Ec k 21 Rev 6 Ingles

GENERAL SPECIFICATION FOR INSTRUMENT INSTALLATION

EC-K-21/4

ISSUE 6 SHEET 1 OF 23

AAA/RPT EDLO/JLFL 6 15/03/11 REVISIÓN GENERAL JAIL ASO 5 18/06/07 REVISADO POR CAMBIO DE RAZÓN SOCIAL JAI ASO 4 NOV.2005 REVISIÓN GENERAL (Incluidos comentarios de Construcción) JPL ASO 3 11.98 REVISIÓN GENERAL JPL ASO 2 2.84 REVISIÓN GENERAL JPL ASO 1 5.77 EMISIÓN

APPROV. CHECKED. ISSUE DATE DESCRIPTION

MI-5

.E

GENERAL SPECIFICATION FOR

INSTRUMENT INSTALLATION


EC-K-21/4


INDEX 1 OBJECT ................................................................................................................... 4

2 APPLICABLE STANDARDS AND REGULATIONS ................................................ 4

3 INSTALLATION GENERAL CRITERIA ................................................................... 4

4 SCOPE OF WORKS ................................................................................................ 5

5 SITE WORKS DESCRIPTION ................................................................................. 7

5.1 Tray Installation .............................................................................................. 7

5.2 Cable Installation ............................................................................................ 8

5.3 Cable Connections ......................................................................................... 9

5.4 Installation of Junction Boxes, Cabinets and Local Panels in Plant area ..... 10

5.5 Installation of the Air Distribution System ..................................................... 10

5.6 Installation of Structural Supports and Bedplates ......................................... 11

5.6.1 Structural Supports ....................................................................................... 11

5.6.2 Bedplates and Equipment Special Supports ................................................ 11

5.7 Conduit Installation ...................................................................................... 11

5.8 Heat Tracing Installation ............................................................................... 11

6 DESCRIPTION OF WORKS IN RACK AND CONTROL ROOMS ........................ 12

6.1 Installation of consoles, cabins and cabinets ............................................... 12

6.2 Cable Entry to Rack-Control Rooms ............................................................ 12

6.2.1 Entry to Buildings through wall bushings ...................................................... 12

6.2.2 Direct Entry to Buildings ............................................................................... 12

6.3 Technical Floor ............................................................................................. 12

7 PRE-CALIBRATION, CALIBRATION AND TEST WORKS ................................... 13

7.1 Calibration Procedures ................................................................................. 14

7.1.1 Temperature Instruments .................................................................. 14

7.1.2 Pressure Instruments ........................................................................ 14

7.1.3 Level Instruments .............................................................................. 14

7.1.4 Flow Instruments ............................................................................... 14

7.1.5 Control Valves ................................................................................... 15

7.1.6 Safety Valves .................................................................................... 15

7.1.7 Analyzers .......................................................................................... 15

7.1.8 Control Panels .................................................................................. 15

7.1.9 Especial Instruments ......................................................................... 16

8 INSTRUMENTS INSTALLATION .......................................................................... 16

8.1 Installation of Temperature Instruments ....................................................... 16

8.2 Installation of Pressure Instruments ............................................................. 17


EC-K-21/4


8.3 Installation of level instruments .................................................................... 17

8.4 Installation of Flow Instruments .................................................................... 17

8.5 Installation of Instrumentation Valves ........................................................... 18

8.6 Installation of Safety Valves, Pressure-Vacuum, Rupture Disc .................... 18

8.7 Installation of analyzers ................................................................................ 18

8.8 Installation of Remote Local Indicators ......................................................... 19

8.9 Installation of Several Local Instruments ...................................................... 19

9 LOOP TESTS ........................................................................................................ 20

10 TRENCH CONDITIONING .................................................................................... 21

11 MEASUREMENT AND PAYMENT SYSTEM ........................................................ 22

11.1 Tray Installation ............................................................................................ 22

11.2 Cable Installation .......................................................................................... 22

11.3 Cable Connections ....................................................................................... 22

11.4 Installation of Junction Boxes, Cabinets & Local Panel in Plant area .......... 22

11.5 Installation of Air Distribution System ........................................................... 22

11.6 Installation of Structural Supports and Bedplates ......................................... 22

11.7 Installation of conduit .................................................................................... 22

11.8 Tracing Installation ....................................................................................... 22

11.9 Equipment Installation in Rack and Control Rooms ..................................... 22

11.9.1 Installation of Consoles, Cabins and Cabinets. ................................ 22

11.9.2 Cable Entry to Rack & Control Rooms .............................................. 23

11.9.3 Technical Floor ................................................................................. 23

11.10 Pre-calibration, Calibration and Instruments Installation .............................. 23

11.11 Loop Tests .................................................................................................... 23

11.12 Trench Conditioning ..................................................................................... 23


EC-K-21/4


1 OBJECT The object of this specification is to establish the requirements and conditions that the Contractor should meet regarding the execution of the works included in the instruments installation and control equipment.

2 APPLICABLE STANDARDS AND REGULATIONS In the execution of any work, the standards listed in this specification will be observed, as well as those HSE rules established by official regulations, by the Client or by the Supervisors. Among others :(always last issue applies)

- Low Voltage Electro technical Regulations - National Electrical Code - ISA - API - Current Official Regulations.

It will be the Contractor’s responsibility that the employees and subcontractors comply with the regulations, and responsible also of the consequences of no fulfillment.

