NIOEC-SP-70-02(1) DOCUMENT CODE NO. OF PAGES: 17

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE NIOEC 000 EG IN SP 7002 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING

& CONSTRUCTION COMPANY

NIOEC SPECIFICATION

FOR

INSTRUMENT INSTALLATION

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY, REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

JULY, 2005 NIOEC-SP-70-02(1)

JULY, 2005 NIOEC-SP-70-02(1)

REVISION INDEX

REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5 REV. PAGE

1 2 3 4 5

1 26 51 76

2 27 52 77

3 28 53 78

4 29 54 79

5 30 55 80

6 31 56 81

7 32 57 82

8 33 58 83

9 34 59 84

10 35 60 85

11 36 61 86

12 37 62 87

13 38 63 88

14 39 64 89

15 40 65 90

16 41 66 91

17 42 67 92

18 43 68 93

19 44 69 94

20 45 70 95

21 46 71 96

22 47 72 97

23 48 73 98

24 49 74 99

25 50 75 100

NOTES: 1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.

2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.

3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL DOCUMENT.

4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

5 4 3 2 1 0 JULY, 2005 KHATIB ORDOOBADI M.R.FARZAM SAJEDI

REV. DATE PREPARED CHECKED APPROVED AUTHORIZED

JULY, 2005 NIOEC-SP-70-02(1)

CONTENTS: PAGE NO. 1. SCOPE.............................................................................................................................................. 2 2. REFERENCES................................................................................................................................ 2 3. UNITS............................................................................................................................................... 3 4. ABBREVIATIONS ......................................................................................................................... 3 5. REPRESENTATION & SYMBOLS............................................................................................. 3 6. GENERAL REQUIREMENTS ..................................................................................................... 3 6.1 Work Experience........................................................................................................................... 3 6.2 Instrument Work Schedule .......................................................................................................... 4 6.3 Instrumentation Monthly Progress Reports............................................................................... 4 6.4 Instrumentation Weekly Meeting ................................................................................................ 4 7. INSTRUMENT CALIBRATION .................................................................................................. 4 8. INSTRUMENTATION INSTALLATION DESIGN................................................................... 5 9. INSTRUMENT AIR PIPING & SUPPLY.................................................................................... 7 10. INSTRUMENT PROTECTION AND INSULATION.............................................................. 8 11. INSTRUMENT TECHNICAL INSPECTION & TEST ........................................................... 8 12. FIELD INSTRUMENTS-LOCATION ....................................................................................... 8 13. INSTRUMENTATION SUPPORTS........................................................................................... 9 14. CONTROL ROOM AND THE INSTRUMENTS ................................................................... 10 14.1 CONTROL ROOM................................................................................................................... 10 14.2 CONTROL ROOM INSTRUMENTS .................................................................................... 10 15. INSTRUMENT ACCESSIBILITY ........................................................................................... 10 16. MAIN CABLE LAYING WORK.............................................................................................. 11 17. CABLE TRAYS AND CABLE CONDUITS............................................................................ 12 18. PANELS ....................................................................................................................................... 14 19. JUNCTION BOXES ................................................................................................................... 14 20. INSTRUMENT WAREHOUSING .......................................................................................... 14 21. DRAWING PROCEDURE ........................................................................................................ 14

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1. SCOPE This specification defines NIOEC's requirements of for the installation of the instrumentation.The specification also addresses the work demarcation, special notation, and necessary information for instrumentation construction work. Deviations from this specification will only be permitted on obtaining written approval from NIOEC.

2. REFERENCES Throughout this specification the following dated and undated standards and codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this specification. For undated references, the latest edition of the referenced document (including any supplements and amendments) applies. For dated references, the edition cited applies. The applicability of changes in the dated references that occur after the cited date shall be mutually agreed upon by NIOEC and the vendor /contractor. ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

Process Piping: ASME B31. 3 “ Process Piping”

ASME B16. 5. “ Flanges” ASME B2. 1 “ Pipe Threads”

Boiler, Pressure Vessels, and Piping: ASME Boiler and Pressure Vessel. Codes Sections I and VIII

Relief Valves: ASME Unifired Pressure Vessel Code, Section VIII Division I Para s UG-125 through UG-134.

