly reviewed with ADWEA/ENGINEER. Criticalcircuitry tie-ins will be subject to ADWEA's approval.

5.2 Storage and Protection of Equipment

Control Systems and instrumentation shall be properly stored and protected from damage atall times. Storage and protection shall be in compliance with manufacturers'recommendations and this specification, unless stated otherwise by ADWEA/ENGINEER inwriting. Precautions for proper storage and protection shall include, but are not limited to, thefollowing.

a. Storage shall be inside a clean dry building or enclosed shelter, unless material can bestored outdoors without suffering damage.

b. All equipment shall be stored in enclosed and environmentally controlled locationswherever recommended by the manufacturer.



c. Valves with electronic instruments shall be stored indoors. Valves without electronicinstruments may be stored outside on platforms or blocks at least 150mm above gradeand covered with tarpaulins to protect them from the weather. Valves shall be stroked(operated) periodically in accordance with manufacturer's instructions.

d. Ends of cable and air connections shall be completely sealed to prevent entry ofmoisture.

e. All batteries shall be stored indoors in a dry environment. Batteries shall be visuallyinspected for cracks when they are received at the site. Batteries with crack damageshall not be installed. Batteries shall be covered or protected by other means to preventaccidental short circuits across terminals.

f. All electronic instruments and panels containing electronic instruments shall be stored inan enclosed and environmentally controlled location.

g. Protective finishes that have sustained damage during storage or installation shall beproperly repaired. The material used and method of application shall be compatible withthe original equipment manufacturer's finish.

5.3 Installation Instructions

Each instrument equipment shall be provided with a three-ply phenolic nameplate(white/black/white) showing its identity and service. This nameplate shall be supplied andmounted by the CONTRACTOR unless otherwise supplied.

Any proposal to deviate from the recommended installation methods, or from the projectengineering documents and drawings shall be submitted to ADWEA/ENGINEER for approval.The approved documentation and procedures of the project shall be used, as reference, toauthorize all such changes.

The CONTRACTOR shall verify the exact locations for cable trays, panels, boxes, fixtures,pipes, branches, fittings, supports, etc., and shall be responsible to avoid interferences witheach other and also with existing equipments/piping.

The CONTRACTOR shall install any and all supplementary supports, brackets, hangers, etc.,(in addition to those shown on the contract drawings) as required to complete the installation.

Supports, brackets, hangers, etc., for equipment and materials shall be installed so as not toweaken the structure to which they are to be attached.

Fastening hardware (bolts, nuts, screws, washers) shall be stainless steel. Supports forinstrument pipe, conduit and equipment shall be hot-dipped galvanised steel.

Conduits, fittings and angle shall have all burrs and foreign materials removed beforeinstallation.

All unused conduit entries in fittings, junction boxes and equipment shall be plugged usingmanufactured threaded plugs or caps.



Indoor circuit breakers shall be provided with a typed circuit directory sheet that correctly liststhe circuit associated with each circuit breaker.

Instruments and equipment shall be installed in conformance with manufacturer's instructions.

Interface wiring to electrical equipment shall be connected in accordance with contractdocuments and manufacturer's instructions.

Doors on panels shall be kept closed and locked except when erection of the equipmentrequires them to be open, or when access is required to work/inspect panel internals.

Equipment enclosures, panels and cubicles shall be levelled by shimming before bolting tothe prepared foundations.

Travel and shipping stops shall be removed prior to the installation of an instrument.

Cable and air entries of all equipment shall be made weathertight as soon as they aremounted in the field.

Vents open to atmosphere shall be protected against ingress of foreign matter. Unprotectedopenings should have a gooseneck or equivalent to protect against falling particles. Unlessfurnished by the equipment supplier, the CONTRACTOR shall install an austenitic stainlesssteel bug screen in instrument air vents and breather ports.

5.4 Coordination of Work

The CONTRACTOR shall be responsible to check other discipline drawings for coordinationto eliminate conflicts prior to installation of materials or equipment. Failure to perform thischeck will imply that the CONTRACTOR bear all relocation costs, including labour, equipmentand material, at no cost to ADWEA. All conflicts with other disciplines shall be brought to theattention of the ADWEA/ENGINEER for authorisation to change or modify location ofinstrument/ equipments.

5.5 Clean Working Areas

Working areas shall be kept clean and free of debris to the maximum extent possible.Working areas shall be cleaned on a daily basis.

Sand and dust ingress shall be kept to a minimum, especially during cable pulling.

Computer floor tiles shall be removed only from those areas where access for installation andcable routing is necessary.



6. CONSTRUCTION SPECIFICATION

6.1 Field Instrumentation

6.1.1 Instrument Mounting and Hook-Ups

The installations shall be designed in such a way that all instruments, their measuring pointand their process connections are safely and permanently accessible.

All instruments shall be installed, unless otherwise stated, so that they:

a) are not subject to excessive vibration or to mechanical stress and not exposed toextreme high temperatures and direct sun radiation.

b) can be easily read.

c) can be easily mounted and removed.

d) provide a accurate representative measurement of the process condition (IP rating).

e) are sufficient weatherproofed (IP rating).

For pipelines the branch nipple and isolating valve shall form part of the process piping andshall comply fully with the relevant piping specifications.