3 INSTALLATION GENERAL CRITERIA The Contractor should consider the following points for the good practice of the works: The cabinets, consoles, local panels, trays or instruments supports, etc., must be perfectly leveled before being anchored.

Instruments or their connection will not be supported on pipes, or structures or any equipment subjected to vibration.

Tubing, pipe and accessories of pneumatic and process hook-ups will be carefully cleaned before being connected to the corresponding instruments, in order to eliminate foreign materials.

All instruments connections will be kept with plastic plugs until just before their installation, in order to prevent foreign particles from entering.

All welding to be carried out by Contractor will be according to a homologated welding procedure and approved by Client, Engineering or Work Supervision.

In case of insulated piping, the Contractor will have the responsibility to foresee enough space among them and any part of the instrumentation installation (tubing, cable). This applies both for pipes already with insulation and for those to insulate. The Contractor will run with the costs deriving from a malpractice, being also responsible for the global scope.

Primary connection for pressure and flow instruments must have a minimum slope of 5%. In the installation, temperature expansion must be also foreseen in pipes and equipment, so that the connection lines will have the flexibility required. For instruments with liquid seals or condensation pots it will be necessary to keep in mind the pressure of the liquid column.


EC-K-21/4


In the connections specified as threaded, the thread will be executed carefully, using PTFE tape as joint element. Should the process requires, welding seal will be also made. Pipes, trays, etc., will be settled so that they allow a clearance in height of two and half meters onto platforms or walkways.

In those points that, during the installation, any anticorrosive finish of a material may result damaged due to reasons such as by cutting, bending activities, etc., the damaged surface must be painted and protected to ensure a complete anticorrosive coating.

All instruments which situation is not determined in the documentation will be located in accessible places for their easy calibration and maintenance and also in accordance with the instructions of the work supervision.

As the calibrations and instruments tests are being carried out, the instruments will be labeled indicating their check status. The Contractor will be able to present a report at every time, indicating the status of the tests performed and remarking the possible anomalies that might arise. During the erection, Contractor will be responsible to preserve of rainwater, dew, dust and other contingencies to all equipment that must be kept open, and to provide provisional protection in case the items could have water for any reason, and to dry and clean them properly. It will be Contractor’s responsibility to maintain the work area properly clean, and he will be in charge of unpacking the instruments, local panels, distribution panels, consoles, cabins, etc., and to deposit the packing in the waste collecting point.

4 SCOPE OF WORKS The Contractor has the obligation of transmitting the content of this specification for general knowledge of all his employees. Contractor will be responsible for the installation of all the instruments indicated in the material requisitions (MR), following drawing indications, and also instructions and recommendations of the manufacturer. This information will be given by Engineering and Contractor will be in charge of the “in situ” verification of the viability of the location of the different elements of the installation. In the case that there were any equipment or material not possible to install according to forwarded drawings, its installation will be carried out according to the good practice of this discipline, but always with the previous approval of the Work Supervision. In the case of those instruments directly installed on the process line, the erection will be carried out for others; notwithstanding, the Contractor will be responsible for verifying the correct installation. As an example, these instruments could be the following:

- Control, on-off, self-regulating and motorized valves. - Safety valves, rupture discs, pressure-Vacuum valves. - Displacer type levels, Magnetic and glass level gauges, flotation type switches, Servo-

Gauge Transmitters. - Thermowells and associated items, such as thermometers, Thermocouples, etc. - Orifice Plates, venture tubes, restriction Orifices, calibrated tubes, rotameters. - Mass-Flow transmitters, Vortex type, Magnetic, turbines. - Any other instrument assembled directly on a line or recipient.


EC-K-21/4


Installation battery limits will be defined in detail on the hook-up drawings forwarded by Engineering. Contractor will be responsible for the supply, unload, transportation and storage of its own material. Contractor will be responsible for providing the necessary means to unload, transport and to locate in provisional and/or final place all cabins, consoles, panels and analyzer shelters. The general warehouseman will supply to Contractor the materials provided by others when required for the advance of the installation. The transportation of materials from the general warehouse to the Contractor laboratory or the Plant will be carried out by staff and by means of Contractor.

Once material has been delivered to the Contractor, it will remain under his custody, and he will be responsible for any defect, damage or loss, as well as for the replacement of any damaged or stolen element of the installation. The Contractor will consider in his offer all necessary requirements for a complete and correct installation, including both personnel and materials required for a good organization of the work. As an example, but non restrictive, the following obligations must be considered:

- Manpower, equipment and tools to carry out the installation. - Management of work permits. - All expenses regarding insurances, taxes, rights concessions and licenses for its work. - Laboratory equipped with the appropriate instrumentation to carry out the tests and

required calibrations, and qualified personnel able to achieve these tests and calibrations.

- Foremen, staff and team leaders for installation supervision. - Supply of fungible material and small accessories, as PTFE tape, electrodes, gaskets,

insulation material, screws, nuts, staples, washers, labels, connectors, pressure terminals, small copper connections, supports, separators, small civil work tasks (included concrete and mortar), small steel structures necessary for the work (steel included), etc., and in general all the materials not included in the documents mentioned in the Material Requisition.

- All materials supplied by Contractor will be completely new and of first quality, both regarding design and construction considering their specific use in the area on which they will be assembled. The Site Supervision will be responsible for the approval of all these materials.

