LAYING AND ASSOCIATED WORKS FOR …tender.tractebelindia.com/GAIL/8000014928/Technical Vol...DESIGN...

LAYING AND ASSOCIATED WORKS FORSULTANPUR JHAJJAR HISSARPIPELINE(SJHPL) PROJECT Project No. P.013312Document No. P.013312 D11031 001E - Tender No. 8000014928

GAIL (India) Ltd.Noida | INDIA

PUBLIC

31 July 2019

TECHNICAL DOCUMENTATIONTechnical Vol IIG of II, Rev. 0

DESIGN BASIS FORINSTRUMENTATION AND

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P.013312D 11065

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GAIL (INDIA) LIMITED

SULTANPUR-JHAJJAR HISAR (SJHPL) PIPELINEPROJECTS

TRACTEBEL ENGINEERING PVT. LTD.

DESIGN BASIS - INSTRUMENTATION AND CONTROLS

1 17.07.19 Issue for Procurement MA SHD AR

0 14.12.18 Issue for Procurement MA SHD AR

Rev. Date Subject of revision Author Checked Approved

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Rev. 0 Sultanpur Jhajjar Hisar Pipeline (SJHPL) Project Page 1 of 1

TABLE OF CONTENTS1.0 INTRODUCTION ........................................................................................................ 1

2.0 INSTRUMENTATION SYSTEM SUMMARY ................................................................. 1

3.0 POWER SUPPLY ......................................................................................................... 2

4.0 APPLICABLE CODES & STANDARDS ......................................................................... 2

5.0 STATUTORY APPROVALS / CERTIFICATES (AFTER GETTING ORDER) ................... 6

6.0 ENGINEERING UNITS ............................................................................................... 6

7.0 INSTRUMENTATION EARTHING SYSTEM ................................................................. 6

8.0 FIELD INSTRUMENTS SPECIFICATION .................................................................... 7

9.0 INSTRUMENT CABLES ............................................................................................... 8

10.0 LOCAL CONTROL PANEL ............................................................................................ 9

11.0 FIRE DETECTION SYSTEM ......................................................................................... 9

12.0 GAS DETECTION SYSTEM ........................................................................................ 10

13.0 OPTICAL FIBRE CABLE ............................................................................................ 10

14.0 PLB HDPE DUCT ....................................................................................................... 11

15.0 CORROSIVE MONITORING SYSTEM ....................................................................... 11

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1.0 INTRODUCTION1.1 This document presents the design specifications for the Field instruments, Relay based Local control Panel,

Instrument Cables, optical fiber-based, Corrosion monitoring system, armoured Optical fiber Cable (24 fibers),PLB HDPE Duct, Fire & Gas detection System for SULTANPUR JHAJJAR HISAR PIPELINE PROJECT ofM/s GAIL.

2.0 INSTRUMENTATION SYSTEM SUMMARY

2.1 The entire project is comprised of dispatch station, receiving station, IP station & SV Stations along withassociated instrumentation and protection system.

i. Dispatch Station, SV1, SV2 & IP Station is in spread-A.

ii. SV3, SV4 and Receiving station is in spread-B.

2.2 Following facilities shall be provided at stations

I. DESPATCH STATION-Sultanpur

a. Field instruments as per P&ID.

b. Standalone local control panel (use existing) in control room for monitoring the process parameters andGOOVA operation.

c. Conventional type Fire detection including smoke and heat detector.

d. Addressable type Gas detection system with point gas detectors.

e. Corrosion monitoring system along with corrosion probe and corrosion coupon.

f. Armored 24 core optical fiber with FTC, joint chamber, joint closure, electronic router marker andlocator, manual route marker. OF cable shall be laid inside the HDPE duct from Sultanpur to Hisar.

g. New Optical fiber cable shall be connected at Sultanpur and interface with existing system.

II. SV STATION -Jhajjar (SV1)


b. Standalone local control panel provided in control room for monitoring the process parameters andGOOVA operation.



Metering system shall be consisting of following facility at Jhajjar (Free Issue item by GAIL)

a. Dual stream coalescent single chamber filtration skid with instruments.

b. Single stream Turbine flow metering skid with flow computers and metering cabinet.

c. Dual stream pressure reduction skid with active & monitor valve and slam shutoff valve with Pilotheater.

d. HMI system with processor, monitor and printer with furniture & revolving executive chair.

III. SV STATION (SV2, SV3 & SV4)



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c. Conventional type Fire detection including smoke and heat detector.d. Addressable type Gas detection system with point gas detectors.

IV. IP STATION






V. RECEIVING STATION-Hisar

a. Field instruments as per P&ID as per recommended vendor list

b. Standalone local control panel in control room for monitoring the process parameters and GOOVAoperation.




Metering system shall be consisting of following facility at Hisar (Free Issue item by GAIL)

a. Dual stream coalescent single chamber filtration skid with instruments.

b. Single stream Turbine flow metering skid with flow computers and metering cabinet.

c. Dual stream pressure reduction skid with active & monitor valve and slam shutoff valve with Pilotheater.

d. HMI system with processor, monitor and printer with furniture & revolving executive chair.

3.0 POWER SUPPLYNormal supply : 230 V AC, 24 V DC and 48 V DC power supply shall be provided at all the stations for local

control panel , F&G panel, RTU, telecom and all the associated facility available at station.

4.0 APPLICABLE CODES & STANDARDSThe following Indian/ international or relevant codes and standards shall be used for designing the system. In allcases, latest revisions with amendments, if any, to be followed Apart from the specific codes mentioned herein,all other relevant and related codes concerning the specific job under consideration and/or referred to in thesecodes and technical specifications shall be followed wherever applicable. All codes shall be of the latest revisionas on the date of issuing the tender/ bid document.

In the event of any conflict between this specification, related standards and codes, any other attachment to thistender, the Contractor shall refer the matter to OWNER’S/OWNER’ REPRESENTATIVE for clarification andonly after obtaining the confirmation on the same, should proceed with the manufacture/ supply / engineering ofthe item in question. The decision of the OWNER’S/OWNER’ REPRESENTATIVE shall be binding on theContractor.

CONTRACTOR shall seek COMPANY's final interpretation of any conflicts prior to the execution of work.Rework of engineering and relevant scope arising out of underestimation shall be done at no additional cost tothe COMPANY.

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Sr.No

Codes Description

1 OISD-STD-226 Natural Gas Transmission Pipelines and City Gas DistributionNetworks.

2 ANSI/ISA S 51.1 Process Instrumentation Terminology.

3 ISA 5.4 Instruments Loop diagrams.

4 IEC 60529 / IS2147 / NEMA

Specification for Weather Proof Enclosure.

5 IEC 60079 Specification for Flame Proof Enclosure

6 IEC 61000 Electromagnetic Compatibility for Industrial Process Measurementand Control equipment.

7 IEC 60801 EMI and RF interference

8 IS-1554 Part 1 PVC insulated (heavy duty) electric cables- working voltage up to andincluding 1100V.

9 BS-5308 Part 1,Type 2

Specification for PVC insulated cables.

10 IS 8130 Conductors of insulated cables

11 IS 5831 Specification for PVC insulation and sheath of insulated cables.

12 IS-3975 Mild steel wires, formed wires and tapes for armoring of cables.

13 ASTM D 2843 Test method for Max smoke density for cable

14 ASTM D 2863 Test method for measuring of Temp and O2 Index.

15 IEC 60754 Acid generation test

16 IEC-332-3 Part 3 Tests on bunched wires and cables.

17 BS 6121, EN50262

Cable gland – flame proof Ex”d” or Exe increase safety.

18 DIN- 50049 Document on Material Testing.

19 ASME PTC 19.3 Temperature Measurement- calculation of natural frequency.

20 IEC 751 / DIN43760

RTD

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Sr.No

Codes Description

21 IEC 584/DIN43710 / ANSIMC 96.1

Thermocouple

22 ISO 5167 Measurement of fluid flow by means of orifice plates, Nozzles andVenturi tube inserted in filled piping circular profile.

23 ASME B 16.36 Orifice flange with flange pressure tap.

24 ASME B16.5 Pipe line flanges and flanged fittings

25 API-RP-520 Sizing and selection of safety relief valves.

26 IS 3624 / BS EN837

Pressure gauge

27 AGA 3 Orifice flow measurement

28 AGA 9 Ultrasonic flow measurement

29 AGA 8 Compressibility factor of natural gas.

30 AGA 10 Calculation of Speed of sound in Natural gas

31 API Spec 6A Valve design methodology

32 API 6D Petroleum and natural gas valve

33 ISA 75.01 Flow equation for sizing of control valve

34 ISA 75.02 Testing of CV rating , control valve capacity test

35 ISA 75.05 Control valve terminology

36 ISA 71.07 Laboratory measurement of aerodynamic noise generated by controlvalves.

37 FCI 70.2/ANSI B16.104

Control valve seat leakage.

38 ASME/ANSI B16.34

Valves-Flanged, Threaded and welding end.

39 IEEE 802 The LAN standards.

40 IEC-60870-5- SCADA Communication protocol

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Sr.No

Codes Description

104/101

41 DNP 3 (TCP/IP),DNP 3 (Modbus) SCADA Communication protocol

42 IEC 61131 RTU, remote terminal unit

43 IEC 60870-5-101 Modbus serial RS232/Rs485

44 ISA 5.3-1983 Graphic Symbols for Distributed Control/Shared DisplayInstrumentation, Logic, and Computer Systems.

45 ISA-5.5-1985 Graphic Symbols for Process Displays

46 TIA/EIA 58 Communication standard

47 OISD Oil Industry Safety Directorate Government of India

47.1 OISD 118 Layouts for Oil & Gas installations

47.2 OISD 152 Safety Instrumentation for Process System in Hydrocarbon Industry

47.3 OISD 153 Maintenance and Inspection of Safety Instrumentation in HydrocarbonIndustry

47.4 OISD 163 Process Control Room Safety

47.5 OISD 195 Safety in Design, Operation, Inspection and Maintenance ofHydrocarbon Gas Compressor stations and Terminals

48 NFPA National Fire Protection Association

48.1 NFPA-70 National Electrical Code

48.2 NFPA-497 Electrical installation, classification of Class1 & Class 2 hazardouslocations

48.3 NFPA-101 Life Safety Code

48.4 NFPA 325M Fire Hazard Properties of Flammable Liquids, Gases, and VolatileSolids for LEL of Gases

49 PNGRB Technical & safety standards statutory requirements for natural gaspipelines.

50 AGA7 Turbine flow meter

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5.0 STATUTORY APPROVALS / CERTIFICATES (AFTER GETTING ORDER)

5.1 The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments andinstrumentation systems.

5.2 Equipment / instrument / systems located in electrically hazardous areas shall be certified for use by statutoryauthorities for their use in the area of their installation. In general, following certification shall be provided bythe bidder.

a. For all flameproof equipment / instrument / systems, which are manufactured abroad (outside India)certification by any approving authority like BASEFA, FM, UL, PTB, LCIE, CENELEC etc. shall berequired.

b. For all flameproof equipment / instrument / systems manufactured locally (within India), certification shallbe carried out by any of the approved testing houses – Central Mining Research Institute (CMRI) etc. Themanufacturer shall hold a valid Bureau of Indian Standards (BIS) license.

c. Approval certificate from Chief Controller of Explosives (CCE) or Petroleum and Explosive Safetyorganisation (PESO) is mandatory for all electronic / electrical instruments / equipment to be installed inIndia, irrespective of country of origin.

6.0 ENGINEERING UNITS

a

Flow

Gas Sm³/hr / MMSCMD

Mass flow kg/hr.

Volumetric flow m³ / hr.

b Pressure Barg

c Temperature °C.

d Level %.

7.0 INSTRUMENTATION EARTHING SYSTEM7.1 General

The earthing for electrical earth and electronic earth shall be arranged to provide safe installations, and toprevent electrical interference with their operation.

All earthing and shielding shall comply with the requirements of all standards applicable to the areaclassification in which the equipment is installed.

7.2 Instrument cases, panels. etc.

a) All parts of field installations, e.g. Cable trays, junction boxes, local panels, instrument housings,conduits, cable armour, etc.., shall be effectively grounded via the general plant earthing system.

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b) Earthing of cable trays shall be in accordance with the IEC requirements as a minimum.

7.3 Each supplied instrument, local control panel, fire detection panel, gas detection panel system shall haveearthing lugs with their frames. All these lugs/ strips shall properly have secured to the electrical earthing bus.

7.4 All system grounds of various cards and equipment, shields of signals (instrument) cables shall connect tosystem ground bus, which is electrically isolated from the AC mains earthing bus. The equipment shall provideseparate earthing strip for the same. The system ground bus shall have independent ground buses throughinsulated wires.

a) System grounding (earth resistance less than 1 ohm)

b) Frame and AC mains grounding (earth resistance less than 5 ohms)

7.5 Lightning protection

Where connections between control systems and/or distant equipment may be affected by lightning surges or byother inducted high voltages, the connection cables shall be equipped with over-voltage arresters.

8.0 FIELD INSTRUMENTS SPECIFICATION8.1 PT shall be intrinsically safe electronic SMART type transmitters compatible with HART protocol of latest

version. All transmitters shall be 2-wire type with integral digital indicator. Enclosures shall be Weather proofto IP 65. Pressure transmitters shall be capacitance / piezo-resistance type. Process entry and cable entry shall be½” NPT (F). Accuracy of Pressure transmitter shall be ± 0.075% of span. Transmitters O/P shall be 4-20 mADC. Surge protection device shall be provided with the transmitter to protect the instruments from lightning orany kind of hazardous surge

8.2 Temp transmitters shall be intrinsically safe electronic smart type transmitters compatible with HART protocolof latest version. Transmitters shall be 2-wire type with integral digital indicator and dual compartment type.Enclosures shall be Weather proof to IP 65. Temp sensor entry and output cable entry shall be ½” NPT (F).Transmitter shall be ± 0.18% of FSD. Transmitters O/P shall be 4-20 mA DC. Transmitters shall be providedwith output meters (LCD in Engineering Unit). Surge protection device shall be provided with the transmitter toprotect the instruments from lightning or any kind of hazardous surge

8.3 A universal type Hand Held Configurators with carrying case and charger shall be provided for this project.

8.4 PG shall be Direct-mounting type having element of bourdon tube and dial size of 150 mm. It shall haveshatterproof glass. Connection shall be ½” NPT (M) from bottom. Enclosure shall be weather proof to IP65.Protection shall be 130% over range. Accuracy shall be ±1% of FSD. PG shall have blown out disc facility. Forhigher pressure applications (above 60 Barg), it shall be solid front type.

8.5 Temperature element shall be immersion type and skin type with temperature transmitter. Skin type elementshall be provided at vent line as per P&ID along weld pad and associated accessories

RTDs are 4 wire type and element shall be Pt100 as per DIN/IEC, accuracy class A and thermowell’simmersion length shall be suitable for the line size. All RTDs shall have duplex elements. RTDs sheath ODshall be 10 mm and material SS 316. Cable entry shall be ½” NPT (F). Enclosure shall be WP to IP-65. AllRTD shall be supplied with thermowell. The thermowell shall be flanged type.

8.6 Differential pressure switch enclosure shall be Weather proof IP65, process entry from Bottom /side entry,Process connection ½” NPT (F), Pressure element shall be Diaphragm (material SS316), Setting adjustable,Switch DPDT switch, Cable entry ½” NPT (F).

8.7 SOLENOID VALVES

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The solenoid valve shall be of 3 way, universal type with manual operation facility. The body and internals shallbe of SS 316. Valve shall be made leak proof with 'O' ring seals. The solenoid valve shall have weather proofand intrinsically safe, suitable for the hazardous area. The power supply shall be 24VDC. Instrument air/naturalgas supply connection shall be 1/4" or 1/ 2” NPT (F). Solenoid valve shall be provided with integral junctionbox, having 1/2" NPT (F) cable entry. Surge suppression diodes shall be provided across the coil. Coil classshall be Class “F”

8.8 VALVE POSITION SWITCH

Valve position switches for open / close position indication shall be of sealed micro type lever operated. Theswitch shall be of DPDT type with contact rating 24V DC, 2 Amp suitable for inductive load. The switchenclosure shall be dia cast aluminum, weather proof and intrinsically safe suitable for hazardous area. Valveposition switch shall be provided with integral junction box having 2 nos. of 1/2" NPT (F) cable entries.

8.9 All instruments impulse line (1/2” tubes) shall be consist of tubing and piping. The impulse tube shall be SS316and all the impulse pipes shall be CS/LTCS. Compressed type ferrule fitting such as ½” NPT (M) to NPT (F)fittings (male/female connectors), ½” tee, ½” union including ½” isolation needle/ball valves & otheraccessories shall be according piping material.

9.0 INSTRUMENT CABLES

9.1 1P X 1.5 mm², 2P X 1.5mm², 1Q X 1.5mm², 6Qx0.5mm², 6P X 0.5mm², 12P X 0.5mm², 1T X 1.5mm² and 12TX 1.5mm²cables shall generally be used for connecting instruments to local control panel through junction box.

9.2 All instrument cables shall be FRLS. Cables shall be individually and overall shielded for analog signals andoverall shielded for digital signals. All cables shall be galvanized steel wire type armour as per IS-1554 Part 1.

9.3 For power cables refer electrical specification.

9.4 CABLE GLANDS

Cable gland shall be provided for all the above mentioned cables both at field instrument, junction boxes andlocal control panel.

Instrument cable gland shall be ½” NPTM insulating glands double compression type, weather proof (WP) IP65 in field instrument side only for underground instruments tapping to protect the CP current drainage.

Except that, all other shall be standard metallic gland. All cables glands shall be of nickel-plated brass WP IP65and they shall be double compression type suitable for armoured cables.

Flame proof Ex (d) glands in hazardous area shall be supplied and along with Ex (d) certification.

9.5 CABLE TRAYS AND CABLE DUCTS

All branch cables/trench cable shall run on cable trays.

These cable trays shall be made out of galvanized iron-perforated type of 2.5 mm thickness. These trays aresupported with

Suitable clamps shall be supplied for binding the cables/tubes at every 500 mm interval. All the cable/tubesshall be laid in trench, false flooring/ ceiling trays, instrument support structures and supported with 50 mm x 50mm angles as a minimum.

Maximum width of the cable tray shall be 600mm and height 50mm, 75mm or 100mm as applicable. 25% sparecapacity shall be provided for cable trays.

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9.6 JUNCTION BOXES

Junction boxes shall be provided for intrinsically safe and non-intrinsically safe instruments also as required forpackages such as gas detection system, corrosion monitoring system, fire detection system etc.

For non-intrinsic safe signals, junction box shall be explosion proof to Exd. IIA/IIB, T3 and weather proof to IP65 and made up of dia cast aluminium.

For intrinsic safe signals, junction box shall be weather proof to IP 65 made up of di-cast aluminium.

9.7 MUTICABLE TRANSIT

MCT shall be provided at cable entry to control room from field (hazardous area). The MCT frames shall be ofstandard modular variable diameter RGB type, steel construction MCT frames shall be suitable to withstandblast intensity. The MCT shall be supplied complete with insert blocks, spare blocks, stay plates, end packingetc. The MCT shall be sized considering 20% spares for each cable size/cable OD. Intrinsically safe cables andnon-intrinsically cables shall be suitably separated within the MCT frame. For HT cables, LT cables/powercables and other electrical cables separate MCT frame shall be provided. Spare space shall be filled withdummy block of suitable size.

10.0 LOCAL CONTROL PANEL

10.1 The panel shall be self-standing/wall mounted supplied in dust & vermin proof, floor mounted, sheet steelenclosure. Minimum degree of protection for panel shall be IP 42 as per IS-2147.

10.2 Enclosure shall be fabricated with cold rolled closed annealed (CRCA) sheet steel of minimum thickness 1.6mm and gland plate thickness shall be 3 mm.

10.3 Panel shall have single front door & double rear door. Mounting height of equipment/components inside thefloor mounted panel requiring operation and observation shall not be less than 300 mm and higher than 1600mm. Tentative Size of self-standing cabinet shall be 2100 (including 100 mm base frame) (H) x 1000 (W) x 800(D) mm and for wall mounted as per vendor standard.

10.4 Panel shall be liberally designed. All components shall be so mounted that they are easily accessible forinspection & maintenance.

10.5 Color of panel: RAL 7035 for the panel exterior & interior and black for the base frame.

10.6 Panel shall have door switch, cable glands, MCBs, 5A power supply socket, Hooter, Reset and acknowledgepush button, panel light, lugs, exhaust fan, digital indicator, lamp, analog & digital barriers/Isolator, repeater/Relay, pressure and temp indicator as minimum accessories.

11.0 FIRE DETECTION SYSTEM

11.1 Conventional type fire detection system shall be comprised of multisensory detectors, includes optical /Photoelectric type smoke detectors and heat detectors based on rate of raised. Multi sensor detectors shall be installedin the miscellaneous rooms like electrical room, control room/equipment room battery room, false ceiling, andfalse flooring as applicable of the different stations along the pipeline network. Two detectors shall beconnected in loop to avoid false notification.

11.2 Optical/Photo electric type smoke detectors for timely detection of smoke/fire. Smoke detectors installed abovethe false ceiling and below false flooring wherever applicable in order to sense the fire occurred in the electricalwiring & fittings etc. The smoke detectors above the false ceiling and below false flooring are not be visible,these detectors shall be fitted with remote Response Indicators located below the false ceiling, and above falseflooring (on adjacent wall) which shall glow in the event of actuation of these detectors.

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11.3 On the alarming, two red flashlights located in the Control Room and in the guard room at site and two hornsone inside and other outside shall be actuated at the same time.

11.4 A break glass unit (BGU) shall be installed at the outer side of each rooms and in field wherever feasible(decided during engineering stage) for manual actuation of the fire alarm.

11.5 When a detector shall be in alarm condition, the information shall be sent to the central unit and the same signalshall be sent to LCP panel & LCP panel to SCADA through RTU. The alarm situation of the detector shallremain “ON” until a manual reset device is activated on the central unit. An indicating LED shall permit thedirect identification of the detector that is the cause of alarm.

11.6 The fire control panel shall derive its power from a 48V DC main UPS, which shall be converted to requirevoltage (DC) level by the contractor inside the panel. The fire control panel shall provide the required power tothe sensors and accessories and shall monitor the zonal circuits for open and short circuit faults. The fire controlpanel shall also be provided with a secondary power source comprising two nos. of Maintenance free batteries,which automatically takes over the system in the event of 48 V DC UPS power failure to the panel.

11.7 Contacts used in intrinsically safe circuit shall be gold plated. All electronic circuits used in the system shall befree from the effects of any RF interference.

11.8 Fire detection panel shall be wall mounted for all unmanned station. Size of the wall mounted panel as per thevendor standard. Fire detection panel shall be floor mounted free-standing type for manned stations.

11.9 Fire detection system shall be suitably hooked up with CO2/Clean agent fire suppression system forauto/manual flooding in control room/equipment room and electrical.

11.10 Field mounted Electrical Operated Siren with audible range of min 1 KM integrated with fire detection system.

12.0 GAS DETECTION SYSTEM

12.1 The addressable type hydrocarbon gas detection system shall be comprised of flame proof flame proof point gasdetectors (PGD) with integral type digital indicator and main control unit at control room/equipment room.

12.2 Point gas detectors shall be “IR” type. PGD shall be mounted at the possible leakage point and near equipmentand tap-off node.

12.3 The high and high high gas concentrations and a failure/default state shall be detected and signalized by thecontrol unit.

12.4 Gas detectors output shall be digital communication. Control unit shall be interface with LCP panel & LCPpanel interface with RTU/SCADA system on RS 485/RS232

12.5 Main control unit shall be wall mounted. Size of the panel as per the vendor standard.

13.0 OPTICAL FIBRE CABLE

13.1 The optical fiber cable shall be armored comprising of 24 nos. single mode fibers comprising of 24 fibers ITU-T-G-652D suitable for working in 1550 / 1310 nm wavelength region suitable for laying through silicon coatedHDPE duct. The cable shall be fire retardant, chemical resistant, termite & rodent proof and moisture proof. Thedrum length shall be 4 km.

13.2 OFC shall be laid inside a permanently lubricated HDPE pipe (Dia 50mm) adjacent to pipe.

13.3 Total length of OFC shall be pipeline length including minimum loop length upto the control room at eachstation and loop length in inspection chamber + 1 km extra

13.4 Single Mode Optical Fiber, Fully ITU T rec. G652 Oct 2000, IEC 60793-1 AND Telecordia GR – 20 corecompliant

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13.5 Inspection chambers of required dimensions shall be provided at every 4 Km intervals along the pipeline route.The 24 F splice enclosure shall be placed in the inspection chambers after splicing of the Optical Fibre cable atevery 4 Km intervals along the optical fibre route.

13.6 Route markers of required dimensions shall be provided at every Kilometer along the pipeline route. The routemarkers shall be also placed at top of every inspection chamber, crossings etc.

13.7 OFC shall be laid inside the each HDPE duct if crossing length greater than 500 mtrs.

13.8 Additionally, at each jointing location, Electronic locating system suitable for field use to locate underground-buried OFC joint locations. The system shall consist of-

a) Electronic marker (to be buried underground along-with OFC joints)

b) Marker locator (including probe & locator electronics)

14.0 PLB HDPE DUCT

14.1 The PLB – HDPE Duct shall consist of two concentric layers, the outer layer being HDPE; co-extruded with aninner layer of solid permanent lubricant, to reduce the internal co-efficient of friction (ICF). The lubricant shallbe of a solid layer of uniform thickness so formulated to provide a permanent, low friction boundary layerbetween the inner surface of the duct & optical fiber cable. The lubricant layer shall be clearly visible in cross-section, concentric with the outer layer.

14.2 PLB HDPE ducts shall be suitable for installation of underground unarmored optical fiber cables (OFC) byblowing techniques. The life expectancy of these ducts shall not be less than 30 years.

14.3 PLB-HDPE duct shall be laid throughout the pipeline and stations. Additional PLB-HDPE duct shall be laid atall crossing, river, nalah, culvert, road/railway, canal etc. inside the separate 6” CS casing pipes.

14.4 Total quantity of HDPE duct shall be pipeline length including the minimum loop length at each station + 1 kmextra length. Extra length shall be used for hooking up of OFC to telecom unit at all stations.

15.0 CORROSIVE MONITORING SYSTEM

15.1 The electrical resistance (ER) type probes and coupons to be installed at the stations as mentioned above shallbe retrievable from the line under pressure. The probes and coupons shall be flush mounted on the pipeline. Allmaterials in contact with fluid shall be in accordance with NACE Standard MR-01-75. Pipeline inlet pressuremay vary according to pipeline pressure drop due to different flow rates. The corrosion monitoring system shallbe suitable for operation under this fluctuating pressure conditions.

15.2 Each probe shall be connected to a transmitter (2 wire systems) to give an output of 4-20 mA, proportional tocorrosion rate.

15.3 Local monitoring equipment of CMS shall be mounted in the local control panel.

15.4 Barrier, display unit, terminal blocks etc shall be provided in the LCP cabinet. Single shall be repeated throughdual output channel repeater or barrier to provide the independent signals to RTU as well local indicator.

S S S

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MATERIAL REQUISITIONP.013312D-11071

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MATERIAL REQUISITION

DOC. NO. P.013312 D 11071 101

0 17.07.2019 Issued for Procurement MA SHD AR

REV. DATE Subject of Revision Prepared By Checked By Approved By

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MATERIAL REQUISITIONP.013312D 11071

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Rev.0 Sultanpur Jhajjar Hisar Pipeline (SJHPL) Project Page 1 of 13

A. DESCRIPTION OF GOODS AND/OR SERVICES

1. SPREAD - A

Item Description Unit Quantity Remark

A SUPPLY

1Supply of Pressure Transmitter along with 2 valve manifolds withall accessories as per Data sheet, PTS-Instrumentation withappendices (P.013312-D-11077-081) and Scope of Work C&I(P.013312-D-11039-001)

Nos. 10

2

Supply of Pressure gauge including high range and low range alongwith 2 valve manifolds, gauge saver with all accessories as per Datasheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos. 37

3

Supply of temperature element (RTD) along with flangedthermowell mounted for underground and above ground pipelinewith all accessories as per Data sheet, PTS-Instrumentation withappendices (P.013312-D-11077-081) and Scope of Work C&I(P.013312-D-11039-001).

Nos. 10

4Supply of Temperature Transmitter with all accessories as per Datasheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos. 14

5Supply of skin type temperature element (RTD) for above groundpipeline with all accessories as per Data sheet PTS-Instrumentationwith appendices (P.013312-D-11077-081) and Scope of Work C&I(P..013312-D-11039-001).

Nos. 4

7Supply of Local control panel with all accessories as per Data sheet,PTS-Instrumentation with appendices (P.013312-D-11077-081 andScope of Work C&I (P.013312-D-11039-001).

Nos. 3

10Supply of Ex-proof junction box with all accessories as per Datasheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos 4

11Supply of Corrosion Monitoring system with corrosion coupon,Corrosion probe, transmitter and digital indicator (mounted in LCP)as per Data sheet, PTS-Instrumentation with appendices ( P.013312D 11077 081) and Scope of Work C&I (P.013312-D-11039-001).

a Corrosion coupon along with accessories. Nos 3

b Corrosion probe along with transmitter, digital indicator, barriersand accessories.

Nos 3

12

Supply of Conventional Type Microprocessor based fire detectionsystem along with smoke detector, heat detector, cabinet, manualcall point, Independent 24 Hrs battery backup with 15 min in alarmstate, repeater panel and Electrical Operated Siren, exit signs as perData sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work.

a Controller along with cabinet Nos 3

b Multisensor (Smoke detectors + Heat) Nos 24

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c Manual call points Nos 15

d Ex Proof manual call point Nos 3

e Repeater panel Nos 3

f Exist sign Nos 9

g Electrical siren Exd Nos 3

h 24 Hrs battery backup Nos 3

13

Supply of Addressable type gas detection system along withcontroller, ex proof point gas detectors, beacon hooter, flasher, ,cabinet, portable gas detector, calibration kit, alignment kit as perData sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

a Controller with cabinet Nos 4

b Point gas detectors Nos 25

c OPGD Pairs 13

d Dual tone Hooter & Beacon Nos 3

d Dual tone Hooter & Beacon Ex “d” Nos 3

e Portable gas detectors Nos 1

f Calibration kit Nos 1

g Junction Box (Ex d) Nos. 4

14

Supply of Universal type Hand Held Configurators for transmitterswith carrying case, rechargeable batteries (one working and onestandby), and battery charger as per Data sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work C&I (P..013312-D-11039-001).

Nos 1

19

Suppy of 24 Fibre Composite armoured Optical Fibre Cable drum(24 fibre G-652) of 4 km +/-5% Cable drum length with fiberterminal closure, inspection chamber, electronic route marker allalong pipeline route, Two number electronic locater as per PTS-Optical Fibre cable (P.013312-D-11077-083) and Scope of WorkC&I (P.013312-D-11039-001).

Mtrs 72000Mtrs

a Inspection chamber (fabricated or readymade) Nos 18

b Supply of jointing closure 24 Fiber, 2 way including all accessories(3M, Siemens, Reychem make only)

Nos 19

c Supply of FTC with pig tails other accessories for termination ofOFC - 24 Fibre in the Telecom Room

Nos 4

d Electronic marker Nos 18

f Electronic locator Nos 1

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20 Supply of HDPE duct along with all the required accessories as perPTS- HDPE ( P.013312 D 11077 084) and Scope of Work .

Mtr 73000Mtrs

21

Supply of Instrumentation signal cable, control cable,communication cable/LAN cable, Power cables along with all sizescable glands (WP & Exd), PVC hood, lug, ferrule, etc as per PTS-Instrumentation with appendices P.013312 D 11077 081), andScope of Work.

a 1Px1.5mm2 Mtrs 900

b 12Px0.5mm2 Mtrs 320

c 1Qx1.5mm2 Mtrs 350

d 12Tx1.5mm2 Mtrs 400

6Tx1.5mm2 Mtrs 160

e 1Tx1.5mm2 Mtrs 1275

f 6Px0.5mm2 Mtrs 480

g Cat 5 (LAN) Mtrs 280

22

Supply of Instruments cable tray with tray cover as per requirementand as per PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).Branch Cable tray (50mm x 50mm), Main cable tray 900 mm, cabletray 300mm, cable tray 150 mm.

LS 1

23

Supply tubes and fittings as per requirement and as per PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work C&I (P.013312-D-11039-001).SS 316L TEE (1/2”, Class 3000#, Screwed, NPTF, Seamless),SS316L GLOBE/BALL VALVE (1/2”, Class 800#, Screwed,NPTF, Seamless), SS316L PLUG (1/2”, Screwed, NPTM, Hexhead, class 3000#), SS316L PIPE NIPPLE (½” NPTM, seamless,schedule #160) Length of the pipe nipple as per requirement,SS316L MALE CONNECTOR (1/2" OD x 1/2" NPTM), SS316LFEMALE CONNECTOR (1/2”OD x 1/2” NPTF), SS316L UNION(1/2” OD), SS316L TUBE (1/2" OD x 0.065" WT), SS316L TUBE(1/4" OD x 0.035" WT)

LS 1

24 Supply of mandatory spares as per Mandatory Spare (P.013312-I-11087-101)

LS 1

25 MCT (Multi cable transit) LS 1

26 FM-200 LS 1

27 CO2 LS 2

Note

All above given quantities of equipment and cable sizes are tentative and may vary as per site &functionality requirement. Bidder is also required to ascertain the equipment & quantity those are notmentioned herein but require according to functionality and their standard practices/ system. No extraclaim will be entertained after award.

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B ERECTION/ SERVICES

1 Erection, Installation, testing, site calibration and commissioningalong with associated accessories, fittings, tubing etc of Fieldinstruments as per scope of work.

LS 1

2. Erection, Installation testing, commissioning, SAT of local controlpanel, integration with GDS, FDS etc. along with supports/ framefabrication including earthing and screwing plug for unused entriesand painting along with associated accessories as per scope of work

LS 1

3 Erection, Installation testing, commissioning, SAT of gas detectionsystem, along with supports/ frame fabrication including earthingand screwing plug for unused entries and painting along withassociated accessories as per scope of work

LS 1

4 Erection, Installation testing, commissioning, SAT of Fire detectionsystem, along with supports/ frame fabrication including earthingand screwing plug for unused entries and painting along withassociated accessories as per scope of work

LS 1

5 Erection, Installation testing, commissioning, SAT of corrosionmonitoring system, along with supports/ frame fabricationincluding earthing and screwing plug for unused entries andpainting along with associated accessories as per scope of work

LS 1

6 Erection, Installation of metering panel, along with supports/ framefabrication including earthing and screwing plug for unused entriesand painting along with associated accessories as per scope of work

LS 1

7 Erection, Installation junction boxes along with supports/ framefabrication including earthing and screwing plug for unused entriesand painting along with associated accessories as per scope of work

LS 1

8. Cable laying (buried as well as tray) as per scope of work forsignals / control/ power/Triad / earthing / communication cable (Rs-485)/LAN along with termination, glanding, meggering and loopchecking including supply of ferrule, lugs, cable tie, cable clamp,cable marker etc.

LS 1

9 Cable try laying as per scope of work of each size includinginstallation of support, cable clamping, installation of tray coverand support painting.

LS 1

10 Erection, Installation MCT. LS 1

11 Installation of FTC & Wire mesh, termination of OFC on FTC /DDF inside control room, splicing with steet fibre, fibre test, OTDRtest, power testing of laid OFC, identification of fault, rectification,earthing, final testing and commissioning, preparation of reports,etc. work complete in all respect with all necessary accessories forall location till final Handing Over and Taking Over by Owner oflaid OFC.