Instrument piping starts at the first detachable connection (screw thread or flange)downstream of the 1st isolation valve, except for connections installed in control valves anddisplacement chambers for level instruments, if applicable.

All instrument process connections for instrumentation shall be provided with valves withstraight through trim to allow rodding out of plugged connections. Type and material ofinstrument valves shall be ball or gate valve and AISI 316 respectively.

Process connections on the surge vessel shall be made by means of 1" flanged brancheswith minimum ratings ASA 300 lbs, depending on the standards which are applied; stiffenedwhen necessary for strength, branches shall be fitted with isolating valves for the connectionof instrument piping. Different connections may be allowed to suit level instruments provided,but require specified ADWEA/ENGINEER's approval.

Welding is not allowed on instrument piping and connections.

The process connection shall normally terminate in a DN 15 lapped joint flange unless othersizes are dictated by the size of connections on the connections on the instrument.

Size and material of instrument piping shall be ½" and stainless steel AISI 316L/Ti.

All pressure instruments shall be installed at the pressure source with a block valve and avent to facilitate zero checking and to enable the system to be depressurised prior to removalof the instrument. When the pressure instrument is located at a distance from the process



connection, an additional block valve and a vent valve shall be placed adjacent to theinstrument.

For ease of removal of alignment, pressure gauges shall be screwed into unions and notdirectly into valves or sockets.

Pressure piping to instrument shall be such that under no circumstances vapour locks or trapsformed, and that piping is completely "full of liquid".

Pressure gauges on pump suction and discharge lines shall be easily visible from the relevantpump starter switch as well as from the suction and discharge valves, the gauges shouldpreferably be installed close to the discharge valves.

When measuring pulsating pressure, suitable dampening methods shall be provided(dampening devices in the process connection etc.).

Where pressure gauges are installed on liquid measurement, allowance must be made for thestatic head in the instrument line.

Pressure transmitters shall be suitable for field mounting and be connected with the processvia block and bleed valves.

Magnetic flow elements shall be mounted strictly according to the manufacturer's instruction.The flow meter must be oriented with the electrodes in a horizontal line. Precautions must betaken to ensure that the metering tube is filled at all times during measurement. The sensorshould be mounted away from turbulence – generation components (e.g. valves, elbows, t-sections) whenever possible so that the upstream distance shall be min. (5 to 10) X pipe dia.and the downstream distance shall be min (2 to 5) X pipe dia.

In case of using a remote transmitter unit then the cable type and length shall be according toVendor recommendations and specifications.

Magnetic flowmeters and their converter shall be protected against direct sun radiation.

Level gauges shall be installed with a shut-off valve in both the top and bottom processconnections.

The float for the level switches shall be mounted in an external float chamber which shall beinstalled with a shut-off valve in both the top and bottom process connection.

All liquid level instruments shall be provided with drain valves and vent valves.

The ADWEA/ENGINEER reserves the right to direct the removal and replacement of anywork which, in his opinion, does not present an orderly or reasonably neat workmanlikeappearance, provided that such work can be properly installed in an orderly way by usualmethods. Such removal and replacement shall be carried out solely at the CONTRACTOR'sexpense.



Instruments shall not be installed until heavy construction work adjacent to instruments hasbeen completed to an extent that there can be no damage to the instrument installation bythis construction work. After installation suitable guards for the protection of panels, localinstruments and enclosures shall be provided to prevent damage during other constructionactivities.

6.1.2 Instrument Locations

CONTRACTOR shall verify the location of each field instrument prior to installation using, asa reference, instrument location plans and installation details.

Instruments shall be installed in accordance with the approved project instrument installationdetails.

Instruments shall be orientated so that the display faces the direct access approach to theequipment with which they are associated.

Instruments shall be located with due regard to maintenance activities, vents, drains andfilling points to minimise the impingement of process fluids on housings and cables.

Care shall be taken to ensure that no passage ways or access to other plant equipment,electrical panels, other instruments etc., are obstructed.

Indicating instruments shall be orientated to permit viewing from walkways or platforms.Instruments shall generally be accessible for adjustment or maintenance without the use ofladders.

Each instrument shall be provided with a support as detailed in the approved hook-updiagrams.

No instrument support shall be welded to a vessel, pipe or any other equipment.

No instrument shall be installed so that it depends for support or rigidity on the impulse pipingor electrical connection to it.

Instruments shall not be supported from process piping, unless specifically shown ondrawings.

Handrails shall not be used for mounting or supporting instruments, nor shall any instrumentor support be located within 150mm of the top handrail.

Local mounted instruments shall be bracketed or sub-panel mounted on the neareststeelwork or masonry, or on a piping stand.

All instrument locations shall be finalised in consultation with ADWEA/ENGINEER and priorapproval obtained.



6.1.3 Instrument Process Tubing

All impulse lines shall be run with a slope of not less than 1:12 except where otherwise stated.The slope shall be down from the tapping point for liquid and condensibles, and up from thetapping point for gases.

The CONTRACTOR shall ensure that vents are sited at the highest point of the installationand drains at the lowest.

Impulse lines shall be kept as short as possible consistent with good construction practiceand accessibility and the number of joints in the impulse lines shall be kept to a minimum.

Joints made in adjoining tubing shall be such that the joints are not adjacent at the samelevel.

All screwed connections shall be sealed off with a sealing compound compatible with the fluidwithin the tubing. PTFE tape shall not be used.