- Protection against rain, dust or possible damage typical of a plant.

The Contractor will submit, based on the schedule of works, a construction program for the works of his responsibility which will be subjected to approval during the bidding and execution phase. The Contractor will carry out monthly progress and site construction program reports during the execution phase.


EC-K-21/4


5 SITE WORKS DESCRIPTION

5.1 Tray Installation Trays supply will be carried out by others, but their installation will be carried out by Contractor. The different tray types to be installed will be defined in the material specification of each project.

Contractor must inform to the supervisor, at least 15 days before the execution of the works, whatever material requirements to perform the works. Parallel routes with electrical trays shall be avoided; trays will not be subjected to any heat coming from pipes or mechanical equipment, and will be placed at a minimum distance of 300mm. Trays will be segregated from each other for:

- Intrinsically safe circuits - Analog signals and/or circuits 24 V - Power Supply Cables and/or circuits 110/220 V

The supporting accessories must always be to structural fixed elements, not susceptible of being disassembled. All necessary cuts to achieve the correct assembling of the trays will be carried out with cutting machines eliminating the edges that may damage cables while pulling. Contarctor also shall protect the cutting areas. All welding and cuts of metallic elements must be reviewed and colored according to the painting specification of the project. It is included within the scope, if necessary, the fireproofed removing and the supply and later placement of the new fireproofed in similar quantity and quality to the existing one. Main tray routes will be assembled preferably in horizontal on and among racks until the entrance in control rooms. The clamping will be spaced in such a way that the cables or tubing on it shall remain perfectly aligned, remaining a minimum of 20% of spare space. The routings of the main trays will be given in drawings by Engineering. The secondary trays between the instruments and the junction boxes will be mounted preferably in vertical with the purpose of protecting the cables from the inclemency of the weather. The supply and installation of the supports will be performed by the Contractor.

It is in Contractor’s scope the responsibility of carrying out a study about the secondary routings of the plant trays (not defined in the drawings provided by Engineering), considering the following points:

- To achieve the shortest ways. - Not to interfere with other equipment. - Not to block the future maintenance works of the unit. - To finish as near as possible from the hook-up of the instrument.


EC-K-21/4


Installation per Tray-type

Ladder type Trays Within the “installation" concept, are included the works of rungs and side rails cutting, mechanization of new drills for the fixation of the junction pieces, mechanization of any adaptation piece, repair of all damaged surfaces during manipulation and production of elbows, change directions, derivations, crosses, etc. During the installation a meticulous inspection of the installed units will be made, to check that there are no surfaces or accessories with edges that can damage the cables during its pulling. The Contractor will include the supply, production and placement of any support or required accessory required for the installation of the trays. Perforated and Grid tray-type. Included within the concept of “installation" are the works of cuttings, tray manipulation and manufacture of all kinds of special pieces: elbows, derivations, reductions, etc. The Contractor will include in his scope the supply, manufacture and placement of all type of supports, fixings to concrete or metallic structures, supports painting, accessory elements, separators, fixation staples, screws in stainless steel, etc. In the secondary routings out of the rack, the distance between supports will be such, that once laid all the cables, dips up to 10mm will not occur, and in any case the distance between supports will not be more than 2m in the case of perforated-type trays and to 1,5m in the case of grid-type trays.

5.2 Cable Installation The supply of cables will be carried out by others. Cables will be supplied in coils with measurement and multicable assignment elaborated by Engineering; the cable length indicated in the lists supplied will be approximated and the Contractor will verify them on the Plant before cutting the cable and he will have to inform the Site Supervision in case of any significant discrepancy. Each coil will be meggered in its endings and the corresponding report will be prepared for approval of the Site Supervision. The cables will be laying without any intermediate connection, aligned, straight and with no crossings. Traction equipment that can get to mechanical stress will not be used, and all necessary cautions will be considered to avoid damages in the cover. Once a cable has been laid and until it is connected, the end remaining outdoors must be immediately and properly protected with an insulating element, which can prevent from incoming humidity and dirt.

The laying of fiber optic will be carefully carried out, considering the manufacturer’s indications, and it will be performed under conduit tube or tray with cover. The cables will be pulled in trays in layers while they are being laid. They will be clamped to the trays in a provisional way as they are being laid. The definitive clamp will be made with metallic tape of stainless steel.


EC-K-21/4


The cable bending radius will be as a minimum 10 times of their nominal external diameter. The entry of the cable through the cable gland must present no curves and it has to be foreseen a pigtail of 20-30cm with the cable. All the cable shields will maintain the continuity and they will be isolated from the instrument housing and from the junction box. As a general rule, they will only be connected on earth at the side of the control room. The cable armour will be put to earth by its cable gland, except in the cabins at the control room, in which it will be connected to the earth bar by means of copper pigtails supplied by the Contractor. All the cables will be identified in their ends with a stainless steel plate, supplied and fixed by the Contractor.

5.3 Cable Connections The scope of works includes the electrical connection of the cables, field instruments (primary elements, transmitters, indicators, power sources, solenoids, positioners, converters), junction boxes, panels and control cabinets according to the drawings provided by Engineering. All the cables will have a continuity test and the corresponding report shall be given to the Supervision of Work. The cables will always enter the boxes by the lower or side part, but never through the superior part in order to avoid water entrance. The connecting includes cutting, peeling of the cover, armour and shield; pass through the cable gland; cut and peel of the isolation; insulating tape for isolation and support of the cable and fixation elements if necessary. Also it is included in the unit price the supply and placement of the compression terminal; identification of wires (label included); complete connection of all the wires, earthing of the armour inside the cable gland, placement of the fixed part of the cable gland in the housing and change of position if necessary of the terminals in the box.