LS 1

12 Installation of CO2 system with its control panel. Interface with firedetection system. (2 Stations)

LS 2

13 installation of Clean agent system with its control panel. Interfacewith fire detection system. (1 Stations)

LS 1

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2. SPREAD - B

Item Description Unit Quantity Remark

A SUPPLY

1Supply of Pressure Transmitter along with 2 valve manifoldswith all accessories as per Data sheet, PTS-Instrumentationwith appendices (P.013312-D-11077-081) and Scope of WorkC&I (P.013312-D-11039-001)

Nos. 6

2

Supply of Pressure gauge including high range and low rangealong with 2 valve manifolds, gauge saver with all accessoriesas per Data sheet, PTS-Instrumentation with appendices(P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos. 19

3

Supply of temperature element (RTD) along with flangedthermowell mounted for underground and above groundpipeline with all accessories as per Data sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work C&I (P.013312-D-11039-001).

Nos. 6

4

Supply of Temperature Transmitter with all accessories as perData sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos. 9

5Supply of skin type temperature element (RTD) for aboveground pipeline with all accessories as per Data sheet PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work C&I (P..013312-D-11039-001).

Nos. 3

7Supply of Local control panel with all accessories as per Datasheet, PTS-Instrumentation with appendices (P.013312-D-11077-081 and Scope of Work C&I (P.013312-D-11039-001).

Nos. 3

10Supply of Ex-proof junction box with all accessories as perData sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

Nos 3

11Supply of Corrosion Monitoring system with corrosion coupon,Corrosion probe, transmitter and digital indicator (mounted inLCP) as per Data sheet, PTS-Instrumentation with appendices (P.013312 D 11077 081) and Scope of Work.

a Corrosion coupon along with accessories. Nos 3

b Corrosion probe along with transmitter, digital indicator,barriers and accessories.

Nos 3

12

Supply of Conventional Type Microprocessor based firedetection system along with smoke detector, heat detector,cabinet, manual call point, Independent 24 Hrs battery backupwith 15 min in alarm state, repeater panel and ElectricalOperated Siren, exit signs as per Data sheet, PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work.

a Controller along with cabinet Nos 3

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b Multisensor (Smoke detectors + Heat) Nos 24

c Manual call points Nos 15

d Ex Proof manual call point Nos 3

e Repeater panel Nos 3

f Exist sign Nos 9

g Electrical siren Exd Nos 3

h 24 Hrs battery backup Nos 3

13

Supply of Addressable type gas detection system along withcontroller, ex proof point gas detectors, beacon hooter, flasher,, cabinet, portable gas detector, calibration kit, alignment kit asper Data sheet, PTS-Instrumentation with appendices(P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).

a Controller with cabinet Nos 4

b Point gas detectors Nos 25

c OPGD Pairs 13

d Dual tone Hooter & Beacon Nos 3

d Dual tone Hooter & Beacon Ex “d” Nos 3

e Junction Box (Ex d) Nos. 3

19

Suppy of 24 Fibre Composite armoured Optical Fibre Cabledrum (24 fibre G-652) of 4 km +/-5% Cable drum length withfiber terminal closure, inspection chamber, electronic routemarker all along pipeline route, Two number electronic locateras per PTS-Optical Fibre cable (P.013312-D-11077-083) andScope of Work C&I (P.013312-D-11039-001).

Mtrs 67000 Mtrs

a Inspection chamber (fabricated or readymade) Nos 17

b Supply of jointing closure 24 Fiber, 2 way including allaccessories (3M, Siemens, Reychem make only)

Nos 17

c Supply of FTC with pig tails other accessories for terminationof OFC - 24 Fibre in the Telecom Room

Nos 3

d Electronic marker Nos 17

20Supply of HDPE duct along with all the required accessories asper PTS- HDPE (P.013312-D-11039-084) and Scope of WorkC&I (P.013312-D-11039-001).

Mtr 69000 Mtrs

21

Supply of Instrumentation signal cable, control cable,communication cable/LAN cable, Power cables along with allsizes cable glands (WP & Exd), PVC hood, lug, ferrule, etc asper PTS-Instrumentation with appendices (P.013312-D-11077-081), and Scope of Work C&I (P.013312-D-11039-001).

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a 1Px1.5mm2 Mtrs 475

b 12Px0.5mm2 Mtrs 240

c 1Qx1.5mm2 Mtrs 225

d 12Tx1.5mm2 Mtrs 320

e 1Tx1.5mm2 Mtrs 750

f 6Px0.5mm2 Mtrs 240

g Cat 5 (LAN) Mtrs 210

22

Supply of Instruments cable tray with tray cover as perrequirement and as per PTS-Instrumentation with appendices(P.013312-D-11077-081) and Scope of Work C&I (P.013312-D-11039-001).Branch Cable tray (50mm x 50mm), Main cable tray 900 mm,cable tray 300mm, cable tray 150 mm.

LS 1

23

Supply tubes and fittings as per requirement and as per PTS-Instrumentation with appendices (P.013312-D-11077-081) andScope of Work C&I (P.013312-D-11039-001).SS 316L TEE (1/2”, Class 3000#, Screwed, NPTF, Seamless),SS316L GLOBE/BALL VALVE (1/2”, Class 800#, Screwed,NPTF, Seamless), SS316L PLUG (1/2”, Screwed, NPTM, Hexhead, class 3000#), SS316L PIPE NIPPLE (½” NPTM,seamless, schedule #160) Length of the pipe nipple as perrequirement, SS316L MALE CONNECTOR (1/2" OD x 1/2"NPTM), SS316L FEMALE CONNECTOR (1/2”OD x 1/2”NPTF), SS316L UNION (1/2” OD), SS316L TUBE (1/2" ODx 0.065" WT), SS316L TUBE (1/4" OD x 0.035" WT)

LS 1

24 Supply of mandatory spares as per Mandatory Spare(P.013312-D-11077-101)

LS 1

25 MCT (Multi cable transit) LS 1

26 FM-200 LS 1

27 CO2 LS 2

Note

All above given quantities of equipment and cable sizes are tentative and may vary as per site &functionality requirement. Bidder is also required to ascertain the equipment & quantity those are notmentioned herein but require according to functionality and their standard practices/ system. No extraclaim will be entertained after award.

B ERECTION/ SERVICES

1 Erection, Installation, testing, site calibration andcommissioning along with associated accessories, fittings,tubing etc of Field instruments as per scope of work.

LS 1

2. Erection, Installation testing, commissioning, SAT of localcontrol panel, integration with GDS, FDS etc. along withsupports/ frame fabrication including earthing and screwingplug for unused entries and painting along with associated

LS 1

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accessories as per scope of work

3 Erection, Installation testing, commissioning, SAT of gasdetection system, along with supports/ frame fabricationincluding earthing and screwing plug for unused entries andpainting along with associated accessories as per scope of work

LS 1

4 Erection, Installation testing, commissioning, SAT of Firedetection system, along with supports/ frame fabricationincluding earthing and screwing plug for unused entries andpainting along with associated accessories as per scope of work

LS 1

5 Erection, Installation testing, commissioning, SAT of corrosionmonitoring system, along with supports/ frame fabricationincluding earthing and screwing plug for unused entries andpainting along with associated accessories as per scope of work

LS 1

6 Erection, Installation of metering panel, along with supports/frame fabrication including earthing and screwing plug forunused entries and painting along with associated accessoriesas per scope of work

LS 1

7 Erection, Installation junction boxes along with supports/ framefabrication including earthing and screwing plug for unusedentries and painting along with associated accessories as perscope of work

LS 1

8. Cable laying (buried as well as tray) as per scope of work forsignals / control/ power/Triad / earthing / communication cable(Rs-485)/LAN along with termination, glanding, meggeringand loop checking including supply of ferrule, lugs, cable tie,cable clamp, cable marker etc.

LS 1

9 Cable try laying as per scope of work of each size includinginstallation of support, cable clamping, installation of traycover and support painting.

LS 1

10 Erection, Installation MCT. LS 1

11 Installation of FTC & Wire mesh, termination of OFC on FTC/ DDF inside control room, splicing with steet fibre, fibre test,OTDR test, power testing of laid OFC, identification of fault,rectification, earthing, final testing and commissioning,preparation of reports, etc. work complete in all respect with allnecessary accessories for all location till final Handing Overand Taking Over by Owner of laid OFC.

LS 1

12 Installation of CO2 system with its control panel. Interfacewith fire detection system. (2 Stations)

LS 2

13 installation of Clean agent system with its control panel.Interface with fire detection system. (1 Stations)

LS 1

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B. REMARKS / COMMENTS

2.0 GENERAL NOTES

VENDOR's compliance

Vendor shall submit his bid in full compliance with the requirements of this MR and attachments.

Vendor must include the following statement in his bid:

We certify that our bid is fully complying with your enquiry dated…………… andreferenced………………….

Compliance with this material requisition in any instance shall not relieve the Vendor of his responsibilityto meet the specified performance.

3.0 COMPLIANCE WITH SPECIFICATION

The VENDOR shall be completely responsible for the design, materials, fabrication, testing, inspection,preparation for shipment and transport of the item strictly in accordance with the Material Requisition andall attachments thereto.

4.0 VENDOR'S SCOPE

Vendor's scope of work includes all the items with its internals and accessories as shown on the data sheets,specifications and all unmentioned parts necessary for a satisfactory operation.

5.0 INSPECTION

Vendor shall appoint anyone of the following TPIA for inspection purpose.

a) Lloyd Register of Industrial Services

b) TUV NORD

c) DNV-GL

d) Bureau Veritas (BV)

e) SGS

f) CEIL

Apart from inspection by TPIA, inspection shall also be performed by Owner and / or Owner authorisedrepresentative.

6.0 APPLICABLE DOCUMENTS

General prescriptions, requirements and information are listed in annex C of this Material Requisition.

7.0 VENDOR'S DOCUMENTS

Vendor shall submit the documentation as listed under point D of this Material Requisition.

All documents shall be submitted in English language.

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B. LIST OF ATTACHMENTS

The table herebelow lists the documents which are integral part ofthis MaterialRequisition. The applicable revision index of each document ismentioned in the column below the current Material Requisitionrevision index.

Material Requisition revision

When the Material Requisition revision index is “A” or “1”, alllisted documents are attached. For other Material Requisitionrevision index, only modified or new documents are attached.

0 1 2 3

Documents Revision of documents

1. Design basis Instrumentation 0

2. Material Requisition -

3. Scope of Work – 0

4. PTS- Instrumentation with Appendices-Appendix -1 – Spare capacityAppendix- II – Instrument IndexAppendix – III – Instrument Data sheets

a. Pressure Transmitterb. RTD with thermowellc. Skid type RTDd. Temp Transmittere. Pressure gaugef. WP junction boxg. Ex Junction boxh. Gas detectors controlleri. Point gas detectorsj. Open Path Gas detectork. Hooterl. Beaconm. Local control paneln. Panel indicatoro. Multisensorp. Manual call pointq. PSV

0

5. PTS – Optical Fiber cable 0

6. PTS – HDPE Duct – 0

7. Mandatory spares 0

8. QAP- Pressure and temp transmitter 0

9. QAP -Pressure gauge 0

10. QAP- RTD with thermowell 0

11. QAP- Optical Fiber cable 0

12. QAP- HDFE duct 0

13. QAP – Instrument cables 0

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The table herebelow lists the documents which are integral part ofthis MaterialRequisition. The applicable revision index of each document ismentioned in the column below the current Material Requisitionrevision index.

Material Requisition revision

When the Material Requisition revision index is “A” or “1”, alllisted documents are attached. For other Material Requisitionrevision index, only modified or new documents are attached.

0 1 2 3

Documents Revision of documents

14. QAP – Junction box 0

15. QAP – Gas detection system 0

16. QAP – Local control panel 0

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C. DOCUMENTS & DATA REQUIREMENTS

The table hereunder specifies the quantities and the nature of the documents to be submitted by the CONTRACTOR tothe ENGINEER.The documents required at the inquiry stage and to be included in the bid are listed under column A.The documents required after award of the AGREEMENT and subject to the written approval of the ENGINEER arelisted under column B.The final and certified documents are listed under column C.Any document, even when preliminary, shall be binding and therefore duly identified and signed by the CONTRACTOR.THE DOCUMENTS ARE FULLY PART OF THE SUPPLY WHICH SHALL BE COMPLETE ONLY IF AND WHENTHE DOCUMENTS COMPLYING FULLY WITH THE MATERIAL REQUISITION REQUIREMENTS ARERECEIVED BY THE ENGINEER.

Documents and DataDoc.Index

No

A B C

Numberof copies

Numberof

copies

Requireddate

Numberof copies Required

date

Sign and stamp copy of all the PTS, MR,scope of work and recommended vendorlist

- 1 - - - -

Station-wise Power Consumptionrequirement of all electronic instruments.Fire & Gas Detection system, CMS and LCP,RTU, Telecom system

PCR - 6 2 weeks 8 2 Weeks

G.A, wiring and termination details Drawingalso specification, data sheet, catalogues ofFire Detection system

FDS - 6 2 weeks 8 2 Weeks

G.A, wiring and termination details Drawingalso specification, data sheet, catalogues ofGas Detection system

GDS - 6 2 weeks 8 2 Weeks

G.A, wiring and termination details Drawingalso specification, data sheet, catalogues ofCorrosive monitoring system

CMS

G.A, wiring and System ArchitectureDrawing , termination details , specificationfor local control panel system

LCP - 6 2 weeks 8 2 Weeks

Specification, data sheets of OFC, PLB-HDPE duct.

OFC - 6 2 weeks 8 2 Weeks

Specification, data sheets, test certificate ofinstrumental cables

ICS - 6 2 weeks 8 2 Weeks

Field instruments data sheets, catalogues,Statutory approvals / certificates etc. asapplicable.

IDS - 6 2 weeks 8 2 Weeks

Bill of material BOM - 6 2 weeks 8 2 Weeks

Mandatory spares list ECS - 6 2 weeks 8 2 Weeks

Operation & Maintenance manuals OMM - 6 2 weeks 4 2 Weeks

NOTES

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1) Durations in column B (Required date) are weeks after LOA date or as indicated in table

2) Durations in column C (Required date) are weeks before final despatch.

3) Final technical document file shall be supplied in hard copy as indicated and in electronic format(pdf Acrobat files) on six (6 Nos.) CD-ROMs.

S S S

Page 27 of 261

PTS – INSTRUMENTATION WITHAPPENDICES

P.013312D 11077

081



PTS – INSTRUMENTATION WITH APPENDICES

DOC. NO. P.013312 D 11077 081



Page 28 of 261


P.013312D 11077

081


TABLE OF CONTENTS1.0 SCOPE ................................................................................................................................. 1

2.0 REFERENCE ......................................................................................................................... 1

3.0 DEFINITIONS ...................................................................................................................... 1

4.0 REVIEW AND/OR APPROVAL .............................................................................................. 1

5.0 APPLICABLE CODES & STANDARDS ................................................................................... 2

6.0 STATUTORY APPROVALS / CERTIFICATES (AFTER GETTING ORDER)............................... 4

7.0 ABBREVATIONS .................................................................................................................. 4

8.0 ENGINEERING UNITS ......................................................................................................... 4

9.0 DESIGN PRINCIPLES .......................................................................................................... 5

10.0 INSTRUMENTATION EARTHING SYSTEM ........................................................................... 7

11.0 ENVIRONMENTAL SPECIFICATIONS .................................................................................. 7

12.0 POWER SUPPLY .................................................................................................................. 8

13.0 INSTRUMENTS SPECIFICATION ......................................................................................... 8

14.0 LOCAL CONTROL PANEL ..................................................................................................... 9

15.0 INSTRUMENT CABLES ....................................................................................................... 13

16.0 FIRE DETECTION SYSTEM ................................................................................................ 16

17.0 GAS DETECTION SYSTEM.................................................................................................. 20

18.0 INSTALLTION MATERIAL SPECIFICATION ....................................................................... 23

19.0 CORROSION MONITORING SYSTEM ................................................................................ 24

20.0 INSPECTION AND TESTING .............................................................................................. 26

21.0 PAINTING, MARKING AND SHIPMENT ............................................................................. 27

S S S

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P.013312D 11077

081


1.0 SCOPE

1.1 This document covers design, engineering, testing at works, supply, installation, calibration, erection,testing at site and commissioning, guarantee run, handing over of control and instrumentation systempackage which includes all field instruments, local control panel, fire and gas detection system, instrumentcables, OFC cables and PLB HDPE Duct for this PROJECT.

1.2 Scope also includes the supply, erection and installation of erection material, fabrication, cable laying,fittings, flanges, connectors, impulse tubing and all the associated accessories as required.

1.3 Refer Instrumentation scope of work as enclosed with tender document.

2.0 REFERENCE

· Scope of work – P.013312 D 11039 001

Note –

In the event of any conflict between GTS and PTS, PTS shall prevails over the GTS

3.0 DEFINITIONS

Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in thisspecification are given the following meaning:

AGREEMENT Designates the agreement concluded between the CLIENT and theCONTRACTOR, under which the latter undertakes to the former theGOODS and/or SERVICES according to the stipulations which are agreedand specified in the form of an order.

CLIENT Designates the purchaser of the GOODS and/or SERVICES which are thesubject of the AGREEMENT.

CONTRACTOR Designates the individual or legal entity with whom the order has beenconcluded by the CLIENT. The term "CONTRACTOR" may be usedindifferently for a supplier, a manufacturer, an erection contractor, etc.

DAYS - WEEKS – MONTHS Specify the number of calendar days, weeks or months and not of workingdays, weeks or months.

ENGINEER Designates the individual or legal entity to which the CLIENT hasentrusted various tasks in relation with the carrying out of his PROJECT

GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents,substances, materials, materiel, equipment, structures, plant, tools,machinery to be studied, designed, manufactured, supplied, erected, built,assembled, adapted, arranged or put into service by the CONTRACTORunder the AGREEMENT, including all the studies, tasks, works andservices specified by the order. The Terms GOODS or SERVICES may byindifferently used one for the other as required by the context.

PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided byone or more CONTRACTORS.

4.0 REVIEW AND/OR APPROVAL

Whenever CLIENT and/or ENGINEER review and/or approval is requested on a document to be submittedby the CONTRACTOR, or before an action is implemented by the CONTRACTOR, such review and/orapproval shall always be requested in writing by the CONTRACTOR to the CLIENT and/or theENGINEER, before any action subject of this review and/or approval is taken.

CLIENT and/or ENGINEER approval shall always be given in writing.

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P.013312D 11077

081


5.0 APPLICABLE CODES & STANDARDS

The following Indian/ international or relevant codes and standards shall be used for designing the system.In all cases, latest revisions with amendments, if any, to be followed Apart from the specific codesmentioned herein, all other relevant and related codes concerning the specific job under considerationand/or referred to in these codes and technical specifications will be followed wherever applicable. Allcodes will be of the latest revision as on the date of issuing the tender/ bid document.

In the event of any conflict between this specification, related standards and codes, any other attachment tothis tender, the Contractor shall refer the matter to OWNER’S/OWNER’ REPRESENTATIVE forclarification and only after obtaining the confirmation on the same, should proceed with the manufacture/supply / engineering of the item in question. The decision of the OWNER’S/OWNER’REPRESENTATIVE shall be binding on the Contractor.

CONTRACTOR shall seek CLIENT final interpretation of any conflicts prior to the execution of work.Rework of engineering and relevant scope arising out of underestimation shall be done at no additional costto the CLIENT.

Sr.No

Codes Description

1 OISD-STD-226 Natural Gas Transmission Pipelines and City Gas Distribution Networks.2 ANSI/ISA S 51.1 Process Instrumentation Terminology.3 ISA 5.4 Instruments Loop diagrams.4 IEC 60529 / IS

2147 / NEMASpecification for Weather Proof Enclosure.

5 IEC 60079 Specification for Flame Proof Enclosure6 IEC 61000 Electromagnetic Compatibility for Industrial Process Measurement and

Control equipment.7 IEC 60801 EMI and RF interference8 IS-1554 Part 1 PVC insulated (heavy duty) electric cables- working voltage up to and

including 1100V.9 BS-5308 Part 1,

Type 2Specification for PVC insulated cables.

10 IS 8130 Conductors of insulated cables11 IS 5831 Specification for PVC insulation and sheath of insulated cables.12 IS-3975 Mild steel wires, formed wires and tapes for armoring of cables.13 ASTM D 2843 Test method for Max smoke density for cable14 ASTM D 2863 Test method for measuring of Temp and O2 Index.15 IEC 60754 Acid generation test16 IEC-332-3 Part 3 Tests on bunched wires and cables.17 BS 6121, EN

50262Cable gland – flame proof Ex”d” or Exe increase safety.

18 DIN- 50049 Document on Material Testing.19 ASME PTC 19.3 Temperature Measurement- calculation of natural frequency.20 IEC 751 / DIN

43760RTD

21 IEC 584/DIN43710 / ANSI MC96.1

Thermocouple

22 ISO 5167 Measurement of fluid flow by means of orifice plates, Nozzles and Venturitube inserted in filled piping circular profile.

23 ASME B 16.36 Orifice flange with flange pressure tap.24 ASME B16.5 Pipe line flanges and flanged fittings25 API-RP-520 Sizing and selection of safety relief valves.

26 IS 3624 / BS EN837

Pressure gauge

27 AGA 3 Orifice flow measurement

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Sr.No

Codes Description

28 AGA 9 Ultrasonic flow measurement29 AGA 8 Compressibility factor of natural gas.30 AGA 10 Calculation of Speed of sound in Natural gas31 API Spec 6A Valve design methodology32 API 6D Petroleum and natural gas valve33 ISA 75.01 Flow equation for sizing of control valve34 ISA 75.02 Testing of CV rating , control valve capacity test35 ISA 75.05 Control valve terminology36 ISA 71.07 Laboratory measurement of aerodynamic noise generated by control valves.

37 FCI 70.2/ANSI B16.104

Control valve seat leakage.

38 ASME/ANSI B16.34

Valves-Flanged, Threaded and welding end.

39 IEEE 802 The LAN standards.

40 IEC-60870-5-104/101 SCADA Communication protocol

41 DNP 3 (TCP/IP),DNP 3 (Modbus) SCADA Communication protocol

42 IEC 61131 RTU, remote terminal unit

43 IEC 60870-5-101 Modbus serial RS232/Rs485

44 ISA 5.3-1983 Graphic Symbols for Distributed Control/Shared Display Instrumentation,Logic, and Computer Systems.

45 ISA-5.5-1985 Graphic Symbols for Process Displays

46 TIA/EIA 58 Communication standard

47 OISD Oil Industry Safety Directorate Government of India

47.1 OISD 118 Layouts for Oil & Gas installations

47.2 OISD 152 Safety Instrumentation for Process System in Hydrocarbon Industry

47.3 OISD 153 Maintenance and Inspection of Safety Instrumentation in HydrocarbonIndustry

47.4 OISD 163 Process Control Room Safety

47.5 OISD 195 Safety in Design, Operation, Inspection and Maintenance of HydrocarbonGas Compressor stations and Terminals

48 NFPA National Fire Protection Association48.1 NFPA-70 National Electrical Code

48.2 NFPA-497 Electrical installation, classification of Class1 & Class 2 hazardouslocations

48.3 NFPA-101 Life Safety Code

48.4 NFPA 325M Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solidsfor LEL of Gases

49 PNGRB Technical & safety standards statutory requirements for natural gaspipelines.

50 AGA 7 Turbine flow measurement

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6.0 STATUTORY APPROVALS / CERTIFICATES (AFTER GETTING ORDER)

6.1 The bidder shall be responsible for obtaining all statutory approvals, as applicable for all instruments andinstrumentation systems.

6.2 Equipment / instrument / systems located in electrically hazardous areas shall be certified for use bystatutory authorities for their use in the area of their installation. In general, following certification shall beprovided by the bidder.

a. For all flameproof equipment / instrument / systems, which are manufactured abroad (outside India)certification by any approving authority like BASEFA, FM, UL, PTB, LCIE, CENELEC etc. shall berequired.

b. For all flameproof equipment / instrument / systems manufactured locally (within India), certificationshall be carried out by any of the approved testing houses – Central Mining Research Institute (CMRI)etc. The manufacturer shall hold a valid Bureau of Indian Standards (BIS) license.

c. Approval certificate from Chief Controller of Explosives (CCE) or Petroleum and Explosive Safetyorganisation (PESO) is mandatory for all electronic / electrical instruments / equipment to be installedin India, irrespective of country of origin.

7.0 ABBREVATIONS

· ISO (International Standards Organisation)

· IS (Indian Standards).

· IEC (International Electro technical Commission).

· ASTM (American Society for Testing Materials).

· EIA (Electronics Industry Association).

· BIS (Bureau of Indian Standards).

· IEEE (International Electrical and Electronics Engineers).

· CCE (Chief Controller of Explosives, Nagpur).

· PT – Pressure transmitter

· TE – Temperature element

· TT – Temperature Transmitter

· RTU – Remote terminal unit

· SCADA – Supervisory control and data acquisition system

· GOOAV – Gas over oil actuated valve

· HOV – Hydraulic operated valve

8.0 ENGINEERING UNITS

a

FlowGas Sm³/hr / MMSCMDMass flow kg/hr.Volumetric flow m³ / hr.

b Pressure Bargc Temperature °C.d Level %.

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9.0 DESIGN PRINCIPLES

9.1 General

Instrumentation and control and monitoring systems shall be in accordance with this specification and asdefined in the P & I Diagrams.

9.2 Instrument Selection

Instruments and instrumentation systems of proven reliability and latest technology shall be used.

Selection of instrumentation shall be made from the RECOMMENDED Instrument Supplier Lists.

Any exception has to be justified and is subject to approval by the CLIENT.

9.3 Tagging

All instruments and instrumentation equipment shall be permanently identified by tags, labels and/ornameplates. Use of adhesive tapes shall not be allowed.

9.4 Painting

Manufacturer's standard colours shall be used for all instrumentation equipment in control and instrumentrooms, unless otherwise specified.

Field instruments shall generally be epoxy painted, unless otherwise specified.

9.5 Transmission Systems

Transmission of the process variables shall generally be by means of electronic or low level signals. Theoutput signal for electronic instruments shall be 4 to 20 mA DC or digital.

No process fluid shall be piped into the control rooms or the instrument rooms.

9.6 Enclosures And Materials

All instruments shall be suitable to withstand the environmental conditions specified for the plant location.

All parts subject to moisture, fungus growth or insect attack shall be suitably treated (Tropicalisation).

Local instrument housings shall be weather-proof (IP 65 minimum) and meet the electrical areaclassification requirements.

All parts of instruments exposed to process fluids shall be resistant to corrosion by the corresponding fluid.

9.7 Electronic Instrumentation In Hazardous Areas

In hazardous areas, intrinsically safe instrumentation shall be provided in general.

If not possible or not practical, flameproof protection concepts may also be used wherever applicable.

All electrical instruments to be installed in hazardous locations shall be ATEX certified. Contacts shall beencapsulated, hermetically sealed and, if used in intrinsically safe circuits, contacts shall be gold plated.

9.8 R.f. Immunity

All instruments and control systems shall be immune from the effects of any R.F. interference that mayoccur at the plant location in accordance with IEC 801 "Electromagnetic compatibility for industrial-processmeasurement and control equipment".

Equipment to be installed inside the control room shall be in compliance with the European Communitydirective requirements, denoted by the "CE mark". This compliance shall extend to each relevant item.

9.9 Electromagnetic Interference

The equipment offered shall incorporate the most effective techniques available to minimize theelectromagnetic interference effects to ensure that other electronic systems neither adversely affect nor get

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adversely affected by the system supplied by the contractor. The contractor shall ensure that theelectromagnetic interference generated by the system is well below the permissible levels as per applicablestandards.

The equipment shall be required to meet one or more of the following standards:

a) IEC 801 – 3 –Latest edition

b) BS 6667- PART 3 - Latest edition

c) ANSI/ IEEE C 37.1- Latest edition

d) MIL – STD - 461

e) VDE 0871

The equipment to be supplied shall be type tested for Electromagnetic Compatibility if certificate ofcompliance from an independent test authority or test laboratory cannot be furnished.

9.10 Engineering And Design Documents & Drawings

The documents and drawings to be prepared by the CONTRACTOR are listed hereunder.

9.11 Documents

As a minimum requirement, the following documents shall be provided, whenever applicable.

· Instrument data sheets

The data sheets shall comprise all necessary technical data associated with the Instruments as per theenclosed format.

· Certification files

They shall contain copies of all electrical safety certificates and all documents applicable to the safety ofelectrical equipment installed in hazardous areas (e.g. intrinsically safe loop specifications, " Explosionproof certificate, CCOE certificate etc").

9.11.1 DRAWINGS

As a minimum requirement, the following drawings shall be prepared, when applicable.

· Logic drawing

Plant logic drawings with all the interlocks details for GOOAV, fire detection system, gas detectionsystem and wherever applicable.

· Cable schedule

The cable schedule shall indicate details of the required cables (e.g. cable number, type, length,termination points, pair no, colour code etc.).

· Cable layout drawings

The cable layout drawings shall show the main routing of instrument cables and the location of allinstrument junction boxes and local panels.

· Wiring diagrams

The wiring drawings shall show all cable termination details for junction boxes, cross boards, controlcabinets, power supply cabinets, auxiliary cabinets, control panels, desks, etc.

· Earthing drawings

The earthing drawings shall show the requirements of earth strip / cable cabling up to the earthingsystems.

· Loop diagrams

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The loop diagrams shall show the connections between components of each loop with identification ofterminals and cables.

· Control room layout drawings

Those layout drawings shall show the location of panels inside control room, front and reararrangements and all the main sizes of panels, cabinets and desks.

· Process hook-up drawings

The process hook-up drawings shall show installation details for the various instruments, complete witha schedule of required material. Contractor to refer attached standard drawings.

10.0 INSTRUMENTATION EARTHING SYSTEM

10.1 General

The earthing for electrical earth and electronic earth shall be arranged to provide safe installations, andto prevent electrical interference with their operation.

All earthing and shielding shall comply with the requirements of all standards applicable to the areaclassification in which the equipment is installed.

10.2 Instrument cases, panels. etc.

a) All parts of field installations, e.g. Cable trays, junction boxes, local panels, instrument housings,conduits, cable armour, etc.., shall be effectively grounded via the general plant earthing system.

b) Earthing of cable trays shall be in accordance with the IEC requirements as a minimum.

10.3 Each supplied instruments, local control panel, fire detection panel, gas detection panel system shall haveearthing lugs with their frames. All these lugs/ strips shall properly secured to the electrical earthing bus.

10.4 All system grounds of various cards and equipment, shields of signals (instrument) cables shall connect tosystem ground bus, which is electrically isolated from the AC mains earthing bus. The equipment shallprovide separate earthing strip for the same. The system ground bus will have independent ground busesthrough insulated wires.

a) System grounding (earth resistance less than 1 ohm)

b) Frame and AC mains grounding (earth resistance less than 5 ohms)

10.5 Lightning protection

Where connections between control systems and/or distant equipment may be affected by lightning surgesor by other inducted high voltages, the connection cables shall be equipped with over-voltage arresters.

11.0 ENVIRONMENTAL SPECIFICATIONS

All equipment shall be designed for operation, storage and transportation under the following environmentalcondition:

Max. / Min. Temperature : 0 °C / 55 °C

Design temperature : (-) 20 °C to 60 °C

Relative Humidity : 95%

Hazardous Area Classification : Zone 2, Gas Group II A or B, Temp.Class T 3

Control Room & Electrical Room : Safe Area

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12.0 POWER SUPPLY

Electrical power supply shall be provided at one point inside the battery limit as per the details providedbelow. Further distribution shall be in the scope of the CONTRACTOR. If any other voltage levels arerequired, then all necessary conversions shall be in the scope of CONTRACTOR.

Normal supply : 230 V AC, 24 V DC and 48 V DC power supply shall be provided at all thestations for local control panel , F&G panel, RTU , telecom and all theassociated facility available at station. (Refer electrical PTS for details)

13.0 INSTRUMENTS SPECIFICATION

13.1 Pressure Gauges (PG)

PG shall be Direct-mounting type having element of bourdon tube and dial size of 150 mm. It shall haveshatterproof glass. Connection shall be ½” NPT (M) from bottom. Enclosure shall be weather proof to IP65.Protection shall be 130% over range. Accuracy shall be ±1% of FSD. PG shall have blown out disc facility.For higher pressure applications (above 60 Barg), it shall be solid front type.

Pressure gauge dial shall be white, non-rusting plastic with black figures. The dial face shall be markedwith pressure element material. Pointers shall have micrometer adjustment.

Pressure gauge sensing element shall be of SS 316 and moving elements of SS 304, as a minimum.

13.2 Pressure Transmitter (PT)

PT shall be intrinsically safe electronic SMART type transmitters compatible with HART protocol of latestversion. All transmitters shall be 2-wire type with integral digital indicator. Enclosures shall be Weatherproof to IP 65. Pressure transmitters shall be capacitance / piezo-resistance type. Process entry and cableentry shall be ½” NPT (F). Accuracy of Pressure transmitter shall be ± 0.075% of span. Transmitters O/Pshall be 4-20 mA DC. Surge protection device shall be provided with the transmitter to protect theinstruments from lightning or any kind of hazardous surge

13.3 Temperature Transmitters (TT)

TT shall be intrinsically safe electronic SMART type transmitters compatible with HART protocol of latestversion. All transmitters shall be 2-wire type with integral digital indicator. Transmitter shall have dualcompartment housing. Enclosures shall be Weather proof to IP 65. Two Cable entry shall be provided, one½” NPT (F) for output signal and one ½” NPT (F) for RTD input. Accuracy of Temperature transmittershall be ± 0.18% of FSD. Transmitters O/P shall be 4-20 mA DC. Surge protection device shall beprovided with the transmitter to protect the instruments from lightning or any kind of hazardous surge

13.4 Resistance Temperature Detector (RTD)

Temperature element shall be immersion type and skin type with temperature transmitter. Skin type elementshall be provided at vent line as per P&ID along with weld pad and associated accessories

Resistance temperature detector (RTD) shall be spring loaded, mineral insulated and shall have stainlesssteel sheath as a minimum.

RTD are four wire type and element shall be Pt100 as per DIN 43760/IEC 60751 & accuracy class A. RTDshall be thermowell mounted. All RTDs shall have duplex elements with Pt-100 ohms, Type A. Cable entryshall be ½” NPT (F). Two separate cable entries shall be provided with one plug. RTD sheath OD shall be10 mm and material SS 316.

13.5 THERMOWELL - Refer data sheet- P.013312 D 11077 081

All temperature measuring instruments shall be provided with thermowell. The process connection shall beflange type. Minimum line size for thermowell connection shall be 4”. For lower line size, same shall beexpanded to 4”.

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The thermowell shall be constructed from drilled bar stock of SS316 material. Thermowell shall have asufficient internal bore to properly accommodate the devices, which are to be placed in the bore.

All thermowells shall be stress analysed for velocity conditions. Calculation shall be done as per ASMEPTC 19.3 code. 100% radiography shall be conducted for all fabricated thermowells. Thermowells of longlength shall be provided with alternate arrangements as per standards.

Immersion length of thermowell shall be a follows

Line size Immersion length

From 4” to 6” 280mm

From 8” onward 320mm

Vessel/ Column 400mm

13.6 Differential Pressure Switch

Differential pressure switch enclosure will be Weather proof IP65, process entry from Bottom /side entry,Process connection ½” NPT (F), Pressure element will be Diaphragm (material SS316), Setting adjustable,Switch DPDT switch, Cable entry ½” NPT (F). Differential pressure switch shall be intrinsically safe.

13.7 All instruments impulse line (1/2” tubes) shall be consist of tubing and piping. The impulse tube shall beSS316 and all the impulse pipes shall be CS/LTCS. Compressed type ferrule fitting such as ½” NPT (M),NPT (F) fittings (male/female connectors), ½” tee, ½” union including ½” isolation needle/ball valves &other accessories shall be SS316.

13.8 A universal type Hand Held Configurators for transmitters with carrying case, rechargeable batteries (oneworking and one standby), and battery charger shall be provided for this project.