Tubing shall not sag. Adequate support shall be provided at 1 m intervals. Thermallyinsulating spacer shall be supplied to separate the tubing from the supports.

Tubing shall run with a minimum number of changes of direction consistent with good practiceand neat appearance.

Tubing shall not be supported from handrails.

Tubing shall not be supported from process lines.

Due regard shall be given to hot service installation that is subject to expansion, to ensurethat sufficient flexibility is allowed for expansion.

Where stainless steel tubing with compression fittings is installed, CONTRACTOR shallensure that the correct procedures, as specified by the fittings manufacturer, are followed.This shall include, but not be limited to, the following:

- Proper cutting of the tube. Only approved cutting tools shall be used.

- Proper installation of the ferrules.

- Checking that the tube is round and free from burrs and distortions.

6.1.4 Piping and Tubing Supports

Piping and tubing shall be kept free from vibrating structures or equipment.

Trays shall be used to support four or more tubes. The tubes shall be secured to the tray atnot more than 0.5 metre intervals.



6.2 Instrument Cabling

Field runs are classified as follows: -

Main Runs

Main runs are cables, (multicores, pairs or triads) that run between control room and fieldjunction boxes, local panels or instruments.

Local Runs

Local runs are cables, (pairs or triads) that run between instruments and junction boxes orlocal panels.

6.2.1 Installation Methods

Cables run between the control room and the field junction boxes, local panels etc, shall berouted as per approved project drawings and specifications.

Multicore cables shall be terminated at suitably positioned junction boxes and connections tofield instruments completed by individual cables routed overhead on cable ladder rack and/orcable tray.

Instrument cables shall be routed separately from electrical power and lighting cables. Thephysical separation of signal and power cables on parallel runs shall not be less than thatshown below.

Minimum Separation – Instrument Cables and Power Cables

125V or 10A - 500mm

50V or 50A - 600mm

440V or 200A - 750mm

5kV or 500A - 1250mm

11/33kV or 800A - 2000mm

Cross overs that bring power and signal cables into close proximity shall be made at rightangles, with a minimum separation distance of 300 mm.

The above may be relaxed on entries to instruments and panels.

Instrument cables carrying more than 10 Amps shall be treated as power cables.

All instrument cables may be combined in the same tray/ladder but cables of a particularcategory/functionality shall be bundled together such that the maximum separation can beachieved between high level signal wiring and low level signal wiring.



6.2.2 Overhead Cable Tray and Ladder Racking

Ladder/tray bends shall conform and comply with the minimum bending radius recommendedby the cable manufacturer.

Proprietary earth bonding straps shall be installed at all joints of ladder rack/cable traysystems.

The tray shall be of adequate width, perforated with turned edges for extra strength.

Site fabrication bends may be used, for nonstandard bends, the support fixing shall be eitherside of the bend or in the centre. The bend shall conform and comply with the minimumbending radius recommended by the cable tray manufacturer.

Tray shall be supported at not more than 1m distances unless supported by a mild steel anglesection racking. Supports shall be welded to steelwork, prior to painting. No Instrument/ Traysupports shall be welded to vessels or pipework.

Tray shall be fixed with Galvanised nuts, bolts etc.

Individual cable runs near to terminal point e.g. an instrument, may be run in MS anglesection only, No conduit shall be used.

All support steelwork shall be painted prior to cables being installed. Painting shall be as perADWEA Specifications.

All cable trays shall be located to avoid obstructions.

With the exception of pre-wired package units; routing and fixing of all trays, angles, shall bedetermined on-site by the CONTRACTOR, subject to approval by ADWEA.

6.2.3 Cable Fixing

Cables shall be fixed by performed saddles or by PVC covered stainless steel strapping.Strapping shall not support more than 12 single pair cables, or 5 multipair cables dependingon their overall size.

Cable fixing shall not be more than 250mm apart on vertical run tray and 500mm onhorizontal run cable tray/ladder.

6.2.4 Cable Transits

Where cables enter buildings which require positive sealing against fire, positive pressures,moisture or gas ingress, then a cable sealing system of approved multicable transits shall beused.

Cables shall be tagged/numbered at both sides of the sealing system.



6.2.5 Cable Sheath Identification

All local run cables shall be identified with cable marker at each end i.e., instrument andjunction box, or Junction box and Marshalling cabinet end (control room).

All signal conductors should be individually marked on each termination side with thecorresponding terminal number.

All cables shall be marked with embossed S. S. Strips attached with PVC covered S.S.bands.

6.2.6 Terminal and Core Identification

Instruments

Signal cable cores to be identified by the terminal number to which they connect.

Junction Box

Signal cable cores to be identified by the terminal number of the Junction box terminal.

Cable Connections in Cabinet

Individual cores shall be identified, adjacent to each terminal to which it is connected. Corenumbers shall be the terminal number to which they are connected.

6.2.7 Earthing

Screen Earthing

Cable screens shall be earthed at one point only and connected to the instrument earth. Thispoint shall be at the marshalling cabinet.

Cable screens shall be electrically continuous throughout the cable run. Screen shall beisolated from earth at the field instrument and junction box ends.

Armour Earthing

Armoured cables shall have their steel wire armour (SWA) earthed (i.e. connected to safetyearth) at both ends of the cable run. Cable glands shall also be connected to plant earth(safety earth).