The cables will be go though the corresponding gland cable so that they are firmly fixed by the external cover and by the cone of retention of the armour in order to avoid to transmit the cable stress to the equipment. In the external part of the equipment, between the housing and the cable gland, it should be always placed a polypropylene joint. The part of the cable gland jointed with the housing, must be tightened as the manufacturer recommends, made with the corresponding dynamometric keys, in order to guarantee the appropriate tightness. The final isolations of the individual cables will be cut trying not to damage the copper and adding the terminals afterwards (provided by the Contractor). The spare cable wires will be connected to provided spare terminal blocks. Each wire must be identified when reaching the terminal block by means of indelible mechanical sleeve. The identification will be in Contractor's scope.


EC-K-21/4


5.4 Installation of Junction Boxes, Cabinets and Local Panels in Plant area

The scope of works includes the installation of all junction boxes, cabinets and local panels supplied by others according to the drawings provided by Engineering. Any discrepancy with the Engineering drawings regarding the installation of this equipment, will have to be communicated immediately to the Site Supervision before their installation. In case of additional cable glands to be installed in boxes, cabinets or panels, they will be quoted as cost of unitary installation.

Junction Boxes on Site and rooms

The Contractor will install the junction boxes in accessible places for their maintenance and not in crossing areas, at a height of 1350mm from the inferior face of the box to the floor and he will check that the box is grounded. The Contractor will supply and install the necessary supports to fix the boxes to existing elements or metallic supports, including all kind of mechanical works, necessary accessories (screws, nuts, washers, etc.) and re-painting of the elements deteriorated as consequence of welding, cuttings, etc. All the supports will be approved by the Site Supervision before their production. The price of all these actions and also the substitution of the cable gland for plugs in the spares will be included within the unit price of the installation. Cabinets and Panels

The scope of work includes the collecting of equipment from the general warehouse or similar; its transport considering the characteristics of its location and according to the drawings supplied by Engineering; placement and fixation, leveling and grounding. It is also included within the unit price the protection and cleaning of the equipment against dirt, dust and water, by means of a plastic cover supplied by the Contractor.

5.5 Installation of the Air Distribution System Within the scope of the Contractor's unit price it is included the tubing or pipe installation with all their accessories, the sealing and necessary identifications, the pneumatic test and the supporting of all the elements. The pipe supply, tubing, elbows, Ts, reducers, unions, sleeves and valves, will be performed by others. Nevertheless, the Contractor will carry out the cleaning of all the materials before their installation. The documentation concerning the air distribution system will be provided by Engineering, as well as the diagrams for pneumatic installation for the final connection to the consumers of the air system. The system will be subjected to a hydrostatic test with dry air containing no oil, at a pressure 1, 5 times the operation pressure. The air distribution can be carried out by Air Tree Manifolds or Sub-headers. The Contractor will install the air distribution system starting from the first valve of the main air collector located in the pipe rack when having Sub-headers.


EC-K-21/4


In case of installation with air tree manifolds, the Contractor will provide and install all the valves of the manifold and a stainless steel plate to identify the corresponding consumer's tag.

5.6 Installation of Structural Supports and Bedplates

5.6.1 Structural Supports The scope of work includes the execution of all necessary structural supports for the instrumentation equipment. Structural supports will be considered those structures of a weight bigger than 50 kg. If not, there will be considered included in the unitary prices of the instrumentation works. The Contractor will be responsible for making these supports whenever required, being included in the unit prices the steel profiles supply, the manufacture, installation and the painting of the support. The Contractor will make sketches and drawings, with the structure dimensions and weight and they will be given to the Site Supervision for approval before their production.

5.6.2 Bedplates and Equipment Special Supports The scope of work includes the fabrication of all the steel bedplates and special supports necessary for the installation of the instrumentation equipment. The Contractor will be responsible for making these supports whenever required, being included in the unit prices the steel profiles supply, the manufacture, installation and the painting of the support. Previous to their manufacture the Contractor will prepare a sketch with the weight and appropriate dimensions to be delivered to Site Supervision for approval before production.

5.7 Conduit Installation The scope of work consists in the installation of the conduit routings including the accessories and its support. This work will be made according to the drawings provided by Engineering. Conduit bars will be supplied by others.

5.8 Heat Tracing Installation The scope of work consists in using the tracing connections left by others in the surroundings of the instruments to be heat-tracing. This work will be made according to the drawings provided by Engineering. Heat tracing materials will be supplied by others.


EC-K-21/4


6 DESCRIPTION OF WORKS IN RACK AND CONTROL ROOMS

6.1 Installation of consoles, cabins and cabinets The scope of work includes the transportation of the consoles, cabins and cabinets from the Site general warehouse by own means to its location inside a building according to the drawings provided by Engineering. It also includes its placement, fixation, leveling grounding and protecting. Within the unit price, it will be checked previously to the transportation to the definitive location that the consoles, cabins and cabinets have no damage or dents. Contractor will also be responsible for the protection and cleaning of the equipment, from dirt, dust and water. When necessary it will cover with plastic supplied by the Contractor the equipment. The support structures as bedplates are not included in this unit price. The consoles, cabins and cabinets will be all supplied by others, with their internal electric wiring completely made.