13.9 Solenoid Valves

The solenoid valve shall be of 3 way, universal type with manual operation facility. The body and internalsshall be of SS 316. Valve shall be made leak proof with 'O' ring seals. The solenoid valve shall haveweather proof and intrinsically safe, suitable for the hazardous area. The power supply shall be 24VDC.Instrument natural gas supply connection shall be 1/4" or 1/ 2” NPT (F). Solenoid valve shall be providedwith integral junction box, having 1/2" NPT (F) cable entry. Surge suppression diodes shall be providedacross the coil. Coil class shall be Class “F”

13.10 Valve Position Switch

Valve position switches for open / close position indication shall be of sealed micro type lever operated.The switch shall be of DPDT type with contact rating 24V DC, 2 Amp suitable for inductive load. Theswitch enclosure shall be dia cast aluminium, weather proof and intrinsically safe suitable for hazardousarea. Valve position switch shall be provided with integral junction box having 2 nos. of 1/2" NPT (F) cableentries.

14.0 LOCAL CONTROL PANEL

14.1 GENERAL

14.1.1 Refer -INSTRUMENTATION OPERATIONAL PHILOSOPHY enclosed with tender document.

14.1.2 This specification covers the design, manufacturing, testing at works and dispatch in well packed conditionof Local Control Panels. Contractor’s scope shall also include the panel erection, commissioning, test atsite.

14.1.3 However, this does not absolve vendor of their responsibility for proper design of the control panel to meetall the functional requirements as per the tender specification.

14.1.4 All the instrumentation cables including laying, glanding, and termination & ferruling from local instrumentto JB, JB to Control Panel shall be in Contractors Scope for making the system functional.

14.2 SPECIFICATION OF PANEL

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14.2.1 The panel shall be self-standing/wall mounted (Refer scope of work) supplied in dust & vermin proof, floormounted, sheet steel enclosure. Minimum degree of protection for panel shall be IP 42 as per IS-2147.

14.2.2 Enclosure shall be fabricated with cold rolled closed annealed (CRCA) steel sheet of minimum thickness1.6 mm and gland plate thickness shall be 3 mm. Panel door shall be 2mm thick.

14.2.3 Mounting height of equipment/components inside the floor mounted panel requiring operation andobservation shall not be lower than 300 mm and higher than 1600 mm. Size of the self-standing panelcabinet shall be 2100 (including 100 mm base frame) (H) x 1000 (W) x 800 (D) mm and size for wallmounted cabinet shall as per vendor design.

14.2.4 Cabinet shall have single door from front and double door from back for self-standing. Doors shall beprovided with lockable handles (flush pull chrome plated handles) and concealed hinges with pull pins foreasy door removal. Panel Doors shall be provided with pockets for storing of manuals/ drawings etc.

14.2.5 Panel shall be liberally designed. All components shall be so mounted that they are easily accessible forinspection & maintenance.

14.2.6 Colour of panel: RAL 7035 for the panel exterior and interior. Black for the base frame.

14.3 Panel shall have the following minimum accessories (as applicable):

a) Door switch

b) Cable glands

c) M.C.B.

d) 15A Power supply socket

e) Panel light

f) Lugs

g) Cooling Fan

h) Instrument / Electronic Earth bus 25 x 6mm copper

i) Body Earth bus 25 x 6mm copper

14.4 PANEL CONFIGURATION

14.4.1 Panel shall have the following minimum components:

· Pushbuttons,

· Indicating lamps,

· Selector switches,

· Digital display indicators,

· Power supplies,

· Barriers,

· Relays,

· Contactors,

· Terminal strips,

· Trough etc.

14.4.2 The panel shall be configured for instrumentation scheme as shown in the tender P&ID. The quantity ofindicators, lamps, push buttons, selector switches, barriers and signal multiplier shall be selectedaccordingly to fulfil the operational requirement of instrumentation scheme.

14.4.3 Panel shall have microprocessor based digital type channel indicator, LED, Push buttons, 3 position selectorswitches etc. as per requirement.

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14.4.4 All the signals from hazardous area shall be routed through suitable isolator/ barriers. The isolator / barriersshall be capable of powering the two wire transmitters in the field. All isolated 4-20 mA DC analog signals& potential free Digital signal shall be available for SCADA system. These signals shall be available atterminal block of instrument local control panel.

14.4.5 The barriers used shall be of isolator type and 1 in 2 out analog input barriers shall be used. Output fromisolator/barrier shall be connected to display unit in local control panel and repeated to SCADA/RTU as perrequirements.

14.4.6 The isolator/barrier for digital input shall be 1 in 1 out type and the multiplication of signal if required fordigital input shall be through interposing relays.

14.4.7 All field digital input/output (Non-IS) shall be connected through interposing relays.

14.4.8 The relays shall be of miniature type and shall have LED indication lamps with minimum of 2 NO and 2NC contacts. The digital signals repeated from local control panel to SCADA RTU shall be throughpotential relay contact.

14.4.9 Three position (P/S/M) selector switch shall be considered in the local control panel for selection of Panelmode (local panel), SCADA mode (SCADA) & Maintenance mode.

14.4.10 All the panel instruments shall be mounted on the panel as indicated in P&ID and instrument index/IO listincluding utilities like UPS/battery charger on/off, DG on/off, MEDB on/off, etc.

14.5 DATA SHEET OF INSTRUMENTS

14.5.1 Item : LED

Function Status display

Mounting Flush mounted

14.5.2 Item : Signal Multiplier & Barrier

Function To repeat signal to RTU /SCADA

Type Galvanically isolated

Signal Analogue

Input 4-20 mA

Output 4-20 mA

Output drive capability 0-600 ohm

No. of channels Two isolated output (minimum)

Accuracy 0.25% of full scale

Isolation Voltage 500 V DC or higher

14.5.3 Item : Push Button (with Execute / Cancel provision)

Type Stay put

Standards IEC 947-4-1, VDE 0660 CSA C22, UL 508 solid state.

Redundant As per IEC 86-2-27

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Electric Shock Protection As per IEC 536

Mechanical life 1 million operations

14.6 PANEL WIRING

14.6.1 All wiring shall conform to API-RP-550 Part I Section 7 & 12. Different signal level cables shall be routedunder false flooring with separation distances as recommended by API-RP-550 Section 7.

14.6.2 All wiring inside racks, cabinets and back of the panels shall be housed in covered, non-flammable plasticraceways arranged to permit easy accessibility to various instruments for maintenance, adjustments, repairand removal.

14.6.3 All wiring in the raceways shall be properly clamped. Total wiring cross-sectional area shall not exceed50% of the raceway cross-sectional area. Rubber / plastic grommets shall be used for wire entry intoindividual instrument and entry / exit of wires through raceways.

14.6.4 Separate wiring raceways shall be used for power supply wiring, DC and low level signal wiring andintrinsically safe wiring. Parallel runs of AC and DC wiring closer than 300 mm shall be avoided.

14.6.5 Vendor can alternately offer prefabricated cables for interconnection between different cabinets and panels.

14.6.6 Wire termination shall be done using self-insulating crimping lugs.

14.6.7 No more than two wires shall be terminated on one side of single terminal. Such a practice shall be avoidedas far as possible. The use of short-links for looping shall be avoided.

14.6.8 Terminal housing shall be strictly sized with considerations for accessibility and maintenance. Followingpoints shall be considered:

Description Distance

Distance between terminal strip and side of the cabinet parallel to the strip up to50 terminals

Min 50 mm

Distance between terminal strip and top & bottom of the cabinet Min 75 mm

Distance between two adjacent terminal strips Min 100 mm

Addition distance for each additional 25 terminals Min 25 mm

Distance between cable gland plate and the bottom of the strip Min 300 mm

14.6.9 All terminal strips shall be mounted on suitable anodized metallic or plastic standoff.

14.6.10 No splicing is allowed in between wire / cable straight run.

14.6.11 Terminal strips shall be arranged group wise for incoming and outgoing cables separately.

14.6.12 Cabinet and rack layout shall be made considering proper accessibility and maintenance.

14.6.13 Entire panel wiring including internal wiring shall be cross-ferruled.

14.6.14 All the instruments, switches, relays, timer as required shall be in the bidder’s scope to completeoperational scheme.

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15.0 INSTRUMENT CABLES

15.1 DESIGN & CONSTRUCTION

15.1.1 All cables shall be Flame retardant low smoke (FRLS) type.

15.1.2 Voltage Grade of cables shall be 650/1100 V.

15.1.3 1Px1.5 mm², 1Qx1.5mm², 2Px1.5 mm², 12Tx1.5mm², 6Px 0.5 mm², 12Px0.5 mm², 1Tx1.5mm² cables shallbe used for instrumentation purposes. No other combination shall be acceptable.

15.1.4 Cable shall be supplied in drum and negative tolerance in cable length for each drum shall not beacceptable.

15.1.5 1T x 1.5mm² shall be used for gas detection system. Quad cable shall be used for RTD. Single pair or twopair cable shall be used from field instruments to junction box.

15.1.6 Multi pair cable individual and over all shielded shall be used for all the analog signals from junction box tocontrol room and panel to panel inside the control room as applicable

15.1.7 Multi pair over all shielded cable shall be used for all the digital input /output signals from junction box tocontrol room and panel to panel inside the control room as applicable.

15.2 SINGLE PAIR AND QUAD SHIELDED CABLE

15.2.1 Each core shall be 1.5 mm2 made of 7 stranded annealed electrolytic copper conductor. Each strand shallbe 0.53 mm dia.

15.2.2 For Intrinsically safe application, primary insulation shall be low density poly ethylene (LDPE). For non-intrinsically safe application, primary insulation shall be 85°C polyvinyl chloride (PVC) as per IS5831 TypeC. Thickness shall be 0.5 mm minimum.

15.2.3 A pair shall have twisted cores and number of twists shall be not less than 10 per metre. Colour of coreinsulation shall be black blue in pair and black, blue and brown in triad.

15.2.4 Individual pair shall be shielded. Shield shall be Aluminium backed by Mylar/polyester tape with themetallic side down helically applied with either side 25% overlap and 100% coverage. Minimum shieldthickness shall be 0.05 mm. Drain wire shall be 0.5 mm2 multi-strand bare tinned annealed copperconductor. The drain wire shall be in continuous contact with Aluminium side of the shield.

15.2.5 Inner and outer jacket shall be made of extruded flame retardant 90oC PVC to IS 5831-Type ST2. Oxygenindex of PVC shall be over 30%. Temperature Index shall be over 250°C. The thickness of the jacket shallbe as per IS-1554 Part 1.

15.2.6 Inner jacket colour shall be black. Outer jacket colour shall be black except, for cables to be used inintrinsically safe systems it shall be light blue. A rip cord shall be provided for inner jacket.

15.2.7 Armour over inner jacket shall be galvanized steel wire as per IS-1554 Part 1.

15.3 MULTIPAIR CABLE WITH INDIVIDUAL PAIR SHIELD AND OVERALL SHIELD:

15.3.1 Generally the cable shall be same as single pair shielded cable except conductor sizes shall be 0.5 mm2made of 7 strands of annealed electrolytic copper conductor. Each strand shall be of 0.3 mm dia.

15.3.2 Overall shield shall be of Aluminium backed up by Mylar/polyester tape helically applied with the metallicside down with either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.05 mm.Drain wire shall be similar to individual pair drain wire and shall be of the overall shield.

15.3.3 A pair of communication wire shall be provided for multipair cables. Each wire shall be 0.5 mm2 of plainannealed single or multi-strand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shallbe green and red colour coded.

15.3.4 Pair identification shall be with numbers at interval of not more than 250 mm as per vendor’s standard.

15.4 MULTIPAIR CABLE WITH ONLY OVERALL SHIELD

15.4.1 These cables shall be same as above except that the individual pair shall not have shielding.

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15.5 ELECTRICAL CHARACTERISTICS

15.6 RESISTANCE:

Maximum DC resistance of the conductor of the completed cable shall not exceed 12.3 Ω / km at 20oC forcables with 1.5 mm2 conductors and 39.7 Ω / km at 20oC for cables with 0.5 mm2 conductors.

15.6.1 Capacitance:

Mutual Capacitance:

The mutual capacitance of the pairs or adjacent cores shall not exceed a maximum of 250 pF / m at afrequency of 1 kHz.

Capacitance between any core or screen:

The capacitance between any core or screen shall not exceed a maximum of 400 pF / m at a frequency of1kHz.

15.6.2 L/R ratio of adjacent core shall not exceed 40 μH / Ω for cables with 1.5 mm2 conductors and 25 μH / Ω forcables with 0.5 mm2 conductors.

15.6.3 The drain wire resistance including shield shall not exceed 30 Ω / km.

15.6.4 Electrostatic noise rejection ratio shall be over 76 dB.

15.7 INSPECTION AND TESTING

CLIENT reserves the right to test and inspect all the items at the manufacture’s works.

Manufacturer shall furnish documents such as test certificates to prove the quality and composition of thematerials used for manufacturing the cable to the satisfaction of CLIENT/CLIENT’s Representative duringexpediting and inspection.

15.7.1 Type Test:

a) Type Certificates shall be furnished.

b) Cable shall be flame retardant to IEC 332-3 Part 3 Cat A.

15.7.2 Routine Tests:

a) These tests shall be carried out by manufacturer during various stages of manufacturing. CLIENT shallreview the related documents.

b) Insulation and Sheaths: All tests as per IS-5831 except insulation resistance, voltage and spark test shallbe as per BS-5308 Part 2.

c) Armour test as per IS-3975.

d) Conductor resistance.

e) Cable capacitance, L/R ratio.

15.7.3 Acceptance Test:

These tests shall be carried out in the presence of CLIENT / CLIENT’s Representative.

15.7.4 Continuity test:

a) Voltage test as per BS-5308 Part 2.

b) Conductor resistance and drain wire resistance.

c) Cable capacitance and L/R ratio test.

d) Electrostatic noise rejection test, type wise for each lot.

e) Tests for uniformity of galvanization of armour as per IS-2633.

f) Oxygen index test as per ASTM D 2863, temp. index test, smoke density rating test, acid gasgeneration test and flammability test.

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g) Dimensional check for overall diameter and under armour/over armour diameter.

h) Overall finish check. In case of any lump purchaser shall have the right to cut outer sheath for lumpportion and reject the cable.

i) Check of Drum length and overall length tolerances.

Immediately after completion of electrical tests, the ends of the cable shall be sealed to prevent ingress ofmoisture with suitable PVC/Rubber caps.

15.8 CABLE GLANDS

15.8.1 Cable gland shall be provided for all the above mentioned cables both at field instrument, junction boxesand local control panel.

15.8.2 Instrument cable gland shall be ½” NPTM insulating glands double compression type, weather proof (WP)IP 65 in field instrument side only for underground instruments tapping to protect the CP current drainage.

15.8.3 Except that, all other shall be standard metallic gland. All cables glands shall be of nickel-plated brass WPIP65 and they shall be double compression type suitable for armoured cables.

15.8.4 Flame proof Ex (d) glands in hazardous area shall be supplied and along with Ex (d) certification.

15.8.5 Cable gland shall have PVC shroud.

15.8.6 Reducer/adapter & plug shall be supplied as per requirement. These shall be Nickel plated brass, Weatherproof and Flame proof as require.

15.9 CABLE TRAYS AND CABLE DUCTS

15.9.1 All branch cables/trench cable shall run on cable trays.

15.9.2 These cable trays shall be made out of galvanized iron-perforated type of 2.5 mm thickness. These trays aresupported with suitable clamps shall be supplied for binding the cables/tubes at every 500 mm interval. Allthe cable/tubes will be laid in trench, false flooring/ ceiling trays, instrument support structures andsupported with 50 mm x 50 mm angles as a minimum.

15.9.3 Maximum width of the cable tray shall be 600mm and height 50mm, 75mm or 100mm as applicable. 25%spare capacity shall be provided in cable trays.

15.9.4 The above ground outdoor field cables shall be laid in durable, non-corrosive hot dipped galvanizedperforated cable trays of suitable sizes shall be provided for cable routing between junction boxes/instruments and buried trench in the station/unit facilities. The cable trays shall be supported at regularintervals.

15.9.5 Contractor shall submit details of cable trays including size, layout drawings etc. during detailedengineering stage. Supply, installation and fixing of Prefabricated hot dipped galvanized perforated cabletrays of width 50 mm / 100 mm / 150 / 300 mm as per site requirement for laying of cables. The workincludes cutting to size, fixing with all accessories on concrete / wall / structures etc.

15.9.6 The proper NEMA strength classification trays shall be used in accordance with loading requirements. Thetray shall be installed with standard vendor/contractor components and shall be covered with perforatedcovers (of same material) after laying cables.

15.9.7 Cable tray shall be rigidly supported to carry the weight of the cables laid within, as well as any vibrationswhich may be experienced in normal operation of work. At no time shall the cable tray be used to sit orstand on, nor shall tools or pipe be placed on the tray.

15.9.8 Cable trays and supporting steel structure etc. to be painted as per standard procedures of painting to meetthe corrosive area requirement. Proper color shall be provided in the cable trays. Epoxy based paint is to beapplied on the all MS structures including support structures. Cable trays shall be installed with cabling etcas per site requirements. Cable laid in horizontal trays shall be fixed to the trays by means of suitabledetachable type, non-corrosive straps at intervals not exceeding 500 mm.

15.9.9 Cable trays shall be supported at each 2500 mm or less of horizontal run and shall be so routed that there isno danger of mechanical damage. Routing shall follow major structure axis.

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15.9.10 Cable trays for Hydrocarbon detectors cabling etc as per site requirement.

15.10 JUNCTION BOXES

15.10.1 Junction boxes shall be provided for intrinsically safe and non-intrinsically safe instruments also as requiredfor packages such as gas detection system, fire detection system etc.

15.10.2 For non-intrinsic safe signals, junction box shall be explosion proof to Exd. IIA/IIB, T3 and weather proofto IP 65 and made up of dia cast aluminium.

15.10.3 For intrinsic safe signals, junction box shall be weather proof to IP 65 made up of di-cast aluminium.

15.10.4 Enclosure: Cast in corrosion resistant light aluminium alloy (LM-6) suitable for Group C & D gases. Theconstruction shall comply to IS: 2148 - 1981 and relevant international standard (IEC - 79.1), BS: 229 -1957). The enclosure shall have ample space for proper termination of cables as per summary ofrequirement attached and as mentioned in these specifications.

15.10.5 In addition, the enclosure shall be totally dust, vermin and weather proof suitable for outdoor installationwithout any canopy. Degree of protection should be minimum IP-65 as per IS/IEC: 60529 – 2001.

15.10.6 Terminals: Junction boxes shall be provided with vibration proof terminals (as per vendor list) clip on type2.5 sq.mm suitable for 500 VAC working voltage. Arrangement of fixing terminals strip shall be made suchthat cable connections can be made easily.

15.10.7 Earthing: External and internal earthing terminals complete with set of washers shall be provided.

15.10.8 Mounting: The junction boxes shall be suitable for field mounting on M.S supporting structures.

15.10.9 Painting: Junction boxes shall be pre-treated by first coat of epoxy zinc chromate primer followed by anti-corrosive industrial epoxy grey paint shade IS 631.

15.10.10 Cable entries: The junction boxes shall have bottom entry and should be of NPT threads only.

15.11 MUTICABLE TRANSIT

15.11.1 MCT will be provided at cable entry to control room from field (hazardous area).The MCT frames shall beof standard modular variable diameter RGB type, steel construction MCT frames shall be suitable towithstand blast intensity. The MCT shall be supplied complete with insert blocks, spare blocks, stay plates,end packing etc. The MCT shall be sized considering 20% spares for each cable size/cable OD. Intrinsicallysafe cables and non-intrinsically cables shall be suitably separated within the MCT frame. For HT cables,LT cables/power cables and other electrical cables separate MCT frame shall be provided. Spare space shallbe filled with dummy block of suitable size.

15.11.2 MCT block shall be peel type.

15.11.3 In addition to installed spares, contractor shall also provide 30% spare insert block for each cable size/ODas loose supply.

15.11.4 Contractor shall also consider MCT blocks for the System Cables of Electrical Control system,telecommunication system, SCADA/RTU, Fire alarm system, any other system and repeat signals betweencontrol rooms while considering the requirement.

15.11.5 One additional separate MCT frame with 12 Nos. dummy blocks suitable for 12 Nos. 12P x 1.5mm2 multicore cable complete with frames, dummy blocks, plate inserts, clamps etc. shall be provided and installedall stations.

16.0 FIRE DETECTION SYSTEM

16.1 Fire detection system shall be Conventional Type Microprocessor based system. Fire detection system shallbe comprised of multisensory detectors, includes optical photo electric type smoke detectors and heatdetectors based on rate of raised. Multi sensor detectors shall be installed in the miscellaneous rooms likeelectrical room, control room/equipment room battery room, false ceiling, and false flooring as applicable ofthe different stations along the pipeline network. Two detectors shall be connected in loop to avoid falsenotification.

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16.2 Multi sensor shall have combined feature of smoke detectors and thermal sensor (heat detectors). Smokeactivity shall be monitored by optical sensing technology in a single detectors/base assembly. Heat detectorsshall be fixed with selectable rate of rise setting.

16.3 Optical/photo electric type smoke detectors for timely detection of smoke/fire. Smoke detectors installedabove the false ceiling and below false flooring wherever applicable in order to sense the fire occurred inthe electrical wiring & fittings etc. The smoke detectors above the false ceiling and below false flooring arenot be visible, these detectors shall be fitted with remote Response Indicators located below the falseceiling, and above false flooring (on adjacent wall) which shall glow in the event of actuation of thesedetectors.

16.4 The Fire Detection and Alarm System shall be of high quality fast-acting conventional system. The systemshall consist of compatible microprocessor-based fire alarm control panel, repeater panel, junction boxes,detectors, hooters, beacons, exit signs, response indicators, siren with starter, Break glass unit (Manual callpoints) etc. with associated wiring.

16.5 The detecting units shall be installed, tested and commissioned in accordance with NFPA-72, IS & otherinternational standards on Automatic fire detectors.

16.6 All system components and devices shall be connected to two wire loop circuits in such a way that removalor disconnection of any device from the loop shall not affect the functioning and performance of the system.

16.7 The system should also have provision to give fault signal which shall be a distinct signal audible and/orvisual indicating a failure of electric supply, presence of a break, an earth or other electrical fault on acircuit or system of circuits.

16.8 Devices like hooters, horns, sirens or like which give the sound signals shall be installed to give sounds withthe electrical alarm signals from the detectors or when there is fault in the system.

16.9 Electrical wiring must conform to IS: 732-1963 or equivalent International Standards.

16.10 All electrical cables shall conform to IS: 1554 / BS: 5308 Part 2 or equivalent international Standards withlatest amendments. All cables to be laid underground in the field shall be armoured type. Cables laid insideconduits in buildings may be unarmoured type

16.11 On the alarming, two red flashlights located in the Control Room and in the guard room at site and twohorns one inside and other outside will be actuated at the same time.

16.12 A break glass unit (BGU) shall be installed at the outer side of each rooms and in field wherever feasible(decided during engineering stage) for manual actuation of the fire alarm.

16.13 When a detector is in alarm condition, the information shall be sent to the central unit and the central unitshall send to SCADA through RTU. The alarm situation of the detector shall remain “ON” until a manualreset device is activated on the central unit. An indicating LED shall permit the direct identification of thedetector that is the cause of alarm.

16.14 The fire control panel will derive its power from a 24V DC main, which will be converted to require voltage(DC) level by the contractor inside the panel if require. The fire control panel shall provide the requiredpower to the sensors and accessories and will monitor the zonal circuits for open and short circuit faults.The fire control panel shall also be provided with a secondary power source comprising two nos. ofMaintenance free batteries, which automatically takes over the system in the event of 24 V DC powerfailure to the panel.

16.15 Contacts used in intrinsically safe circuit shall be gold plated. All electronic circuits used in the system shallbe free from the effects of any RF interference.

16.16 Fire detection system shall be suitably hooked up with CO2/Clean agent fire suppression system forauto/manual flooding in control room/equipment room and electrical.

16.17 Field mounted Electrical operated Siren with audible range of min 1 KM integrated with fire detectionsystem.

16.18 fire detection system shall have provision for interface with LCP Panel & LCP Panel to RTU/SCADAsystem on RS 485/RS232

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16.19 HEAT DETECTORS

Heat detectors shall be used negative temperature coefficient thermistor for sensing and for reference. Thedetectors shall be designed to give a response that depend on both absolute temperature and rate of raise.

The rate of raise element shall be carefully calibrated to ignore any normal fluctuation in temperature, but torespond quickly when the temperature rise is 9 °C or more per minute (also decided during detailedengineering stage).

The fixed temperature feature should be entirely independent of the rate of raise element. The operatingtemperature of fixed temperature element should be factory set at 57 °C ±5 °C.

The detectors shall be self-restoring type ensuring repeated use and easy maintenance.

16.20 OPTICAL/PHOTO ELECTRIC SMOKE DETECTORS

Optical smoke detectors shall work on the principle of light scattering utilizing a light emitting diode.16.21 Input/output signals

The input signals of the central unit of the fire detection system shall be from:

a) Smoke detectors and Heat detectors, (Multisensor) etc.

b) Break glass units for a manual actuation of the fire alarm,

c) Break glass units connected in series, located in the plant and actuated manually when fire isdetected.

16.22 SYSTEM COMPONENTS

The system shall for each site comprise:

a) Smoke detectors and Heat detectors (Multisensor)

b) Red flash lights (common for fire and gas detection system by gas detectors vendor) in controlrooms & Guard room.

c) Two horns (common for fire and gas detection system by gas detectors vendor) in control rooms &Guard room

d) Break glass units, (Exit gate of each room & Field)

e) Electrical operated Siren with audible range of min 1 KM

f) A central unit equipped with “silence alarms” and “reset” key push-button. RS 485 port forcommunication interface with third party system.

16.23 THE FOLLOWING TECHNICAL DATA SHALL BE SUPPLIED BY THE CONTRACTOR:

a. Power supply:

· Operating

· minimum

· maximum

b. Consumption during normal condition.

c. Consumption during alarm condition.

d. Operating temperature range.

e. Operating humidity range.

f. Sensibility,

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16.24 DETECTOR

The detector shall consist of:

a) an I.R. source LED,

b) a SI-diode receiver,

c) electronic connections and electric contacts with high impedance,

d) heat sensor

e) a metallic protection,

f) sensitive elements impregnated with silicone rubber,

g) an anti-condensation system,

h) an indicating LED,

i) A mounting base.

16.25 CENTRAL UNIT

The central unit shall consist mainly of:

a) A power supply module comprising power supply and charger for one 24 V safeguard battery.

b) A monitor module for earth leak faults, short-circuits, lamp or LED test and general reset push button,

c) A monitor module for power supply and battery failures associated with a general alarm switch and anindicating lamp or LED,

d) A general alarm module associated with a reset push button of the audio signal,

e) A module able to monitor the state of the input signals and to generate the right action with regard tothe output signals,

f) A front panel with lamps or LEDS to indicate the state of the input and output signals.

g) Sensor fault shall be provided from Fire Alarm Control Panel (FACP) to SCADA.

h) All devices connected at the inputs of the central unit shall be supplied with electronic connections andelectric contacts with high impedance to facilitate the immediate detection of short-circuit or line cuts.

i) Fire detection panel shall be wall mounted for all unmanned station. Size of the wall mounted panel asper the vendor standard.

16.26 Input supply and battery backup

· Input Supply 24 V DC

· 24 hrs backup (normal state) & 15 min in alarm state

· Batteries VRLA

16.27 Battery charger provided in the FACP shall be modular mounted on a draw out chassis. Charger moduleshall be located on the front allowing withdrawal with the help of handle bars for maintenance.

16.28 Logic of operation shall be preferably built on "Fail safe" feature i.e. NC contact of field devices shall beconsidered as healthy condition and NO as fire condition. 1 NO+ 1 NC contact of output relays shall bewired to terminal block for interface with Owner's other equipment.

16.29 It shall be possible to test lamps, hooters, flasher circuit, and carry out functional tests etc. through common"Test" push button.

16.30 The circuit shall be so designed that silencing of the current alarm by ACCEPT push button shall notprevent annunciation of subsequent fire alarm received from any other location.

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16.31 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiringbecause of proximity with power cables. Cables for field devices shall be multicore copper conductor,unscreened, armoured, copper conductor cable.

16.32 Detectors and BGUs shall be wired through 1.5 mm2 multi-core, copper conductors, PVC insulated,armoured FRLS cable.

16.33 LEDs shall be provided for fire/ fault visual annunciation on the panel front. LED shall also be provided forPower supply healthy, Battery backup ON, Battery/ Charger status.

16.34 If zone is protected with clean agent/CO2 system, the detectors and BGUs of the zone shall be wired incross-zones by providing minimum two signaling circuits in a zone. The last device in each circuit shall beprovided with end of line resistor of suitable value as per circuit design to facilitate cable open circuit andshort circuit detection.

16.35 Vendor shall decide the zones according to area/rooms. These zones shall be created in coordination withCO2/Clean agent supplier. Zone wise alarm output signals shall go to the Beacon, Hooter, Siren actuation,CO2/Clean agent flooding system and RTU.

16.36 FDS shall be interface with RTU on RS 485

16.37 SCHEME FOR FIRE/ FAULT ANNUNCIATION:

System condition AUDIO VISUAL

NORMAL OFF OFF

FIRE ON (tone 1) Flasher ON, Fire LED Steady ON

Accept OFF Flasher steady, Fire LED steady ON

Reset OFF Flasher OFF, Fire LED OFF

FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON

Accept OFF Flasher OFF, Fault LED Steady ON

Reset OFF Flasher OFF, Fault LED OFF

16.38 Repeater panel

Repeat fire alarm panel shall be similar to FACP except providing zones for detector. Fire/ faultannunciation of FACP shall be repeated at repeater panel. Depending on the size Repeat Fire Alarm panelmay be floor mounting type or wall mounting type. Repeater shall also have the facility to acknowledge thealarms and hooter

These panels shall be required for repeat of alarm in Guard rooms at approx. 100 meters from FACP.

17.0 GAS DETECTION SYSTEM

17.1 Addressable type Hydrocarbon Gas detection system shall consist of point detectors and one control unit.

17.2 Addressable IR type Point gas detectors shall be considered for metering & filter skid, piping instruments,station sectionalisation valve, pig launcher/ receiver terminals, tap-off node and else wherever needed inhazardous area.

17.3 The equipment which is nearest to Insulating joint (IG), the Point gas detectors shall be placed in such waythat, same shall also cover the IJ leakages area wherever applicable or if it is not possible to cover IJ areawith same PGD, then separate detectors shall be provided. Contractor shall explore the possibility andprovide the PGD as per site conditions and requirement.

17.4 All the PGD shall be multidrop in field mounted junction and main/trunk cable shall be connected with gasdetection controller.

17.5 The LEL indication for high, high high gas concentrations and a failure/default state shall be detected andsignalized by the control unit.

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17.6 Gas detectors cabinet shall be wall mounted. Size shall be decided by vendor. The outer and inner colour ofthe gas detection panel shall be as per RAL 7035.

17.7 Gas detectors output will be digital communication. Control unit will be interface with LCP Panel & LCPpanel interface with RTU/SCADA system on RS 485/RS232

17.8 Potential free contacts for alarm at 20% and 40% LEL per channel and sensor fault. Adjustable high, high-high alarm (SPDT free potential relay contacts) and sensor fault alarm per channel shall be provided.Vendor shall group all the LEL high alarms and give common potential free contact for high alarm forinterfacing with RTU. Same for common LEL high high and common sensor fault alarm potential freecontact for RTU.

17.9 SYSTEM COMPONENTS

a) Field Mounted flame proof point gas detectors

b) Monitors / controllers for Gas Detectors.

c) Gas detection Panel

d) Ex”d” Junction box

e) Portable hydrocarbon gas detector

f) Calibration kit

g) Beacon flasher and hooter.

17.10 TECHNICAL DESCRIPTION OF THE COMPONENTS-REFER DATA SHEET ENCLOSED WITHTHIS DOCUMENT-APPENDIX-3

17.10.1 FOLLOWING INDICATIONS SHALL BE AVAILABLE ON EACH DETECTOR/CHANNEL:

a) Power-on indication.

b) Alarm high indication.

c) Alarm high high indication.

d) Malfunction indication (this shall include short circuit, line-breaking, over-range and earth fault).

e) Latched type of relay contacts shall be provided for each channel for;

Alarm high

Alarm high high

Malfunction alarm

f) Each channel shall also have calibration switch to allow sensor calibration without alarm output.

17.11 PORTABLE GAS DETECTOR

One number portable gas detectors shall be supplied for hydrocarbon, complete with its controller, audio-visual alarm. The portable gas detectors shall be suitable (intrinsically safe/Ex Proof) for use in hazardousarea specified. Hand-held type Portable Gas Detectors shall be supplied for measuring Methane from 0% to100% by Volume, 0% to 100% LEL and 0% to 25% by volume of Oxygen as well

These units shall be supplied with rechargeable batteries and 230 V AC Battery charger. Sufficient numberof battery charger/number of points per charge shall be provided based on quantity of such portable units.These units shall be supplied complete with its accessories like carrying case, maintenance kit, calibrationkit etc.

17.12 CALIBRATION KIT

Contractor shall supply calibration kit for calibration of open path and point gas detectors along with all thenecessary equipment require completing calibration activity. Contractor shall provide the list of calibrationequipment comprise in kit.

17.13 BEACON AND HOOTER

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Beacon flasher and hooter shall be provided as per requirement. Infield Placement of flasher in such a waythat, it should be easily visible to Person/guard present there. Consideration of beacon and hooter in gasdetection system same shall be applicable for fire detection system. Contractor shall provide necessaryprovision to integrate alarm signals with hooter and flasher.

1 no. beacon/hooter shall be provided in control room.

1 no. beacon/hooter with reset push button shall be provided in Field.

The hooter shall be electronic type and shall have sound intensity of 100dBA, as a minimum.Different tones shall be provided for fire/smoke and hydrogen carbon gas releases.

Both Beacon and hooter units shall operate at 24 V DC and shall be certified explosion proof (flameproof) when installed in hazardous area. The beacon shall be of stroboscopic type and shall have sufficientintensity to provide the visibility and clear contrast during full daylight".

Beacon light shall follow the following sequence:

Gas leakage/smoke detect - Flashing beacon light

Different tone for gas /smoke-Hooter continues

Control room acknowledge - Flashing beacon light

Hooter stops

Gas leakage stops - Flashing beacon light

Hooter off

Control room reset - Beacon Off

Hooter Off

17.14 Minimum No. of Detectors / Manual call points / Hooters at each station

Below given quantities are tentative, this may vary as per site condition. Contractor shall ascertain thequantity as per site requirement and supply accordingly without additional cost to client

Sr.No Description Point

DetectorOPGD

MultisensorDetector

Manual callpoint

Ex proofManual

call pointBeacon/Hooter

1. Station Control Room 2 1 WP - 1

2. Electrical Room 2 1

3. Battery Room 2 1

4 Maintenance room 2 1

5 Pig launcher/ receiver 2 2 Pairs 1

6 IJ/ leakage prone point 2 0

GOOAV 1 1 Pairs

7 Metering skid 2 2 Pairs

Tap-off point (if any) 1 0

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Sr.No Description Point

DetectorOPGD

MultisensorDetector

Manual callpoint

Ex proofManual

call pointBeacon/Hooter

8 Field 1 Ex”d”-1

9 Siren-site Ex”d” -1

18.0 INSTALLTION MATERIAL SPECIFICATION

18.1 The impulse tube shall be SS316, Compressed type ferrule fitting such as ½” NPT (M) , NPT (F) fittings(male/female connectors), ½” tee, ½” union including ½” isolation needle/ball valves & other accessoriesshall be SS316.

18.2 Instrument Impulse tubing

1/2" OD x 0.065" and 1/4" OD x 0.065" (if applicable) wall thickness, seamless, fully annealed 316stainless steel tubing shall be used.

Tubes shall be cold drawn as per ASTM A 269.

Hardness of the tubes shall be Rockwell RB 70 – 79.

18.3 Compression fittings

· Compression fittings shall be of the two-ferrule type in 316 stainless steel.