Equipment Earthing

Marshalling cabinet and field junction box frames shall be earthed to the nearest safety earthbar using a 4.0mm2 stranded green/yellow insulated copper conductor.



6.2.8 Cable Glanding

Cable glands shall be applied at all places where electrical signal cables enter the housings ofinstruments and junction boxes.

All cable glands shall be of stainless steel and of the type which provide an armour clamp, asper BS 6121 or equivalent.

The gland thread form shall match the equipment threaded cable entries directly without theuse of adaptors wherever possible. Cable entries shall be ISO thread form whereverpossible.

All glands shall be protected by the use of PVC shrouds and silicon grease (Type M54).

All cable installation shall be designed to prevent any ingress of moisture. Bottom glandentries to instrument and junction boxes shall be used wherever possible. Where this is notpossible, e.g. side entries to junction boxes then cables shall be looped downwards, ('U'shaped loop to be used).

P.C.P sealing washers shall be used on all field gland entries except those with a taperedthread.

Sufficient slack cable shall be left at junction boxes, instruments and individual core terminalsto allow for remaking connections.

6.2.9 Wire Terminations

Crimped ferrules shall be used for stranded conductors.

Sufficient slack cable shall be left neatly at the terminals to allow for the remarking ofterminations, additions and testing.

All spare cores within multicore cables shall be terminated in terminals at field junction boxes,local panels and termination cabinets within the cable entry room.

6.2.10 Junction Box Mounting

Junction boxes, wherever possible, will be grouped into a common area, mounted onto aframe referred to as a "JB Frame".

6.3 Fiber Optic Cables

6.3.1 Pre-installation testing

Pre-installation testing shall be performed on a reel of fiber optic cable after it is received fromthe supplier and before it is installed on the job site. The pre-installation testing shall verify :

• Cable has not been damaged during shipment.

• Cable contains no factory defects.



• Attenuation of the fiber matches the factory test results, shipped with each reel of cable.

If a defect is found during the pre-installation testing, replacement shall be initiatedimmediately.

Pre-installation testing can be performed with a fiber optic flashlight, a light source and powermeter or an optical time domain reflectometer (OTDR).

A fiber optic cable on a spool or reel shall be ordered wound so that both ends of the cableare accessible for testing.

To use a light source and power meter, connectors, reusable mechanical splices, or bare fiberadapters shall be installed on each end of every fiber strand. The measurement results usingbare fiber adapters are less accurate than when employing standard connectors, but areadequate for this purpose.

Pre-installation testing utilising an OTDR requires access to only one end of the cable.Typically, a pigtail is temporarily spliced to each fiber strand. A pigtail is a length of fiber whichhas a connector on one end and no connector on the other end. The pigtail is connected tothe OTDR and measurements taken. An OTDR can measure the following:

• End-to-end attenuation. This should be compared to the test report on the reel and anydifferences reported.

• Distance to a point of high attenuation. This could be a defect in the fiber strand or itcould be the end of the cable. An example of the need for this form of testing would beto identify the location where a forklift damaged a cable during shipment. The OTDR willshow the distance from the beginning of the reel to the damaged area in either feet ormeters. The footage markers on the cable sheath can be used to assist in locating thedamaged section.

6.3.2 Fiber Optic Cable Installation

All work shall be carried out in accordance with the highest standards of craftsmanship in thecommunication industry.

The project site shall be surveyed to establish the exact cable routing and cutting lengths priorto the commencement of any work or commitment of any materials.

When ordering fiber optic cable, extreme caution to be exercised to ensure that no additionalsplicing will be required. Splicing is allowed for the programmed connection of reels only.

All work areas shall be made clean and orderly at the completion of work and at timesrequired by Purchaser during process of work.



6.3.3 Cable Placement

Fiber optic cables shall be installed in continuous lengths without intermediate splicesthroughout the project, except at the location(s) specified on the construction plans. Thecable installation personnel shall be familiar with the cable manufacturer's recommendedprocedures including but not limited to the following :

• Proper attachment to the cable strength elements for pulling during installation.

• Cable tensile limitations and the tension monitoring procedure.

• Cable bending radius limitations.

Equipment Requirements :

• Standard plowing equipment may be used. However, modifications may be required toconform to the cable manufacturer's specifications.

• The equipment shall be large enough to perform the task.

• A Dynamometer shall be used for measuring cable tension.

• The cable feed system shall comprise of a reel carrier, rollers or guide tubes, and a cablechute which must allow the cable to be placed while following the manufacturer's productspecifications for tension and minimum bend radius. The cable chute shall have aremovable gate to allow the cable to be inserted or removed at intermediate points.

• The reel carrier shall accommodate one or more reels of adequate size and shall ensureeasy and safe loading and unloading.

• When required the cable shall be buried at least one (1) meter deep or in accordancewith local zoning regulations.

At locations to be designated, selected lengths of fiber optic cable shall be coiled andsecured with tie raps to racking hardware. The minimum bending radius of the fiber opticcable shall not be compromised when preparing this stored cable slack. Slack isrequired in case of emergency splicing needs.

When power equipment is used to install the fiber optic cables, low speeds shall beused, not to exceed 30 meters per minute. The tensile and bending limitation for fiberoptic cables shall not be exceeded under any circumstances.