6.2 Cable Entry to Rack-Control Rooms The entry of all cables and tubes from the plant will be in general by means of trays on racks or trenches. The passing route to reach the control rooms, racks, etc, will be through wall bushings or free, as specified in the drawings by Engineering. The Contractor will protect all cable intakes from possible weather inclemency, in order to keep the cable intakes and the rooms watertight. In the case of trenches, during the installation works untill the trench is closed, it will be Contractor’s responsibility to keep the trench clean of dirt and water or of any other object or material.

6.2.1 Entry to Buildings through wall bushings The scope of works includes the installation and sealing of cable intakes through wall bushings according to the documentation of Engineering. The supply of these wall bushings will be carried out by others and all the rest of the works necessary for the performance of the installation will be the Contractor’s responsibility.

6.2.2 Direct Entry to Buildings The unit price includes the installation of a seal around the tray or trench, or even around the cables or individual tubes, as well as the placement of the corresponding enclosure. In the case that there is an existing rack or control room, the Contractor's scope of works will include the breaking of the enclosure, and also its replacement, once the cable pulling works are finished and it is in optimal conditions for usage.

6.3 Technical Floor The Contractor will be responsible for carrying out all the necessary works inside the rack rooms or control rooms regarding the technical floor.


EC-K-21/4


Within the scope of unit prices it is included the lifting of the false floor (assembled by others) for the installation of trays, cabinets, and lying of cables. It is also included the cutting and necessary manipulation of the tiles for the final conditioning of the floor and the covering of it, till it is in perfect conditions for usage.

7 PRE-CALIBRATION, CALIBRATION AND TEST WORKS The object of the pre-calibration is to ensure that each instrument has been supplied according to the specifications determined in its data sheet, checking its good operation and readiness to be installed. Once the instruments are ready for operation by means of the pre-calibration, they should be prepared for the specific application of the calibration. This consists basically on the calibration of ranges, and of setpoint. It is also included within the scope of works a previous inspection of the instruments when they arrive into the plant and a confirmation of its characteristics and/or accessories considering the last revision of the specifications and data sheets as for model, options, accessories, etc, and from this point their pre-calibration procedure will follow.

The calibrations can be carried out in-situ or in the field laboratory provided by the Contractor. This laboratory will be equipped with testing and calibrating tools which will have a precision and discrimination ten times higher than that establish by the manufacturers of the instruments to be calibrated. The Contractor will have to show the updated certificates of the calibration instrumentation. The results of the tests done will be registered in the corresponding reports and the failures found will be immediately communicated to Site Supervision. The pre-calibrations works will be the following:

- It will be observed that the equipment is labeled with their corresponding tag, in case of not having identification plate, the Contractor will supply it and has to placed in the instrument.

- Lubrication of the control valves when necessary. - Filling of the instruments with sealing liquid when necessary. - Adjustment of air filters. - When the instrument has mobile parts, it will be verified the correct operation of them. - Checkout of all the joints and packing to ensure sealing.

The calibration works will be as follows:

- In general, all ranges, alarms, zero point and the values of minimum four points will be proven and adjusted in all the instruments. The Contractor will be responsible for the calibration even for the instruments already installed by others, such as package units like boilers, compressors, etc.

- For the calibration of any instrument, the manufacturer's instructions will be followed. - In the case of safety circuits and alarms, all signals will be checked and adjusted. The

checkout will include switches, lamps, solenoid valves, relays and alarms, simulating different possible conditions.

- The air for the calibration of pneumatic instruments must be clean and dry, if it is not available during the period of instrument calibration, the Contractor will have to provide his own bottles of dry air or nitrogen.


EC-K-21/4


7.1 Calibration Procedures Generally the range of the instruments will be tested and adjusted in four points: zero, 25%, 50% and 100%. The contacts will be calibrated adjusting the set and action point.

7.1.1 Temperature Instruments The thermometers will be calibrated in the Contractor’s workshop, using a controlled temperature immersion and observing the indicated temperature. The transmitters will be tested at zero, 25%, 50% and 100% of the range. In the thermostats the setpoint will be adjusted and it will be checked the action and the differential. In the thermocouple it will be checked the type, polarity, isolation and state of the hot welding. Once assembled, it will be checked that the thermocouple reaches the bottom of the thermowell. The temperature instruments working by thermo-resistance will be calibrated according to the vendor’s instructions.

7.1.2 Pressure Instruments The pressure transmitters, differential pressure and gauges will be tested and calibrated at zero, 25%, 50% and 100% of the range. The pressure transmitters with sealing diaphragm will be tested and recalibrated with heated diaphragm at process temperature, when it is higher than 100°C, using for this purpose controlled temperature immersion. The pressure switches will be calibrated at a workshop with a pressure indicator, being adjusted the setpoint, the differential and checking the commutation action.