ASME Boiler and Pressure Vessel Code, P-269 through P-290. Thermocouples and Thermocouple Extension Wire:

ASME MC-96.1 Materials ASME (Section II) Welding: ASME Boiler and Pressure Vessel Code,

Section IX, (for pressure parts). ASME B 31.3, “Petroleum Refinery Piping”

AWS (AMERICAL WELDING SOCIETY) AWSD 1.0, “Structural Steel”

API (AMERICAN PETROLEUM INSTITUTE) API-RP-552 “Transmission systems” API ST 2000 “Venting Atmospheric and Low-Pressure Storage Tanks API RP 520, “API Recommended Practice for the Design & Installation of Pressure Relieving System in Refineries Rart I, Latest Edition & Part II”

ISA (INSTRUMENTATION, SYSTEM, AUTOMATION SOCIETY OF AMERICA) Electrical: ISA-RP 12.1 “Electrical Instruments in hazardous atmospheres”

ISA-RP 12.6 “Wiring Practices for Hazardous (Classified) Locations Instrumentation”

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-70-01 “Specification for Instrumentation” NIOEC-SP-70-07 “Specification for Control Systems Field Pressure Testing”

NIOEC-SP-70-17 “Specification for Instrument protection” 2

JULY, 2005 NIOEC-SP-70-02(1)

NIOEC-SP-80-02 “ Specification for Painting” NIOEC-SD-0100-1 to 4 “Standard Drawing for P&ID Symbols and Legends”

NIOEC-SD-0101-1/1 “Standard Drawing for P&ID Abbreviations” NIOEC-SP-00-10 “Specification For Units”

NIOEC-SP-00-75 “Specification for Pressure Relieving Systems”

IEC (INTERNATIONAL ELECTRO-TECHNICAL COMMISSION)

3. UNITS Units shall be as per NIOEC-SP-00-10, unless otherwise specified.

4. ABBREVIATIONS Throughout this document the following abbreviations and acronyms are used: ESD: Emergency Shutdown System. F&G: Fire and Gas PCS: Process Control System. PES: Programmable Electronic System. PLC: Programmable Logic Controller. SGS: Safeguarding System. SIL: Safety Integrity Level. SIS: Safety Instrumented System.

5. REPRESENTATION & SYMBOLS The method for repesenting instruments on piping and instrument flow diagrams and control and utility flow sheets shall be in general accordance with NIOEC standard drawings SD-00-0100-1 TO 4 “Standard Drawing for P&ID Symbols and Legends” and SD-00-0101-1/1” Standard Drawing for P&ID Abbreviations”.

6. GENERAL REQUIREMENTS

6.1 Work Experience Where the construction work is to be performed by a contractor, the contractors' and their subcontractors' construction engineers and staff shall be qualified with sufficient relevant experience. Contractors/subcontractors shall submit to NIOEC or his representative their relevant organization chart for all key personnel prior to the start of the construction work. Subcontractors' engineers and staff shall have sufficient instrument construction work experience; in this regard the resume and qualification of all subcontractors will be checked and verified by contractor and NIOEC or his representative. The Contractor shall be responsible for the installation, calibration; test and commissioning of all instruments and control systems during the construction phase.

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6.2 Instrument Work Schedule Contractor shall be responsible to submit to NIOEC relevant work schedules. Any deviation from the agreed work schedule shall be reported to NIOEC for his resolution.

6.3 Instrumentation Monthly Progress Reports Contractor/subcontractors for each job site are responsible to prepare and submit to NIOEC or his representative relevant instrument and control work monthly progress reports on the agreed date before the end of each month.

6.4 Instrumentation Weekly Meeting Contractor shall arrange for weekly meetings with the presence of subcontractors and NIOEC or his representative to establish the required coordination amongst all parties. Amongst the agenda, the following items will be discussed: • Progress evaluation

• Work discrepancy between each party.

• Manpower survey

• Work schedule survey

• Decisions regarding the work program for the following week

Minutes of meetings will be prepared by contractor and will be sent to all parties, maximum two days after the meeting.

7. INSTRUMENT CALIBRATION 7.1 Test Equipment 7.1.1 The calibration of all test equipment must be checked before being used for any calibration of instruments. 7.1.2 The test equipment calibration check shall be made against NIOEC standards wherever possible. If NIOEC standards are not available, the test equipment shall be sent to an independent testing laboratory for certification 7.1.3 The test instrument calibration check shall be recorded on a label, showing date and person performing check, and attached to the piece of equipment in such a place as to be easily visible,but not easily removable. 7.2 Procedure 7.2.1 A calibration check of indicating and recording instruments, in general, shall be made at four points, 0%, 25%, 75% , and 100% of Range or Span. Instrument such as pressure switches which are two-position devices, should not be calibrated over their range or span. A check of trip point and re-set point is considered sufficient. A two-point calibration is satisfactory for analysis portion of analytical instruments. 7.2.2 A record showing instrument number, date of calibration, and calibration data shall be kept for all instruments. This record shall be available to NIOEC. 7.2.3 Transmitters and receivers are to be calibrated independently using one of the test standards for transmitter output and received input. 7.2.4 A separate system or operational check will be required in certain critical services such as switching or shutdown systems. NIOEC shall determine where such system checkouts are required. 7.3 Instruments which shall be calibrated 7.3.1 The list of instruments given hereunder is to be considered as a guide and as a minimum requirement:

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a) All transmitters and indicating instruments. b) Pressure gauges used in conjunction with controllers and any special purpose gauges. c) Panel-mounted instruments. d) Analytical instruments.

e) Control valves and positioners ( to be stroked and aligned as required). 8.3.2 Instruments not normally calibrated: a) Thermometers, thermocouples and resistance thermometers (Potentiometers of T/C’s and R/T’s are calibrated). b) Gauge glasses. c) Self-operated regulators. d) Steam traps. e) Pressure, temperature and level switches. (The trip and reset points are checked and set.)