6.3.4 Cable Splicing

The following are minimum requirements for splicing and connecting of the specified fiberoptic cables.

a) All required brackets and other racking hardware required shall be provided for the fiberoptic cable racking operations as specified.

b) All splicing equipment shall be in good working order, properly calibrated, and meet allindustry standards and safety regulations. Cable preparation, closure installation andsplicing shall be accomplished in accordance with respective manufacturer's procedure.

c) Upon completion of the splicing operation, all waste material shall be deposited incontainers, removed from the job site, and disposed of in an environmentally acceptablemanner. Determination for appropriate disposal of waste material shall be at thediscretion of the Purchaser.

d) Contractor shall use the fusion method for all fiber optic splicing.

e) The average splice loss of each fiber shall be 0.15 dB or less. The average splice loss isdefined as the summation of the attenuation as measured in both directions through thefusion splice, divided in half.

f) No individual splice loss measured in a single direction shall exceed 0.25 dB.

g) Splices shall be contained in a splice joint box designed for use on fiber optic cables.

6.3.5 Cable Termination

Optical fibers shall be terminated by means of a fusion splice connection to a factoryconnectorized pigtail. Pigtail terminations shall be accomplished in accordance with thedesign drawings.

Cable armour shall be grounded/bonded in accordance with EIA/TIA 607.

6.3.6 Optical Link Testing and Acceptance

An advanced notification of fourteen (14) working days of any test shall be provided. All testsshall be witnessed. Upon completion of the fiber optic cable installation (and splicing) thefollowing tests shall be performed and documented:

• Verify and record the total attenuation of all passive components in the link and ensure itis within the design parameters.

• Verify and record the passive components were installed properly.

• Establish accountability when circuits are configured with multiple links connectedtogether, including links installed by others.

• Provide a benchmark for comparing future measurements.



A recording OTDR shall be utilised to test for end-to-end continuity and attenuation of eachoptical fiber link. The OTDR shall be equipped with an 850 nm and 1330 nm light source formulti mode optical fibers. The OTDR shall have an X-Y plotter to provide a hard copy recordof each test measurement. The OTDR shall be calibrated with sufficient internal masking toallow the entire cable section to be tested. This shall be accomplished by using an OTDRwith sufficient normalisation to display the required cable section.

An insertion loss test shall be performed using an 850 nm and a 1300 nm stabilised lightsource, with an 850 nm and 1300 nm optical power meter. This transmission testing shall beconducted end to end on each optical fiber.

Attenuation tests shall be performed through the fiber interface equipment, connectors, andpigtails, and shall demonstrate that the fiber links are in compliance with the optical linkperformance as indicated herein and on the drawings.

Optical fibers connectors and jumpers shall be measured at the fiber optic termination panel,in accordance with the tests defined in FOTP-34.

The test results of each measurement shall be recorded on the "Fiber Optic Link AttenuationRecord." The record shall show test date, OTDR model no. and serial number, OTDRdistance, wavelength, splice location (point), sheath distance and name of technician whoperform the test. All test documentation shall be assembled into loose leaf binder(s). One (1)original set and two (2) copies of said test documentation shall be submitted:

a. End-to-End Attenuation Data sheet. This form shall record OTDR traces of each opticalfiber.

b. Optical Link Attenuation Data sheet. This form shall document the results of the bi-directional insertion loss test.

c. Connector Loss Data Sheet. This form shall record each connector dB loss, fibernumber, unit I.D. and fiber colour.

d. Splice Loss Data Sheet. This form shall record each splice loss.

Submittal and approval of the test documentation is required prior to acceptance of the Work.

6.3.7 Site Installation & Testing

The Supplier shall carry out all required cable fiber splicing, performance testing and furtherservices to achieve a properly documented and operational cable network.



7. INSTRUMENT CABINETS AND PANELS

CONTRACTOR shall supply and install all required cabinets and panels. The quantity ofcabinets and panels shall be determined by the CONTRACTOR. 20% spare space for futureexpansion shall be available in these cabinets and panels.

The cabinets shall be accessible from two sides and shall be approximately 2100 mm high,1200 mm wide and 600 mm, deep the two opening doors at both sides shall be turnable over180°. It shall be possible to lift the doors up and off their hinges to allow easy removal of thedoors.

Cabinets and panels shall be completely wired to the terminals, requiring only connections tothe external wiring circuits at site.

The cabinets shall be shop tested.

The cabinets shall be adequately ventilated through natural circulation in order that the heatgenerated by the equipment mounted there shall remain within the rated temperature limit,should mechanical ventilation be used, it should be an addition to the free cooling and not tobring the working temperature to the acceptable limits, the IP rating shall be to IP 54.

Extra electrical sockets for test and repair purposes shall be provided in the control panel andcabinets. These sockets shall be according to British Standards suitable for flat and roundpins, instrument cabinets and panels shall also equipped with space heaters.

The door shall have separate handle and locks. Each lock shall be provided with 2 keys.Internal fluorescent type illumination shall be provided for every cabinet. Door switches shallbe provided to switch off the illumination.

Internal wiring shall be adequately sized for the required voltages and currents. Cable ductsshall be provided with at least 30% spare capacity after complete wiring. Separate ductingshall be provided for the wires carrying different voltages.