7.1.3 Level Instruments The level instruments such as radar, ultrasounds and capacitive will be tested and calibrated at zero, 25%, 50% and 100% of the range, according to the manufacturer’s indications, whenever it is possible. The level instruments of displacer type will be calibrated by filling the chamber with clean water and measuring the level with a transparent plastic tube connected to the lower drainage. After the calibration, the density will be adjusted to the service conditions. In the switches float-type, vibration, capacitive and conductive, the commutation points will be tested considering the measure principle, adjusting them and checking their action. Regarding the glass and magnetic levels, it will be tested the perfect condition of the instruments in each case, the sheets and their action, the glasses, valves and illuminators in case there are some.

7.1.4 Flow Instruments For all the flow instruments in which the measure is through transmitters of differential pressure, the instruments will be tested and calibrated at zero, 25%, 50% and 100%. For such instruments as coriolis, vortex, thermal-mass, magnetic, etc, the checkout and calibration will be carried out once they have been assembled, following the


EC-K-21/4


manufacturer's instructions. In case that, together with them, any remote local indicators have been supplied, it will be checked the range for which they have been calibrated.

7.1.5 Control Valves All the control valves actuated by diaphragm or piston will be pneumatically auctioned checking that the action, stroke and range of the spring meet the characteristic shown on the nameplate. The positioners will be calibrated according to the characteristics plate, checking the air failure and linearity. The butterfly-valves will be checked working freely the internal disk and being sure that the stroke indicator marks the correct position. For the motor operated valves their operation and the motor spin direction will be tested. All the accessories (manual remote control, booster, solenoids, proximity switches, etc.) will be functionally tested.

7.1.6 Safety Valves According to the nameplate and data sheet provided, it will be checked the orifice size, process connections and set point. It is included in the unit price the transport from the general warehouse to the workshop, where the operation, setpoint and leakage of the valve will be checked, as well as the transport from the workshop to the warehouse again or to its final location. The test will be carried out on a homologated test bench with the presence of an authorized quality Inspector and Site Supervision. In the event the test is not correct, the valve will be adjusted. The cost associated to this valve re-setting shall be out of the Contractor's scope. In the rupture discs it will be checked that their nameplate meet the specifications required in the data sheet.

7.1.7 Analyzers In simple analyzers like Ph-type, conductivity, disolve oxygen and similar, the Contractor will be in charge of checking and calibrating the equipment in his workshop, according to the manufacturer’s instructions and documents, with appropriate equipment for this task. Regarding more complex analytical equipment, such as gas detectors, chromatographs, and those in cabins or shelters the calibration and start-up proceedings shall have been contracted to the analyzer supplier. The Contractor's scope will be to support the representative of the analyzers in the calibration and start-up of the analyzers according to his instructions and under his direction.

7.1.8 Control Panels The Contractor will check according to the specifications and manufacturer’s drawings all the labels on instruments and panels, to be sure they were not lost or damaged during the transport and installation, and he will also check the functionality of the assembled elements on them, push-buttons, lamps, selectors, etc.


EC-K-21/4


7.1.9 Especial Instruments All instruments not detailed in this specification, will be calibrated according to vendor’s instructions. If the project particular specifications would request the technical support of the instrument vendor for calibration and start-up, the Contractor will assist the representative person of the equipment supplier to carry out the works under his instructions.

8 INSTRUMENTS INSTALLATION In general, all instruments assembled on pipes and on equipments directly, will be installed by others, although this does not exclude the Contractor to supervise it, checking the correct installation. Within the scope of the unit prices, it is included the verification of the location in the process line, considering the Engineering diagrams. All installations will meet the requirements shown in the diagrams and specifications, and be installed considering their easy access. The Contractor will supply, manufacture and install all necessary supports for the correct fixation of the instruments, so that the installation provides enough rigidity and no stress on the instruments connection. The supports will have to be approved by the Site Supervision before they are manufactured and they will be painted according to the painting specification that applies for the project. Once the custody of the instruments have been given to the Contractor in the warehouse, he will be responsible for protecting them against possible damages that may occur before, during or once installed, and with this purpose the Contractor will protect them against weather inclemency or any other possible damages. Any damage the equipments may suffer will be under Contractor responsibility and Contractor will run with the costs.

8.1 Installation of Temperature Instruments The Contractor will carry out the following works: Temperature instruments such as thermocouples and thermometers, will be assembled by others and the Contractor will be in charge of verifying their correct installation according to the hook-ups supplied by Engineering. In case any instruments may require it, they will be oriented so that they are visible from the operation places. Regarding Skin-Points, the Contractor will be responsible for their installation according to the documentation provided by Engineering (hook-up) and manufacturer's drawings. The remote temperature transmitters will be assembled on supports according to the provided hook-up. 8.1.1 Thermocouples/RTD/Integrated Transmitters 8.1.2 Bimetallic and Bulb thermometers 8.1.3 Skin points 8.1.4 Temperature transmitters


EC-K-21/4


8.2 Installation of Pressure Instruments The Contractor will carry out the following works: All instruments will be assembled according to the hook-up provided by Engineering. Primary connections to process should be properly supported. The instruments will always be located near their primary connections and accessible for their calibration and maintenance from the floor, platform, etc. It will be included a hydrostatic leakage test with a pressure test of 1,5 times more than the operation pressure, to all the connection pipes to process, being necessary to previously isolate or to move away those instruments that could result damaged by it. 8.2.1 Flow Differential Pressure Transmitters 8.2.2 Level Differential Pressure Transmitters 8.2.3 Differential Pressure Transmitters 8.2.4 Pressure Transmitters 8.2.5 Pressure Gauges 8.2.6 Pressure Switches