8. INSTRUMENTATION INSTALLATION DESIGN 8.1 General Requirements 8.1.1 All threaded fittings not subject to seal welding shall be provided with a suitable Teflon band. 8.1.2 Minimum slope of the primary connections shall be 10% where required. 8.1.3 Process connections to remote located instruments shall be securely bracketed to existing members to relieve any vibration of instruments. 8.1.4 When necessary to prevent corrosive or solids bearing fluids from entering instruments or instrument lines, seals or purges will be provided. Where diaphragm type seals are most applicable, they will be given first consideration. 8.1.5 Piping system and/or equipment shall be field pressure tested in accordance with field pressure testing specification 8.1.6 Instrument piping shall generally be routed through pipe-ways and-areas provided for the routing of plant piping, and shall be such as to protect the piping from damage during plant operation and maintenance. Routing of instrument piping will be controlled by the Field Instrument Supervisor. 8.2 NIOEC Standard Drawings for Instrument Installation Attachment I represents NIOEC’s Standard Drawings for Instrument Installation which shall be used as the basis of all instrument installation design and work. 8.3 Instruments Connection Design The following design criteria for the connection of the instruments are extensively covered in NIOEC-SP-70-01 and as such shall be referred to:

• Pressure/Temperature Rating of Instruments and Valves • Impulse Lines • Manifold valves • Process Isolation Valve • Instrument Nozzle Rating on Vessels

8.4 Component Design The requirements of NIOEC-SP-70-01 shall be followed for the components design. 8.4.1 Temperature Instruments, Thermometers, Thermocouples and Test Wells

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8.4.1.1 All temperature elements and temperature gauges shall be installed in protecting wells. 8.4.1.2 Thermocouple wells shall be installed with the connection at or below the horizontal centre line or bottom half of pipe for services at or below minimum ambient temperature. 8.4.1.3 Thermowells rating and connection design shall be in accordance with the requirements of NIOEC-SP-70-01. 8.4.1.4 Thermocouples shall be installed on fired heater as required by NIOEC. 8.4.2 Pressure Instruments and Pressure Gauge The relevant requirements of NIOEC-SP-70-01 shall be referred to. 8.4.3 Flow Instruments 8.4.3.1 Location of Pressure taps for the flow instruments shall be as per NIOEC Standard Drawings. Instrument leads shall be steam traced where the fluid boiling point lies between the maximum and minimum design ambient temperatures. 8.4.3.2 The minimum length of straight pipe preceding an orifice plate shall be in accordance with NIOEC Standard Drawings. 8.4.3.3 All orifice plates shall be installed under the supervision of instrument engineering, taking into account the direction of flow in the pipe and observing the location of the bleed hole in the plate. Where counters and pulsers for positive displacement meters have been received in separate packing, they shall be mounted after the meters have been installed.

8.4.4 Liquid Level Instruments and Level Glass 8.4.8.1 Displacement transmitters shall be specified with left-hand or right-hand mounting of the instrument with respect to mechanism chamber or cage, depending on the relative position of process vessel and displacer chamber, access from platforms, etc. 8.4.8.2 Liquid level controllers and gage glasses shall be located so as to be easily accessible from grade, platform or permanent ladder. 8.4.5 Control Valve 8.4.5.1 Control valves shall be installed in accordance with the applicable I.S.A .Recommended Practice and NIOEC Standard Drawings. 8.4.5.2 During the installation of control valves, attention shall be paid to the following: The valve shall be clean internally and the flange faces shall be undamaged.

8.4.5.3 The valves shall be installed in the prescribed position with the flow passing in the correct direction. This applies in particular to those (safety) shut-off or depressurizing valves where the process pressure is intended to assist in keeping the valve closed.

8.4.5.4 The drain valve shall be installed on the line.

8.4.5.5 The valve positioner shall be accessible and visible for calibration and adjustment.

8.4.5.6 The block and by-pass valves size shall be according to the requirements of NIOEC-SP-70-1. The spacing between the control valve and the bypass valve shall allow for easy removal of the control valve.

8.4.5.7 Air tube size between valve positioner and actuators shall be minimum 3/8 inches.

8.4.6 Safety and Relief Valve Piping

8.4.6.1 Safety and Relief valve piping shall be in accordance with applicable code requirements as specified in NIOEC-SP-00-75: Standard Specification for Pressure Relieving Systems.

8.4.7 Drain valves for Level Instruments

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Drain valves shall be ¾ inch and shall be installed on the bottom connection to level instruments, level switches and gage glasses. Drains should be piped away from the instruments to a safe area of disposal. Vent valves shall be ¾ inch and shall generally be piped to safe location.