Safety earth connection shall be provided for every cabinet. 2 tinned copper earth-bars forsignal earth connection shall be provided one of them shall be isolated from cabinet frame,another earth bar shall be used for safety earth. They shall be wired to separate earth-pits byContractor.

Panels shall be provided with two copper earth bars of minimum dimensions 6*25*100 mm.

The cabinets shall be fabricated of cold rolled sheet-steel and shall be rigid and stable theminimum thickness of the ground plate shall be 5 mm, for doors and other plates a minimumthickness of 2 mm.

The cabinets shall be of high standards quality in terms of visual appearance, colour, finish,smoothness of surface, etc.

Materials for nameplates shall be selected in accordance with the weather data and areaconditions and shall be of the non-metallic type, with black inscriptions on white background.



All cabling, tubing and terminal boxes shall be marked clearly in a consistent manner withdurable markers.

Terminals in the cabinets shall be numbered consecutively in accordance with the relevantcable connection diagrams.

All the cores of the field cables shall be terminated on the terminal strip. All the spare I/Ochannels shall also be terminated on the terminal strip. 25% spare capacity shall be providedin the panel after complete wiring for future additions.

Use shall be made of exclusively new and modern materials suitable for the intendedpurpose.

Only first class modern trade practices shall be used and all work shall be carried out to thesatisfaction of the ADWEA/ENGINEER.

Wiring to equipment mounted on hinged doors shall be carried out through flexible conduits orspiral wrap.

Wiring terminal block shall be arranged and positioned to afford easy access for carrying outexternal cabling, testing, inspection and maintenance. All internal wiring to be ferruled at bothends.

Provision shall be made for bottom entry cables and suitable removable gland plate shall beprovided.

Wires shall be laid in flame retardant PVC trunking.

7.1 System/Remote I/O Cabinets

The system cabinets shall be freestanding type. Cable entry shall be from the bottom. Extraopenings shall be blanked. The cabinets of remote I/Os shall have IP 65 enclosure. The sizeshall be decided by the CONTRACTOR subject to ADWEA/ENGINEER approval.

Separate remote I/O Cabinets shall be supplied and installed for individual pump, reservoirlevel, MCC, LDC… etc.

7.2 Field Mounted Panels

Field mounted panels shall conform the following requirements:

- Panel shall be non-corroding.

- Weatherproof construction shall be used, IP65 minimum.

- Exposed devices on the panel shall be weatherproof to IP65.

- A sunshade/rain shall be provided with front and rear overhang.



7.3 Remote Area Enclosures

All electronic equipment, cabinets and panels installed in remote areas shall be additionallyprovided with a second GRP enclosure to IP 55 rating.

This enclosure shall be weatherproof and there shall be enough space between theequipments to allow proper ventilation and access.

8. IDENTIFICATIONS

8.1 Labelling and Name Plates

A nameplate with the panel description shall be permanently attached to a prominent positionon the front door of the panels. An identical nameplate shall be permanently attached insidethe panels. The nameplate shall be indelible, non-removable and with black lettering on whitebackground.

All warning or danger labels shall be indelible, non-removable with white lettering on redbackground. The panel doors shall be fitted with a warning label stating "Isolate beforeworking on equipment". Where voltages exceed 110 V ac, warning labels showing thevoltage level shall be attached to the terminals, using nylon screws. The label shall span allthe terminals carrying the higher voltage.

All wiring shall be ferruled at each end, using slip-on-colour coded markers. All wiring shallbe uniquely identified with a number. The markings shall be as shown on the assembly wiringand circuit diagrams.

All instruments mounted in field/panel shall be provided with traffolyte nameplates engravedwith unique identification tag number and description, which shall be subjected to approval byADWEA/ENGINEER.

Fixing screws of all nameplates, tags or inscriptions shall be non-corrosive type.

Each relay, contactors, switch and every other item of equipment within the panel shall beidentified by labels permanently attached adjacent to the equipment concerned, indicatingcircuit reference, description and rating. Where equipment is terminated in a plug-and-sockettype connection both the plug and the socket shall have permanently attached identifyinglabels.

8.2 Tag Numbers

All instruments shall have engraved stainless steel nameplates showing their tag number andservice in the English language. On the panels these name plates shall be mounted visiblenear or on the instruments. For station mounted instrumentation equipment the nameplatesshall be mounted on a bracket near the equipment.

The numbering system standard shall be according to the KKS, AKS or ADWEA identificationstandard.



For each panel mounted instrument an additional stainless steel nameplate shall be providedfor mounting at the back; it shall be engraved with tag numbers only. These plates shall beattached to the panel or instrument support near the instrument.

Method of fixing nameplates shall be submitted for ADWEA's/ENGINEER's approval.

All instruments shall be delivered to job site immediately prior to their installation to minimizethe possibility of damage. No instruments, motor operated valves etc. shall be left lyingaround on the construction site.

Materials and equipment not required for immediate installation shall be stored in a separatestore protecting them from shock, weather, dust and damage from chemical and constructionmaterial. Do not stack instruments in a store unless crated.

Upon receipt check each item for complete compliance with purchase specifications, damage,shortage and shortage of components. Repair, replace or notify vendor of non-conformanceas required.

All cover sand plugs on instrument connections shall be left in place until the moment theconnection is used.

Rubbish and scrap material shall not be allowed to remain at site. This shall be collected dailyand removed from the site.