8.3 Installation of level instruments The Contractor will carry out the following works: To verify the installation of these instruments (installed by others) in the vessels according to the hook-up provided by Engineering, confirming that the indication is visible from the operation place, the vertical alignment of the equipments and that they do not block the passing to the platforms or walkways. He will also verify orientation of instruments that need that the indication was visible from the operation place. 8.3.1 Displacer Level Transmitter 8.3.2 Radar Level Transmitter 8.3.3 Nuclear Level Transmitter 8.3.4 Capacitive Level Transmitter 8.3.5 Ultrasound Level Transmitter 8.3.6 Magnetic Level 8.3.7 Glass Level 8.3.8 Level Switch 8.3.9 Agar Probe

8.4 Installation of Flow Instruments The Contractor will carry out the following works: To verify the installation of the elements mounted on line by others, checking their installation, location and flow direction, even in those instruments that, due to installation requirements, have not been placed in first instance but have to be place later for cleaning matters. He will also verify orientation of instruments that need that the indication was visible from the operation place. 8.4.1 Orifice plate


EC-K-21/4


8.4.2 Calibrated Tube 8.4.3 Restriction Orifice 8.4.4 Venturi 8.4.5 Nozzle 8.4.6 Pitot 8.4.7 Vortex 8.4.8 Turbine 8.4.9 Mass-Flow (Coriolis) 8.4.10 Thermal-Mass 8.4.11 Magnetic 8.4.12 Ultrasonic 8.4.13 Positive displacement 8.4.14 Flow switch 8.4.15 Rotameter 8.4.16 Gauges

8.5 Installation of Instrumentation Valves The Contractor will carry out the following works: to verify the installation of instrumentation valves mounted by others, checking installation, location and flow direction, even for valves that, due to installation requirements, have not been placed in first instance but have to be place later for cleaning matters. The Contractor will include in the unit prices the disconnection and re-connection of pneumatic and electric signals when required to proceed with the hydraulic test, cleaning of piping and afterwards, will verify again the installation of the valve in the pipeline. 8.5.1 Control valves 8.5.2 Motorized valves 8.5.3 On-Off Valves 8.5.4 Solenoid Valves 8.5.5 Pressure regulating Valves 8.5.6 Temperature regulating Valves

8.6 Installation of Safety Valves, Pressure-Vacuum, Rupture Disc The Contractor will carry out the following works: He will verify the correct installation and it will attend to the installation of the valves mounted by others, checking the connections and that the tamper-proof seal is correct. 8.6.1 Safety valve 8.6.2 Pressure-vacuum valve 8.6.3 Rupture Disc

8.7 Installation of analyzers The Contractor will carry out the following works: Considering the analyzer's type, he will carry out the installation of the equipment or will simply assist the analyzer vendor in the start up. Anyway, the instructions of the equipment manufacturer will be always followed. In general, the installation, operation and hydraulic leak test of the probe will always be checked, as well as the installation, inner tubing and the analyzers cabling.


EC-K-21/4


The analyzers and its sample conditioning routing will be mounted by the Contractor based on the hook-up provided by Engineering. In the case of the gas detectors, the Contractor will be the in charge of the equipment installation. The documentation about the location and the installation drawings of the equipment will be provided by Engineering. Regarding the analyzers located inside cabinets or in shelters, their price includes also the installation of the equipment in their locations according to the drawings supplied by Engineering and the necessary connections of the service collectors according to the hook-up provided by Engineering. For the analyzers cabins or shelters it will be in the Contractor's scope to collect, to transport and to position them as indicated in the layout drawings. The cable layout and the associated bed plate is excluded from this unit price. 8.7.1 Oxygen Analyzer 8.7.2 Humidity Analyzer 8.7.3 Analyzer of Oil in Water (Water-cut) 8.7.4 Analyzer of Water in Hydrocarbon (BSW) 8.7.5 Ph Analyzer 8.7.6 CO2 Analyzer 8.7.7 H2S Analyzer 8.7.8 Dissolved Oxygen Analyzer 8.7.9 Corrosion Analyzer 8.7.10 Gas Detectors

8.8 Installation of Remote Local Indicators The Contractor will carry out the following works: The indicators will be mounted on supports as specified in the corresponding hook-up. They will be installed in visible places in order to actuate the valves, to show the level at the tank foot, etc, and oriented to facilitate the operation. 8.8.1 Remote local indicators

8.9 Installation of Several Local Instruments The Contractor will carry out the installation of any local or remote instrument not explicitly indicated in previous sections. Their correct installation will be carried out according to the vendor’s instructions and the particular specifications of the project. 8.9.1. Vibration sensor 8.9.2 Heavy Cells 8.9.3 Push Buttons, selectors 8.9.4 Acoustic and luminous horns 8.9.5 I/P Convertor 8.9.6 Punctual Fire and Gas Detector 8.9.7 Gas Detector Open Path 8.9.8 Lighting Panel / Pushbuttons


EC-K-21/4


9 LOOP TESTS After all the instruments have been calibrated and installed, there will be a functional test of the control loops including the following operations: - Zero Confirmation. All the loop components should be set at zero within the accuracy

specified.

- Functional Test. Each loop must be operated simulating its operation from the transmitter to the final element. The perfect operation of the complete loop has to be tested (Close Loop test), or that of each individual component (Open loop test) and the control action according to the project specifications.