9. INSTRUMENT AIR PIPING & SUPPLY 9.1 Instrument Air Piping & Supply shall include all instrument air lines, except the main instrument air header and its valve connections. 9.2 The instrument air feeding and distribution system shall ensure instrument operation continuity and allow, at the same time, normal maintenance of the equipment. 9.3 Instrument air headers shall be made of galvanized seamless steel pipe, and size of the branch shall conform to the following:

• ½ inches for 1 to 5 taps • ¾ inches for 6 to 10 taps • 1 inch for 11-15 taps

• 11/2 inches for 16 to 20 taps

9.4 The signals relevant to local controls and measurements shall consist of copper tubing, PVC coated, connected to the ends with brass ¼ inches NPT compression fittings with vinyl cap. The copper tubing shall make a “loop” bend before connection to the instrument so as to allow easy disconnection. 9.6 Tubing bends shall be made with an approved tubing bender and connections shall be made using suitable and sufficient tools. Where tubing requires bending, care shall be taken to assure that a reasonable bending radius is maintained and tubing is not flattened nor pinched. Tubing fittings for transmission and control tubing shall be as specified on the contract documents. Fitting sealing shall be made by utilizing Teflon tapes. 9.7 Tray or punch angle shall be installed for fixing the copper tubes. Stainless steel ties shall be used for fixing the tubes. 9.8 Instrument air supply piping for distribution headers up to individual take-offs from branch headers shall follow appropriate piping specification. 9.9 Individual instrument air supply and pneumatic field transmission lines to and from instrument and Junction box shall be PVC sheathed or coated ¼ inches copper tubing. 9.10 Individual tube runs shall be supported continuously in channel, angles or pipe. 9.11 Multi-tube bundles shall be supported on overhead distrubution trays, The trays shall be attached to structures, It is not permitted to attach these trays to piping. Contractor will furnish drawings, showing the routing of tubing. Tubing installations must present a Neat Appearance and be of good workmanship as determined by NIOEC. 9.12 A clean, dry air supply shall be used for testing instrument tubing and calibrating instruments, The following precautions are required: a) Before any instrument air header or supplyu line is put into service, it shall be blown down with air at a velocity sufficient to blow out all dirt or other lose foreign matter. b) If the plant instrument air system is not in service, then the following additional precautions must be obeserved: A knockout pot with low-point drain shall be provided to remove water from the air supply. A dessicant cartridge type drier shall be mounted immediately downstream of the knockout pot. A filter set of the packed, fiber element type shall be mounted downstream of the dessicant drier.

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The filter shall be designed for the removal of oil from air. 9.13 Instrument air tubing shall be supported in accordance with the relevant NIOEC Standard Drawing for Instrument Installation.

10. INSTRUMENT PROTECTION AND INSULATION For detailed requirements of instrument protection, including heat tracing reference shall be made to NIOEC-SP-70-17; “Instrument Protection”.

11. INSTRUMENT TECHNICAL INSPECTION & TEST 11.1 General 11.1.1 After the instruments have been installed they shall be inspected and tested for correct operation as part of the system. Instructions for instrument inspection, test and calibration are covered in NIOEC-SP-70-07. Contractor and subcontractor are responsible to prepare test application forms for instrument inspection and submit to NIOEC prior to the tests. This procedure covers the complete inspection and testing of all instruments and instrument systems received on site up to and including the pre-commissioning. 11.1.2 The progress of inspection and testing shall be indicated on a bar chart. The bar chart shall be updated at least weekly to indicate the state of readiness and the remaining workload. 11.1.3 Contractor shall be responsible to inform NIOEC inspector of the test date of the instrumentation at an early stage. 11.1.4 Faults found in the Contractor’s work shall be corrected by the Contractor at his own expense. 11.1.5 Contractor shall make sure that all individual instruments will have been tested and (re)calibrated before installation. 11.1.6 All instrument loops shall be fully tested for correct functioning, where necessary by simulating the signals. All interlocks and sequential logics, PCS loops, SGS loops and F&G shall be checked and inspected. 11.2 Pressure Testing Piping system and/or equipment shall be field pressure tested in accordance with field pressure testing specification NIOEC-SP-70-7.

12. FIELD INSTRUMENTS-LOCATION 12.1 Field instrument shall be installed in accordance with the approved relevant instrument construction drawings/documents and vender instruction. 12.2 instruments in vapour or gas service shall generally be mounted above the sensing point. Instruments in liquid and steam service shall generally be mounted below the sensing point. if accessibility, visibility or clearance requirements preclude either of these situations, provisions will be made in the instrument piping arrangement to insure proper operation of the instruments. Closed couple pressure gauges are mounted above the sensing point, and are excluded from the above mentioned. 12.3 Instrument block valves at piping or equipment connection shall be accessible from grade, platform, stairway or permanent ladder except for isolating valves of flow elements. At times the location of a line mounted (close coupled) flow transmitter is predetermined by the location of the flanged flow orifice.