· Fittings shall be of flareless compression type and four-piece (for double compression type)construction consisting of two ferrules, nut and body suitable for use on SS tubes conforming to ASTMA 269 TP 316 with hardness in the range of RB 70 to 79.

· Hardness of the ferrules shall be in the range of RB 85-90 so as to ensure a hardness difference of theorder of 5 to 10 between tubes and fittings for better sealing.

· Nuts and ferrules of a particular size shall be interchangeable for each type.

· Spanner hold shall be metric.

· Threaded ends of fittings shall be NPT as per ANSI B 1.20.1

· Specific techniques like silver plating shall be used over threading in order to avoid jamming andgalling.

· It shall be ensured by the contractor that all fittings shall match the seamless ½” OD SS 316 instrumenttube with wall thickness of 0.065” conforming to ASTM A 269

18.4 Instrument valves and manifolds

· Vendor shall supply instrument valves (miniature type) and valve manifolds wherever required.

· Body rating shall be as per piping class or higher.

· Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim material shallbe selected as required by process conditions. Packing material in general shall be of PTF

· The isolation valves for instrument service shall be 316 stainless steel, unless process conditionsrequire another material.

18.5 Instrument Sunshades

Instrument sunshades shall be made from Fiber glass reinforced, polyester/Metallic, supplied with mountingclamp (epoxy coated) suitable for a 2" instrument stand.

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For instruments located in hazardous area, sunshades shall be as described here above but anti-static type.

18.6 Instruments supports/structural steel

The supports for instruments and junction boxes shall be in accordance with the “Instrumentation Standardhook up drawing “as attached. Vendor shall supply instrument stands, stanchions and other structural steelmaterial required for supporting the cable trays, impulse line and instruments.

18.7 Cable Ties

· All cable ties shall be constructed from black PVC and have a breaking load greater than 20 kg. Theyshall be of a self-locking style and non-slip, but shall be releasable for the addition of extra cables.Cable ties for use on trays shall fix into the tray slots (two piece ties).

18.8 Nameplates Tags labels

· The nameplates, tags and labels for identifying junction boxes, instruments, panels, cabinets, etc shallbe made from engraved trifoliate and shall be in accordance with the specification as mentioned inGTS.

19.0 CORROSION MONITORING SYSTEM

19.1 General

The corrosion monitoring system shall be used to establish the internal corrosion profile of the pipelineusing electrical resistance (ER) corrosion probes and corrosion coupons in conjunction with inspectiontechnology.

ER-Probes and coupons shall be located as per the P&ID’s.

1. Despatch

2. Receiving

19.2 SPECIFICATION

The electrical resistance (ER) type probes and coupons to be installed at the stations as mentioned aboveshall be retrievable from the line under pressure. The probes and coupons shall be flush mounted on thepipeline. All materials in contact with fluid shall be in accordance with NACE Standard MR-01-75.Pipeline inlet pressure may vary according to pipeline pressure drop due to different flow rates. Thecorrosion monitoring system shall be suitable for operation under this fluctuating pressure conditions.

Each probe shall be connected to a transmitter (2 wire systems) to give an output of 4-20 mA, proportionalto corrosion rate.

Local monitoring equipment of CMS shall be mounted in the local control panel.

Barrier, display unit, terminal blocks etc shall be provided in the LCP cabinet. Single shall be repeatedthrough dual output channel repeater or barrier to provide the independent signals to RTU as well localindicator.

19.3 MATERIALS

The scope of supply shall consist as a minimum requirement the following components:

19.3.1 ER Probe

Probes shall be high pressure retrievable type, flush, mounted, body in SS-316 with element of carbon steelfor installation with high pressure hollow plug access fitting assembly. The probe shall be suitable formeasurement of corrosion rate in the range of 0-10 Mils Penetration Per Year (MPY).

Probe life shall be at least 2 years at 2-3 MPY corrosion rate.

Ø Access Fitting Assembly – for ER Probe

2” NB, 5.25” height, flare weld Access Fitting Assembly (Non-Tee), body carbon steel, and ACME threadoutlet with hollow plug assembly of AISI-316 along with heavy duty protective C.S. cover complete withessential spare.

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Ø Transmitter – for ER Probe

Transmitter shall be 2 wire types to give an output of 4-20 mA, proportional to corrosion rate, to panelmounted corrosion meter.

19.3.2 Coupons

Mild steel flush disc coupons 1.25” dia. x 1/8” thickness with one mounting hole of ID 0.312”.

Retrievable coupon holder shall be of SS-316.

Ø Access Fitting Assembly – for Corrosion Coupon

2” NB, 5.25” height, flare weld Access Fitting Assembly (Non-Tee) carbon steel, acme threat outlet withsolid plug assembly in AISI-316 along with heavy duty protective C.S. cover complete with essential spare.

19.3.3 Retriever kit complete with repair and seal kit for ER probes and coupon holders

Service Valve Kit, complete with blanking plug, extension lever, 1 hammer, spare face-to-access fitting O-ring, heavy duty field service box, essential repair and seal kit.

19.4 DOCUMENTATION TO BE PROVIDED BY VENDOR

- All components data sheets.

- Engineering, Purchasing and Construction Schedule.

- Spare Parts List for Erection and commissioning

- Operating and maintenance Manual

- Quality Control Plan

19.5 ANNEXURE I – PROBE DATA SHEET

General

Tag no.

Line no.

Wall thickness 10.3 mm

Pipe material API 5L GR.X-70 PSL 2

Service Hydrocarbon

Probe

Type Retrievable ER probe with temperature compensation

Material Body : SS-316

Element: Carbon steel

End connection 2” FLARE WELD

Probe element type Flush mounted

Element thickness – 10 mil min.

Probe length To be decided by vendor

Access fittings

Type 2” NB, 5.25” height flareweld (Non-Tee), ACMEthread outlet with hollow plug assembly

Material Body : carbon steel hollow plug assembly : SS-316

Accessories

Protective cover Required

Retriever & servicevalve kit

Required

Monitoring Type Mounted in CMS cabinet.

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NOTES:

1. Vendor to note that manufacturing flaw, if any, of ratio between sample reference elements shall benormalized by an ‘intelligent’ in built device.

2. Probe length and Retriever size shall be decided by Vendor.

3. 1 no. coupon holder with corrosion coupons will be installed on each line. Coupon holder length shallbe decided by the vendor accordingly.

19.6 ANNEXURE II – TRANSMITTER DATA SHEET

Tag no.

Line no.

Type 2 wire / 4 wire type

Input From retrievable ER probe with temperature compensation

Output 4-20 mA.

Cable lead 5’ for ER probe connection

Power supply 24 V DC from receiver unit

Mounting At site near probe by bracket/yoke support

Intrinsically safe Yes

Safety barrier to beprovide betweentransmitter andreceiver

Yes,

Signal from Corrosion Monitoring System shall be repeated throughdual channel isolator/barriers. Corrosion Monitoring System shallbe hooked up with LCP & RTU.

20.0 INSPECTION AND TESTING

20.1 The manufacturer shall carry out inspection and testing as per relevant codes and service requirements ofthis specification, for all items of work prior to shipment. Manufacturer’s test certificates in proper formatmust be sent with the despatch paper of all supply items.

20.2 All instruments and system oriented items shall undergo factory testing and inspection by Contractor’sauthorized representatives, Owner/Consultant unless specified otherwise.

20.3 Wherever inspection at manufacturer’s shop is waived because of any reason, the sub vendor’s own testingreports shall be verified before dispatch. In no case, items shall be released without proper inspection/verification.

20.4 The instrumentation inspection and testing shall be carried out as per inspection and test plan attached withbid document, other specifications and documents. Where, the inspection and test plan is not available,Contractor shall develop the inspection and test plan and submit for review/approval by theOwner/Consultant.

20.5 Testing and inspection of all instrumentation items shall be carried out as per approved factory testingprocedures. For instrumentation items where no testing is witnessed by the Owner/Consultant, followingtest certificates shall be forwarded for review before dispatch of such instrument:

Ø Verification of certificates as applicable for the material certificates, NDT reports like radiography/ X-ray/ die-penetration/ MP etc., statutory certificates for Intrinsic safety and explosion proof, certificatesof conformity etc.

Ø Visual verification for quantity, quality and workmanship.

Ø Hydro testing and pneumatic testing as applicable.

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Ø Functional and performance test certificates including calibration, accuracy, and repeatability testing ofinstruments.

Ø Test certificates for pressure relief valves, set pressure & seat leakage test

Ø Radiographic test for pressure relief valves and thermowells.

20.6 Contractor shall submit all instrumentation test records / test results for records to Owner/Consultant asbound volume along with the test procedure for each test carried out.

20.7 Acceptance test

After completion of the CONTRACTOR tests, the CONTRACTOR shall perform, at the CONTRACTOR'sfacility, a functional test on 100 % of inputs and outputs with simulation panel provided and wired up by theCONTRACTOR.

All deficiencies shall be recorded, and corrections made.

Appropriate tests shall be run to demonstrate that the deficiencies have been corrected and that there hasbeen no degradation to the system.

20.8 On-site acceptance test

These tests shall be basically a repeat of the system factory acceptance test. To the extent possible, thesimulation of I/O signals shall be replaced by the actual signals.

21.0 PAINTING, MARKING AND SHIPMENT

All items shall be painted and marked as per manufacturer’s standard before shipment. All items shall beproperly packed and protected to avoid damage during shipment. Insurance during shipment shall beensured by the manufacturer.

S S S

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APPENDIX - 1

SPARE CAPACITYSpare capacity is depending on the type of equipment and is defined in the following table. Spare quantity is minimumone number or as specified whichever is higher.

ITEM DESCRIPTION SPARE QUANTITY

1 Multicore cables

· Spare cores (all cores have to be connected to the terminals ofjunction boxes, marshalling racks or any other terminal strip)

20 %

2 Cable ladders and trays

· Spare room for additional cables

20 %

· Spare opening for cable entry in JB and all panel/cabinets with blindcaps.

20%

· Spare cable gland for JB and panel/cabinets 20 %

3 Spares terminal blocks are required in junction boxes and in all panel/cabinets. 20%

4 Spare digital and analog isolators/barriers and relay in local control panel 10%

5 Spare channels/multidrop capacity/ slots in gas detection system. Spare slotshall be plugged 10%

6 MCT shall be sized considering spare for each cable size/ O.D. In addition toinstall spares. 50%

7 Spare insert MCT blocks for each cable size/O.D. as loose supply. 30%

8 Power distribution system shall have equipped spares and capacity. 20%

10 Electrical switches/ MCBs considering minimum 1 no. for each rating 20%

11 Electrical terminals/ TBs 20%12 Electric connectors 20%13 Fuses, LEDs with full assembly, and other electrical accessories. 20%

It is Contractor’s responsibility to have commissioning spares as required for commissioning of total InstrumentationSystem. It is deemed to be included in his scope of supplies/ work.

S S S

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Tag Number Instrument Type Service Location P&IDNumber Source Destination Indication in

LCPType of Signals

in RTU Range Remarks

Despatch Station, SultanpurSIGNALS FROM FIELD INSTRUMENTS TO LOCAL CONTROL PANEL AND RTU

PT-0201 Pressure Transmitter Upstream Pressure of GOV 0201 Field 102 0-100 Barg

PY-0201A Dual output Channel GalvanicIsolator LCP

PI-0201A SCADA Pressure indication at SCADA SCADA Channel-1 RTU AI

PI-0201B Indicator Pressure Indication at LCP LCP Channel-2 LCP Digital Indicator

PG-0201 Pressure Gauge Upstream Pressure of GOV 0201 Field 102 0-100 Barg

TE 0201 Temp Element- RTD Upstream Temp of 1GOV 0201 Field 102 -20 to 100 deg C with thermowell

TT-0201 Temp Transmitter Upstream Temp of 1GOV 0201 Field 102 -20 to 100 deg C

TY-0201A Dual output Channel GalvanicIsolator LCP

TI-0201A SCADA Temp indication at SCADA SCADA Channel-1 RTU AI

TI-0201B Indicator Temp Indication at LCP LCP Channel-2 LCP Digital Indicator

PT-0202 Pressure Transmitter Downstream Pressure of GOV 0202 Field 102


PI-0202A SCADA Pressure indication at SCADA SCADA Channel-1 RTU AI 0-100 Barg


PG-0202 Pressure Gauge Downstream Pressure of GOV 0201 Field 102 0-100 Barg

TE 0202 Temp Element- RTD Downstream Temp of 1GOV 0201 Field 102 -20 to 100 deg C with thermowell

APPENDIX 2

INSTRUMENT INDEX WITH SIGNALS

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TT-0202 Temp Transmitter Downstream Temp of GOV 0201 Field 102 -20 to 100 deg C




GOV 0201 Isolation Valve ON/OFF Type(Gas Over Oil actuated valve)

Isolation Valve ON/OFF Type (GasOver Oil actuated valve) Field 102

ZSH0201 Limit Switch (OPEN) Valve GOV 0201 Open Field

ZYH-0201A Galvanic Isolator LCP

ZYH-0201B Relay Multiplier/Repeater LCP

ZLH-0201A SCADA Open Position Indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

ZLH-0201B Indicator Open Position Indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp

ZSL-0201 Limit Switch (Close) Valve GOV 0201 Close Field

ZYL-0201A Galvanic Isolator LCP

ZYL-0201B Relay Multiplier/Repeater LCP

ZLL-0201A SCADA Close Position Indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

ZLL-0201B Indicator Close Position Indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp

XSOV-0201A Open Solenoid Valve Valve GOV 0201 open command Field DO

XYSOV-0201A Galvanic Isolator LCP

XSOV-0201B Close Solenoid Valve Valve GOV 0201 close command Field DO

XYSOV-0201B Galvanic Isolator LCP

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HS-0201A SCADA Open command from SCADA SCADA RTU Pot free contract to LCP

HS-0201C SCADA Close command from SCADA SCADA RTU Pot free contract to LCP

HS-0201B Push button open Open command from LCP LCP LCP XSOV 0201A Press to releasePB

HS-0201D Push button close Close command from LCP LCP LCP XSOV 0201B Press to releasePB

HS-0201F Local/Remote Selection switch Local/Remote selection Field

HY-0201A Galvanic Isolator LCP

HY-0201B Relay Multiplier/Repeater LCP

XI-0201G SCADA L/R indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

XI-0201F Indicator L/R indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp

DPSH -0201 Differential Pressure Switch Differential pressure across valveGOV 0201 Field

DPSY 0201A Galvanic Isolator LCP

DPSY 0201B Relay Multiplier/Repeater LCP

DPAH 0201 A SCADA DPAH indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

DPAH 0201 B Indicator DPAH indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp

HS 0201E P/S/M selector switch P/S/M selection LCP

XI-0201G SCADA Panel mode selection at SCADA SCADA XI-0201G RTU DI

XI-0201F SCADA Maintainence Mode selection atSCADA SCADA XI-0201F RTU DI

XI-0201E SCADA SCADA Mode selection at SCADA SCADA XI-0201E RTU DI

PG-0203 Pressure Gauge Pig Launcher Y-0201 pressure Field 102 0-1 Barg with Gauge saver

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PG-0204 Pressure Gauge Pig Launcher Y-0201 pressure Field 102 0-100 Barg


PG-0206 Pressure Gauge Down-stream Pig Launcher Y-0201pressure Field 102 0-100 Barg

PG-0205 Pressure Gauge 0204-NG-4"-6C1-N Field 102 0-100 Barg


PG-0209 Pressure Gauge Ventline-0203-BD-4"-1C1-N Field 102 0-100 Barg

TE-0203 Temp Element RTD -20 to 100 deg C Surface Mounted

TT-0203 Temp Transmitter Ventline-0203-BD-4"-1C1-N Field 102

TY-0203A Dual Channel Galvanic Isolator LCP



XXS 0201 Pig indicator Minor Barrel-Y-0201 Field 102 Non Intrusive type

XXSY-0201A Galvanic Isolator LCP

XXSY-0201B Relay Multiplier/Repeater LCP

XXS-0201A SCADA Pig Indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

XXS-0201 B Indicator Pig Indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp

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XXS 0202 Pig indicator Downstream of Barred Tee Field 102 Non Intrusive type





.

XXS 0203 Pig indicator Main Barrel-Y-0201 Field 102 Non Intrusive type





.Corrosion MonitoringProbe CMS system 0202-NG-12"-6C1-N LCP 0-10 MPY

CM-B Indicator CM Indication at LCP LCP Channel-2 LCP Digital Indicator Note-1,LCP to RTU

SIGNALS FROM CPPSM TO RTU

DC Ouput Voltage CPPSM system DC Ouput Voltage SCADA CPPSM system LCP AI Note-1,LCP to RTU

DC Ouput Current CPPSM system DC Ouput Current SCADA CPPSM system LCP AI Note-1,LCP to RTU

Pipe to soil Potential (PSP) CPPSM system Pipe to soil Potential (PSP) SCADA CPPSM system LCP AI Note-1,LCP to RTU

SIGNALS FROM GAS DETECTION SYSTEM TO RTU

GDS system Gas detection system GDS system GDS Panel 102 GDS Panel LCP RS-485

LEL High Alarm indication Common Gas Detection High alarm GDS Panel GD Panel(Signal Repeater) LCP DI Note-3,LCP to RTU

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LEL High High Alarm indication Common Gas Detection Highhighalarm GDS Panel GD Panel(Signal Repeater) LCP DI Note-3,

LCP to RTU

Sensor fault Alarm indication Gas Detection Sensor Fault Alarm GDS Panel GD Panel(Signal Repeater) LCP DI Note-3,LCP to RTU

Grid Power Available Grid Power Status RTU/SCADA LCP RTU DI

Tel/SCADA room Open Door status RTU/SCADA Control room LCP RTU DI

UPS SIGNALS UPS SIGNALS RTU/SCADA Control room UPS LCP RS 485 Note-2,LCP to RTU

Incomer-1 Voltage Phase-1 Soft(AI) Note-2,LCP to RTU



Incomer-1 curent Phase-1 Soft(AI) Note-2,LCP to RTU

Incomer-1 current Phase-2 Soft(AI) Note-2,LCP to RTU







MISCELLANEOUS SIGNALS

UPS SIGNALS

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Out put Voltage Soft(AI) Note-2,LCP to RTU

Out put Current Soft(AI) Note-2,LCP to RTU

Battery Charger-1 Voltage Soft(AI) Note-2,LCP to RTU

Battery Charger-1 Current Soft(AI) Note-2,LCP to RTU



Note1 Vendor shall interface all the signals from invidual system to LCP.

2 UPS shall be interfaced with LCP on Modus RS 485. Necessary provision shall be provided in UPS

3 GDS detection system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in GDS system

4 FDS detection system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in FDS system

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SV1 -STATIONSIGNALS FROM FIELD INSTRUMENTS TO LOCAL CONTROL PANEL AND RTU






PG-0305 Pressure Gauge Tap-off point Field 103 0-100 Barg













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XI-0301FA SCADA L/R indication at SCADA SCADA Relay Multiplier/Repeater RTU DI

XI-0301FB Indicator L/R indication at LCP LCP Relay Multiplier/Repeater LCP Indication Lamp










PG-0303 Pressure Gauge On De-pressurized line Field 103 0-100 Barg

TE-0303 Temp Element RTD -20 -100 deg C Surface Mounted





GG-ON GG panel GG set ON indication GG shed

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GGY-ON Relay LCP DI Note-6,LCP to RTU

GG-OFF GG panel GG set OFF indication GG shed

GGY-OFF Relay LCP DI Note-6,LCP to RTU

GG-Trip GG panel GG set Trip indication GG shed

GGY-Trip Relay Multiplier/Repeater LCP DI Note-6,LCP to RTU

MEDB-ON MEDB panel (Normal) MEDB set ON indication Electrical room

MEDBY-ON Relay LCP DI Note-7,LCP to RTU

- MEDB panel (Normal) MEDB set ON indication Electrical room LCP RS-485 Note-7,LCP to RTU

MEDB-ON MEDB panel (Emergency) MEDB set ON indication Electrical room


- MEDB panel (Emergency) MEDB set ON indication Electrical room LCP RS-485 Note-7,LCP to RTU


DC Ouput Voltage CPPSM system DC Ouput Voltage SCADA CPPSM system LCP AI Note-1, LCP to RTU

DC Ouput Current CPPSM system DC Ouput Current SCADA CPPSM system LCP AI Note-1, LCP to RTU

Pipe to soil Potential (PSP) CPPSM system Pipe to soil Potential (PSP) SCADA CPPSM system LCP AI Note-1, LCP to RTU

SIGNALS FROM FIRE DETECTION SYSTEM TO RTU

FDS SYSTEM Fire detector Fire detection alarm FDS 103 Fire panel (signal repeater). LCP RS-485 Note-4,LCP to RTU

Fire detector Alarm indication Common sensor fault alarm FDS Fire panel (signal repeater). LCP DI Note-1 Note-4,LCP to RTU

Fire detector-Zone-1 Alarm indication Zone-1 alarm FDS Fire panel (signal repeater). LCP DI Note-1 Note-4,LCP to RTU




SIGNALS FROM CO2 SYSTEM TO LCP & RTU

CO2 Gas release-1-Equipment room CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP RS-485 Note-5,

LCP to RTU

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CO2 Gas releas-2 -Electrical Room CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,

LCP to RTU

CO2 Gas releas-3 -Common Room CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,

LCP to RTU

CO2 Gas releas-4 - BatteryRoom CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,

LCP to RTU

CO2 Cylinder weight loss CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,LCP to RTU

SIGNALS FROM GAS DETECTION SYSTEM TO LCP & RTU

GDS system Gas detection system GDS system SCADA 102 GDS Panel LCP RS-485

LEL High Alarm indication Common Gas Detection High alarm SCADA 102 GD Panel(Signal Repeater) LCP DI Note-3,LCP to RTU

LEL High High Alarm indication Common Gas Detection Highhighalarm SCADA 102 GD Panel(Signal Repeater) LCP DI Note-3,

LCP to RTU

Sensor fault Alarm indication Gas Detection Sensor Fault Alarm SCADA 102 GD Panel(Signal Repeater) LCP DI Note-3,LCP to RTU












UPS SIGNALS

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Note

Vendor shall interface all the signals from invidual system to LCP.

UPS shall be interfaced with LCP on Modus RS 485. Necessary provision shall be provided in UPS

GDS detection system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in GDS system

FDS detection system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in FDS system

CO2 Gas release status system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in CO2 release system.

Gas generator system shall be interfaced with LCP on modbus RS485. Necessary provision shall be provided in Gas generator system.

MEDB panel shall be interfaced with LCP. Necessary provision shall be provided in MEDB panel.

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GOV 0401 Isolation Valve ON/OFF Type (GasOver Oil actuated valve)


















HS-0401B Push button open Open command from LCP LCP LCP XSOV 0401A Press to release PB

HS-0401D Push button close Close command from LCP LCP LCP XSOV 0401B Press to release PB




APPENDIX 2


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DPSH -0401 Differential Pressure Switch Differential pressure across valve GOV0401 Field








































LCP to RTU


LCP to RTU

CO2 Gas releas-3 - CommonRoom CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,

LCP to RTU


LCP to RTU





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LEL High High Alarm indication Common Gas Detection High highalarm SCADA 102 GD Panel(Signal Repeater) LCP DI Note-3,LCP to RTU























NoteVendor shall interface all the signals from invidual system to LCP.








UPS SIGNALS

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LCP

Type ofSignals in

RTURange Remarks

IP StationSIGNALS FROM FIELD INSTRUMENTS TO LOCAL CONTROL PANEL AND RTU

















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HS-0501A SCADA Open command from SCADA SCADA RTU Pot free contract toLCP

HS-0501C SCADA Close command from SCADA SCADA RTU Pot free contract toLCP

















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RTURange Remarks

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.





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.






Corrosion MonitoringProbe CMS system 0502-NG-12"-6C1-N LCP 0-10 MPY

CM-A SCADA CM indication at SCADA SCADA Channel-1 RTU AI

CM-B Indicator CM Indication at LCP LCP Channel-2 LCP Digital Indicator

.









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.






.




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.

Corrosion MonitoringProbe CMS system 0602-NG-12"-6C1-N LCP 0-10 MPY


















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Pipe to soil Potential(PSP) CPPSM system Pipe to soil Potential (PSP) SCADA CPPSM system LCP AI Note-1, LCP to RTU










LCP to RTU


LCP to RTU


LCP to RTU

CO2 Gas releas-4 -Battery Room CO2 Gas release status CO2 System CO2 System 102 CO2 System LCP DI Note-5,

LCP to RTU






LCP to RTU

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LCP to RTU


LCP to RTU


LCP to RTU


LCP to RTU





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UPS SIGNALS

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LCP to RTU


LCP to RTU


LCP to RTU


LCP to RTU





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Despatch Station, HissarSIGNALS FROM FIELD INSTRUMENTS TO LOCAL CONTROL PANEL AND RTU


















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.Corrosion MonitoringProbe CMS system 0902-NG-12"-6C1-N LCP 0-10 MPY
















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LCP to RTU


LCP to RTU


LCP to RTU


LCP to RTU






LCP to RTU

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1 Transmission & Indication --

2 --

3 MFR. Std. --4 Yoke --

5 --6 WP to IP 65 as per IEC 60529 20 Silicone Oil7 Yes 21 100% of span

8 Power Supply:- 24 V DC 22

9 Cable Entry:-23 PTFE

10 Accuracy:- +/- 0.075% of span (Note1) 24 *11 Rangeability:- 40:1 or better12 Transmitter Output:- 4-20 mA DC MISCELLANEOUS13 Load driving capability :- 600 ohms at 24 V DC 25 Over Range Protection:- Yes

26 Options:-14 Natural Gas a) Intrinsically safe output meter :- Yes (LCD in Engg. Unit)15 Diaphragm b) Air Filter Regulator:- --

16 SS316 c) Yes17 SS316 d) 2 valve manifold:- required18

Bottom 27 Model :- *19 -- 28 Quantity :- *

-- -- -- -- --

Natural Gas

NOTES:*: Vendor to furnish

1 Accuracy includes the combined effect of repeatability, linearity,hysteresis etc.2 Operating principle of transmitters shall be capacitance / pieizo resistance.3 Transmitter shall be CCOE certified4 Contractor shall develop detailed data sheet with all required information like span, make/model etc during detail engineering5 Refer the applicable PTS - P.013312 D 11077 081

DEVIATION NO DEVIATION VENDOR'S SIGNATURE WITH SEAL

CLIENT:

VENDOR: REV.

SHD AR

DATE PREP CHKD APPD

17.07.19 MAPROJECT:

0SJHPL

Sheet No. 1 of 18 GAIL

APPENDIX 3 P.013312 D 11077 081

OPTIONSOP. MAX. DES. OP. MAX. DES.

SERVICERANGEBarg

Process Conn.:-Size & Rating:-

Facing and Finish:-

SL. NO. TAG NO.PRESSURE Barg TEMPERATURE

Diaphragm Seal:-Wetted Parts Material:-Other Material:-

Element Material:-Process Connection:- 1/2" NPT(F) thru flange adapter with plugProcess Conn. Location:-

Measuring Unit:-Service:-Element:-

Body Material:-

Zero & Span adjustment:- Continuously adjustableexternally, non-interactive type

Adapter "O" Ring:-

Body Rating:-

Mounting accessories suitable for2" NB pipe:-

2 Nos -1/2" NPT(F) with 1 nos aluminiumplug

Enclosure:- Fill Fluid:-Intrinsically Safe:- Zero Suppression & Elevation:-

Mounting:- Capillary length:-

Elec. Area Class:- IEC Zone 2, Gr. IIA/IIB, Temp. class T3 Flushing/Filling Conn. with

Type:- 2 Wire, Electronic smart transmitter withHART Protocol of latest version Armour Flexible:-

Case:- Armour Flexible Material:-

PRESSURE TRANSMITTERSUNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> Barg Temperature<-> oC Level/Length<-> mm

Function:- Capillary Material:-

1 of 1Page 109 of 261

1 Panel Type

2 Panel Size (W X D X H)

3 MOC

4 Cable Entry

5 Colour

6 Internal Wiring

7 Protection Class

8 Indication on Panel

9 System capacity

10 Rest / Acknowledge

11 SIL 2 certification

12 Power Supply

13 Power Conversion

14 Meter range

15 Sensor Input

16 Alarm output

17 Digital Communication

18 Front Panel Option

19 Display

20 Operating Temp

21 Accuracy

22 Zero Drift

NOTE :

CLIENT: GAIL

PROJECT: SJHPL

VENDOR: 0 17.07.19 MA SHD AR

REV. DATE PREP CHKD APPD

Appendix 3

Sheet 9 of 18

Signal isolator / barriers, reapeters, multiplier shall be provided inside the panel.1

P.013312 D 11077 081

2 3 wire system is considered. Triad cables for interconnecting between gas detectors transmitter to gas detection system will be provided by contractor. In case of contractor provides 2 wire transmittter, 3 core will be retained as spare.

Digital & Bar graph (LED lamp) indication for Power, inhibit, short circuit, open circuit,over range, fault & Alarm. Reset / Accept Button. Zero & Span & alarm setting through Potentiometer.

Digital display in %LEL and 20 segment Bar graph display in % LEL.

0 deg C to + 50 Deg C

±3% of full scale over specified temperature range.

Less than 1% LEL per month.

Expandable to 1.5 times

Push Buttons for Reset and Acknowledge shall be illumination Push Button Switch

SIL 2 Certification as per IEC 61508

CO

NT

RO

LL

ER

24 VDC Solar Supply

Vendor to decide if any

0-100 % LEL/ 0 - 5 LEL Meter

Digital

Potential free contacts for alarm at 20% and 40% LEL per channel and sensor faultAdjustable high, high high alarm (SPDT free potential relay contacts) and sensor fault alarm per channel and interfce with RTU.

RS 485 Port for RTU/ SCADA Connectivity and one number spare

Datasheet-Addressable type Gas Detector Controller

Gas

Det

ecti

on P

anel

Wall Mounting

600 X 400 X 600(Wall Mounted) (to be finalized during detail Engneering)

MS CRCA Thickness: 1.6 MM, Gland Plate: 3MM. The outer colour of the gas detection panel shall be as per RAL 7035

Bottom

RAL 7035

0.5, 1.5 & 2.5 Sq MM Flexible Wires

IP 42 minimum

UPS/battery charger supply ON-OFF, 24VDC ON-Off , Rectifier/Diode Ring On-Off, Lamp Test , Battery On-Off

3 Gas detection system contractor shall provide logic for reset of hooter and beacon and implement the same in gas detection system

4 Suitable terminal blocks shall be provided for terminating cables. Flying leads shall not be provided.

5 Gas detector controller cards shall be of OEM make

6 Refer the applicable PTS - P.013312 D 11077 081

7

Page 110 of 261

1 Tag No.

2 Sensor Type

3 Model

4 Make

5 Operating Voltage

6 Range

7 Repeatability

9 Response Time

10 Temperature Range

11 Humidity range

12 Power Consumption

13 Digital Signal Outputs

14 Current Signal Outputs

15 Ingress Protection

16 Housing Material

17 Dimension

18 Cable Entry

19 Electrical Area Classification

20 Enclosure Class

21 Alarm at

22 Accuracy *

23 Calibration Kit

SIL 2 Certificate

Accessories

1

2

3

4

5

6

7

8

CLIENT: GAIL

PROJECT: SJHPL



SS 316

*

Two entries,inch NPT (F), for one spare cable entry stop plug shall be provided

Zone-1,2, Gr. II A & II B, T3 or better

Armoured cable between detector & controller shall be supplied by contractor along with installation accessories like cable connectors, double compression type cable gland (WP & Eexd at field end and WP at panel end).

Explosion proof EEx'd' / Intrinsically Safe EEx'ia'

All the detectors shall be provided with dust guard and splashguard

" * " Indicate Vendor to fill data

Detectors shall be located on the downwind side of the prevailing wind direction

Electrical input protection shall be provided against surges and spikes and Instrument shall be protected against Electromagnetic Interference (EMI) .

Refer the applicable PTS - P.013312 D 11077 081

Gas detectors shall be provided at suitable strategic location to monitor the leakage of failure prone equipment patrs, accessories, valve and pipe depending upon the wind diraction and gas density. The quantities of gas detectors indicates in the tender in minimum. Actual nos of gas detectors shall be finalized by contractor during detail engineering bases on final layout.

Appendix 3

Sheet 10 of 18

P.013312 D 11077 081

20 % & 40% of Range

± 2% FSD or better

Required

required

NOTE :

OT

HE

R

24

Required

Detectors shall be approved by ATEX, IECEX, CCOE etc.

T 90 < 15 second or better

0 deg C to 50 Deg C

0 to 99 % RH

IP 65 or better NEMA 4X

Vendor to indicate

required

24V DC

DATA SHEET - ADDRESSABLE TYPE POINT GAS DETECTOR

GE

NE

RA

LAs per P&ID

Infrared Absorption

*

As per approved/Recommended vendor list

GA

S D

ET

EC

TO

R

0-100 % LEL (Low Explosive Limit)

Better than +/-3% of Full Scale

Page 111 of 261

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

CLIENT: GAIL

PROJECT: SJHPL



P.013312 D 11077 081

3 Provision of alarm setting with buzzer sounder and visual indication shall be provided.

4 Accessories for mounting on panel shall be provided

5 Terminals shall be screwless clamp on type

Appendix 3

Multicolour back light LCD

*

Equipment Name

Type

Make

Model

Function

Mounting

DIGITAL PANEL INDICATOR

Microprocessor basaed , LED display, with engineering units (Dual channel)

Sheet 14 of 18

2 Indicator shall accept the 4-20 mA signals from pressure transmitter, temp transmitter, Level transmitter etc. Range shall configurable according to instrument range.

Dimension

Panel cut out

Power supply

*

24V DC

Area Classification


SAFE , control room munted

SAFE area

Required

As per Recommended vendor list

*

Indication , Engineering unit , Display

Flush mounted on Local control panel

5 digit, 7 segment back light display

Tag no.

Qty

Input Signal

NOTE :

+/- (0.1 %) of FS or betterMeasurement accuracy

Enclosure

Datasheet-Panel mounted Indicator

Alarm status

As per approved LCP BOM

4-20 mA(Refer Note 3)

Display

character type

Refer instrument index enclosed with tender.

Page 112 of 261

1 Equipment Name

2 Type

3 Make

4 Model

5 Panel Type

6 Panel Size (W X D X H)

7 MOC

8 Cable Entry

9 Colour

10 Internal Wiring

11 Protection Class

12 Indication on Panel

13 Instrument/Electronic Earth

14 Electrical Earth

15 Accessories of Panel

16Three Poisition selector switch

17 Operating Voltage

18 Non UPS input Voltage

19 Power consumption

20 Application

21 Area Classification

22 Earthing bolt

CLIENT: GAIL

PROJECT: SJHPL



P.013312 D 11077 081

4 Contractor shall develop finalize the requirements of barriers, relays, terminals and other LCP component as per PTS- Instrumentation and other technical specfication attached with bid document.


6 Contractor shall develop & implement the logic for SV station and other logic requirements as per P&ID in the LCP.

7

LOCAL CONTROL PANEL

CONVENTIONAL

As per vendor list

*

Indoor

Safe Area

IP 42 minimum

UPS/battery charger supply ON-OFF, 24VDC ON-Off , Rectifier/Diode Ring On-Off, Lamp Test . Selector switch, process indicators, valve poisition indications etc.

Cabinet shall have single door from front and double door from back. Doors shall be provided with lockable handles (flush pull chrome plated handles) and concealed hinges with pull pins for easy door removal. Panel Doors shall be provided with pockets for storing of manuals/ drawings etc.

2

NOTE :

Required. SCADA Mode/Panel Mode/Maintenance mode

Local control panel shall be provided with nicket palted brass cable glands of suitable size.3

1 Signal isolator / barriers, reapeters, multiplier , relay etc. shall be provided inside the panel.

Appendix 3

Sheet 13 of 18

Earth bus 25 x 6 mm copper

Earth bus 25 x 6 mm copper

Door Switch, Cable Glands, MCBS,Panel Light,Cooling Fan, 15 A Power socket, filter kit, anti vibration pad.