Upon completion of the work all tools shall promptly be removed.

9. INSPECTION AND FUNCTIONAL TESTING

This section broadly specifies requirements and gives recommendations for inspection andtesting of instruments, before and after installation, during the construction and start-upphases. It deals with activities and requirements to confirm that instrumentation conforms toADWEA/ENGINEER requirements and is installed and functioning according to the approvedengineering/construction drawings and data.

9.1 Quality Plan

CONTRACTOR shall prepare a comprehensive Quality Plan to be approved byADWEA/ENGINEER in accordance with ISO 9000 or equivalent. The Quality Plan shalldescribe the quality documents (i.e. procedures, specifications and work instructions) to beused in the dedicated organisation to assure quality in each activity. All documents anddrawings that are used shall be listed and properly controlled. Changes during the course ofactivities shall be handled according to the agreed change procedure. The organisation andreporting hierarchy of all involved in testing and inspecting shall be included in the QualityPlan.

Formal Inspection and Functional testing procedures shall be submitted forADWEA/ENGINEER approval by the CONTRACTOR.



9.2 Field Instrumentation

Static testing and calibration should be done in a specifically designed site workshop prior toinstallation in the plant.

CONTRACTOR shall ensure that :

The calibration procedure demonstrates a proper and accurate method of performing statictesting and alignment operations of the instrument, as well as full range (and overrange)capabilities according to the manufacturers specifications.

All testing and calibration is to be witnessed by the ADWEA's/ENGINEER’s representativeand documented on approved test-sheets. Appropriately, "defects" should also be recorded.

A full record is submitted to the ADWEA's representative following calibration completion.

9.3 Instrument Calibration

The purpose of instrument calibration is to obtain a permanent record of the equipmentprecision and to verify that it measures, indicates, and records within the tolerancesguaranteed by the manufacturer. Instrumentation shall be calibrated using conventionaloutput signals measured, adjusted to correlate with the relevant input signals.

As far as possible instrument re-installation testing and calibration shall be carried out in adedicated workshop located near to the plant area. This workshop will be equipped with allnecessary testing materials, tools and consumable media (clean instrument air, nitrogen,temperature bath oil etc.). Portable calibration equipment will also be available for testinginstrumentation not destined to be removed from it’s site location.

All the test and measuring instruments shall be certified with ADWEA/ENGINEER recognisedtesting laboratory. Proposed list of Test and Measuring instruments shall be listed in the biddocuments by the CONTRACTOR.

9.4 Calibration Guidelines

Electronic instrumentation shall be energised for a suitable "warm-up" period prior tocalibration tests.

All field mounted analogue signalling instruments will be calibrated by simulating anappropriate process signal. Outputs will be recorded at (5) selected intervals correspondingto 0% - 25% - 50% - 75% - 100% of input range. This calibration will be recorded for rising aswell as falling input signals.

Digital on/off devices such as pressure switches need only be checked at the required set-point (with either rising or falling input as specified in the detailed specification). The resettingvalue will be verified and any hysteresis within acceptable manufacturing limits accepted.

All calibrations shall be witnessed by the ADWEA's/ENGINEER’s representative at hisdiscretion.



All the findings shall be properly recorded and signed off with relevant remarks about thestatus and any "hold" point. Before installation, all the "hold" points shall be fully addressedand approved by ADWEA/ENGINEER.

9.5 Field Inspection

The following are the minimum requirements for field inspection.

9.5.1 Underground Cable Installation

Trench Inspection:

This inspection is required to ensure, prior to pulling cables, that the trench preparation iscomplete and in accordance with the specification and route drawings.

Cable Laying:

This inspection is required to ensure that cables have been laid and identified in accordancewith the specification and route. This inspection is required for each layer of cables within atrench. Cable ends shall be protected from moisture ingress.

Glanding & Termination:

This inspection is required to ensure that the cables have been glanded and terminated inaccordance with the specification and termination drawings. Care shall be taken to ensurethat the field cabling is not energised by the instrument systems. The fieldtermination/isolation (knife terminals) shall be opened and clearly labelled.

Cable Testing:

Megger test of underground cables should be carried out after laying, trench backfilling,glanding & termination have been completed for the cable and prior to paving.

9.5.2 Above Ground Cable Installation

Cable Supporting Infrastructure:

This inspection is required to ensure that the cable supporting infrastructure is complete (priorto pulling cables) and in accordance with the specification and route.

Cable Laying:

This inspection is required to ensure that the cables are correctly installed to their finaldestination. Cable ends shall be protected from moisture ingress.

Glanding & Termination:

This inspection is required to ensure that the cables have been glanded and terminated inaccordance with the specification and terminal drawings.



Testing:

Megger test of above-ground cables should be carried out after laying, glanding andtermination activities have been completed.

9.5.3 Instrument Air Sub Header

This inspection is required to ensure that the instrument air sub headers supporting andinfrastructure is complete and in accordance with the specification.

9.5.4 Instrument Impulse and Air Lines

Impulse/Air Lines:

This inspection is required to ensure that instrument impulse and Air lines have been installedin accordance with the specification and drawings.

Visual Inspection:

Tubing shall be checked to ensure that wall thickness and tubing material are proper for theservice conditions. Disconnect the compression fitting to verify that the tubing is cleanly cutwithout burring, and that it rests firmly on the base of the fitting with ferrules present andproperly positioned.