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12.4 All the instruments must be installed so as to avoid excessive vibration, and so that they are not subject to damaging temperatures. In high solar exposure temperatures, aluminium or better sunshade shall be provided for the instruments. The instruments shall neither be mounted under drain points nor immediately above vent point 12.5 The instruments shall be installed with consideration of visibility from associated control valves and the accessibility from the maintenance point of view. 12.6 Field instruments shall be mounted with the specified mounting materials and by the specified methods. 12.7 Instruments shall be installed in a manner as to be about 130 cm above the grade or platform, measured from the centre of instrument. 12.8 Electronic pressure transmitters shall not be located too close to hot lines, vessels, or other hot equipment, with ambient temperatures in excess of 60°C. 12.9 The contractor shall check that the tag-plates of instruments are installed on the pertinent instrument without damage or dirt on it and to correspond to the specified instrument. 12.10 No electric welding will be permitted on existing instrument panels containing electronic instruments. Any cut outs, brackets etc. shall be cold cut, drilled or bolted as applicable.

13. INSTRUMENTATION SUPPORTS 13.1 All the brackets, pedestals, frames and supports, which shall be used to support the instruments, junction boxes, trays, conduits and various installations, shall be fabricated at site. The iron works will be prefabricated in the instrument construction contractors work shop in according with the requirements the various field instruments and standard drawings. 13.3 After prefabrication, the brackets, pedestals, frames and supports must be cleaned from rust and slag and then painted before their installation in accordance with painting specification NIOEC -SP-80-2 all supports included galvanized supports shall be painted. 13.4 Iron work will preferably be anchored down to the fixed structure by welding, in case fixed structure are not available. Iron work will be either fixed to the ground by means of suitable expansion bolts or fastener to the process pipe by appropriate collars. 13.5 The supports for instruments and brackets for cable trays and instruments and piping shall not be welded to columns, vessels, process piping or utility piping. 13.6 It is not permitted to attach the instruments or their support to process pipes. Exception shall be the close coupled flow transmitters. 13.7 Instrument piping shall be supported from pipe supports, pipe and any other permanent structure, except as follows: Instrument piping shall not be supported from un-insulated hot (52°C and above) or cold (5°C and below) pipes. Also, pipe or pipe supports that would be subjected to above the normal vibration. Supporting Instrument piping from un-insulated (hot or cold) piping shall be done only when no other practical way is available. Instrument piping supports shall not be welded to stress relieved pipe and equipment or internally lined pipe and equipment. Instrument piping supports shall be sufficient to maintain the piping in a neat manner. Instrument air tubing shall be supported in accordance with NIOEC Standard Drawings other instrument piping support shall be controlled by the Field Instrument Supervisor. 13.8 Care shall be taken to avoid the possibility of imposing stresses from the pressure piping, conduit, etc., which may cause malfunction. Pressure instruments (Local controllers, transmitters) shall be mounted on stand-pipe or local panels as specified in the specific project hook-up drawings (Installation and support of instruments on process piping is not permitted).

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14. CONTROL ROOM AND THE INSTRUMENTS

14.1 CONTROL ROOM a) Operator rooms shall normally be concrete floor type with suitable anti-static charge floor finish. Rack rooms shall be false-floor type with suitable anti-static charge floor finish with flexible and removable supports. b) The installation of PCS, SGS, F&G and any other auxiliary equipment and package shall be carried out in accordance with the detailed instructions supplied by the system suppliers. c) Testing of the cabinet and signal wirings shall be required after the panel has been completely installed and the field connection mode. d) The positioning of the operator stations, printers, cabinets and other auxiliary equipment in the control room and marshalling room shall be carried out in accordance with the panels and cabinets layout drawings in control rooms. e) Grounding system shall be prepared as per NIOEC-SP-70-13. Safety ground, instrument ground, and the grounding for intrinsically safe equipment connection shall be separate from each others, only to join at the “ground electrode”. f) Proper cable support is necessary to avoid having cable weight supported from wire terminations. The cable supports shall be installed under the panels and false floors to fix the cables.

14.2 CONTROL ROOM INSTRUMENTS a) Horizontal clearance between the rear of the control panel structure and any permanent part of the control house shall be 1200 mm minimum. Instruments, instrument piping, electrical wiring and structural members which comprise the control panel shall be considered as part of the control panel structure. b) Instrument racks, electrical equipment, etc., which is located behind the control panel adjacent to the control house walls, shall be considered as a permanent part of the control house. c) Cabinets or racks for distributed control system may be installed in another rack room if possible.