24 V DC

NA

*

Datasheet-Local Control Panel

Floor Mounted

1000 X 800 X 2100 (to be finalized during detail Engneering)

MS CRCA Thickness: 1.6 MM, Gland Plate: 3MM. Door thickness: 2mm

Bottom

RAL 7035-Exterior and Interior and Black for base frame

Gen

eral

Loc

al C

ontr

ol P

anel

Required

0.5, 1.5 & 2.5 Sq MM Flexible Wires

Page 113 of 261

1 Equipment Name

2 Type

3 Make

4 Model

5 Mfg.Std.

6 Principle of Detection

7Maximum current stand by -mA

8 Operating Voltage

9Max Permissible Alarm Current - mA

10 Body

11 Mounting

12 Dimension

13 Colors

14 Weight

15 Application

16 Indication

17 Humidity Range

18 Temp. Range

19 Detector wire size

Approval 20 Product Certification

NOTE :

1

2

3

4

5

6

7

CLIENT: GAIL

PROJECT: SJHPL


REV DATE PREP CHKD APPD


Remote response indicator for detectors installed above flase ceiling and in the cable trenches shall be considered along with detectorsMounting accessories and tag plate shall be provided for detectors.

DATA SHEET-MULTI SENSOR OPTICAL-PHOTO ELECTRIC SMOKE / THERMAL DETECTOR

Genral

Multi Sensor Photo Electric Smoke/Thermal Detector

Conventional


*

EN 54 Part 5(2000)

Function

Light Scattering & Thermistor

*

24 VDC

*

MOC

*

Surface

*

*

*

Service Condition

Indoor

Alarm condition : RED LEDHealthy condition : GREEN LED

5% to 95% Rh(Non condensing)

0 to +50 ° C

*

Appendix 3

LPCB/Vds/CE

Sheet 15 of 18

* - Vendor to Furnish

Bidder shall provide necessary Test / Calibration certificate

Bidder shall give more details as on above for better clarity of detector.

Bidder shall submit product catlogue with technical datasheet for reference , review and approval.

P.013312 D 11077 081

Page 114 of 261

1 Model

2 Make

3 Type


5Material of Construction

6 Finish

7 Terminals

8 Cable Entry

9 Supply Voltage

10 Humidity

11 Temperature

1

2

3

4

5

6

7

CLIENT: GAIL

PROJECT: SJHPL



24 V DC or 48 VDC

0 - 95 % R.H.

0 - 65 degc

Beacon shall be of stroboscopic type


2 nos. 3/16" Stud type terminals

Two. Entries, spare entry to be plugged with suitable plug

DATA SHEET - BEACON

BE

AC

ON

Flashing colour shall be orange

*

*

Rotating & Flashing Light

IP 65

CAST Aluminium Alloy LM6

Inside & Outside light grey Epoxy Powder coating

Common beacon shall be provided for gas detection system and fire detection system. Contractor shall provide necessary provision to integrate alarm signals from two different systems. Also contractor shall make necessary provision for two different visual alarms for gas detection system alarm and fire detection system alarm with same beacon.


Appendix 3

Sheet 18 of 18

NOTE :

P.013312 D 11077 081

Beacon for hazardous area shall be explosion proof to Eexd, IIA/IIB, T3

Beacon flashing frequency shall be 1 flash/sec

Page 115 of 261

1 Model

2 Make


6 Material of Construction

7 Flameproof Group

9 Finish

10 Terminals

11 Sound Level

12 Supply Voltage

13 Cable Entry

14Field Mounted Reset Push Button

15 Humidity

16 Temperature

1

2

3

4

5

6

CLIENT: GAIL

PROJECT: SJHPL




Two entries, NPT (F), for one spare cable entry stop plug shall be provided.

Required

*


Flameproof , E'exd and WP to IP65 or better

CAST Aluminium Alloy LM 6

Zone - 1 & 2, Gas Group IIC, TEMP. Class - T3

Inside & Outside light grey Epoxy Powder coating

0 - 95 % R.H.

0 - 65 degc

DATA SHEET - HOOTER

HO

OT

ER

90 to 110 db @ 3 Mtr.

24 V DC or 48 VDC

CLIP - ON Type Terminals

NOTE :

Appendix 3

Sheet 11 of 18

P.013312 D 11077 081

Hooter for safe area shall be weather proof to IP 65 or better

Common hooter shall be provided for gas detection system and fire detection system. Contractor shall provide necessary provision to integrate alarm signals from two different system. Also contractor shall make two necessary provision for two different alarm tones for gas detection system alarm and fire detection system alarm with the same hooter


Hooter for LEL High & High highAlarms shall be provided in Station Control Room Gas Detection Cabinet / Panel and also in outdoor.

Hooter shall be CCOE/ PESO certified for explosion proof (flame proof) .

Page 116 of 261

1 Equipment Name

2 Type

3 Make

4 Model

5 Mfg.Std.

6 Principle of MCP

7 Operating Voltage

8 Current Consumption - A

9 Body

10 Mounting

11 Dimension

12 Colors

13 Weight

14 Application

15 Indication

16 Humidity Range

17 Temp. Range

18 MCP wire size

Approval 19 Product Certification

Note

1

2

3

4

5

6

7

8

CLIENT: GAIL

PROJECT: SJHPL


REV DATE PREP CHKD APPD

Manual call point for hazardous area shall be CCOE certificate.


Accessories like mounting accessories, tag plate, SS316 hammer & chain shall be supplied along with manual call point

Manual call point for hazardous area shall be explosion proof to Eexd IIA/IIB and weather proof to IP 65

MANUAL CALL POINT

Genral

Manual Call Point

Conventional (Break glass type)


*

EN 54 Part 11

Function

PRESS - Type Re-Settable

24 VDC

*

MOC

LM6 dia cast Aluminum

Surface

*

*

*

Service Condition

Indoor / Outdoor

Required, Alarm LED

0-to 95% Rh(Non condensing)

0 to +50 ° C

*

Appendix 3

Sheet 16 of 18

LPCB/Vds/CE

P.013312 D 11077 081

* - Vendor to Furnish

Bidder shall provide necessary Test / Calibration certificate

Bidder shall give more details as on above for better clarity of Manual call point during detail engineering.

Bidder shall submit product catalogue with technical datasheet for reference , review and approval.

Page 117 of 261

1 Tag No.

2 Sensor Type

3 Model

4 Make

5 Operating Voltage

6 Range

7 Repeatability

8Distance Between Transmitter & Receiver

9 Response Time

10 Temperature Range

11 Humidity range

12 Power Consumption

13 Transmitter Lamp

14 Digital Signal Outputs

15 Current Signal Outputs


17 Housing Material

19 Dimension

20 Cable Entry

22 Electrical Area Classification

21 Enclosure Class

22 Alarm at

23 Accuracy *

24 Warm up time

25 Calibration Kit

26

OT

HE

R

Accessories

1

2

3

4

5

6

7

8

9

10

CLIENT: GAIL

PROJECT: SJHPL


REV. DATE ATHR CHKD APPD

Appendix 3 P.013312 D 11077 081

Sheet 12 of 18

Detectors shall be approved by ATEX, IECEX, CCOE etc.


All the detectors shall be provided with dust guard and splashguard

Gas detectors shall be provided at suitable strategic location to monitor the leakage of failure prone equipment patrs, accessories, valve and pipe depending upon the wind diraction and gas density. The quantities of gas detectors indicates in the tender in minimum. Actual nos of gas detectors shall be finalized by contractor during detail engineering bases on final layout.

Armoured cable between detector & controller shall be supplied by contractor along with installation accessories like cable connectors, double compression type cable gland (WP & Eexd at filed end and WP at panel end).

The open path type gas detectors shall be provided with source (transmitter) and detector (receiver) separated over line of sight distance to detect and quantify flammable gas presence. The open path gas detector shall not be influenced by solar radiation and other external IR radiation sources. the detector output of 4-20mA DC shall cover the whole measurement range including associated fault level. open path detector shall have diagnostic feature like low signal strength and significant loss of signal as min. The gas detector shall be firmly installed with proper alignment for line of sight and shall have immunity for false alarm and environment tolerance.

Swivel mounting along with mounting brackets (Refer Note 4)

NOTE :


Detectors shall be located on the downwind side of the prevailing wind direction

Electrical input protection shall be provided against surges and spikes and Instrument shall be protected against Electromagnetic Interference (EMI) .

All other accessories like Alignment Kit, Gas test filters, Test films shall be provided.

Zone-1,2, Gr. II A & II B, T3 or better

Explosion proof EEx'd' / Intrinsically Safe EEx'ia'

20 % & 40% of Range

± 3% FSD

*

Required

-

4-20 mA , HART

IP 65 or better NEMA 4X

SS 316

*

Two entries, NPT (F), for one spare cable entry stop plug shall be provided

DE

TE

CT

OR

24V DC

0 - 5 LEL

Better than +/-3% of Full Scale

*

T 90 < 5 second

-20 deg C to +65 Deg C

0 to 99 % RH

Vendor to indicate

Dual xenon flash lamps, Replaceable Type

DATA SHEET - OPEN PATH GAS DETECTOR

GE

NE

RA

L

As per P&ID

Infrared Absorption

*


Page 118 of 261

1 Tag No. Quantity * *2 Line No. Schedule * *3 Vessel No. *4 Safety / Relief Safety relief5 Full Nozzle Full Lift/Mod. Nozzle Full nozzle full lift6 Bonnet type Closed7 Conv./Bellows/Pilot Operated Conventional8 Inlet Conn. Size & Rating *9 Facing & Finish *10 Outlet Conn. Size & Rating *11 Facing & Finish *12 Cap Over Adj. Bolt Yes13 Screwed / Bolted Bolted14 Lifting Gear - Type15 Test Gag Yes161718 Body and Bonnet A351 CF8M19 Nozzle and Disc SS31620 Spring SS30421 Bellows --222324 Resilient Seat Seal --252627 Code API282930 Fluid State Natural Gas Gas31 Corrosive Constituent32 Required Flow Capacity33 Mol.Wt. S.G. at Rel. Temp34 Oper. Pressure Normal35 Oper. Temp. Rel. Temp. 36 Valve Discharges to Atmosphere37 Back Press. Const. Or Variable Variable38 Set Pressure39 Cold Bend Test Pressure40 % Over Pressure % Blow Down 21%41 Cp/Cv Compressibility Factor42 Viscosity @ Rel. Temp. mPas(cP)43 Vess. Wall Temp. Surf.Area-m24445 Calculated Area cm2 *46 Sel. Area cm2 Orifice Design * *47 No. of Valves Reqd. for capacity *48 Tota Area - cm2 *49 Actual Flow Capacity *5051 Model No. *52 IBR Certification No5354

NOTES: '*' : Venodr to furnish


PRESSURE RELIEF VALVEUNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm

General

Valve

Material

Options

Basis

Service conditions

Orifice

APPENDIX 3 P.013312 D 11077 081

Sheet 17 of 18 CLIENT: GAIL

PROJECT: SJHPL

0 17.07.19 MK SHD AR

VENDOR: REV. DATE PREP CHKD APPD

Page 119 of 261

1 To generate digital signal 21 a

2 Diaphragm actuated b

322

4 23 a)

5 IEC Zone 2, Gr. IIA/IIB, Temp. class T3 b)

6 WP to IP 65 as per IEC 60529 c)

7 Ex"d" d)

9 Set Point adjusment

10 Accuracy:- +/- 1%

11 +/- 1.5%

12 Switch Configuration:- Two SPDT

13 Switch Type:- Snap acting, shock and vibration proof

14 Switch Rating:- 24 V DC

14 Natural Gas

15 1/2" NPT(M)

16 Bottom 24 Model :- *17 Viton, Buna-N 25 Quantity :- *

18 150% of maximum pressure

19

20 two numbers, 1/2" NPT(F) with SS plug

Natural Gas


Note:-1 Process Data shall be as per Specification23 Refer the applicable PTS - P.013312 D 11077 0814 Vendor shall select the suitable model for each Tag no. such that the switch differential shall be with in the following limits.

5 Differential pressure Switch shall be mounted on Valve Actuator.6 Calibration Report


LM-6 Cast Aluminum

DIFFERENTIAL PRESSURE SWITCH

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> kg/cm*2 G Temperature<-> oC Level/Length<-> mm

Function:- Adjustibility:-

Type:-j y

span(minimum)Nameplate:- Tag number, service engraved in

stainless steel tag plateCase Material:-

Sensing Element Material:- SS-316L Accessories / Options:- 1/2" NPT 5 valve SS-316

Elec. Area Class:-

Service:-

Process Connection:-

Process Conn. Location:-

Enclosure:-

Protection

Internal

Accuracy of setting indication:-

Sealing Ring:-

Over Range:-

Terminal Block:-

Cable Entry:-

SL. NO. TAG NO.

PRESSURE kg/cm2 TEMPERATURE ºc RANGE

SERVICE OPTIONSOP. MAX. DES. MIN MAX. DES. SPAN SET

At the time of approval of DS, Supplier shall furnish DS along with Catalogues.

APPENDIX 3 P.013312 D 11077 081

The sum of the differential & repeatability (in Engg.Units)Shall be less than the difference between the set point and the normal operating pressure. In other words, it shall be ensured that at no point of time the switch shall remain in Alarm status while the process is within the normal operating range.

Sheet No. 8 of 18

CLIENT: GAIL

VENDOR: 0 17.07.19 MA

APPD

PROJECT: SJHPL

Suitable for full ring lugs for cable connection

Set-point adjustable over span range

SHD AR

REV. DATE PREP CHKD

Page 120 of 261

1 Direct 15 Diaphargm Seal:- --

2 Local Type:- --

3 150 mm Wetted Parts Material:- --

White with black inscriptions Others Material:- --

4 SS316 Process Connection: Size & Rating --

5 Beyonet type SS316 Facing & Finish:- --

6 Shatterproof glass Capillary Material:- --

7 WP to IP 65 as per IEC 60529 / IS 2147 Armour - Flexible Material:- --

8 Bourdon Capillary Length:- --

9 SS316 Flushing/Filling connection with:- --

10 SS316 16 Over Range Protection:- 130% of FSD

11 +/-1% of FSD 17 Blow Out Protection:- Yes

12 Micropointer 18 Options :- a) Snubber

13 1/2" NPT(M) b) Syphon c) Gauge Saver

Connection Location:- Bottom d) Liquid Filled casing e) Vaccum Protection

14 SS316 f) Solid front g) Two valve manifold

19 Quantity :- *

* Venodr to furnish1 Contractor shall develop details data sheet with all the required information like make/model etc, during detail engineering2 Refer the applicable PTS - P.013312 D 11077 0813

DEVIATION NO DEVIATION VENDOR'S SIGNATURES WITH SEAL

SJHPL

P.013312 D 11077 081

DATE PREP APPD

PROJECT:

CHKD

0 17.07.19

VENDOR: REV.

MA SHD SK

Sheet No. 5 of 18 CLIENT: GAIL

APPENDIX 3

Zero adjustment:-

Connection:-

PRESSURE TEMPERATURESERVICE OPTIONS

OP. OP.MA

DES.

Pressure Element:-

Element Material:-

MAX. DES.

Socket Material

Accuracy:-

Movement:-

SL. NO. TAG NO.RANGE Kg/Cm²

PRESSURE GAUGE

UNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> Barg Temperature<-> oC Level/Length<-> mm

Type:-

Mounting:-

Window Material:-

Enclosure:-

Dial Size:-

Colour:-

Case Material:-

Bezel Ring:-

5 of 18

Page 121 of 261

1 Tag No. Quantity * *

2 Application For Instrumentation IS cables

3 Area Classification Zone 2, Gr.IIA/IIB, T3

4 Enclosure WP to IP 65 as per IEC 60529 / IS 21475 Material of Construction Die cast aluminium (LM6 alloy)

6 Overall Dimension *

7 Cover Screwed

8 Painting Surface : Light blue & Inside : White

9

10 Left Side 6 nos. - 1/2" NPT(F)

11 Right Side 6 nos. - 1/2" NPT(F)

12 Top Side -

13 Bottom Side -

14 Other -

15 Type Double compression type, Nickel plated Brass & WP to IP 65 as per IEC 60529 / IS 2147

16 Size 1/2" NPT(M)

17

18

19

20 Entry 2 nos, 1 1/2" NPT, Bottom

21 Type Double compression type, Nickel plated Brass & WP to IP 65 as per IEC 60529 / IS 2147

22 Size 1 1/2" NPT(M)

23

24

25 Type Spring loaded, antiloosening & vibration-proof, screwless clamp type26 Quantity 48 Nos.27 No. of Rows 2 Nos.28 Numbering System Terminal strips & terminals shall be suitably numbered29 Size 2.5 mm230 Make *31

32 Telephone Socket & Plugs Not required33 Plug 1/2" NPT(M) & 11/2" NPT(M)34 Ground Busbar Required35 Rail(s) for terminals Required36 PVC hood alongwith Cable gland Required37 Hinges Required38 Nameplate Fixture Required39 Gasket Neoprene Rubber40 Hardware MS Zinc passivated41 Mounting Suitable for mounting wall, column, steel structure42 Manufacturer As per Approved /Recommended vender list43 Model *44454647

NOTES:

* : Vendor to furnish

1 Junction boxes shall have doors which shall be hinged type and these shall be fixed by plated countersunk screws.

2 Quantity of Cable glands & plugs shall be as per requirement.

3 Junction box numers based on cable schedule along with data sheet shall be submitted by contractor for approval



APPDVENDOR: REV. DATE PREP CHKD

0 17.07.19 MA SHD AR

Others

APPENDIX 3 P.013312 D 11077 081

GAIL

Multi CableCable Gland

Terminals

Options

PROJECT: SJHPL

JUNCTION BOXES

General

Single Cable

No. of Entry

Cable Gland

Sheet No. 6 of 18 CLIENT:

6 of 18

Page 122 of 261

1 Transmission & Indication --

2 --

3 MFR. Std. --4 Yoke --

5 --6 WP to IP 65 as per IEC 60529 20 Silicone Oil7 Yes 21 100% of span

8 Power Supply:- 24 V DC 22

9 Cable Entry:-23 PTFE

10 Accuracy:- +/- 0.075% of span (Note1) 24 *11 Rangeability:- 40:1 or better12 Transmitter Output:- 4-20 mA DC MISCELLANEOUS13 Load driving capability :- 600 ohms at 24 V DC 25 Over Range Protection:- Yes

26 Options:-14 Natural Gas a) Intrinsically safe output meter :- Yes (LCD in Engg. Unit)15 Diaphragm b) Air Filter Regulator:- --

16 SS316 c)Yes

17 SS316 d) 2 valve manifold:- required18

Bottom 27 Model :- *19 -- 28 Quantity :- *

-- -- -- -- --

Natural Gas


1 Accuracy includes the combined effect of repeatability, linearity,hysteresis etc.2 Operating principle of transmitters shall be capacitance / pieizo resistance.3 Transmitter shall be CCOE certified4 Contractor shall develop detailed data sheet with all required information like span, make/model etc during detail engineering 5 Refer the applicable PTS - P.013312 D 11077 081


CLIENT:

VENDOR: REV.

SHD AR

DATE PREP CHKD APPD

17.07.19 MAPROJECT:

0SJHPL

Sheet No. 1 of 18 GAIL

APPENDIX 3 P.013312 D 11077 081

OPTIONSOP. MAX. DES. OP. MAX. DES.

SERVICERANGE

Barg

Process Conn.:-Size & Rating:-

Facing and Finish:-

SL. NO.

TAG NO.

PRESSURE Barg TEMPERATURE

Diaphragm Seal:-Wetted Parts Material:-Other Material:-

Element Material:-Process Connection:- 1/2" NPT(F) thru flange adapter with plugProcess Conn. Location:-

Measuring Unit:-Service:-Element:-

Body Material:-

Zero & Span adjustment:-Continuously adjustable externally, non-interactive type

Adapter "O" Ring:-

Body Rating:-

Mounting accessories suitable for 2" NB pipe:-

2 Nos -1/2" NPT(F) with 1 nos aluminium plug

Enclosure:- Fill Fluid:-Intrinsically Safe:- Zero Suppression & Elevation:-

Mounting:- Capillary length:-

Elec. Area Class:- IEC Zone 2, Gr. IIA/IIB, Temp. class T3 Flushing/Filling Conn. with

Type:-2 Wire, Electronic smart transmitter with HART Protocol of latest version

Armour Flexible:-

Case:- Armour Flexible Material:-

PRESSURE TRANSMITTERSUNITS: Flow<-> Liquid- m*3/hr Gas- Sm*3/hr Steam- kg/hr Pressure-> Barg Temperature<-> oC Level/Length<-> mm

Function:- Capillary Material:-

1 of 18

Page 123 of 261

1 * 14 1/2" NPT(F)

2 4 Wire RTD 15 Two

3 Duplex 16 WP to IP 65 as per IEC 60529 / IS 2147

4 As per IEC 60751

5 Pt100 17 SS316

6 100 Ohm 18

7 Hermatically Sealed 19 Flange type

8 20 1/2" NPT(F)

10 mm 21 TEIND-STD-G-J-4002

SS316 22

9 SS316

10 Four Wires a) 150 mm

11 Mineral(MGO)Insulated b) ________________

12 c) ________________

13 Accuracy Class A 23 Quantity :-

NOTES: 1 Element length shall be suitable for thermowell.2

3 Vendor shall submit wake frequency and other test related test certificates,T/W drawings etc for approval during detailed engineering stage4 RTD to be provided with 2 nos cable entries with one no. cable entry provided with suitable plug5 Thermowell shall be of 900# rating6 Refer the applicable PTS - P.013312 D 11077 081

* VENDOR TO FURNISH


MA SHD0 17.07.19PROJECT: SJHPL

AR

VENDOR: REV. DATE PREP

P.013312 D 11077 081

CHKD APPD


APPENDIX 3

Thermowell's immersion length shall be selected in such a way that tip of the thermowell shall preferably be at the centre of pipe to sense temperature properly.

FLANGELINE NO. / VESSEL NO. / PIPING CLASS

OPTIONNOR. MAX. DES. U T MATERIAL

RATING, FACING, FINISH

SL. NO. TAG NO.

TEMP.°C WELL DIM.

No. of Wires:- Extra Nipple Extens

Insulation

Head Cover Type:- Screw Cap of Die Cast Aluminium with SS Chain

Matl.:- Options:-

Nipple & Union Matl.:-

Sheath: Inst. Conn.:-

O.D.:- Thermowell Dwg:-

Resistance at 0°C:- Construction:-Drilled bar stock upto immersion length 500 mm, otherwise fabricated

Leads:- Process Conn:-

Calibration:- Thermowell:

Element Material:- Material:-

Element: No. of Entries:-

No. of Elements:- Enclosure Type:-

RESISTANCE TEMPERATURE DETECTORS ALONG WITH THERMOWELL


Assembly as per Drawing:- Cable Entry:-

2 of 18

Page 124 of 261

1 * 14 1/2" NPT

2 4 Wire RTD 15 Two

3 Duplex 16 WP to IP 65 as per IEC 60529 / IS 2147

4 As per IEC 60751

5 Pt100 17 SS304

6 100 Ohm 18

7 Hermatically Sealed 19 Welded pad

8 20 1/2" NPT(M)

10 mm 21

SS316 a) Extra Nipple Extens as per site condition

9 SS316 b) Clamp

10 Four Wires c) ________________

11 Mineral(MGO)Insulated

12 22 Quantity :- -

13 Accuracy Class A

NOTES:

1 Vendor to element length as per site condition.

2 Vendor shall supply & select CLAMP thickness and size also related accessories which is suitable for available pipeline size3 Contractor shall refer dwg no. TEIND-STD-G-J-4007 enclosed with tender. Element shall be direct surface contact type4 Element lenth to suit the pad dimensions5 RTD shall be provided with two cable entries with one cable entry provided with suitable plug

6


* VENDOR TO FURNISH


RESISTANCE TEMPERATURE DETECTORS SKIN TYPE


Assembly as per Drawing:- Cable Entry:-

Element: No. of Entries:-

No. of Elements:- Enclosure Type:-

Calibration:- PAD:

Element Material:- Material:-

O.D.:-

Matl.:-

Nipple & Union Matl.:-

Resistance at 0°C:- Construction:- PAD

Leads:- Process Conn:-

Sheath: Inst. Conn.:-

RATING, FACING, FINISH

No. of Wires:-

Insulation

Head Cover Type:- Screw Cap of Die Cast Aluminium with SS Chain

SL. NO. TAG NO.

TEMP.°C WELL DIM. FLANGELINE NO. / VESSEL NO. / PIPING CLASS

OPTIONNOR. MAX. DES. U T MATERIAL

APPENDIX 3

Contractor shall develop detailed data sheet with all the required information like element length, pad dimension, make, model etc. during detail engineering

P.013312 D 11077 081


PROJECT: SJHPL0

VENDOR: REV. DATE PREP CHKD

Options:-

APPD

17.07.19 MA SHD AR

3 of 18

Page 125 of 261

1 Transmission & Indication

2 2 Wire, Electronic Smart with HART protocol of latest version

3 MFR. Std.

4 Yoke

5 WP to IP 65 as per IEC 60529 / IS 2147

6 Elec. Area Class:- IEC Zone 2, Gr. IIA/IIB, temp. class T3

7 Yes

8 24 V DC

9 Cable Entry:- 1/2" NPT(F)

10 Accuracy:- +/- 0.1% of FSD

11 Self Diagnostic Facility:- Yes

12 Cold Junction compensation :- --

13 Transmitter Output:- 4-20 mA DC, HART

14 Load Capability:- 600 ohms at 24V DC

15 Pt100

16 As per IEC 60751

17 Options:-

a) Mount. Acc. For 2" pipe:- Yes

b) Yes (In Engg. Unit)

18 Model :- *

19 *

NOTES:* : Vendor to furnish

1 TT shall be remote mounted

2

3 TT shall be dual compartment type

4 TT shall be CCOE certified

5 Contractor shall develop detailed data sheet with all the required information like make/model etc. during detail engineering.



APPDVENDOR: REV. DATE PREP CHKD

MA SHD AR

GAILSheet No. 4 of 18 CLIENT:

TEMP.

OPTIONNOR. MAX. DES.

APPENDIX 3 P.013312 D 11077 081

TEMPERATURE TRANSMITTERS


Function:-

Type:-

Case:-

Mounting:-

SL. NO.

TAG No.

PROJECT: SJHPL

The input for TT shall be RTD Pt 100, 4 wire Class-A. Two cable entries shall be provided with 1/2" (NPT (F) for RTD and 1/2" NPT(F) for out put signals

0 17.07.19

Enclosure:-

Intrinsically Safe:-

Power Supply:-

Sensor Element:-

Calibration:-

SERVICERANGE °C

Intrinsically safe output meter (LCD) :-

Quantity :-

4 of 18

Page 126 of 261

1 Tag No. Quantity * *2 Application For Instrumentation Non-IS cables3 Area Classification Zone 2, Gr. IIA / IIB, T3 4 Enclosure WP to IP 65 as per IEC60529 & Exd IIB T6 as per IEC 60079 / IS 21485 Material of Construction Die cast aluminium (LM6 alloy)6 Overall Dimension *7 Cover Screwed8 Painting Surface : grey & Inside : White910 Left Side 6 nos. - 1/2" NPT(F)11 Right Side 6 nos. - 1/2" NPT(F)12 Top Side -13 Bottom Side -14 Other -15 Type Double compression, Nickel plated brass & WP to IP 65 & EExd IIB T6 as per IEC 60079 / IS 214816 Size 1/2" NPT(M)17181920 Entry 2 Nos, 1 1/2" NPT, Bottom

21 Type

22 Size 11/2" NPT(M)232425 Type Spring loaded, antiloosening & vibration-proof, screwless clamp type26 Quantity 48 Nos.27 No. of Rows 2 Nos.28 Numbering System Terminal strips & terminals shall be suitably numbered29 Size 2.5 mm230 Make *3132 Telephone Socket & Plugs Required33 Plug 1/2" NPT(M) & 11/2" NPT(M)34 Ground Busbar Required35 Rail(s) for terminals Required36 PVC hood alongwith Cable gland Required37 Hinges Required38 Nameplate Fixture Required39 Gasket Neoprene Rubber40 Hardware MS Zinc passivated41 Mounting Suitable for mounting wall, column, steel structure42 Manufacturer As per Approved /Recommended vender list43 Model *44454647

NOTES:* : Vendor to furnish

1 Junction boxes shall have detachable cover which is fixed to the box by means of cadmium plated triangular head / hexagonal head screws.

2

3 Quantity of Cable glands & plugs shall be as per requirement.

4 Junction box numers based on cable schedule along with data sheet shall be submitted by contractor for approval



Double compression, Nickel plated brass & WP to IP 65 & EExd IIB T6 as per IEC 60079 / IS 2148

Others

Junction boxes shall have a warning engraved / integrally cast on the cover as "ISOLATE POWER SUPPLY ELSEWHERE BEFORE OPENING".

APPENDIX 3

Multi CableCable Gland

Terminals

Options

P.013312 D 11077 081

JUNCTION BOXES

General

Single Cable

No. of Entry

Cable Gland


REV.

0 17.07.19 MA SHD

DATE

PROJECT: SJHPLAR

PREP CHKD APPDVENDOR:

7 of 18Page 127 of 261

PTS – OPTICAL FIBER CABLEP. 013312D 11077

083



PTS – OPTICAL FIBER CABLE

DOC. NO. P.013312 D 11077 083



Page 128 of 261


083


TABLE OF CONTENTS

1.0 INTRODUCTION .....................................................................................................................1

2.0 SCOPE ....................................................................................................................................1

3.0 REFERENCE ............................................................................................................................1

4.0 APPLICABLE codes & standards..............................................................................................2

5.0 GENERAL GUIDELINES ...........................................................................................................2

6.0 SPECIFICATION OF Optical fibre cable ...................................................................................2

7.0 JOINTING CLOSURES ...........................................................................................................11

8.0 FIBRE TERMINATION CLOSURE ...........................................................................................12

9.0 LOOP BOX ............................................................................................................................12

10.0 OFC JOINT pit/Inspection chamber ......................................................................................12

11.0 ELECTRONIC JOINT LOCATION MARKERS. ..........................................................................12

12.0 PROCEDURE FOR OF CABLE BLOWING ................................................................................14

13.0 JOINTING KIT TESTS ...........................................................................................................16

14.0 BUILDING ENTRY .................................................................................................................17

15.0 QUALITY ASSURANCE PROGRAMME ....................................................................................17

16.0 TESTING THE OFC ...............................................................................................................17

17.0 PACKING ..............................................................................................................................18

18.0 DOCUMENTATION ................................................................................................................18

19.0 ACCEPTANCE TESTING ........................................................................................................20

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INTRODUCTION1.1. This document presents the technical specification for the Armoured Optical Fibre cable required for this

Pipeline Project.

1.2. Optical Fibre Cable is proposed to be laid along the pipeline between Dispatch station, SVs to Receivingstation.

2.0 SCOPE2.1. Design, Engineering, Manufacturing, Testing and Supply and laying of armoured Single Mode Optical fibre

cable (24 Fibres as per ITU-T G652D) and blowing/pulling through PLB-HDPE duct from dispatch stationto receiving Station including SV stations. OFC shall be laid across each PLB-HDPE duct if crossing lengthis equal or more than 500Mtrs.

2.2. Design, Engineering, Manufacturing, Testing and Supply and laying of PLB-HDPE duct throughout thepipeline and stations. Additional PLB-HDPE duct shall be laid at all crossing, river, nalah, culvert,road/railway, canal etc. inside the separate 6” CS casing pipes.

2.3. Supply and installation of 24 F splice encloser. The splice enclosures shall be placed in the jointpit/inspection chambers after splicing of the Optical Fibre cable at every 4 Km intervals along the opticalfibre route.

2.4. Supply and installation of joint pit/ inspection chambers of required dimensions, at every 4 Km intervalsalong the pipeline route marker. The inspections chambers may either is constructed on site or providedreadymade. Chamber shall be filled with sand after joining of cable.

2.5. Supply of underground electronic markers along the Optical fiber cable. Electronic marker shall be keptinside the joint pit/ inspection chamber and capable of being located from a distance of minimum 2.5 meter.Marker quantity shall be as per the requirement. Two number electronic locater shall be provided and havecapability to locate the marker from minimum distance of 2 meter.

2.6. Supply and installation of route markers of required dimensions, along the pipeline route. The route markersshall be placed at every inspection chamber, crossings etc as per pipeline laying practices.

2.7. Supply of 48/24 FTC with FCPC type connectors, end plug & cable sealing for HDPE duct and otheraccessories as per requirement. FTC shall be installed inside the control room and fiber shall besplice/terminate in the FTC by contractor.

2.8. Supply of special tools & Tackles as per requirement of the project.

2.9. Supply of complete technical literature, drawing, rout map & documentation as per requirement of theproject.

2.10. Total quantity of OFC shall be as per SOR including the loop length at each station, joint pit/inspectionchamber + 1 km extra length. Extra length shall be used for hooking up of OFC to telecom unit at allstations. CONTRACTOR shall lay the OFC upto inside the control room.

2.11. Contractor shall provide the extra length of OFC at least 15 meter loop on both sides (IN & OUT) in eachstation inside the control room wherever applicable. The extra OFC length shall be properly covered in themetallic casing inside the control room. FTC (Fiber termination closure) to be provided at each end of thecable for cable protection in the control room/Equipment room.

2.12. Contractor shall provide the extra length of OFC at least 30 meter loop (15 meter each side) inside theinspection chamber at both end side of the OFC before splicing.

3.0 REFERENCEa. Scope of work – P.013312/I/11075/101- scope of work C&I

Note –

In the event of any conflict between GTS and PTS, PTS shall prevails over the GTS

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4.0 APPLICABLE CODES & STANDARDSThe optical fibre cable / materials provided shall conform to the latest editions of standards like ITU-T,TIA, IEC, EIA, ASTM & BS.

In case of any conflict between the above standards and the specifications, the matter shall be referred toOwner/Owner’s Engineer.

CONTRACTOR shall proceed with design of the cable/equipment only after obtaining clarifications fromOwner /Owner’s Engineer in all such cases.

Latest revisions and amendments of following codes and standards shall be applicable, and the requirementsspecified in the standards shall strictly confirm to by the CONTRACTOR.

IS 2530 Methods for test of polyethylene molding material and

polyethylene

IS 7328 HDPE material for moulding and extrusion

IS 14151 (part 1) Polyethylene pipes for sprinkler irrigation systems (part – 1 pipe).

IS 12235 (part 9) Methods of tests for unplasticized PVC pipes for portable water

supplied impact strength at zero degree centigrade.

IS 9938 Recommended colours for PVC insulations for LF wires and

cables.

ASTM D 1693 Test methods for environmental stress cracking of ethylene plastics

ASTM D 1505 Test methods for density

ASTM D 3895 Methods for oxidation induction test

ASTM F 2160-01 Standard specification for Solid Wall, High Density Polyethylene

(HDPE conduit based on controlled outside diameter OD)

ASTM D 638 Standard test methods for tensile strength of plastics

5.0 GENERAL GUIDELINESa) CONTRACTOR shall be totally responsible for the offered Optical Fibre, cable/ materials /

equipments.

b) CLIENT/ Consultant reserve the right to modify/ revise/ alter the specifications of cable/ equipmentsprior to acceptance of any offer.

c) If during the course of erection of the work any discrepancy of inconsistency, error or omission in anyof the provisions of the contract is discovered, the same shall be referred to the CLIENT/ Consultantwho shall give his decision in the matter and issue instruction directing the manner in which the work isto be carried out. The decision of the CLIENT/ Consultant shall be final and conclusive and thecontractor shall carry out the work in accordance therewith.

d) The model numbers of jointing closure offered for this project must have been in successful field usefor more than one year.

6.0 SPECIFICATION OF OPTICAL FIBRE CABLE6.1. The 24 core optical fiber cable will be armoured type comprising 24 fibres as per ITU-T-G-652D

specifications, suitable for working in 1550 / 1310 nm wavelength and laid through silicon coated PLB-HDPE duct by blowing technique. The cable shall be fire retardant, chemical resistant, termite & rodentproof and moisture proof.