Pressure Testing of Air Lines:

Instrument air tubing and supply piping shall not be hydrostatically tested. Only clean, dry,oil-free air shall be used for the cleaning and testing of air tubing. Testing shall be performedin accordance with ISA RP 7.1 "Recommended Practice for Pneumatic Control CircuitPressure Test". The CONTRACTOR shall verify that the 1/4-inch instrument air tubingleakage rate is less than 1.0 psi/100 feet/5 seconds.

Pressure Testing of Impulse Lines:

All process impulse piping shall require a full inspection and hydro (or pressure) test to atleast 1.5 times the normal operating pressure. Suitable leak detecting agents (or assemblies)shall be used to test the integrity of the tubing.

9.5.5 Cabinet Installation

A full inspection of instrument system cabinets shall be carried out to assess any transportdamage from transportation prior to installation. Any defects found during this inspection shallbe reported to the ADWEA and noted on the delivery notes of the equipment prior to thesupplier being informed.



9.5.6 Grounding System

The grounding systems shall be checked for proper separation and networking. This shallinclude the isolation and checking of "mechanical" earth ; "instrument" earth ; "electronic" and"intrinsic safe" earth.

9.6 Loop Testing

The aim of loop testing is to verify the functionality of equipment, it's compliance with processand engineering requirements, and to prepare the equipment for commissioning.

Loop Testing can start only after completing all the inspection items in 9.5 "Field inspectionminimum requirement".

The internal functions of each instrument system shall be tested live (i.e. with power-on). Thisshall include complete testing of all communications between systems. The limits of a LoopTesting are from the field instrument thro' the Marshalling Cabinets to the Control system andvice a versa.

The Loop Testing shall include all aspects of the instrument system or tag being tested. Thisshall include:

All associated SCADA/DCS/ESD… etc. functions, displays and reports.

The Loop Testing shall verify all entities or items that are internal to all systems (such as theSCADA/DCS … etc.). This shall include Numerics, Timers, Flags, Matrices and Parameters.

The loop test shall be designed to verify that the field instrumentation and the designatedcontrol system (SCADA/DCS/ESD…etc.) function according to the specifications. This isaccomplished by simulating process signals at the sensor of each analogue transmitter anddigital switching device, verifying that the corresponding output is correct and that it isreceived (in accordance with loop diagrams) at the workstation display or other systemconsole of the control system. Control loop output signals shall be manually sent via thecontrol workstation operator interface to field control devices such as control valves,shutdown solenoids, relays etc., and their reponses monitored.

The analogue and digital input signals will be function tested using certified test equipment.These will be used in simulating process variable conditions and to verify the validity oftransmitted data. Following approved procedures simulated process signals will be injected,as far as possible, at the process connection. Analogue output signals will be similarlychecked and shall include parameters such as direction, bias, split-range values etc..

Digital signals will be checked at two points. The process will be simulated at the processconnection and the change-of-state, as well as the re-setting level, recorded.

Engineering documentation and vendor data must be consulted to verify that the calibration iswithin the manufacturer’s tolerances.



On satisfactory completion of the loop check, all covers, doors and access plates shall beproperly secured. All wiring shall be returned to it’s original configuration and any test jumpersremoved.

The CONTRACTOR shall define and submit for approval "Lock-Out" procedures whichsafeguard the operational integrity of equipment not directly associated with the specific loop,but interlocking with it. Personnel will follow "lock out" instructions once equipment is turnedover from Construction and when it is capable of being commissioned.

Technicians qualified for all related disciplines shall be provided by the CONTRACTOR.These shall be capable of operating the test equipment and performing the loop checks andre-calibrations (if necessary) of all components on the control system in preparation for theplant transfer phase. Formal records of all testing shall be compiled on appropriate test formsand witnessed by the ADWEA/ENGINEER representative. This should take the form of a"Functional Test Sheet" which shall be signed by the CONTRACTOR and ADWEA alike.

Two-way communications shall be provided between all parties involved in the loop tests.

Any component found to be faulty or outside design parameters shall be highlighted andbrought to ADWEA/ENGINEER attention. Defects shall be logged on a pre agreed "FaultReport" or "Punch List" format and suitably rectified at the earliest by the CONTRACTOR.

All loop checking results shall be properly documented and signed by authorised personnel ofADWEA. This shall be the milestone activity for completion of pre-commissioning activities.

10. COMMISSIONING AND START-UP

All instruments including packaged units shall be installed and all systems and loops fullytested before the plant is commissioned. Standby of instrumentation specialists shall beavailable. Stores and workshops shall be open for emergency repairs and modifications.

The CONTRACTOR shall assist the representative of package vendors and ADWEA duringthe Commissioning activities.

11. SITE ACCEPTANCE TEST

Instrumentation work shall only be accepted after the plant is in full commercial operation andall instrumentation systems are working satisfactorily.

The normal acceptance procedure shall include handing over of all records made during theconstruction period, such as test results, instruction manuals, “as-built” drawings, etc.

CONTRACTOR shall carryout Site Acceptance Test (SAT) for the Control system based onADWEA/ENGINEER approved procedures. Approval of the SAT reports by ADWEA/ENGINEER completes the milestone activity for SAT.

ADWEA I&C Installation

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