15. INSTRUMENT ACCESSIBILITY Instrument process connections shall be designed to be located for maximum convenience for operating and servicing of the instruments. The following general rules shall be adhered to, unless limited by other requirements in the design of the unit. 15.1 Connections shall be oriented so that instruments or piping will not obstruct aisles, platforms or ladders. 15.2 Control valves shall be vertically mounted and be accessible from the ground or platforms. Sufficient distance shall be given above and below the control valve to allow access and clearance for servicing. Clearance for hand-wheel operations and valve positioners shall be provided in accordance with the valve vendor’s drawing. 15.3 Connections for local pressure gauges, dial thermometers and test wells shall be located so that gauges will be at a visible level and test points will be readily accessible. 15.4 Orifices, line mounted flow transmitters, and thermocouples shall be mounted in pipe-ways or shall be accessible from walkways, ladders, platforms or grade. 15.5 Clearance shall be provided at flow meter orifices for valves, seal pots or instruments which may be located on the lines. 15.6 Connections on vessels for gauge glasses and level instruments shall be oriented to minimize the effect of inlet and outlet streams on the instruments.

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15.7 Gauge glasses and level instruments shall be adjacently located and, if possible, the gauge glass shall be visible from any valve which controls the level in the vessel. 15.8 Indicating instruments which must be readable for automatic control adjustment or manual operation shall be readable from the adjustment or operating point. If plot or piping arrangement precludes this, other provisions shall be made for indication at the adjustment or operating point. Indicating instruments which are not in the above category shall be visible from operating aisles or passageways. 15.9 All instruments requiring adjustment shall be accessible for servicing from grade, walkways, ladders or platforms. 15.10 Instruments shall be located so as to maintain clearances required for walkways, access ways and operation and maintenance of valves and equipment. 15.11 Instrument accessibility shall be in accordance with the following accessibility chart. 15.12 Accessibility Chart I II III IV V Transmitters X Local Indicators X Pressure Gages X Thermowells X Self-Contained Regulator

X

Local Controllers/Recorders

X

Process Actuated Switches

X

Frequently Adjusted Instrument

X

Line Accounting Flow Transmitters

X

Emergency Instrument X Thermocouples X Line mounted flow Transmitters

X

Control Valves X I.: Grade, platform, stairway or permanent ladder below 4500 mm (access from permanent ladder shall be limited to the instruments where plot or piping arrangement precludes accessibility from grade or platform). II.: Grade, platform or stairway. III: Grade only. IV.: Grade, platform, stairway or permanent ladder, Instruments in pipe-way, or line mounted flow transmitters where their location depends on the location of the flanged orifice, will shall be accessible although the height may vary. V.: Grade, or platform upon NIOEC’S written approval.

16. CABLE LAYING WORK 16.1 Main cables (multi- pair cables) shall be laid from control room to junction boxes in the field in one piece only, and without any splice. The same requirement shall apply to the single pair instrument cable between the instruments and the junction boxes. 16.2 For underground cabling, after the completion of the required tests, the trenches shall be filled with the clean sand as soon as possible to protect the cables from the accidental physical damages.

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16.3 After cable laying and prior the sand filling the contractor shall list the worked items for any technical test and inspection. 16.4 Trenches shall be kept away from buried pipes containing hot fluids and from pipes liable to temperature rise due to steaming-out. 16.5 The location of trenches shall be clearly marked and no excavation shall be allowed without permission given by instrument department. 16.6 When entering control room, underground cables, shall pass through proper transit MCT (multi cable transit) to ensure the external sealing. 16.7 Signal lines shall be laid on, and be covered with, sand on top of which tiles shall be laid for mechanical protection. NIOEC Standard Drawing for Instrument Installation. 16.8 In above ground, the cables and instrument air tubes shall be supported continuously in trays, punch angles, or galvanized steel conduits as per project specifications. 16.9 Cables shall be carefully handled during installation to avoid damage of any kind. They shall be unreeled or uncoiled slowly in order to prevent damage to the insulation or sheath due to sudden bending. Repeated bending shall be avoided. Sharp kinks shall be avoided in unreeling, uncoiling and pulling. 16.10 Immediately after cable laying, each cable shall be cut to the suitable length and terminated to the assigned control room cabinet/panel and the field junction box to avoid the making of coil mountain around the control rooms. Underground cables shall be laid and arranged in accordance with the row and layer arrangements shown on the construction drawings. 16.11 Electrical insulation test shall be carried out before termination work. After termination the electrical continuity test shall be performed on the laid main cables .All instrument, control and/or alarm wiring shall be tested for continuity and resistance to ground in accordance with relevant standards. A functional check out shall be made on systems to ensure that the correct wires, capillaries, etc., are connected to the correct terminals. 16.12 Indestructible identification bands, normally in stainless steel, shall be installed on all cables. These bands shall be located at each end of the cable and then over the entire length of the cable at 5m intervals. These band shall also be located where cables enter and leave ducts and at changes in direction. 16.13 At instrument cable crossing with electric power cables, the separation between the instrument and electrical cables shall be in accordance with the requirements of API-RP-552. 16.14 The signal lines shall be at such a depth that they are not damaged by traffic passing over them. 16.15 Cables shall be routed from cable trenches to the junction boxes through 6 inches rigid galvanized steel conduit that is fixed in concrete. 16.16 Cables crossing the roads shall be laid through cable duct-bank. 16.17 Care shall be taken to ensure that cable shields on the signal wires shall never be:

• Left unconnected, • Grounded indiscriminately, • Connected to their signal pair, • Connected at two or more points, • Tied to other signal leads.