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6.2. Single Mode Optical Fibre, Fully ITU T rec. G652 Oct 2000, IEC 60793-1 and Telecordia GR – 20 corecompliant.

6.3. The types of optical fibre cable required are as follows:

a) Desired operation life of cable : Better than 40 years

b) Length of O F Cable drum : 4 Km ± 2.5%

c) Cable weight in single drum : Bidder to provide. No splicing shall be permitted on anyfiber in a drum length of the cable

d) Cable identification:

The outer surface of the cable shall be permanently & legibly marked with colour in contrast to the outersheath at regular intervals not exceeding one meter with name of Owner, Logo of the Owner, name ofmanufacturer, part number and OPTICAL FIBRE CABLE.

The outer surface of each completed cable shall have sequentially numbered metric length markers spacedat regular intervals of one meter.

6.4. CABLE MARKING

a) A suitable marking which can last long shall be applied in order to identify this cable from other cables. Thecable marking shall be imprinted/ indented (the impression shall not exceed the depth of 0.15 mm). Themarking on the cable shall be indelible of durable quality and shall be provided at regular intervals of one-meter length.

b) The marking shall be in contrast colour over the black HDPE sheath and shall be done by hot foilindentation method. The colour used must withstand the environmental influences experienced in the field.

c) The accuracy of the sequential marking must be within –0.25% to +0.5% of the actual measured length. Thesequential length markings must not rub off during normal installation and in lifetime of optical fibre cable.The total length of the cable supplied shall not be in negative tolerance.

d) The legend marking on Optical Fibre cable shall be as follows:

· Company Legend

· Legend containing telephone mark & internationally acceptable Laser symbol.

· Type of Fibre (G.652D)

· Number of Fibres.

· Year of manufacture

· Sequential length marking at every one meter.

· Drum number

6.5. COLOUR CODING IN OPTICAL FIBRE CABLE

a) The colorant applied to individual fibres, fibre units and binders shall be readily identifiable throughoutthe lifetime of the cable and shall match and confirm to the Munsell colour standards (EIA-359-A) andalso IEC Publication 304 (4).

b) Colour code to be adapted for individual fibres in each loose tube shall be:

Blue

Orange

Green

White/ Natural

c) Colour Code to be adapted for individual loose tubes shall be:

Page 132 of 261


083


When the loose tubes are placed in circular format, the marking to indicate the loose tube no. "1" shallbe in Blue colour followed by loose tube no. "2" of Orange colour and so on for other tubes as per thecolour scheme given below-

Loose tube No. 1 shall be of Blue colour

Loose tube No. 2 shall be of Orange colour

Loose tube No. 3 shall be of Green colour

Loose tube No. 4 shall be of Brown colour

Loose tube No. 5 shall be of Slate colour

Loose tube No. 6 shall be of White colour

6.6. CONSTRUCTION DETAILS OF CABLE

6.6.1. SECONDARY PROTECTION:

The primary coated fibres shall be protected by loose packaging within a tube, which shall be filled withthixotropic jelly

· Number of fibres: 24

· Number of loose tubes: 6

· Number of Filler/ Dummy: 0

· Number of fibres per loose tube: 4

· Material for loose tube shall be Polybutylene terephthalate.

· The outer diameter of loose tube shall be 2.0 mm + 0.2 mm without any negative tolerance. The innerdiameter of loose tube shall be minimum 1.2mm.

Bidder/vendor/contractor to specify the outer and inner diameter of the loose tube.

6.6.2. STRENGTH MEMBER:

Solid FRP non-metallic strength member with a minimum diameter of 2.0 mm in the cable core shall beprovided. The strength member(s) in the cable shall be for strength & flexibility of the cable and shall haveanti buckling properties. These shall also keep the fibre strain within permissible values.

6.6.3. CABLE CORE ASSEMBLY:

Primary coated fibres in loose tubes stranded together around a central strength member using helical orreverse lay techniques shall form the cable core. Four fibres shall be placed loosely in each loose tube.

6.6.4. CORE WRAPPING:

The main cable core containing fibres shall be wrapped by layer/ layers of Polyester foil/ tape. Nylon/polyester binder thread shall be used to hold the tape. The core wrapping shall not adhere to the secondaryfibre coating and shall not leave any kink marks over the loose tube.

6.6.5. MOISTURE BARRIER (PROTECTION):

The main cable core (containing fibres & core wrapping) shall be protected by flooding compound (Jelly)having properties of non-hygroscopic dielectric material.

6.6.6. FILLING COMPOUND:

The filling compound used in the loose tube and in the cable core shall be compatible to fibre, secondaryprotection of fibre, core wrapping etc. The drip point shall not be lower than +70 °C. The fibre movementshall not be constrained by stickiness & shall be removable easily for splicing. Reference material testmethod to measures drip point shall be as per ASTM D 556. The filling and the flooding jelly compoundshall be as per the TEC Specs No. TEC/GR/TX/ORM 01/04/ SEP-09 and subsequent amendment issued, ifany.

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6.6.7. INNER SHEATH:

A non-metallic moisture barrier sheath shall be applied over and above the cable core. The core shall becovered with tough weather resistant High-Density Polyethylene (HDPE) sheath black in colour (UVstabilised) and colour shall conform to Munsell Colour Standards. Thickness of the sheath shall be uniform& shall not be less than 1.2 mm. The sheath shall be circular, smooth, free from pin holes, joints, mendedpieces and other defects. Reference test method to measures thickness shall be as per IEC 189 Para 2.2.1and Para 2.2.2.

Note: HDPE material, black in colour, from the finished cable shall be subjected to following tests(onsample basis) and shall conform to the requirement of the material as per GR No.TEC/GR/TX/ORM-01/04SEP.09.

i. Density

ii. Melt Flow Index

iii. Oxidative Induction time

iv. Carbon Black Content

v. Carbon Black Dispersion

vi. ESCR

vii. Moisture Content

viii. Tensile Strength and Elongation at break

ix. Absorption Coefficient

x. Brittleness Temperature

6.6.8. GLASS REINFORCEMENT:

Impregnated Glass Fibre Reinforcement shall be used to achieve the required tensile strength of the opticfibre cable over the cable inner sheath to provide peripheral reinforcement along with solid rigid FRP Rodin the centre at cable core. These flexible strength members shall be Non-water blocking type. ImpregnatedGlass Fibre Reinforcement used shall be equally distributed over the periphery of the cable inner sheath. Itshall be applied helically and shall provide full coverage to inner sheath to provide rodent protection. Thequantity of the Impregnated Glass fibre Reinforcement used per km length of the cable shall be minimum20kg per KM cable. The specification of the glass roving shall be as per Section XII of GR No.TEC/GR/TX/ORM-01/04 SEP.09.

6.6.9. OUTER SHEATH:

A non-metallic moisture barrier sheath (black in colour) shall be applied over the inner sheath and glassroving layer, which shall consist of tough weather resistant made High Density Polyethylene compound(HDPE) with anti-termite and anti-rodent properties. The outer sheath shall be UV stabilized and the colourshall confirm to Munsell colour standards. The thickness of the outer sheath shall not be less than 1.6mm.The outer sheath shall be uniform, circular, smooth; free from pin holes, joints mended pieces and otherdefects. The reference test method to measure thickness shall be as per IEC 811-5-1.

Note: HDPE material from finished product shall be subjected to following tests (on sample basis) and shallconfirm to the requirement of the material as per the GR no. TEC/GR/TX/ORM-01/04/SEP-09 (Section-III):

· Density

· Melt flow index

· Oxidative Induction time

· Carbon black content

· Carbon black dispersion

· ESCR

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· Moisture content

· Tensile strength and elongation at break

· Absorption Coefficient

· Brittleness Temperature

· Anti-termite and Anti-rodent dopants shall be added in the outer sheath to resist termite attack androdent attack on the cable.

Bidder/vendor/contractor shall provide the details of doping material used and same shall be verified duringtesting.

6.6.10. Protection against rodents

For protection against rodents, HDPE sheath shall have rodent repellent properties with the use of an eco-friendly, non-toxic rodent repellent additive. 2%-3% master-batch of rodent repellent material consisting of5% additive & 95% HDPE/ LDPE shall be mixed in the HDPE sheath material/ granules (If otherwise,bidder/vendor/contractor to submit details of additive with OEM recommendation for mixing).

6.6.11. Protection against termites

For protection against termites, HDPE sheath shall have termite repellent properties with the use of an eco-friendly, non-toxic termite repellent additive. The termite protection shall be as per DIN EN117.

A copy of Invoice from OEM of rodent repellent material & termite repellent material shall be submittedwith the pre-FAT internal inspection reports and bidder/vendor/contractor to evidence Original Invoicefrom OEM of rodent repellent master-batch & termite repellent material during Factory Acceptance Test offinished cable.

6.6.12. Termite & Rodent Test

Termite & Rodent test shall be carried out at any recognized lab on finished cable samples. The reports shallbe submitted by the bidder/vendor/contractor. Termite resistance shall be provided with an additive in outersheath and rodent protection shall be provided with an additive in outer sheath and by use of Glass rovingyarns around the periphery of inner sheath. These yarns should spread uniformly around the periphery ofinner sheath. Bidder/vendor/contractor to note that apart from the above test report, it shall be

Owner’s prerogative to get sample of finished cable tested at OEM/ Other recognized test labs to establishpresence of rodent & termite repellent additives in specified proportion.

6.6.13. CABLE DIAMETER:

a) Bidder/vendor/contractor to specify the cable diameter.

b) Bidder/vendor/contractor to note that the overall cable diameter shall be between 13-14mm.

6.6.14. RIP CORD:

a) Three suitable ripcords shall be provided in the cable, which shall be used to open the HDPE sheaths ofthe cable. Two ripcords shall be placed diametrically opposite to the each other at below the outer sheath &one ripcord shall be placed below the inner sheath. It shall be capable of consistently slitting the sheathwithout breaking for a length of 1 meter at the installation temperature. The ripcords (3ply & twisted) shallbe properly waxed to avoid wicking action and shall not work as water carrier.

b) The ripcords used in the cable shall be readily distinguishable from any other components utilized in thecable construction.

6.7. MECHANICAL CHARACTERISTICS OF CABLE

a) Temperature Installation & Operation : 0 Deg. C to 65 Deg.C

Storage : 0 Deg C to 65 Deg C

b) Tensile strength:

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The cable shall have sufficient strength to withstand a load of value T (N) = 9.81 x 2.5 W Newton or2670 N whichever is higher. (Where W=mass of 1 km of cable in Kg). The load shall not produce astrain exceeding 0.25% in the fibre and shall not cause any permanent physical and optical damage toany component of the cable. The attenuation shall be noted before strain and after the release of strain.The change in attenuation of each fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nmwavelength. Test Method: IEC 60794-1-2-E1 :

c) Cable weight in Kg/ Km : Bidder to specify

d) Minimum bending radius : 20 x cable diameter

6.7.1. Average splice loss of all the splices shall be less than 0.1 dB (as per the Bell core Generic RequirementGR-20 Core, Issue 2 July 1998.)

6.7.2. Bidder should submit the proposed / offered cross section diagram of the cable with the bid giving fulldetails. It should conform to the general practice followed internationally.

6.8. ABRASION RESISTANCE:

Specs: The cable surface & the marking printed on the surface of the cable shall be abrasion resistant.

Test Method: IEC 60794-1-2-E2 or by any other international test method

6.9. RESISTANCE AGAINST CRUSH:

Spec: The fibres and component parts of the cable shall not suffer permanent damage when subjected to acompressive load of 2000 Newton applied between the plates of dimension 100 x 100 mm the load shall beapplied for 60 secs. The attenuation shall be noted before and after the completion of the test. The change inattenuation of the fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength.

Test Method: IEC 60794-1-2-E3

6.10. RESISTANCE AGAINST IMPACT:

Spec.: The cable shall have sufficient strength to withstand an impact caused by a mass weight of 50Newton, when falls freely from a height of 0.5 meters. The radius R of the surface causing impact shall be300 mm. ten such impacts shall be applied at the same place. The attenuation shall be noted before and afterthe completion of the test. The change in attenuation of the fibre after the test shall be ≤ 0.05 dB both for1310 nm and 1550 nm wavelength.


6.11. BENDING ABILITY/RESISTANCE:

Specs: The cable sample shall be able to bend to a diameter equal to 20D (where D is outer diameter ofOFC). The change in attenuation of the fibre after the repeatedly bending OFC as per test plan in QAP shallbe ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength. It shall be possible to make figure of 8 ofminimum 1000 meters of the cable uncoiled from the cable reel without any difficulty. No visible damageshall occur.

Test Method: EIA-455-104

IEC 794-1-2-E11 (Procedure –I)

As per the Clause no. 4.8 of the GR alternatively as per ASTM D790

6.12. TORSION RESISTANCE:

Object: The purpose of this test is to determine the ability of an optical fibre cable to withstand torsion.


Specs: The optical fibre cable shall be able to withstand torsion by the load shall be 100 N. The cable shallbe free from any cracks, tearing on the outer sheath and for the damage to other component parts of thecable after application of twist/torsion as per test plan in QAP. The twist mark shall not be taken as damage.The change in attenuation of the fibre after the test shall be ≤ 0.05 dB both for 1310 nm and 1550 nm wavelength.

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6.13. KINK RESISTANCE:

Specs: Kinking of an optical fibre cable shall not result in breakage of any fibre, when a loop is formed ofdimension small enough (minimum bend radius) to induce a kink on the sheath. The kink should disappearafter normalising the cable. The change in attenuation of the fibre after test shall be ≤ 0.05 dB both for 1310nm & 1550 nm wavelength.


6.14. TEMPERATURE RANGE:

Specs: The optical fibre cable shall be suitable for temperature range from –20°C to +70°C for storage andoperation.

Test Method: IEC 794-1-2-F1 (To be tested on standard cable length & drum i.e. 4 Km ± 2.5%)

6.15. RESISTANCE AGAINST WATER PENETRATION:

Specs: The optical fibre cable shall have sufficient components like jelly filling/flooding inside optical fibrecable that will not allow water passage along its length.

Test Method: IEC 794-1-2-F5(Fig. B) 1992.

6.16. FLEXURAL RIGIDITY:

Specs: The fibre and the component parts of the cable shall not suffer permanent damage in the cablesubjected to Flexural Rigidity Test as per QAP. The change in attenuation of the fibre after the test shall be≤ 0.05 dB for 1310 nm and 1550 nm wavelengths. The sheath shall not show any cracks visible to the nakedeye.

Test Method: To be tested as per ASTM D-790

6.17. CABLE AGING TEST:

Objective: To check the cable material change dimensionally as the cable ages.

Method: The test cable shall be exposed to 85+2 degree C for 168 hours. The attenuation measurement at1310 & 1550 nm wave length to be made after stabilisation of the test cable at ambient temperature for 24hours.

Requirement: The increase in attenuation allowed: ≤ 0.05 dB at 1310 & 1550 nm.

Note: The attenuation changes are to be calculated with respect to the base line attenuation values measuredat room temperature.

6.18. CABLE JACKET YIELD STRENGTH AND ULTIMATE ELONGATION:

Specs: yield strength and elongation of the polyethylene (HDPE) cable sheath (jacket) shall be as per tablebelow:

Jacket Material Minimum Yield Strength Minimum Elongation (%)

(MPa) (psi)

HDPE un-aged 16.5 2400 400

HDPE aged 12.4 1800 375

6.19. EASY REMOVAL OF SHEATH:

Easy removal of both the outer jacket and the inner sheath shall of the optical fibre cable shall be possibleby using normal sheath removal tool.

6.20. TECHNICAL SPECIFICATIONS OF FIBRES

Single Mode Optical Fibre, Fully ITU T rec. G652 Oct 2000, IEC 60793-1 and Telecordia GR – 20 corecompliant. The specifications referred below are generally for ITU T 652 standard single mode optical fibrecable. The specifications referred below are notional. The vendor shall specifically and separately complywith the specifications for ITU T 652 optical fibre cable standards in his response.

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SINGLE MODE OPTICAL FIBER AS PER ITU T G.652D

S.No Parameter Requirement

1.0 Transmission characteristics

1.1 Attenuation coefficientAt 1310 nmAt 1550 nmAt 1625 nm

In bare Fibre≤ 0.34 dB/Km≤ 0.19- 0.20 dB/ Km≤ 0.20-0.23- dB/ Km

In Cable≤ 0.36 dB/ Km≤ 0.21 dB/ Km≤ 0.26 dB/ Km

1.2 Attenuation Vs Wavelength1285- 1330 nm1525- 1575 nmAttenuation coefficient in cable at 1625nm shall be :

≤ 0.03 dB/ Km≤ 0.02 dB/ Km

</= 0.26 dB/ Km1.3 Mode field diameter at

1310 nm1550 nm

Any single value 8.6 – 9.5µmAny single value 9.0- 11.0 µm

1.4 Water Peak Attenuation after cablingi) At 1383 nm :ii) Between 1360 – 1480 nm :Note: Water Peak Attenuation aftercabling shall be measured either at 1383nm or between 1360 – 1480 nm.

≤ 0.34 dB/Km≤ 0.34 dB/Km

1.5 Water Peak Attenuation before cablingBetween 1360 – 1480 nm:Note :1. Sudden irregularity in attenuation shallbe less than 0.1 dB2. The spectral attenuation shall bemeasured on un-cabled fibre.3. The spectral attenuation in the 1250 nm– 1625 nm band shall be measured at aninterval of 10 nm and the test results shallbe submitted.

≤ 0.34 dB/Km

1.6 Cut-off wavelength on 2 meter sample offibre (In Cable)

≤ 1260

1.7 Chromatic dispersion1285 – 1330 nm1270 – 1340 nm1550 nm1625 nmZero dispersion wavelengthZero dispersion slope

≤ 3.5 ps/nm.Km≤ 5.3 ps/nm-km≤ 18 ps/nm-km≤ 22 ps/nm-km1300 – 1324 nm≤ 0.089 ps/sqnm-km

1.8 Fibre PMD Maximum individual fibre

≤ 0.2 ps/ √ Km

1.9 Fibre PMDCabled Fibre :Note- Measurement on un-cabled fibremay be used to generate cabled fibrestatistics and correlation established

≤ 0.3 ps/ ÖKm

1.10 Attenuation with bending100 turns on a mandrel of 60mm diameter1 turn on mandrel of 32mm diameter

≤ 0.05db at 1550 nm

≤ 0.5dB at 1550 nm2.0 Dimensional Specification

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S.No Parameter Requirement

2.1 Geometrical parameterPrimary coating diameterCladding DiameterClad non circularityMode field concentricity error

245 ± 5 µm125 ± 0.7 µm≤ 0.7 %≤ 0.5 µm

2.2 Coating / Cladding Concentricity ≤ 12 μm2.3 Nominal Mode FIeld Diameter

For matched clad8.8 – 9.8 μm

a) Protective materials / coatings

Optical fibres shall be coated with UV cured double Acrylate Resin. It should not have any reactionwith cladding or core material

The coatings should provide max resistance to micro bending & abrasion and ensure mechanical &optical strength. The coatings shall easily stripped with mechanical tools.

b) Fiber Identification

The coatings shall be in various distinct colours in order to facilitate fibre identification. Fibre coloursshall correspond to IEC publication 793-2 and 304. The colours shall correspond reasonably withstandard colours and shall readily be identifiable and shall be durable. The colours used should havefast colours properties and should not fade during the lifetime of cable. The coating and the colour shallnot react with surrounding jelly. The vendor shall take prior approval from purchaser/consultant for thecolour scheme for fibre identification before commencement of manufacture of OFC. Vendor isrequired to provide fibre Ids (Manufacturing details etc.) for all individual fibres in cable. These fibreIds should be sent to purchaser/consultant along with internal test report of the cable.

6.21. Mechanical Characteristics of G.652D Fibres

a) Proof test for minimum strain level (Test method IEC–60793-1-30) : 1%

Peak Strippability force to remove primary coating of the fibre (Test method IEC–60793-1-32) : 1.3 ≤F ≤ 8.9 N

Note:

The force required to remove 30 mm ± 3mm of the fibre coating shall not exceed 8.9 N and shallnot be less than 1.3 N.

Dynamic Tensile Strength (Test method IEC–60793-1-31)

Un-aged : ≥ 550KPSI (3.80 Gpa)

Aged : ≥ 440KPSI (3.00 Gpa)

Dynamic Fatigue : ≥ 20 (Test method IEC-60793-1-33)

Static Fatigue : ≥ 20 (Test method IEC-60793-1-33)

b) Fibre macro bend : ≤ 0.05 dB at 1550 nm for G.652D.

Change in attenuation when fibre is coiled with 100 turns on 30 ±1.0 mm radius mandrel

(Test method FOTP– 62/ IEC- 60793-1-47)

c) Fibre macro bend: ≤ 0.5 dB at 1550 nm for G.652D.

Change in attenuation when fibre is coiled with 1 turn around 32 ± 0.5 mm diameter mandrel

(Test method FOTP– 62/ IEC- 60793-1-47)

d) Fibre Curl : ≥ 4 meters radius of curvature

(Test method as per IEC-60793-1-34)

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6.22. Material properties of G.652D fibres

a) Fibre Materials

The substances of which the fibres are made. : Bidder/vendor/ contractor to specify

b) Protective materials requirement : It shall meet the requirement of fibre coating stripping force To beindicated by the bidder/vendor/contractor.

The physical and chemical properties of the material used for the fibre primary coating and for singlejacket fibre.

The best way of removing protective coating material. : To be indicated by thebidder/vendor/contractor.

7.0 JOINTING CLOSURES

7.1. Jointing closures shall be suitable for the offered Optical Fibre cable. Jointing closures should be Dust proof(No dust ingress) and protected against – immersion in water (Suitable for continuous immersion in salinewater) and should be complete with all accessories including splice cassettes, splice protection and all otheritems including electrical continuity of metallic layer of optical fibre cable. The jointing closures shall beprovided with suitable jointing pit support hardware to secure the jointing closures.

7.2. Bidder to specify Dimensions. Bidder to note that the dimensions length shall be suitable for installation inthe RCC joint enclosure specified elsewhere in the document.

7.3. Capacity

· No. of cable entry points: 4 ports (2 incoming and 2 outgoing cables)

· Diameter of cable entry: Suitable for optical fibre cable of diameter 15mm approx.

· No. of splices per tray: Splice tray shall be suitable for splicing 2 cables of 24 fibres each

· No. of trays per closure: 2 Nos.

· No. of fibres / closure: Maximum 48 Fibres

7.4. Sealing: Water tight and dust free.

7.5. Cable entries: Normally closed and shall be opened as and when required.

7.6. Material metal parts exposed to environment, if any: Stainless Steel and corrosion resistant

7.7. Properties of plastic material used: Light weight, corrosion resistant, high impact bearing and compatiblewith metal and other materials used in splice closure like connectors, trays etc.

7.8. Following tests shall be conducted on the closure as per procedures given elsewhere in the tender:

· Impact Test

· Closure to cable integrity test

· Pulling test

· Chemical Test

· Biological test

· Water Ingress Test

· Drop and topple test

· Static load test

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8.0 FIBRE TERMINATION CLOSUREThe Fibre shall be properly terminated on Fibre termination closure FTC. FTC Shall be wall mounted typeas suitable for Optical Fibre Cable. The FTC shall have grounding arrangement for both the metallic layersof the cable. The cable shall be spliced to pigtails on trays provided in the FTC. The connector side of thepigtails shall be secured with suitable coupler/through adapter provided as integral part of the FTC itself.The FTC shall have trays suitable for splicing maximum of 6/12 fibers per tray. FTC for all stations shall beinstalled with trays for minimum 48 fibers.

The complete Fibre Termination Closure including trays, joint protection sleeves, pigtails, couplers, etc.After termination, each pig tail/patch cord shall be properly ferruled for identification of station & fibretype.

9.0 LOOP BOXAfter entering the telecom room/control room/equipment room, the cable shall be secured on ‘Loop Box’ bythe help of cable ties (~5m cable from each side being kept in turns in oval form). This Loop Box shall havesuitable chemical coating/ painted to prevent corrosion. Further, the cable shall be terminated on FibreTermination Box (FTB) / Fibre Termination Closure (FTC)

10.0 OFC JOINT PIT/INSPECTION CHAMBER10.1. The cable joint pit/inspection chamber shall of RCC of 600mm height.

10.2. The cable joint pit/inspection chamber shall be circular having internal diameter of 1200 mm & wallthickness of 50 mm and made of reinforced concrete with lifting lugs cast into the lids during constructionitself.

10.3. Pit shall be provided with suitable arrangement for the entry of one number of HDPE conduit from bothsides so that HDPE conduit and buried OFC should enter the pit at a height of 150 mm above the bottomlevel of the pit. The pits shall be provided with suitable GI brackets to facilitate storage of Optical fibercable loop. Thickness of TOP LID shall be 75 mm.

10.4. The pit shall be completely filled with sand up to 30mm from bottom level of the pit to prevent entry ofrodents. After jointing of OFC, covered joint enclosure and HDPE conduit completely. The pits shall havearrangement to prevent entry of mud, insects etc.

10.5. HDPE conduit shall be sealed with the help of end plugs at jointing pit locations

10.6. HOP TESTING OF OFC

After back filling of the trench, the cable shall be tested for attenuation over the laid length. The test shallbe conducted both before and after the splicing. It shall be ensured that the cable attenuation does notexceed as recommended for G 652 cables (excluding the splice loss) and the splice loss on each fiber shallbe 0.07 db per splice (max.). Contractor shall provide the detailed procedure for cable testing.

The cable test-results shall clearly provide the attenuation for Each cable section

1310 nm wavelength for each fiber

1550 nm wavelength for each fiber

Individual splice.

A total = (wavelength λ loss dB/km x fiber length) + (connector loss x number of connectors) + (splice lossx number of splices).

Results should be within permissible limits. After the testing hop testing results with average losses shall berecorded and report of results as per approved procedure for each fiber shall be submitted hop wise forclient review.

11.0 ELECTRONIC JOINT LOCATION MARKERS.11.1. Contractor shall provide electronic locating system suitable for field use to locate underground-buried OFC

joint locations.

The system shall consist of:

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a) Electronic marker (to be buried underground along-with OFC joints)

b) Marker locator (including probe & locator electronics)

11.2. The electronic markers shall be placed at all joint pit/inspection chamber locations (planned andunplanned).The electronic markers shall be lightweight and shall have a passive tuned resonant circuit,enclosed and sealed within a casing. The marker locator shall be able to locate the electronic markerswith the help of audio and visual signals. The electronic locator system shall be capable of locatingCable/Pipe and location of sheath (earth fault) fault. The markers shall be of color suitable for Oil & Gasapplication.

11.3. The marker locator and the probe shall be of lightweight and portable enough to be carried (in suitablecarrying case, to be provided) on shoulder. The locator shall be able to work on batteries (dry alkaline) forcontinuously 8 hours. The electronic locating system shall be able to work in saline atmosphere in coastalarea and shall be protected against corrosion. The electronic locating system shall not be affected by anymetal, alternating current, etc. The casing of the electronic marker shall be resistant to chemicals,minerals, water ingress and temperature variation normally encountered in underground environments.The material used for the manufacture of electronic markers shall be protected against any damage due torodents or any other insects in the underground environment.

11.4. The marker should be detectable by marker locator unit from anywhere within radius of min. 2 meter fromthe centre of marker.

11.5. Each marker locator provided shall be complete with its set of accessories (i.e., necessary interfaces,connecting cables, software, etc). The electronic markers shall be buried underground 30 mm below the lidof each jointing pits and shall not be in direct contact with any metallic body.

11.6. Apart from the features stated above, the Electronic Marker Locator Unit should have the followingadditional features:-

· Locating conductor or sheath (earth return) faults.

· Tracing the path of underground cables and metallic pipes with estimated depth measurement.

· The Electronic marker locator unit with cable/ pipe locator & sheath fault locator shall consist of thefollowing main sub-systems/ parts:

· Electronic Marker Locator/ Cable, Pipe Locator Unit (Receiver Unit)-Bidder can offer two separateunits for electronic marker locator & pipeline /cable locators) to meet tender specifications.

· Transmitter Unit

11.7. GENERAL REQUIREMENTS:

a) The Electronic Locator System shall be fully solid state and field proven employing state of the arttechnology.

b) The instrument shall be portable and light weight. The actual dimensions and weight of the instrumentshall be furnished by the contractor.

c) All connectors and cables shall be of low loss, suitably shielded, reliable and of standard type to ensurefailure free operation over long periods and under specified environmental conditions.

d) The mechanical design and construction of each card/ unit shall be inherently robust and rigid under allconditions of operation, adjustment, replacement, storage and transport.

e) The instrument shall have self cooling arrangement without use of fans.

f) All controls, switches and indicators shall be clearly marked to show their circuit designation andfunctions.

g) Marker Locator Unit should have the facility of writing/ storing data in the electronic markers such asJoint no., Chainage, location, placement date etc. The locator should also have the facility to read thedata stored in the iD electronic marker.

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h) All required software along with cables, connectors and accessories shall be supplied with the unit forinterfacing the Electronic Marker Locator Unit with Laptop/ Computer and storing/ downloading,uploading electronic marker related data.

i) The Electronic Marker Locator Unit shall be supplied with Transmitter, two sets of transmitterconnection leads, capacitive coupler/ clamp, ground rod, earth frame for locating earth return faults,carrying case, cables, connectors and accessories complete in all respects required for carrying out thefeatures/ functions as detailed in specifications.

j) Installation of Electronic Markers at OFC Joint Pit locations, writing/ storing data in the ElectronicMarkers during installation shall be the responsibility of contractor.

11.8. OPERATIONAL REQUIREMENTS:

a) The Electronic Locator System shall be able to pin-point earmarked buried telecom facilities such ascables, joints etc. using the electronic markers.

b) It should also be able to locate the route of pipes/ cables with depth estimation, locating conductor orsheath (earth return) faults.

c) The Marker Locator shall generate and transmit a specific frequency signal to the buried electronicmarker. The Electronic Marker, tuned to this frequency, reflects the signal back to the locator. Thelocator verifies the reflected signal picked up through the probe and the location is indicated with anaudible & visual indication.

d) The instrument shall be provided with sensitivity control facility.

e) All switches / controls on front panel of shall have suitable safeguards against accidental operation.

f) The instrument shall be adequately safeguarded to prevent entry of dust, insects and lizards.

12.0 PROCEDURE FOR OF CABLE BLOWING12.1. CABLE BLOWING:

12.1.1. Joint pit/Inspection chambers marked during PLB-HDPE duct laying shall be exposed for blowing thecable. The PLB-HDPE duct, left exposed with end caps, at every 2 Km intervals where the O F Cable shallbe brought out after blowing and re-inserted for expose and splicing at every 4 Km intervals.

12.1.2. There may be a situation where the O F Cable may have to be brought out at less than 2 Km intervals.Under such circumstances the PLB-HDPE duct shall be exposed and sealed back after running the OF Cablethrough the duct.

12.1.3. The existing 6 mm PP rope shall be replaced by with PP rope of 8mm dia. between the two consecutivejoint pit/ inspection chambers. This is to ensure that the PLB-HDPE coils are cleaned for blowing the cablewithout exerting tension on the OF Cable. Excessive pressure should not be put which may result inbreaking of PP rope and this may require opening of additional inspection chambers. However, in case thecleaning rope gets stuck up during pulling, the location of digging of HDPE pipe should be measured andlocated accurately. The trench at that location should be opened and the HDPE Pipe should be cleanedproperly or if not possible it should be replaced by a clean new HDPE Pipe to facilitate easy cable blowingat a later stage without any obstruction. If digging of HDPE Pipe is in the location where the pipes areprotected either by RCC Pipe or by concreting and the protection is broken for cleaning/changing the HDPEpipe, the protection thus removed should be brought back to normal by the contractor without any extracost. All tools and machinery for such repair work shall be arranged by the contractor.

12.1.4. The Optical fibre cable is available in drums in length of 4 Kms. The cable shall be blown through the laidPLB-HDPE duct by the contractor. If required, the cable may also be pulled by using the 8 mm P.P. rope.This work is to be carried out under the strict supervision of engineer-in-charge of the contractor so thatsharp bends, twists and turns can be avoided or kept well with in limits. At a time, maximum three personsat every joint pit/ inspection chamber should be deployed to slowly pull the cable as more tension to cablemay lead to damage of fibre cable. Cost of such damages shall be recovered from the contractor.

12.1.5. The O F Cable may be pulled out at a distance of 1 Km and re-inserted for the next length of 1 Km, wherethe fibre is spliced with the next cable drum. The splice encloser is placed in the joint pit/inspectionchamber with properly coiled extra length of O F Cable.

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12.1.6. After the blowing is completed, both ends of the PLB-HDPE duct and the entry points in each jointpit/inspection chamber should be sealed by hard rodent resistant rubber bush, to avoid entry of rodents/mudinto PLB-HDPE duct.

12.1.7. Guide lines shall be based on international standards of practice for installation of optical fibres. Allmachinery like cable blowing machine, compressor, lifting jack for cable drum, transport vehicle, tools,tackles shall be arranged by the contractor to complete the job in all respect.

12.1.8. For HDPE laying and OFC blowing the contractor shall ensure and carry out the activities but not limited tothe following:

· Transportation of machinery and materials to different work sites.

· Minimize joints and identify joint locations.

· Placement of route markers

· Methods of room entries for termination.

· Identify physical hindrances and taking suitable action.

· Recommended best method of installation and plant/ machinery required.

· Determine exact bill of quantities for HDPE and other accessories.

12.1.9. Rotation of the cable drum shall be controlled to ensure that there is always some slack in the cable duringpay-off so as to ensure cable installation at near zero tension.

12.1.10. During blowing it shall be ensured that there is no dust or obstacles remaining in the duct which can damagethe cable. Lubricant shall be used during blowing of the cable in ducts if required.

12.1.11. The cable shall be tested in each hop of pipeline section for individual splice loss, fibre loss, connector lossusing appropriate test instruments and the records of the values so obtained shall be furnished to the Owner.Hop-wise OTDR traces for each fibre shall be taken for each hop from both directions and the printouts tobe submitted to Engineer-in-charge for review.

12.1.12. In case of joint failure/ cable fault / damage of the cable, it shall be the responsibility of the contractor tolocate the cable fault, rectify the same and establish the specified performance.

12.1.13. Sealing of RCC Joint Box/ Transition Pit- Proper sealing of the entries of RCC Joint Box/ Transition Pitwith hard rubber bush of suitable size shall be ensured to prevent entry of insects, rodents and rainwater.Also, the RCC Joint Box/ Transition Pit shall be filled up with clean sand to prevent any rodent/ insect/ pestentry into the enclosure.

12.1.14. Sealing of HDPE Ducts- Cable Sealing plug shall be used to seal the ends of the duct perfectly after thecable is installed in the duct in order to prevent the entry of dirt, water, moisture, insects / rodents etc. Thisis required to be installed at all the places where cable has come out of the duct either for jointing or entryinto the building as required.

12.1.15. The cable shall be spliced/ jointed by skilled personnel using fully automatic splicing machines (fusionsplicer) to achieve the specification of joint loss of not more than 0.07 dB/splice. It should also be ensuredthat during splicing no fibres are interchanged and hop to hop continuity of all 24 fibres in each hop is bemaintained. All splices shall be protected by heat shrinkable sleeves. Dust free environment shall be ensuredfor fusion splicing. The joints shall be housed in appropriate joint kit and the location of the same shall beindicated by providing suitable joint markers. The route markers suitable for the purpose for indicating theposition of the cable shall be provided along the length as defined elsewhere in the tender.

12.1.16. Each splice joint should be coated with epoxy resin to protect against moisture and increase the mechanicalstrength. As an alternative to joints coated with epoxy resin, bidder may provide satisfactory method forpermanently protecting each splice joint against moisture and providing mechanical strength.