It will be held a record of the tests, fulfilling the corresponding protocol. The Owner and the Site Supervision will be previously informed in order they can be present when performing the tests. The calibration, installation and testing works will not be considered as concluded until the instrumentation supervisor has issued the written approval. The tests according to the instrument type will be as follows: Thermocouples Each thermocouple will be checked sending a mV signal from the field, which will be received in the operator station. This signal will be equivalent to the range of operation of the item. Afterwards, when connecting the thermocouple to the head, it will be checked that the indication on the operator station corresponds to the environmental temperature. Electronic transmitters It will be injected in the instrument the signal corresponding to 0%, 50% and 100% of its range. It will be checked in the control room the correct reception of the signal and the indication on the operator station. Final Control Elements From the control room or local panel the signals corresponding to 0%, 50% and 100% of the range will be sent, and it will be checked that the final element is set in the required positions. Instrument Contacts in the Field It will be simulated in the field instrument the conditions caused by changes (for example, in a pressure switch it would be injected the set pressure to cause the state change) and the position will be observed on the operation station. Output from Control Room to Field The output to solenoids or other final elements will be forced from control room and it will be checked in the field the correct operation of the instrument and other elements affected by it (for example, control and on-off valves, hydraulic actuators, lamps …) Special Devices For all the instruments not describe above, (for example: analyzers, special valves, Coriolis, etc.) the loop test will be carried out by injecting the corresponding signal in the equipment and checking its indication on the operation station.


EC-K-21/4


Electric Equipment For the tests of the electric equipment, panels, SAI, electric groups and pump motors, the corresponding signals will be simulated from the equipment and the indication will be verified on the operation station when having a digital input. Regarding a digital output, a signal from the system will be forced and it will be checked that the electric equipment executes the required operation.

10 TRENCH CONDITIONING The Contractor will be responsible for the conditioning of trenches for cable laying and instrumentation ducts as well as the closing of them. The erection of the trenches will be executed by others. During the instrumentation erection until the complete covering of the trench, the Contractor will be in charge of keeping the trench totally clean of dirt and of any other object or material. Before laying the cables in the trench, its bottom will be conditioned and properly leveled and compacted. The cables will be disposed in the trench separated by inner separators according to the documents provided by Engineering. When in the same trench several layers of cables should be installed, these will be separated from each other by means of a layer of clean sand. The supply of this sand will be within the Contractor's scope. If the trench is located in a paved area, its covering will be carried out placing concrete slabs and sealing them to avoid dirt penetrating inside. The opening of existing trenches to make instrumentation works, will be the Contractor’s responsibility, including in his unit price the removal, covering and correct sealing of the trench, once the works are finished.


EC-K-21/4


11 MEASUREMENT AND PAYMENT SYSTEM

11.1 Tray Installation The trays will be certified per lineal meter installed, the reductions will be considered lineal meters equivalent to a tray of smaller width. Elbows, derivations, reductions or any other accessory will be included in the measurement. The Contractor will carry out diagrams of all those layouts that cannot be measured according to the drawings provided by Engineering.

11.2 Cable Installation The cables will be certified per lineal meter laid and measured on the trench, trays or diagrams that the Contractor may elaborate to certify the layouts of trays, conduits, etc.

11.3 Cable Connections The connection of cables will be certified by cable in both ends. The unit price includes the preparation, calibration and placement of the fixation element, the connection of the wires and all the necessary operations for a complete execution.

11.4 Installation of Junction Boxes, Cabinets & Local Panel in Plant area The installation of these equipment will be certified per unit installed, including in the unit price the preparation, support and placement of the equipment to the fixation element and all the necessary actions for an appropriate execution.

11.5 Installation of Air Distribution System The installation of the air supply will be certified per lineal meter, and it will include all type of necessary accessories for the system complete integration, as well as the required supports.

11.6 Installation of Structural Supports and Bedplates The supports and bed plates will be certified per Kg, according to the drawings supplied, including the whole design, manufacturing, painting and installation.

11.7 Installation of conduit The conduit will be certified per lineal meter, including in the unit price shown in the contract the proportional part of accessories and elements required, as well as their supports.

11.8 Tracing Installation The tracing installation will be certified per lineal meter, including in the unit price the required accessories for the final installation.

11.9 Equipment Installation in Rack and Control Rooms

11.9.1 Installation of Consoles, Cabins and Cabinets. The installation of consoles, cabins and cabinets will be certified per unit, in relation with their dimensions, including conditioning and final fixation. The supports and bed plates are excluded of the unit price.


EC-K-21/4


11.9.2 Cable Entry to Rack & Control Rooms The entries of cables and ducts to rooms will be certified by square meter, including all the necessary elements for their proper final installation.

11.9.3 Technical Floor The certification of the technical floor will be done per square meter, including all the works required for its complete conditioning after the conclusion of the works performed in the rack or control room.

11.10 Pre-calibration, Calibration and Instruments Installation All pre-calibration, calibration and instruments installation works will be certified per instrument, including all the requirements necessary for their final conditioning.

11.11 Loop Tests The loop Test will be certified per unit, checking the complete functionality of the loops and signals.

11.12 Trench Conditioning The trench conditioning will be certified per lineal meter of trench, considering the own characteristics of each trench.

Ec k 21 Rev 6 Ingles

Documents

Transcript of Ec k 21 Rev 6 Ingles