17. CABLE TRAYS AND CABLE CONDUITS 17.1 Generally, above ground armoured cables shall run in cable trays, and non-armoured cables in conduits. 17.2 Suitable distance shall be considered for fixing trays and conduits, the maximum distance between supports is 1800 mm.

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Cable tray and tray support materials, when assembled and mounted, shall support workmen and equipment, as required, in addition to the full cable load, without permanent deformation, and a maximum of 20 mm deflection. 17.3 The supports shall be painted as painting specification NIOEC-SP-80-02 before cable tray installation. After cable tray and conduit installation the edge shall be touch up pained. 17.4 After cable tray and conduits and prior to cable laying, the construction contractor shall list the completed items for checking and technical inspection. 17.5 Trays shall be carefully aligned and levelled. Tray section of prefabricated raceways shall be assembled on their supports and joined together, properly aligned and secured. The cable raceways shall have a minimum thickness of 2 mm and shall be hot galvanized. 17.6 The cable trays shall be protected with covers and duly connected to the plant grounding network. Conduits shall also be grounded. 17.7 Tray fittings, such as branches, reducers, flat elbows, tees and crosses, shall be used for changes in direction and elevation. The dimensions of tray fittings shall provide ample bending radius for the cables contained in them at all changes in tray direction. 17.8 Tray shall be carefully aligned and levelled plumb and true. Tray sections and fittings shall be assembled on their supports and joined together, using manufacturers’ standard connector units, properly aligned, and secured. 17.9 Steel angles, trapeze hangers, channels, bolting and miscellaneous materials required for the support of trays from the building structure, shall be supplied and installed. Additional supports as required shall be provided for individual cables where the cables leave trays before reaching their final terminations. 17.10 Instrument cables shall be located at a sufficient distance from any hot surface to avoid damage. 17.11 Where instrument cables are to be pulled through conduit, the conduit shall be completely dry prior to installation and after cable pulling the ends shall be completely sealed with rubber type sealing compound to prevent entrance of moisture and rain into it. 17.12 Instrument multicables from cable trench to junction boxes shall be from rigid steel galvanized conduits, size of conduit shall be minimum 3 inch or higher, both ends shall be equipped by bushings, suitable bending (about 90 degree) shall be done with bending machine 17.13 Cable trays shall be routed away from hot environments; places with potential fire risks such as hydrocarbon process pumps, burner fronts of furnaces and boilers, or where subject to mechanical abuse, spilled liquids, escaping vapours and corrosive gases. 17.14 The maximum number of single pair cables in each cable tray shall be as following table:

CABLE MAXIMUM QUANTITY

TRAY SIZE ( mm )

2 50 5 100 10 200 15 300 20 400 25 500

17.15 The cables shall be laid in one layer. 17.16 Cables shall be fixed to cable trays using stainless steel cable tie with a maximum 500 mm intervals.

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JULY, 2005 NIOEC-SP-70-02(1)

18. PANELS 18.1 Outdoor panels shall be weather proof to IEC 60529, IP 65. Large size outdoor local panels, for which IP 65 may not be applicable, shall be pressurized.

In addition, in hazardous areas, explosion proof, increased safety, or pressurized panels shall be used. If panels are not installed under package shelter, suitable sunshade shall be considered for protect ion .Cable entry shall be from the bottom, cable support with channel shall be consider for fixing cables under cable entry. All opening holes shall be closed and sealed. 18.1 In control rooms, panels shall be mounted on steel frame and supports with galvanized M10 nut/bolts. Under the panels cable supports shall be installed with considering standard drawings and details for fixing the cables by U-bolts to steel supports .The cable entry shall be sealed using sealing compound after cable pulling.