12.1.17. Contractor shall submit methodology for HDPE laying & OFC blowing, QA/ QC procedure to Engineer-In-Charge for Owner’s review & approval prior to installation of HDPE and blowing of OFC.

12.1.18. Contractor shall submit a detailed deployment plan giving details of pipeline segment (chainage etc.),mobilisation plan for excavator, vehicles, machinery, OTDR, splicing machine, truck/ trailer for carrying

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OFC, lifting jacks, engineering, supervisors, labours etc. for each pipeline segment to EIC before start ofjob.

12.1.19. While laying cable, the tensile load of the OFC must not be exceeded.

12.1.20. In all sections, it shall be ensured that during back filling first 20 cm of the soil shall not contain any stoneswhich can damage the HDPE pipe.

12.1.21. After 40 cm of back-filling a warning tape of 200 mm wide marked as “WARNING –OPTICAL FIBRECABLE BELOW” in English, Hindi and local language shall be provided throughout the length of theHDPE pipe. Same shall not be required if wider warning tape is being provided over both Line pipe/ Linepipe + OFC

12.2. Jointing / Splicing

12.2.1. The OFC cable drums are usually of 4 Kms. in length hence optical fibre joints shall be at every 4 Kms. The24 fibre are to be spliced at every 4 Kms. and placed in the joint pit/inspection chamber with some extralength for future maintenance work. The infrastructure required for cable splicing is as follows:

· Splicing machine

· Air Conditioned van

· OTDR

· Optical Talk Set

· Tool kit etc.

12.2.2. These instruments and tools shall be arranged by the contractor at his own cost. Any additional item likeengine-generator required at site for splicing or other works shall be arranged by the contractor at his owncost.

13.0 JOINTING KIT TESTS13.1. Water Ingress Test

The cable joint kit shall be assembled along with a continuous piece of cable passing through. The jointingkit shall then be secured at the bottom of an immersion tank containing water upto a height of 3.0 m withthe help of UV detectable dyes added to the water and joint kit shall be immersed for duration of 24 hours atnormal room temperature. The joint kit will then be opened as per the specified procedure and visuallyexamined for any ingress of water. It shall be declared to have passed in case there is no water presentinside the kit. The joint kit shall be closed again and the same test shall be repeated. The joint kit shall passthe test in case there is no water present inside the joint kit.

13.2. Impact Test

The cable joint kit shall be kept on a metal platform. A weight of 2 kgs cylindrical type having radius of R50 mm at striking end will be made to strike the joint kit at the middle after having been released from aheight of 500 mm for 5 times at approx. 10 secs interval. The joint kit will be declared to have passed thetest in case there are no cracks or fracture inside or outside of the kit.

13.3. Drop and topple test

A drop test platform consisting of a steel plate not less than 6.5 mm thick is to be used. The steel plate isbolted to a fully set concrete block at least 460 mm thick. The joint kit shall then be allowed to topple andfall freely from a height of 2000 mm. The joint kit will be declared to have passed the test in case there is novisible damage to the jointing kit.

13.4. Pulling test

The joint kit should be assembled with a long length of cable so that it can be pulled to the required tensionof 100 kgs to check the strength of fixing arrangement inside the joint kit.

13.5. Static load test

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The assembled cable joint kit shall be kept on a platform with dimension more than that of cable joint kit. Acurved hollow profiled mandrel shall be used for application of load and the mandrel shall be at the middlestraight part of the joint kit. Weights shall be gradually placed on the mandrel till the weight becomes 250kgs. The joint kit shall be kept under the weight for a period of 24 hours. The joint kit shall be declared tohave passed the test in case there is no visible damage.

14.0 BUILDING ENTRY14.1. All building entries shall be done through MCT Blocks.

14.2. A warning marker tape of plastic with a warning message marked as “WARNING –OPTICAL FIBRECABLE BELOW” in English, Hindi and local language shall be placed 40 cm above the cable in the trench(from transition pit to cable entry point) to protect during digging after installation.

15.0 QUALITY ASSURANCE PROGRAMME15.1. CONTRACTOR shall submit the details of Quality Assurance Programme followed by him beginning with

raw materials, fabricated components, assemblies, etc. CONTRACTOR shall obtain and forward theQuality Assurance Programme for equipment supplied by Sub-contractor, if any.

15.2. The Owner/Owner’s representatives and /or third appointed agency reserves the right to inspect and testcable, jointing closures, etc at all stages of production and testing. The inspection and testing shall includebut not be limited to materials, sub- assemblies, prototypes, produced units, guaranteed performancespecifications etc.

15.3. For Factory inspection and testing, CONTRACTOR shall arrange all that is required e.g., quality assurancepersonnel, space, test gear etc. for successful carrying out of the job at the CONTRACTOR /Manufacturer’s works.

15.4. Owner/Owner’s representatives shall have free entry and access to any and all parts of the CONTRACTORsfacilities associated with manufacturing and testing of the system at any given time.

15.5. It shall be explicitly understood that under no circumstances that any approval of the Owner/Owner’srepresentatives relieve the CONTRACTOR of his responsibility for material, design, quality assurance andthe guaranteed performance of the system and its constituent.

15.6. CONTRACTOR shall invite the Owner/Owner’s representatives, at least 10 days in advance, of the date onwhich system shall be ready for inspection and testing. All relevant documents and manuals, approvedengineering drawings, etc shall be provided well in advance of the start of inspection and testing.

15.7. Owner/Owner’s representatives shall after completion of inspection and testing to their satisfaction, issuefactory acceptance certificates to release the cable/ jointing closures for shipment. No cable/ jointingclosures shall be shipped under any circumstances unless a factory acceptance certificate has been issued forit, unless agreed otherwise by Owner/Owner’s representatives.

16.0 TESTING THE OFC16.1. The CONTRACTOR shall provide factory tested OFC in nominal drum length of 4 Kms per drum. Prior to

installation, the Contractor shall physically see the cable for any damage and test the OFC using the OpticalTime Domain Reflectometer (OTDR). The contractor shall be responsible for taking the OTDR traces andother test parameters for each drum and

16.2. Keeping record of the OFC traces of such tests. OTDR Trace results shall be submitted to the Site Engineer/Engineer-in-charge for review.

16.3. After blowing of the each cable drum through the HDPE, the Contractor shall again test the cable and takeOTDR traces. The post installation OTDR traces (hard copy and soft copy) shall be submitted to Engineer-in-charge for review. Testing shall be performed on each fibre and on all the drums.

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16.4. No variation in the test parameters indicates the quality of the cable blowing works. The cable laying isliable for rejection if the variation in test parameters is observed. Under such conditions, the contractor shallbe responsible to supply and install tested cables in the defective stretch / section without any extra cost tothe Owner. The above testing procedure shall be performed for replaced cable also. All costs towardsreplacement of the damaged cables including supply of the cable shall be borne by the contractor.Contractor to note that the cable to be supplied as replacement shall be similar in design to the originallysupplied cable.

16.5. After splicing and termination, the contractor shall test the OFC for each fibre as stated in previous section.The splice loss shall be recorded by the contractor. For each splice, loss of 0.07 dB is allowed. If splice lossis more than 0.07 dB, such splices shall be rectified in consultation with the Engineer-in-charge/ SiteEngineer.

16.6. The Contractor shall be equipped with the following minimum equipment for testing the OFC:

· Optical Fibre Fusion Splicer

· Fusion Splicer Tool Kit

· Optical Time Domain Reflectometer.

16.7. In all cases, the Contractor shall notify the Owner ten working days in advance for testing of the cable sothat the Owner or his representative may be present on mutually agreed date.

16.8. The record of the OFC laid during the day shall be maintained on daily basis. To facilitate the traceabilityafter installation at a later date, this record should contain OFC drum No., sequential meter reading of theOFC laid, pipeline chainage between which the OFC has been laid along with the sequential meter reading.The OFC shall have sequential marking at every 1 meter to facilitate the record maintenance. Record ofCable laying at HDD Crossing shall be maintained.

17.0 PACKING17.1. All equipment/ instruments/ cable drums shall be individually packed in suitable containers/ crates designed

to avoid damage to the equipments during transit and storage in accordance with best commercial practiceand with the requirements of applicable specifications. The materials used for packaging, wrapping sealingmoisture resistant barriers, corrosion preventers etc. shall be of recognized branches and shall conform tobest standards in the areas in which the articles are packaged. The packing shall protect the equipment fromimpact, vibration, rough handling, rain, dust, damp, insects, rodents, etc Each container/ crate shall besubjected to impact, vibration and other mechanical tests.

17.2. Each container shall have a copy of factory acceptance test report enclosed in it. Packages for optical fibrecable shall make provision to allow for two (2) meters of excess cable on the inner end of the package to beaccessed from outside. The outer end of the cable shall have pulling eye with heat shrinkable sleevesattached to it. The inner end of the cable shall be provided with a heat shrinkable sleeve. The ends shall beadequately protected to allow for normal handling during shipment.

18.0 DOCUMENTATION18.1. CONTRACTOR DATA REQUIREMENT AND DOCUMENTATION

18.1.1. Six sets of Documentation shall be supplied with each submission. Prices for all documentation shall beinclusive in the supply/installation charges and no separate prices shall be applicable for documentation.

18.1.2. All documents shall be in English language only.

18.1.3. During engineering stage, ENGINEER-IN-CHARGE shall review/approve drawings/documents.

18.2. After the award of work, the following documents shall be supplied for review and approval in order to startOFC installation at site:

18.2.1. Experience & Proven Track Record details.

18.2.2. OFC construction-showing cross section of the offered OFC, providing details of each layer (specificallymentioning, material used, thickness, fibre color, etc).

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18.2.3. Contractor shall submit HDPE laying methodology and cable blowing methodology to EIC for approvalbefore starting the HDPE laying and OFC blowing works. The methodology shall be submitted well inadvance (minimum three weeks before start of job). The delay in submission / approval due to incomplete /incorrect document shall be to contractor’s account

18.2.4. Fibre manufacturing test reports and supplier test certificates of raw materials to be used in cablemanufacturing.

18.2.5. Detailed testing procedure for OFC, Permanently lubricated HDPE conduit & Jointing

18.3. CLOSURES.

18.3.1. Supply of OFC as built route map OFC as built route map shall comprise the following as a minimum:

· Detailed measurement of length of OFC route along-with details of road, nullah, river crossings etc.

· Location of Terminals, repeaters and planned location of joints.

· Various rail, road, canal, river crossings, etc.

18.3.2. The Contractor shall thereafter prepare OFC route sheet for the entire route with proper scale showing allthe crossings and topographic details as needed to define the route and its characteristics. (For the sectionswhere the OFC route may leave the pipeline route, the Contractor shall make a proper topographic survey todefine the route and to determine the existence of over ground or underground services that could interferewith the installation (Contractors bid should be inclusive of all such survey/requirements and no separatepayment shall be done).The print outs shall be on A2 sheets

18.3.3. Daily OFC installation/jointing/testing report formats.

18.3.4. List of all the materials to be used during OFC installation.

18.3.5. Any other data, document not specifically mentioned, but required for the satisfactory completion, operationand maintenance of the system shall be provided.

18.4. Documents to be supplied before ‘Final acceptance certificate’ issued by OWNER:

a) As built OFC route map with the following additional details at each joint location.

· Progressive OFC length, including the additional length at each joint location.

· Fibre length, fibre length between joints, as measured by OTDR.

· Progressive pipeline chain age

· Distance of joint from nearest pipeline markers & crossings, etc.

b) Final OFC test reports (individual OFC drums, hop to hop between repeaters, section and end to end, asapplicable).

c) Final location of OFC w.r.t the pipeline along the entire route.

d) All final documents for this project in hard as well as electronic (CD) form.

18.5. DOCUMENTS TO BE SUBMITTED DURING DETAILED ENGINEERING

The details / documents pertaining to offered materials under the tender, as mentioned below shall besubmitted by the bidder along with their bid:

a) Make and Model number of the following items as per list of approved vendors for contractor supplieditems out of approved vendor list: -

· OFC

· HDPE pipe, end caps, couplers

· OFC Joint kit

· Electronic marker

· Electronic Marker locator

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· MS Pipes

b) Telecommunications Engineering Centre (TEC) approval certificate for offered model of items asabove (as applicable).

c) Detailed technical literature / technical manual for items in (a) above

d) The name of the party / sub-contractor who shall execute the HDPE Laying, Cable blowing, splicing,testing works along with relevant experience details of the party / sub-contractor of having executedsuch works in the past 5 years.

e) The details of relevant experience (last 5 years) shall be submitted.

f) List of the equipment to be deployed for OFC blowing

g) List of testing equipment for OFC Splicing & testing works

18.6. DOCUMENTATION for Instruments to be supplied as part of tender

Technical literature in English with complete layout, detailed block schematic of the unit shall be provided.All aspects of installation, operation, maintenance and repair shall be covered in the manual. The manualshould include the following:

a) Installation, operation and maintenance manual

b) Safety measures to be observed in handling test instrument:

c) Precautions for setting up, measurements and maintenance;

d) Test equipment required for routine maintenance and calibration including their procedures;

e) Illustration of internal and external mechanical parts.

f) Procedure for trouble shooting of instrument shall be provided. Test fixtures and accessories requiredfor repair shall also be indicated. Systematic trouble shooting charts shall be given for the probablefaults with their remedial actions.

19.0 ACCEPTANCE TESTINGThe Optical Fiber shall be terminated at each of the stations to the Fiber Termination Closure (FTC)installed on the entry point of the stations. On completion of blowing, splicing and termination from end-to-end, the optical fiber cable shall be jointly tested as per the agreed test schedule. Like wise the acceptancetests shall be performed on other items supplied and installed by the contractor. The testing schedule shallbe as agreed and approved by the owner/consultant. Certificate of provisional acceptance shall be issued onsatisfactory testing of all such items. Final acceptance certificate shall be issued only after completion ofwarranty period of 1 year after provisional acceptance.

Upon successful completion of the `Site acceptance testing', any shortfalls when compared to the contractshall be made good by the Contractor.

The Contractor shall then provide as built documents as asked in this tender document. After this,ENGINEER-IN-CHARGE shall notify the Contractor in writing, his final acceptance of the laid OFC andthe OFC shall be considered commissioned.

Nothing herein above provided, inclusive of the `Final Acceptance Certificate; shall absolve Contractor ofhis full liabilities under the contract inclusive of and relative to the system performance and Warranty.

S S S

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PTS – HDPE DUCTP.013312D 11077

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PTS – HDPE DUCT

DOC. NO. P.013312 D 11077 084



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TABLE OF CONTENTS

1.0 INTRODUCTION ......................................................................................................... 12.0 SCOPE ......................................................................................................................... 13.0 SPECIFICATION OF PLB - HDPE DUCT ...................................................................... 14.0 PROCEDURE FOR PLB-HDPE DUCT LAYING .............................................................. 35.0 ACCESSORIES ............................................................................................................ 56.0 QUALITYASSURANCE PROGRAMME .......................................................................... 67.0 FACTORY ACCEPTANCE TESTING (FAT) .................................................................... 78.0 SITE ACCEPTANCE TESTS .......................................................................................... 79.0 IDENTIFICATION AND MARKING .............................................................................. 7

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1.0 INTRODUCTION1.1. This document presents the technical specifications for Permanently Lubricated High-density polyethylene

(PLB-HDPE) duct required for this Pipeline Project.

1.2. PLB-HDPE duct is proposed to be laid along the pipeline between Dispatch station, all SVs to receivingstation.

2.0 SCOPE2.1. Supply and laying of PLB-HDPE duct from dispatch station to receiving station including and all SV

stations.

2.2. Supply and laying of spare PLB-HDPE duct at all crossing, river, nalah, culvert, road/railway, canal etc.inside the separate 6” CS casing pipes.

2.3. Supply of push-fit coupling/sockets, end plugs and cable sealing plugs for the PLB- HDPE duct.

2.4. PLB HDPE ducts shall be suitable for installation of underground unarmored optical fiber cables (OFC) byblowing techniques. The life expectancy of these ducts will not be less than 50 years.

2.5. Total quantity of PLB-HDPE duct shall as per SOR including the length up to the control room at eachstation + 1 km extra length. In addition, extra length for spare shall be considered according to siterequirement.

3.0 SPECIFICATION OF PLB - HDPE DUCT3.1. The PLB - HDPE Duct shall consist of two concentric layers, the outer layer being HDPE co-extruded with

an inner layer of solid permanent lubricant, to reduce the internal co-efficient of friction (ICF). Thelubricant shall be of a solid layer of uniform thickness so formulated to provide a permanent, low frictionboundary layer between the inner surface of the duct & optical fibre cable. The lubricant layer shall beclearly visible in cross-section, concentric with the outer layer. The PLB – HDPE duct shall comply torelevant specifications GR/CDS-08/02 with latest amendments.

3.2. All other materials like silicone inner lubricant master batch, UV stabilizer (if and as required), colourmaster batch, anti-oxidant compounds or any other material required shall be supplied by CONTRACTORto produce two layered HDPE permanently lubricated duct.

3.3. The anti-oxidants used shall be physiologically harmless. None of the additives shall be in quantity as toimpair long term physical and chemical properties of duct. The raw material used for extrusion shall bedried to bring down the moisture content less than 0.1%.

3.4. Suitable ultraviolet stabilizers (if and as required) shall be used in manufacturing for protection against UVdegradation, when stored in open area for a minimum period of 8 months.

3.5. Single pass rework material of the same composition produced from manufacturer's own production shall beused and the same shall not exceed 10% in any condition.

3.6. The inner lubrication material shall be friction reducing polymeric material, which shall be integral withHDPE layer. The lubricant material shall have no toxic or dermatic hazard for safe handling. In the finishedduct, the co-extruded inner layer of solid permanent lubricant shall be white in colour and clearly visible incross section of the duct the inner layer of solid permanent lubricant shall be continuous all through andshall not come out during storage, uses and throughout the life of duct.

3.7. The density of the inner layer material shall be between 0.940 and 0.958 gms / cc at 27 Deg C".

3.8. The raw material used in the manufacture of the duct shall be such that the service life of the duct and all itsaccessories can be expected to be more than 50 years including the life of permanent lubricant.

3.9. The ash content of the colour master batch shall not be more than 12% when tested as per the followingmethod:

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· “About 1 gm of the sample under test shall be taken and dried at 105 Deg C for two hours in a platinumor glazed porcelain or silica or quartz crucible. The weight of the sample shall be noted. Subsequently,the sample with the crucible shall be transferred to a muffle furnace maintained at 600 + 50 Deg C andallowed to remain there for three hours. The ash content may be calculated as a percentage of theweight of the original sample.”

3.10. Source Approval: The HDPE raw material used in the manufacture of ducts shall have source approval ofCACT.

3.11. The PLB HDPE duct shall unroll off the drums without snaking or waving having zero coil set. Thus theduct shall lay straight into the trench without re-coiling. For this purpose, when a minimum length of 50metres duct taken from the coil and laid on the ground, it shall be straight without any bends or kinks andwithout deformation, except 5 metres from each end.

3.12. Performance requirements

Typical requirements are indicated below. However the same shall conform to latest revision and allamendments up to No. 4 or latest, to TEC GR No. GR/CDS-08/02.

Sr No. Parameters ReferenceStandard

Typical Requirements

1 Dimensions and tolerance GR/CDS-08/02.Latest edition

a Length of each duct 1000 ± 100 Mtrs (required no. ofcouplings shall be provided by theCONTRACTOR)

b Outside Diameter 50mm + 0.5 mmc Wall Thickness 4 mm± 0.3 mmd Thickness of inner lubricant layer Min 0.32mm

Max. 0.48mme Bending Radius 1.25 Mtrs minimumf Color Preferably brown with 4 white strips

of 3mm in longitudinal direction.

2 Ovality IS :4984 ≤ 1.4 mm3 Heat Reversion IS:4984 Max 3% in longitudinal direction4 Hydraulic Test

Type TestDuration : 165 Hrs at 80°CInduced stress :3.5 MpaAcceptance testDuration : 48 Hrs at 80°CStress induced : 3.8 Mpa

IS:4984 No failure or leakage.

5 Tensile Strength at yield andElongation at break

when tested as perASTM D 638Type-IVspecimens

Min 20 N/mm² or betterMin 600%

6 Environmental stress crackresistance with 10% legal at 50 ±1°C

ASTM D 1693 No Failure.Specimen tested for 1000 hours.However for factory acceptance (bulktesting) this test shall be carried outfor 96 hours.

7 Impact Strength(Striker weight 10 kg)

IS: 12235 part 9 No crack or split

8 Crush Resistance50 kg load

GR Deflection with load < 10%Deflection after recovery < 2%

9 Oxidation induction test GR Induction time shall not be less than30 minutes

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Sr No. Parameters ReferenceStandard

Typical Requirements

10 Internal coefficient of friction GR < 0.0611 Density of finished product IS:7328 0.940 to 0.958 g/cc at 27°C12 Melt flow rate MFR of finished

DuctChange in MFR

IS:2530

GR

0.2 to 1.10 gm/ 10 minute at 190°Cand 5 kg loadNot more than 30%

13 Ash content of Finished Duct GR 0.3 % Maximum14 Fading of colours of Duct GR / ASTM : D

– 1712No discoloration

15 UV Stabilizer content of Resin FT-IR method 0.15% (min)16 UV Stabilizer content of Duct GR Variation in tensile strength after

aging shall not be more than 20%17 Maximum Pulling Force GR 450Kgf for 50/42mm duct

4.0 PROCEDURE FOR PLB-HDPE DUCT LAYING4.1. The PLB-HDP duct shall be laid and buried at a nominal depth along the pipeline ROW. The steps involved

are as under:

4.2. Excavation of trench for the PLB-HDPE duct shall be according to the applicable soil conditions. .

4.3. PLB-HDPE duct shall be laid in the trench which is suitably levelled with 50 mm sand/soft soil withoutsharp kinks and bends. The PLB-HDPE duct shall be joined together with HDPE joint sockets in such a waythat there is continuity of the PLB surface on the interior of the duct. At a distance of every 2 Km inexcavated trenches, PLB-HDPE duct ends shall be covered with HDPE end caps of suitable size. Theseducts with end caps shall be left exposed on the back filled trench for the blowing of O F Cable. The O FCable shall be brought out at this point and re-inserted for expose at the next 2 Km interval. At the time ofre-insertion of the fibre the duct shall be arranged at the same depth with cover and sealed to ensurecontinuity of PLB surface at the interior of the PLB-HDPE duct. At every 4 Km intervals the O F Cableshall be spliced and the splice closer placed in the Inspection chamber with some extra length of O F Cablecoiled and placed inside the inspection chamber.

4.4. The PLB-HDPE duct shall be placed along with the pipeline. The protection by warning tape, R.C.C.Pipes/GI pipes etc shall be as per the pipeline laying practices and specifications.

4.5. Back filling and dressing of the excavated trenches according to construction specifications of the pipeline.

4.6. The Fibre cable must never be subjected to any sharp bends or kinks. This can cause a permanent damage tothe cable. The bending radius should not be less than 10-12“.

4.7. Contractor shall supply permanently lubricated HDPE pipe of 50mm diameter as per TEC GR NO.TEC/GR/TX/CDS-08/03/MAR-11 with minimum pressure rating of 15 kg/cm2 and wall thickness of 4 mm,in nominal length of 1000 metres.

4.8. Transportation and loading/ unloading of the HDPE pipes safely up to site, shall be the responsibility ofContractor. It will be a pre-requisite to inspect entire length of HDPE against any possible damage/ crushingof HDPE pipe prior to lowering in the trench.

4.9. Laying of HDPE in the same trench of Mainline Pipe for laying of the HDPE pipe in the same trench ofmainline pipe, HDPE pipe shall be placed on the trench bed only after lowering of mainline pipe in thetrench. Contractor shall ensure that the distance between HDPE and mainline pipe (from outer edge ofmainline pipe) is maintained between 30 cm and 40 cm. In case due to positioning of pipe, the specifieddistance is not manageable, width of the trench is to be increased to maintain minimum 30 cm spacing frommainline pipe at all such locations. Contractor shall take extra precaution to ensure maximum possibleclearance and to prevent future contact after backfilling.

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4.10. The HDPE duct length of 1000 metres shall be laid in the trench bed and as far as possible joints should beavoided. Wherever it is not possible to lay 1 Kms continuous length, the contractor shall lay the duct insmaller lengths with due permission of Engineer-in-charge / Site Engineer. These lengths shall then bejointed through push fit split coupler, which shall be made of same material and supplied by the contractor,to make continuous pipe sections. Such joints shall exhibit a strength factor of one and shall be airtight sothat the HDPE pipe with the joints can withstand air pressure of 15 kg/cm2. All efforts shall be made tominimize joints in less than 1000 metres, which is likely to happen due to road/ river/ nallah/ railwayscrossings etc. In all open cut crossings it is to be ensured that no joints take place in subducting and onlyHDPE pipes without joint are used.

4.11. Contractor shall supply and put suitable size end caps at both the ends of each HDPE section to seal eachHDPE duct section after laying to prevent ingress of silt, water, litter, dust etc., prior to back filling.Contractor to note that at the end of each day’s work, the open ends of the HDPE pipe sections shall betightly closed with end caps to prevent the entry of dirt/ mud, water or any foreign matter into HDPE pipesuntil the work is resumed. Soft soil padding shall be done up to the top level of the mainline pipe prior toback filling operation, so that heavy impact on the HDPE pipe is avoided during back filling. During backfilling, Contractor shall ensure that HDPE pipe does not change its position due to heavy impact of soil ordue to any other cause. To ensure the same the following methods may be adopted:-

· Installation of 8 mm diameter steel rods at an interval of about 10 meters along the HDPE pipe(towards mainline pipe on temporary basis) before back filling so as to prevent shifting of HDPE pipeduring back filling.

· After back filling for a certain trench, the steel rods as mentioned in 'a' above shall be taken out for usein the next trench.

· Contractor may use any other better or more economic method with prior approval from the Owner.

4.12. At every 1 km, HDPE duct sections overlap each other (i.e. from both sides) by approx. 1 meter, so as tofacilitate the blowing of optical fibre cable at a later date by the Contractor. Such provision is also to be keptwhere optical fibre cable joints are likely to come, in consultation with Engineer-in-charge/ Site Engineer.The contractor shall plan and install joint box at locations where cable joints are likely to come keeping inview that the nominal cable length / drum is 4 kms. At such joint locations the HDPE shall overlap byapprox. 2 meters to facilitate OFC blowing. Contractor shall try to minimise the number of joints.

4.13. Bidder to note that crossings for Roads/ Drain/River as per details stated elsewhere in the tender shall beexecuted by Horizontal Directional Drilling method (covered under scope for pipeline engineering works)as a part of this tender. Across each HDD crossing for Road/ Drain, the contractor shall:

· Supply and install 2 nos. HDPE pipes along with accessories such as end cap, cable sealing plug and allthe machinery, tools, tackles etc. to complete the job in all respects to lay the HDPE & OFC across eachHDD crossing. The contractor while supplying the HDPE duct shall make sure that the length of theHDPE duct for HDD Crossing shall be at least equivalent to the length of the crossing plus 60 Mtrs (i.e.30 Mtrs on either side of crossing) without any jointing. Jointing of the HDPE in crossing shall not beaccepted.

· Supply & fabrication of the string of 168.3 mm CS pipes is covered under pipeline engineeringscope/specifications attached elsewhere in tender. The CS pipe conduit fabricated as above shall beinner ducted with contractor supplied 2 nos. flexible permanently lubricated HDPE ducts of 50 mm ODas per the specifications defined elsewhere in the tender document. The HDPE ducts sub ducted in a168.3 mm OD schedule 80 API 5L Grade B CS pipe shall be laid by Horizontal Directional Drilling(HDD) Technique across the HDD crossings.

· Pull back the conduit along with the mainline pipe as per the pull back procedure. Any damage in CSpipe and HDPE pipe during the pull back operation will be on Contractors account. If any breakage inCS pipe/ HDPE pipe occurs during laying of HDD, Contractor shall be responsible to re-install theHDPE pipe and/ or CS pipe as required without any extra cost to the Owner.

· Seal the two ends of HDPE conduit immediately after installation with heat shrinkable duct end caps toprevent ingress of water, dirt and rodents. The gap between CS pipe & HDPE conduits shall be sealedwith M-Seal compound to prevent ingress of water, dirt & rodents.

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4.14. At the road and other cased crossing locations where mainline pipe shall be installed in casing pipe byboring or jacking method, 2 nos. 50 mm HDPE duct shall be laid in the separate 168.3 mm CS casing pipe.The contractor shall ensure that single length of HDPE duct is laid at cased crossings; no joints would beacceptable.

4.15. At the railway crossings where mainline pipe shall be installed in casing pipe by boring or jacking method,2 nos. 50 mm HDPE duct shall be laid in the separate 168.3 mm CS casing pipe. The contractor shall ensurethat single length of HDPE duct is laid at cased crossings; no joints would be acceptable.

4.16. Open Cut crossings: For all water crossings, the OFC laid in permanently lubricated HDPE conduit shall befurther sub ducted in CS conduits (specification of Casing conduit, installation of casing conduit withpipeline, etc shall be as per specification).

4.17. At building entry points suitable transition pits shall be installed by the contractor. The HDPE pipe shall belaid up to building entry point i.e. MCT block/frame. A minimum HDPE length of 2 M shall be left in thetransition pit.

4.18. HDPE DUCT TESTING AFTER LAYING

· The 1 km long section 50 mm OD HDPE pipes will be properly positioned and laid in trench followingdetails in pre-paragraphs. After installation of HDPE duct, the duct shall be tested by blowing mandrel(OD of mandrel shall be 80% of ID of the HDPE) through the duct and thus carrying out mandrelpassing test. If any permanent constriction or leakage is observed due to damage in the HDPE duct orotherwise, the constricted/ damaged / leakage portion shall be replaced by a suitable piece of HDPEwith couplers at both ends to join it. The test then shall be repeated, till successful completion.Immediately upon successful completion of this test, both ends of respective section of HDPE shall beplugged using end caps. Testing of the HDPE duct shall be carried out only after backfilling of thetrench.

· After successful completion of the mandrel test, the HDPE section shall be pressure tested at 6 kg/cm2with air for a period of 30 minutes and the pressure shall be recorded at every 5 minutes interval. Suchrecords shall form a basis of acceptance of the HDPE pipe laying work carried out by the contractor.All arrangements for this pressure testing including compressor, couplers, tools, tackles shall bearranged by the contractor. In case of any leak/burst of the HDPE, the contractor shall rectify (includingre-excavating the damage/ leak site and back filling after repair) the same without any extra cost to theOwner. Cost towards supply of required HDPE duct, accessories and associated services forreplacement of defective section shall be borne by the contractor. After rectification, mandrel test shallbe done and the HDPE pipe shall be pressure tested again for a period of 30 minutes to the specifiedpressure.

5.0 ACCESSORIESFollowing accessories shall be supplied for joining of the ducts as indicated. The bidder shall providecomplete design details, testing details, material specification procedures for methods of installation theaccessories

5.1. Plastic Couplers

The couplers used for joining two ducts shall be push fit type having push lock mechanism, which enablesthem to be installed on duct without pre-dismantling. Design shall be simple, easy to install and shallprovide airtight and water tight leak proof joints. It shall withstand air pressure test of 15 kg/cm² for aminimum period of 2 hours without any leakage.

The pulling force required to pull out two pieces of ducts joined by such a coupler, shall be minimum 450Kgf for the duct. This test shall be conducted by loading the coupler joined by two pieces of ducts for 15minutes using a dead load.

5.2. End Plugs

End plugs shall be used for sealing the ends of empty ducts prior to installation of OFC and shall be fittedimmediately after duct laying to prevent entry of any dirt, water, moisture/ insects or rodents etc. The rubber

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components shall be of Nitrile rubber for increased life. This shall be tested for air tightness with pressure of1 bar for 30 minutes, by dipping into water.

5.3. End Caps

End caps shall be made of hard rubber or plastics fitted on each end of the duct coil after manufacturing toavoid ingress of dust, mud, rain/ water etc. during transit and storage.

5.4. Cable Sealing Plug

Cable sealing plugs shall be used to seal the ends of the ducts perfectly after OFC is installed in the ducts toprevent entry of any dirt, water, moisture/ insects or rodents etc. The rubber components shall be of Nitrilerubber for increased life. This accessory shall be tested for air tightness with a pressure 1 bar for 30 minutes,by dipping into water.

5.5. The above mentioned Accessories, viz Push Fit Coupler, End Plug, and Cable Sealing Plug shall besubjected to an ageing test. In this test, the accessory under test shall be installed on a piece or pieces ofducts as the case may be. It shall then be tested for tightness as per the G.R. and it shall pass the test. Theaccessory thus installed shall then be aged in an air circulating oven at 70 ± 2° C for 168 hours. At the endof the period it shall be allowed to cool the room temperature and then be tested for air tightness once againas per the G.R. and it shall pass the test as indicated above.

5.6. The following type of tools shall be used by the contractor during laying of the duct:

- C-Spanner

- Duct Cutter

- Steel Reels

- Chamfering Tool

5.7. The HDPE pipe and HDPE duct accessories shall be of same make".

6.0 QUALITY ASSURANCE PROGRAMME6.1. CONTRACTOR shall submit the details of Quality Assurance Programme followed by him beginning with

raw materials, fabricated components, assemblies, etc. CONTRACTOR shall obtain and forward theQuality Assurance Programme for equipment supplied by Sub-contractor, if any.

6.2. The Owner/Owner’s representatives and /or third appointed agency reserves the right to inspect ducts at allstages of production and testing. The inspection and testing shall include but not be limited to materials,sub- assemblies, prototypes, produced units, guaranteed performance specifications etc.

6.3. For Factory inspection and testing, CONTRACTOR shall arrange all that is required e.g., quality assurancepersonnel, space, test gear etc. for successful carrying out of the job at the CONTRACTOR /Manufacturer’s works.

6.4. Owner/Owner’s representatives shall have free entry and access to any and all parts of the CONTRACTORsfacilities associated with manufacturing and testing of the system at any given time.

6.5. It shall be explicitly understood that under no circumstances that any approval of the Owner/Owner’srepresentatives relieve the CONTRACTOR of his responsibility for material, design, quality assurance andthe guaranteed performance of the system and its constituent.

6.6. CONTRACTOR shall invite the Owner/Owner’s representatives, at least 10 days in advance, of the date onwhich system shall be ready for inspection and testing. All relevant documents and manuals, approvedengineering drawings, etc shall be provided well in advance of the start of inspection and testing.

6.7. Owner/Owner’s representatives shall after completion of inspection and testing to their satisfaction, issuefactory acceptance certificates to release the ducts for shipment. No duct shall be shipped under anycircumstances unless a factory acceptance certificate has been issued for it, unless agreed otherwise byOwner/Owner’s representatives.

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7.0 FACTORY ACCEPTANCE TESTING (FAT)7.1. Factory acceptance tests shall be carried out after review and approval of FAT procedures/documents (In

line with specifications & QAP) and shall be conducted at the manufacturing facilities from where therespective items are offered (e.g. OFC, Permanently lubricated HDPE conduit & jointing closures). Thefactory acceptance testing shall be conducted in the presence of the Owner’s representative. The tests shallbe carried out on all equipment/items including those supplied by Contractor and factory acceptancecertificates shall be issued. The factory tests shall include but not be limited to:

i. Mechanical checks to the equipment for dimensions, inner and outer supports, finishing, welds, hinges,terminal boards, connectors, cables, painting etc.

ii. Check for assuring compliance with standards mentioned in the specifications.

iii. Individual check on each/module/sub-assembly in accordance with the modes and diagnostics programsof the Contractor.

iv. Environmental testing.

v. Functional tests.

vi. Any other test not included in FAT document but relevant to the project as desired by theOwner/Consultant at the time of Factory acceptance testing.

8.0 SITE ACCEPTANCE TESTS8.1. Owner/Owner’s representatives may carry out Site Acceptance Tests on randomly selected samples from

the finished PLB-HDPE duct supplied at Owner designated store or at project site in field.