19. JUNCTION BOXES 19.1 Junction boxes shall be installed in an easily accessible position so as to facilitate maintenance. Instrument junction boxes shall be mounted in the vertical plane, with unused entry holes blanked. 19.2 During installation junction boxes shall be spaced out from pipe-rack pillars or from the equipment on which they are to be fixed, later the distance shall be established in accordance with the fire proofing thickness or insulation thickness. 19.3 All the conductors and shields of each multi-core cable ending up in a junction box will be connected to the terminal strips provided inside. 19.5 The terminal strips shall have tag numbers. Also the wire numbers shall be used for identification of the wires with terminal lugs. 19.6 The armour and lead (if any) of the cables shall be connected through the armoured type conductive cable glands to junction box body. 19.7 Terminals in junction boxes shall be provided with additional spare points equal to or larger than the number of spare wires and cables. The spare wires shall be terminated to the spare terminals. 19.8 Each junction box shall be considered for one multi-core cable. Cable entry shall normally be from the bottom of the box. 19.11 Numbered or lettered wire Markers shall be installed on control and instrument leads and thermocouple cables at all terminal points. Identification shall be in accordance with applicable job drawings

20. INSTRUMENT WAREHOUSING Instruments shall be warehoused to be protected from exposure to moisture and dust, and after installation the instruments shall be covered by appropriate plastic bags. Contractor is fully responsible for protection of instruments from lost and damage up to final delivery time. Electronic instruments shall be covered by plastic bay after installation.

21. DRAWING PROCEDURE 21.1 Construction work shall be in accordance with NIOEC standard drawings and specifications. Notwithstanding the NIOEC standard drawings, variation in installation due to piping configuration and material requirements are permissible in accordance with approved project documents. Instrument hook-up drawings shall be in sufficient detail to show instrument location, orientation, support, piping arrangement and materials. 21.2 Field instrument locations and orientation shall be shown on the piping arrangement drawings. All instruments, except minor components of an instruments system, will be shown.

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JULY, 2005 NIOEC-SP-70-02(1)

21.3 Field Instrument Mounting and Piping Drawings shall be prepared in accordance with the relevant NIOEC standard drawings. Separate drawings may be prepared for process piping, air piping, (control Air & Air Supply), and mounting. The number of drawings required in each of the above categories is determined by instrument make and model, piping configuration, and Instrument Piping Material Class. Field Instrument Piping Drawings are generally diagrammatic isometric drawings. The Instrument Piping Detail Index will be used to correlate these drawings with the proper instrument loop. 21.3 Field instruments bundled tubing, if any, routing and support drawings are plan drawings with details in elevation, when required. These drawings will show structures, equipment, foundations, racks and any other item required to indicate routing of the bundled tubing. Details shall indicate the support for bundled tubing will be shown. 21.5 Control panel layout drawings are generally elevation drawings. These drawings will show overall panel dimensions, vertical height of instruments above floor level, horizontal spacing of instruments and, when required, graphic or semigraphic layout. Control panel fabrication drawings are furnished by the control panel manufacturer. These drawings shall conform to the manufacturer's standard, unless otherwise indicated in the instrument engineer's control panel specification. 21.5 Control room rack drawings are generally elevation drawings. These drawings will show overall rack dimensions, vertical height of instruments above floor level, horizontal spacing of instruments, wiring and fabrication details. 21.7 Panels and junction boxes drawings shall indicate, wire and cable numbers, instrument tag numbers, grounding, equipments tag numbers, as minimum. 21.8 Loop diagrams, ESD and sequence logic diagrams and wiring diagrams for each control room shall be supplied for logic and control loop check. 21.9 Complete set of instrument documents, drawings, loop drawings, operating manuals and others for all system and packages shall be supplied to enable construction and commissioning works.

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JULY, 2005 NIOEC-SP-70-02(1)

ATTACHMENT I

NIOEC INSTRUMENT STANDARD DRAWINGS

ITEM DRAWING NUMBER

TITLE NUMBER OF SHEETS

NIOEC-SD-7001 INSTRUMENT STANDARD DRAWING INDEX LIST

1 A3

NIOEC-SD-7002 KNIFE-EDGE TUBE SKIN THERMOCOUPLE INSTALLATION

2 A3

NIOEC-SD-7003 THERMOWELL INSTALLATION AND ASSEMBLIES OF THERMOWELL, THERMOMETERS, AND THERMOCOUPLE TERMINAL HEAD

2 A3 AND 1 A2

NIOEC-SD-7004 PIPING ARRANGEMENT AT ORIFICE PLATES

2 A3

NIOEC-SD-7005 ORIFICE PLATE FABRICATION 7 A3 NIOEC-SD-7006 INSTRUMENT IMPULSE LINES 30 A3 NIOEC-SD-7007 INSTRUMENTATION AIR HOOK-UP AND

MATERIAL 10 A3

NIOEC-SD-7008 INSTRUMENTATION SUPPORTS AND MATERIAL

24 A3

NIOEC-SD-7009 JUNCTION BOX AND CABLE SUPPORT 12 A3 NIOEC-SD-7010 INSTRUMENTATION INSTALLATION OF

LEVEL TRANSMITTERS 6 A3 AND 1 A2

NIOEC-SD-7011 CONDENSATE AND SEAL POT 1 A3 NIOEC-SD-7012 INSTRUMENT STANDARD PANELS 5 A3 NIOEC-SD-7013 GAS DETECTOR INSTALLATION 3 A3 NIOEC-SD-7014 WIRING AND EARTHING 11 A3

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