8.2. Random checks somewhere in the middle of the coil, by cutting the duct, will be made at site to ensure thatducts supplied are of correct dimension and thickness and there is no compromise on thickness inintermediate length, for saving in materials cost.

8.3. 100% Duct coils being supplied would be weighed to cross check the quantity of plastic used.

8.4. To keep a check on the use of filler material, ash contents would be determined on randomly selectedsamples as per ASTM D 1603 method and the value of ash content, thus determined, shall not exceed 0.3%.

8.5. UV Stabilize content: Identification of UV additive shall be done by FTIR Spectra, NMR Spectra and UVSpectra. UV Stabilizer content of finished duct shall not be less than 0.15%

8.6. Third party inspection on above, in addition to inspection at factory, would be carried out by independentagencies on randomly picked up samples from field for testing of relevant parameters, thereby ensuringright quality of ducts.

Note:

“Nothing herein above provided, inclusive of the `Final Acceptance Certificate; shall absolve Contractor ofhis full liabilities under the contract inclusive of and relative to the system performance and Warranty".

9.0 IDENTIFICATION AND MARKINGThe ducts shall be prominently marked with indelible ink at every 1-meter interval. Following informationshall be clearly printed.Client nameClient LogoManufacturer's NameDuct SizeDate of ManufacturingM/C No. / Specific serial number of duct.Sequential Length marking

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GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

6 14.09.09 Logo Changed AS SD KNC

5 30.04.07 Logo Changed AR PKS KNC

4 13/09/00 First issue MZJ DNP DNP

3 18/12/98 Changed Company name and logo DNP PCA DNP

2 22/01/98 Updated DNP PCA DNP

1 04/10/94 General revision of SG-96-003 VAH PCA DNP


Page 159 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 1 of 8

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Page 160 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 2 of 8

1.

This specification defines the symbolisation and identification of instrumentation to be used for Piping and Instrumentation Diagrams, for instrumentation documents and drawings and for instrumentation tagging.

2.

2.1.

Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this specification are given the following meaning : AGREEMENT Designates the agreement concluded between the CLIENT and

the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.

CLIENT Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.

CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the CLIENT. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.

ENGINEER Designates the individual or legal entity to which the CLIENT has entrusted various tasks in relation with the carrying out of his PROJECT.

GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, material, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The Terms GOODS or SERVICES may by indifferently used one for the other as required by the context.

PROJECT Designates the aggregate of GOODS and/or SERVICES to be provided by one or more CONTRACTORS.

2.2. !"

The terminology conforms to ANSI/ISA S51.1 "Process Instrumentation Terminology".

Page 161 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 3 of 8

3.

3.1. "$ %& %&

1) Instrument symbols and functional identification shall be in accordance with ANSI/ISA S5.1 "Instrumentation Symbols and Identification" and ANSI/ISA S5.3 "Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems".

2) The action of a valve in case of electrical or air failure shall be indicated under the symbol of the valve body by one of the following abbreviations :

FC = fail closed,

FI = fail indeterminate,

FL = fail locked (last position),

FO = fail open.

3) The on-off valves shall be identified by :

the letters XV if they are operated by a Process Control System (PCS), a Programmable Logic Controller (PLC), an Emergency Shut-Down (ESD) system or a relay system; the associated solenoid valves shall be identified by the letters XY;

the letters HV if they are only operated by a hand switch (HS).

4) The auxiliary contact of a contactor (e.g. for a motor), which shows if the contactor is energized or not shall be identified by YS.

The control of a motor will be tagged HS in all cases (PCS or panel/local control).

5) Identification letters, typical letter combinations, and function blocks and function designations are given respectively in Tables 1, 2 and 3 of ANSI/ISA S5.1

Page 162 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 4 of 8

3.2. '%%&

1) Each instrument or function shall be identified by a tag number comprising two groups of characters :

XXXXX - YYYYY Z - W

Optional suffix used to designate a specific function (i.e. B for an intrinsically safe isolator, D for a PCS input/output, P for a PLC input/output, E for an ESD input/output, R for a relay, …)

Optional suffix used when a given loop has more than one instrument with the same functional identification (i.e. A, B, C, ….)

Loop number The two first digits designate the plant area (i.e. 10, 20, 21, …)

The three last digits correspond to the serial loop numbering. The loop numbering sequence starts with 001 for each plant area.

Functional identification comprising five letters maximum (i.e. PDAHH)

2) Inside one plant area, no loop will bear the same serial number.

4.

4.1. & ) %$

1) Each local panel shall be identified as follows :

LP - XXYY

serial number (01 to 99) plant area number (i.e. 10, 20, 21, …) ex. : LP – 2101 2) For local cabinets, the letters LP will be replaced by the two letters corresponding to the cabinet type

(see par. 4.2.).

ex.: PS – 3001

4.2. $%) *%

The cabinets and panels located in the instrument rooms or in the control rooms shall be identified as follows :

Page 163 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 5 of 8

XX - YYY

the first digit designates the room number; the two last digits are serial numbers from 01 to 99.

(i.e. 101, 102, 201, 202, ...) cabinet/panel identification letters : AL = Alarm Cabinet/Panel AU = Auxiliary Cabinet BA = Barrier Cabinet CC = Control Cabinet CD = Control Desk CP = Control Panel EA = Earthing Cabinet FF = Fire fighting Cabinet/Panel FG = Fire/Gas detection cabinet IF = Interface Cabinet EL/IN MA = Marshalling Cabinet PL = PLC Cabinet PS = Power Supply Distribution Cabinet RE = Relay Panel/Cabinet TU = Termination Unit Cabinet

Page 164 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 6 of 8

4.3. +& ,

1) The junction boxes shall be identified as follows :

JB - XXYY - ZZ

signal type : IA = Intrinsically safe analogue signals IF = Intrinsically safe frequency signals IL = Intrinsically safe logic signals IR = Intrinsically safe RTD signals IT = Intrinsically safe thermocouple signals NA = Non-intrinsically safe analogue signals NF = Non-intrinsically safe frequency signals NL = Non-intrinsically safe logic signals NR = Non-intrinsically safe RTD signals NT = Non-intrinsically safe thermocouple signals PS = Power Supply SV = Solenoid Valves serial number (01 to 99)

plant area number (i.e. 10, 20, 21, ...)

ex.: JB - 2201 - IA

2) Inside one plant area, no junction box will bear the same serial number even if type of signals is different.

4.4. $

1) A cable between a field instrument and a junction box or local panel shall be identified by the instrument tag number :

e.g. : FT - 23001

2) A cable between a junction box or a local panel and an instrument room or a control room shall be identified by the junction box or local panel identification number :

e.g. : JB - 2309 - SV LP - 4110 - NL

3) Cables in instrument rooms or control rooms shall take the identification of the cabinet to which they are connected with, when applicable, the signal type letters :

e.g. : TC 101 – NL

4) When several cables are connected to the same equipment, a serial number will be added to the cable identification :

e.g. : LP - 2301/1-IL, LP - 2301/2-IA CC 101/1 - IA, CC 101/2 – IL

Page 165 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 7 of 8

5) For power supply cables, the identification will be completed by the letter "S" :

e.g. : LP - 2101 - S

5.

5.1.

1) Each instrument will be identified by its tag number.

2) The identity plate or tag plate supplied by the instrument manufacturer shall be made of 316 stainless steel. The plate shall have a minimum thickness of 0.5 mm and a maximum thickness of 1.5 mm. The size and shape of the plate is left to the discretion of the equipment manufacturer so that he may supply his own standard item, where one exists.

3) The engraving must be done in upper case letters, with a minimum size of 6mm. The letters may be stamped if this method is preferred.

The engraving or stamping must be heavy duty so that the letters do not become obscured by dirt or tarnishing.

4) The tag plate is to be fixed to the equipment such that it is secure and cannot be accidentally removed.

It must be fixed in such a way that it can be deliberately removed and replaced. This is necessary if a duty is assigned to a spare item, or if it is necessary to reassign an item to another duty.

Acceptable methods of fixing are :

1) Screwing. This shall not be done if it affects the integrity of the enclosure, such as it might be the case with an item which is classified for use in a hazardous area e.g. Zone 1 or Zone 2, or with an item which has an IP (Ingress Protection) rating.

2) Wiring. The wire, which is used, must be 316 stainless steel.

3) Riveting. The rivets used must be 316 stainless steel and they must be capable of being drilled out without creating any danger of swarf entering the equipment.

Glue may not be used to fasten labels to equipment.

4) Complementary to the instrument identity plate, all field instruments shall be equipped with a second and permanent identity plate, fixed to immediate vicinity of the instrument, i.e. on the support itself if possible.

Details on that identity plate are given in standard drawing 70000/734/XX/7001 "Nameplates, tags and labels for instrumentation".

5) Instruments installed in panels, cabinets, racks, etc. shall also be identified by a second identity plate fixed at the location of the instruments.

Details on that plate are given in standard drawing 70000/734/XX/7001.

5.2. ) %$

Panels and Cabinets shall bear an identity label in accordance with standard drawing 70000/734/XX/7001.

Page 166 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 003

Rev. 6 – 14.09.09 Page 8 of 8

The label shall preferably be fixed by screwing at a 1.6 m height.

5.3. +& ,

1) One or two engraved labels per box shall be fixed on the lid.

Label 1 :

Text : JB type and number

Label 2 (When applicable) :

IS application

Text: THIS JUNCTION BOX CONTAINS INTRINSICALLY SAFE CIRCUITS

Voltage above 24 V application

Text: THIS JUNCTION BOX CONTAINS (*) CIRCUITS ALL CIRCUITS TO BE ISOLATED PRIOR TO OPENING

(*) = applicable voltage

2) When applicable, one engraved label per box shall be fixed next to the screen busbar:

Text : SIGNAL SCREEN

3) Details on these labels are given in standard drawing 70000/734/XX/7001.

6.

Reference is made in this specification to the following documents.

6.1. &$ %%%1!

70000/734/XX/7001 Nameplates, tags and labels for instrumentation.

6.2. &"&%%

ANSI/ISA S5.1 Instrumentation Symbols and Identification.

ANSI/ISA S5.3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems.

ANSI/SA S51.1 Process Instrumentation Terminology.

S S S

Page 167 of 261

GTS – INSTRUMENTATION ERECTION J/02/3009


1 14.03.08 Logo Changed AS NS KNC

0 30.04.07 Logo Changed AR PKS KNC

B 04.03.05 Logo Changed SUB AKJ VVA

A 15.09.03 First Issue SUB AKJ VVA


Page 168 of 261


Rev. 2 – 14.09.09 Page I of I

!

!

"

#

S S S

Page 169 of 261


Rev. 2 –14.09.09 Page 1 of 22

This specification covers the technical requirements for installation, calibration, checking, testing and commissioning of Instrumentation for Gas pipeline project.

Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this document are given the following meaning :

AGREEMENT Designates the agreement concluded between the OWNER and the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.

OWNER Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.

CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the OWNER. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.

DAYS - WEEKS - MONTHS Specify the number of calendar days, weeks or months and not of working days, weeks or months.

OWNER’s REPRESENTATIVE Designates the individual or legal entity to which the OWNER has entrusted various tasks in relation with the carrying out of his PROJECT.

GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, materiel, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The terms GOODS or SERVICES may be indifferently used one for the other as required by the context.


$

The Instrumentation erection shall be in accordance with the codes and standards mentioned in the present specification and with the codes, standards and legal requirements listed in various documents for the PROJECT.

Page 170 of 261


Rev. 2 –14.09.09 Page 2 of 22

%&%

Whenever OWNER and/or OWNER’s REPRESENTATIVE review and/or approval is requested on a document to be submitted by the CONTRACTOR or before an action is implemented by the CONTRACTOR, such review and/or approval shall always be requested in writing by the CONTRACTOR to the OWNER and/or the OWNER’S REPRESENTATIVE before any action subject of this review and/or approval is taken.

OWNER and/or OWNER’S REPRESENTATIVE approval shall always be given in writing.

1) The technical requirements laid down in this specification do not relieve the CONTRACTOR from any responsibility resulting from the awarded works.

2) The layout drawings attached to the tender document for the PROJECT and the models regarded as part thereof, show approximate locations of instruments, analysers, single and multicore cable routings, junction box locations, and shall be used as a guide by the CONTRACTOR.

They need not to be strictly adhered to, unless so specified, provided that accessibility, accuracy and lag requirements are taken into consideration.

Any drawing showing connection details and dimensions, or containing any specific information, shall be adhered to and any deviation from the drawings shall be approved by the OWNER’S REPRESENTATIVE before starting installation.

3) Any discrepancy between this specification and other documents shall be immediately notified to the OWNER’S REPRESENTATIVE, in writing, for resolution.

4) Protection of equipment and personnel against damage through malfunctioning or mishandling the instrument or instrument system shall be provided by the CONTRACTOR as an integral part of contract. Adequate protection shall be included for ensuring safety of personnel from any possible hazards.

The CONTRACTOR shall perform the following works (unless explicitly excluded in the tender for the PROJECT):

1) Verification of all instruments, when receiving them, to ensure that all components have been delivered and to ascertain any damage suffered.

Failure by the CONTRACTOR to give notice of visible damages or omissions to the OWNER’S REPRESENTATIVE when receiving a consignment of materials and instruments shall be considered as an implicit confirmation that the CONTRACTOR takes upon himself all responsibilities for their soundness until final testing and acceptance.

2) Installation of all instruments and ancillary equipment.

3) Installation and connection to lines and equipment of instrument process piping including, where specified, seal welding of threaded connections.

4) Tracing of instruments, instrument impulse lines, wherever required.

5) Installation of protection boxes for instruments, wherever required.

6) Installation of junction boxes, wherever required.

Page 171 of 261


Rev. 2 –14.09.09 Page 3 of 22

7) Installation of ladders, trays, trunking and conduits for cables and tubes.

8) Installation of consoles, desks, panels and cabinets for instruments.

9) Installation of electrical power supply cabinets for the Instrumentation.

10) Installation of all the necessary supports for the instruments, cable ladders, trays, trunking and conduits, impulse lines, pneumatic transmission lines, steam tracing lines, cabinets, panels, consoles, desks, junction boxes, connection boxes, cross boards, synoptic panels, etc.

11) Painting of the supports, frameworks and locally manufactured panels.

12) Installation and connection at both ends of instrumentation cables and conductors.

13) Installation of nameplates and/or labels for identification and numbering of instruments, cables, wires, junction boxes, connection boxes, cross boards, terminals, cabinets, panels, desks, pneumatic transmission lines, lines or cables for tracing, etc.

14) Carrying out any auxiliary work necessary for installation of the instrumentation as per technical specifications (e.g. removing and replacing doors to facilitate work, drilling small holes in walls and floors, filling back the holes, reparation of damages made during installation and repainting all damaged paint work).

15) Handling and properly protecting instruments, cabinets, boxes, panels, desks, consoles after receipt and after installation (especially capillary tubes, proximity switches etc.).

16) Removal of oxidation and, if necessary, greasing of parts oxidized during transportation or storage.

17) Performing additional works upon request of the OWNER’S REPRESENTATIVE.

18) Performing all changes and repairs, as required, resulting from CONTRACTOR'S failure to comply with specifications, standards and/or drawings or from incorrect installation.

19) Checking and testing of all instruments.

20) Calibration and precommissioning of all instruments.

21) Installation and removal as per site regulations of temporary stores, workshops and buildings, for performance of the WORKS and in order to properly protect and store all instruments.

22) Cleaning of the site.

23) Fabrication of pipe nipples as necessary including threading as per installation standard.

24) Drilling of holes in blind flanges including cutting threads as per installation standards.

25) Back/seal welding of screwed fittings as required by standards or as per the instruction of Owner/Owner’s Representative. This may involve welding of dissimilar materials using appropriate electrodes.

26) Civil works including the casting of foundation as required for instrument support.

27) Minor civil works like chipping of pavement, grouting of instrument panels, laying of conduits below pavement after chipping and refinishing of pavement as necessary.

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

29) Degreasing of impulse lines, valves, instruments and other instrument items in oxygen and chlorine service as per manufacturer’s instructions.

30) Minor modification/repairs required to be carried out on the instruments namely replacement of dial, glass for pressure gauges or any other similar instrument, replacement of damaged signal tubes on

Page 172 of 261


Rev. 2 –14.09.09 Page 4 of 22

valves, tapping of damaged threads on couplings, tees and other fittings; cleaning of nozzles and relays in pneumatic instruments.

31) Painting of all structural supports for trays, pipes, junction boxes, instruments.

32) Punching of tag numbers on items or tag plates.

33) Fabrication and installation of pipe stanchion as per Instrument support standards including casting of concrete pedestal, grouting, welding etc. as necessary.

34) Drilling holes for providing glands/grommets on panels, shut down cabinets, power supply cabinets, local control panels, pneumatic enclosures, junction boxes etc. wherever required for cables/ multitube entry.

35) Grounding of shields cables to respective instrument earth bus provided in the control room/local panel/RTD head etc. as required.

36) Laying and termination of earth cable at both ends between instrument earth bus provided in control room/local panel to instrument earth pits provided by other contractors.

37) Supply of all types of consumables required for the execution of the job without any exception.

38) Sealing of safety valves with standard lead seals after final setting in the presence of Owner/Owner’s representative.

39) Supply and installation of base frames along with necessary civil works for all the panels / cabinets / consoles including the RTU base frame (RTU size shall be provided during execution) envisaged inside the control room are included in the scope of CONTRACTOR.

40) Co-ordination during installation, pre-commissioning and commissioning with mechanical and other sub-contractors for proper installation of line mounted instruments like control valve, ultrasonic flow meters etc. which involve removal of instruments disconnection of tubes/ cables, reconnection of same for alignment and proper installation.

41) Incorporation of all information in drawings/document as per the actual execution of work at site including preparation and submission of as-built drawings.

42) Any other work not specifically mentioned above, but required for the proper execution of the erection work.

The CONTRACTOR shall supply the following materials and documents (unless explicitly excluded in the tender for the PROJECT) in accordance with the requirements for the PROJECT:

1) All the supports for the installation of instruments, cable ladders, trays, ducts, conduits, instrument process lines, pneumatic transmission lines, cabinets, panels, desks, consoles, junction boxes, connection boxes, cross boards, etc.

2) Material for the instrument process piping (except the first isolating valve).

3) Material for the tracing of instruments, instrument process piping.

4) Material for the pneumatic transmission lines.

5) Junction boxes, the connection boxes, the cross boards including terminals and accessories.

6) Protection boxes for the instruments and ancillary equipments, including all required accessories.

7) Cable ladders, trays, trunking, conduits.

8) Cable glands.

Page 173 of 261


Rev. 2 –14.09.09 Page 5 of 22

9) Accessories for fixing the cables on cable ladders, trays and trunking.

10) Nameplates and labels for identification and numbering of instruments, analyzers, ancillary equipment, cables, wires, junction boxes, connection boxes, cross boards, terminals, cabinets, panels, desks, consoles, pneumatic transmission lines, air supply lines, lines or cables for the tracing, etc.

Numbers to be used shall be given by the OWNER’S REPRESENTATIVE.

11) All the required accessories for an installation in accordance with the prescriptions, drawings and technical specifications and for the verifications, checks and tests of the Instrumentation.

12) All equipment and material asked for by the OWNER’S REPRESENTATIVE on site.

13) Required equipment for the calibration, testing and the precommissioning of the Instrumentation, when applicable.

14) Consumables (electrodes and welding rods, primer, lubricants, sealants, soldering flux, paint, screws, bolts, expansion bolts, nuts, washers, etc.).

15) Necessary tools, equipment and temporary stores, workshops and buildings, in order to perform the works (including lifting engines, scaffolding, etc.).

16) Required test documents and certificates.

17) As-built drawings (marked up copies).

18) Welding procedures and welders qualification certificates, when applicable.

19) Weekly reports with progress status.

20) Planning and organisation documents such as:

work preparation sheets,

activity bar chart schedule

cable cut program for cables delivered by the OWNER.

21) The precommissioning sheets filled in and signed off "ready for commissioning". Those sheets could be an OWNER’S REPRESENTATIVE standard, an OWNER standard or a CONTRACTOR standard approved by the OWNER’S REPRESENTATIVE.

'()*)+,-.('/01

The CONTRACTOR shall strictly adhere to the site regulations.

.()*'.-1

All materials supplied by the CONTRACTOR shall be in accordance with (but not limited to) the requirements laid down in the Technical Specification for the PROJECT and attached documents and drawings.

Page 174 of 261


Rev. 2 –14.09.09 Page 6 of 22

The CONTRACTOR shall ensure that all materials and equipment are adequately protected and stored until they are installed / erected.

/2.-3.4*'2.('/0

All equipment necessary for proper installation of instruments (like supports, frameworks, local panels, etc.) and not supplied in prefabricated form shall be fabricated locally by the CONTRACTOR.

(/*'0+.056.05-'0+/3'01(*,7)0(1

Immediately after receipt, instruments and installation materials shall be stored by the CONTRACTOR (unless stated otherwise in the Particular Technical Specification for the PROJECT).

When instrumentation is taken from stock temporarily (e.g. for testing), it shall be returned to the CONTRACTOR’s store in the original packing.

For preventing damage, the CONTRACTOR shall transport and handle instruments with the utmost care. All covers and plugs on instrument connections and flange facings shall be left in place as long as possible.

Instruments shall be protected against general construction site hazards, and in particular against adverse weather conditions during the construction period, (e.g. extensive use of large size commercial quality polyethylene bags to cover control valves and local instrumentation). All openings shall be properly sealed if the connections are not made immediately after the installation of the instrument, junction box etc.

.4-)1(/*.+)

All cables shall be stored in a locked compound. Partly used drums shall have their ends sealed and an indication of the quantity remaining marked on the drum.

The fenced off area shall be of sufficient size to allow entry of vehicles, and allow the storage of cables by type and size in a neat and orderly manner. The surface of the compound shall be such that it does not get water logged.

)0)*.-

1) The CONTRACTOR shall make a preliminary study of instrument, junction boxes location and instrument cable run.

Locations and runs proposed by the CONTRACTOR shall be in accordance with sound installation practices and submitted to OWNER’S REPRESENTATIVE for approval. The approval of the OWNER’S REPRESENTATIVE cannot be used as an argument for an extra-cost in case of relocation afterwards.

2) All instruments, there measuring elements and their process manifolds and valves shall be safely and permanently accessible from grade, platforms or walkways (2 m above or 1 m either side of).

Where permanent accessibility is impossible, the process connections and measuring elements for instruments may be located so that they are accessible by temporary facilities (ladders or mobile platform, maximum length : 4 m).

In such cases additional block valves shall be provided close to the instrument. This requires approval of the OWNER’S REPRESENTATIVE.

Page 175 of 261


Rev. 2 –14.09.09 Page 7 of 22

All instruments, their process connections shall have such orientation and location as to allow easy reading.

Control instruments and transmitters shall also be located in such a way that they are easily accessible for operation and maintenance.

3) The connections to the process lines and equipment shall be made in accordance with the pipe class up to and inclusive of the first block valves. Their orientation shall be selected so that instruments or instrument process piping will not obstruct walkways or platforms.

Seal welding may be requested on threaded connections for special services. That welding shall be performed in conformity with the welding procedure for threaded connections.

The CONTRACTOR shall check the type, size, material and orientation of the instrument process connections.

4) The run of instrument impulse lines shall be such as to avoid liquid pockets in lines containing gas, even if this is not specified on the typical drawings.

Slopes of instrument impulse lines shall be as specified on the engineering drawings. If not specified, they shall be at least 10 cm/meter to the tapping point when the instrument is mounted above the tapping point and to the instrument when the instrument is mounted below the tapping point.

Vertical instrument impulse lines for differential pressure transmitters shall run as close as possible to each other.

Instrument impulse lines shall be properly supported (maximum distance between supports: 1.50 m).

5) When the pipe class calls for welded connections, welding procedure shall be approved by the OWNER’S REPRESENTATIVE.

6) When seal welds on threaded connections are required, such connections shall be installed with the threads perfectly free of any trace of lubricant or sealing tape.

7) Instruments, associated process piping shall be securely fastened in order to avoid vibrations. When applicable, displacement of process pipes or equipment shall be taken into consideration.

8) In general the instrument supports shall either be fixed to concrete or be welded to structural steel.

It is prohibited to weld supports to platforms, handrails, process piping or process equipment.

If supporting from structural steel or concrete is not feasible, supporting of instruments by means of clamping around piping may be considered but approval of the OWNER’s REPRESENTATIVE is required for each individual case

All surfaces of structural steel which could not be painted afterwards shall be made free of rust, cleaned and painted with a layer of primer before supports, trays, cables, etc. are installed.

All brackets and supports shall be finished smoothly, free from sharp and dangerous edges. Pedestal for yoke mounted instruments shall be closed at top to prevent water accumulation.

In order to avoid electrolytic corrosion, insulating barriers shall be provided when instrument and analyser support are clamped on process piping of a different material.

9) Even when no cathodic protection is installed, all instrument connections to underground metallic lines shall be electrically insulated.

10) Instrument and supports, which must be fixed to fireproofed structures, shall be welded to the steel structure before the fireproofing is applied taking into account the thickness of the applied fireproofing.

Page 176 of 261


Rev. 2 –14.09.09 Page 8 of 22

When it is not possible, the supports shall be clamped around the fireproofing, if allowed by the OWNER’s REPRESENTATIVE.

As a general rule, the support installation method has to be approved by the OWNER’s REPRESENTATIVE.

11) All outdoor instruments shall be absolutely weatherproof. If required, weatherproof housings shall be supplied and installed by the CONTRACTOR.

In sunny areas, the field mounted instruments and analysers shall be protected from solar radiation.

12) Local pressure and differential pressure instruments shall be mounted so as to avoid vibrations.

13) Individual instrument tracing shall be installed as specified on engineering drawings.

The requirements for heavy or light tracing shall be strictly adhered to.

Isolation valves on steam manifolds and steam trap stations for instrument and steam tracing and local isolating switches for electrical tracing shall be clearly tagged with the instrument loop number even if they are not installed by the CONTRACTOR.

14) Instrument impulse lines shall be installed in such a way that enough space is kept all around the lines to install the required insulation.

15) Stainless steel impulse and sample transport lines will be additionally protected against the climatic conditions by the use of PTFE spray after the hydrostatic test. The spray type and method of application are to be agreed by the OWNER’s REPRESENTATIVE.

16) Instrument equipment shall be located such that it is protected against direct drainage of condensate, water and process fluids from adjacent plant equipment that can make the instruments, instrument components, junction boxes, etc. dirty, wet or inoperable.

17) Care shall be taken that no passage ways are obstructed or access to other plant equipment, electrical lighting panels, other instruments, etc. is impossible. All equipment shall remain easily operable. Ample space shall be available for the removal of covers, protection box doors, etc.

18) When API threadings are made by a thread cutting machine dies shall be properly oiled and threads produced shall be agreed by the OWNER’s REPRESENTATIVE. PTFE tape shall be used for the installation of threaded fittings, except where temperatures in excess of 200 °C occur, as indicated on the process piping details; for these cases a suitable dope shall be used.

19) When installing steel or stainless steel tubing with compression type fittings, all the fitting manufacturer's instructions shall be exactly followed which shall include, but are not limited to :

proper cutting of tube and deburring,

proper installation of the ferrules,

taking care that all tubes have the required roundness.

When storing tubes, care shall be taken that no mechanical damage can occur, which makes the tubes unround.

In order to avoid unroundness of the tubes at the places where ferrules are to be applied, it is absolutely necessary to cut the tube at least 5 cm from the end of a bend. Mounting closer to the bend shall not be accepted.

To avoid galling of stainless steel ferrules into the tapered end of the stainless steel fittings, the stainless steel ferrules shall be greased slightly at the outside before installation.

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Rev. 2 –14.09.09 Page 9 of 22

)78)*.(,*)'01(*,7)0(1

All temperature sensing elements shall be firmly bottomed in the thermowells.

*)11,*)'01(*,7)0(1

Refer Standard Drawings enclosed in the tender.

*)026)1

Cable trenches shall be excavated as per requirement and site suitability taking into account the following requirements:

1) The CONTRACTOR shall do all excavation of whatever substances encountered to depth shown on drawings.

Excavated materials not required for backfill shall be removed and disposed of as directed by the OWNER’s REPRESENTATIVE.

2) Unstable soil shall be reported to the OWNER’s REPRESENTATIVE who shall give instructions to the CONTRACTOR for its removal and replacement with suitable material. The CONTRACTOR shall be responsible for the excavation and disposal of this unsuitable material as directed by the OWNER’s REPRESENTATIVE.

3) Unstable materials shall be replaced with approved fill material by the CONTRACTOR as directed by the OWNER’s REPRESENTATIVE who shall approve the replacement fill. All replaced fill shall be compacted as directed by the OWNER’s REPRESENTATIVE.

4) When approved by the OWNER’s REPRESENTATIVE excavated material suitable for backfill may be deposited alongside the trench excavation but at a distance not less than 1 meter from the edge of the trench excavation or as otherwise instructed by the OWNER’s REPRESENTATIVE. When instructed by the OWNER’s REPRESENTATIVE, the CONTRACTOR shall remove all excavated material to a designated dump area.

5) Ground adjacent to all excavations shall be graded to prevent water running in.

6) The CONTRACTOR shall remove by pumping or other means approved by the OWNER’s REPRESENTATIVE, any water accumulated in excavations, and shall keep trenches dewatered until cable bedding is completed to the satisfaction of the OWNER’s REPRESENTATIVE.

The CONTRACTOR shall note that to be effective, dewatering operations may have to be on a 24 hour, round the clock basis to ensure dry working conditions.

7) The CONTRACTOR shall at his own cost supply and install all necessary bracing, sheathing, shoring to perform and protect all excavations as required for conformity with safety regulations and as approved by the OWNER’s REPRESENTATIVE.

8) Temporary crossings shall be built by the CONTRACTOR as directed by the OWNER’s REPRESENTATIVE to maintain traffic on the site. After use, and when instructed by the OWNER’s REPRESENTATIVE such temporary crossings shall be removed by the CONTRACTOR.

9) All open excavations shall be protected at CONTRACTOR'S cost by means of safety barriers, lamps, etc. as required or directed by the OWNER’s REPRESENTATIVE.

10) The depth of the trenches shall be locally increased at crossing or branch-off of large quantities of cables.

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Rev. 2 –14.09.09 Page 10 of 22

11) The curvature of the trenches shall be compatible with the bending radius of cables.

12) The maximum slope of trench bottoms shall be 10 degrees. The transition to horizontal surfaces shall have a smooth curvature.

13) At crossing, signal cables shall be at least 0.3 m lower or higher than electric power cables.

14) In order to allow future laying of cables, sleeves (200 mm diameter) shall be provided at road and railway crossing and where trenches for signal cables pass under trenches for electric power cables as required on engineering drawings. The sleeves shall be provided with a steel wire in order to allow pulling of cables.

15) Trenches shall be kept (at least 0.5 m) away from buried pipes containing hot fluids and from pipes liable to temperature rise owing to steaming-out.

16) All stones and/or rocks shall be removed from the trench prior to laying of the cables.

17) The CONTRACTOR shall lay a 15 cm thick sandbed to receive the cables.

18) The laying of cables in the trenches shall be approved by the OWNER’s REPRESENTATIVE.

19) The backfill of trenches may only start after approval from the OWNER’s REPRESENTATIVE.

The cables shall be covered with a layer of 15 cm of sand on which red or yellow concrete tiles (300 x 300 x 40 mm) shall be installed, after which the trenches shall be backfilled and covered.

20) The backfill of the trenches shall be carried out using approved excavated materials, compacted in lifts of 30 cm max. When instructed by the OWNER’s REPRESENTATIVE, the CONTRACTOR shall use fill from approved stock pile areas.

The work shall be carried out ensuring that the backfill is firm and compacted, using suitable equipment, and to specification requirements.

21) Backfill material shall be deposited by the CONTRACTOR to specification and as instructed by the OWNER’s REPRESENTATIVE.

22) Puddling or water flooding for consolidating the backfill is not allowed.

23) After backfill of trenches, no surface load shall be placed on the backfill until a period of 48 hours has elapsed.

24) The location of the trenches shall be clearly marked and reported on "as built" drawings.

Markers shall be placed at 15 m intervals (or at intervals agreed by the OWNER’s REPRESENTATIVE) and where the trench changes direction.

For trenches 500 mm or more in width, markers shall be provided on both edges of the trench. For trenches less than 500 mm in width, markers shall be placed at one edge of the trench only.

Markers shall have identification plates of corrosion resistant metal. The plate shall indicate the direction of the cable run and give the voltages of the cables in the trench at the point where the marker is located.

25) Excavation of trenches after cables have been laid requires approval of the OWNER’s REPRESENTATIVE.

.4-)-.55)*1(*.91.05(*,0:'0+

Cable ladders, trays and/or trunking shall be installed as indicated on layout drawings or on models and sectional drawings, taking into account the following requirements.

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1) Cable ladders, trays and/or trunking shall be easily and safely accessible for maintenance reasons.

2) Cable ladders, trays and/or trunking shall be installed in such a way that they do not hinder traffic, nor interfere with accessibility or removal space of pumps, motors, compressors and any process equipment or part thereof.

Minimum required clearances, are:

over railways (from top of rail) 7 m,

crane ways (process area) 6 m,

over elevated walkways or platforms 2.5 m,

where accessibility of mobile lifting equipment is required 4 m.

3) Cable ladders, trays and/or trunking shall be kept away from hot environments and places with potential fire hazards (hydrocarbon process pump, burner fronts).

When cable ladders, trays and/or trunking must be installed where they are subject to fire hazards, suitable fireproofing shall be provided by the CONTRACTOR.

4) Cables ladders, trays and/or trunking shall be located so that they are not subject to mechanical abuse, spilt liquids, escaping vapours and corrosive gases, strong electrical interference.

Ladders, tray and/or trunking riser points which can be damaged by traffic shall be suitably protected.

5) Cable ladders, trays and/or trunking shall be firmly supported.

They shall be suitable for an equally distributed load of 120 kg/m and shall withstand an additional point load of 80 kg.

The supports shall be installed at sufficiently short intervals so as to avoid bending exceeding 0.5 % of span. Wherever possible supports shall be arranged so that cables and multitubes can be laid sideways.

Sufficient free space (minimum 0.5 m) shall be provided above ladders, trays and/or trunkings.

6) Cable ladders, trays and/or trunking shall be internally smooth. Attention shall be paid particularly at changes of directions, both in horizontal and vertical plans.

All fabricated pieces shall be free of burrs and sharp edges (plastic covered ends).

7) The curvature of cable ladders, trays and/or trunking shall be compatible with the bending radius of cables.

8) At site, cable ladders, trays and trunking shall be lengthened by bolting, not by welding.

9) The minimum width of the main cable ladders, trays and/or trunking shall be as indicated on the drawings. The height, if not specified, shall be determined by the CONTRACTOR taking into account the quantity of cables and 30 % spare.

The CONTRACTOR shall base his selection of not specified ladder, tray or trunking sizes taking into account the following considerations. The sizing of the cable ladders, trays or trunking for instrumentation cable depends only on the space required to accommodate the cables at various locations in the system. Space for at least 30 % future cables shall be provided. If mechanical separation is required to separate intrinsic safe cables from other low voltage cables installed on one cable tray or trunking, metal barriers extending approximately 5 cm above the top of the higher shall be used.

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Rev. 2 –14.09.09 Page 12 of 22

/05,'(1

1) The conduit system shall be installed in such a way that it will be impossible for rain-water to collect at low points. Conduit material shall be as specified in the Particular Technical Specification for the PROJECT.

2) Sharp edges on conduits shall be removed and any conduits ends shall be protected with metal ring collars or polythene inserts to prevent cable damage. All conduits shall be swabbed clean before wire or cable is installed.

3) Following methods are recommended for the supports and arrangement of the conduits.

Conduit shall not be supported from piping that may have to be replaced or removed for inspection nor from high temperature piping. It is sometimes necessary to support conduits from ordinary piping.

Provision shall be considered for thermal expansion or other movement of the supports, such as swaying of towers in high winds.

Conduits are normally fastened to supports with pipe clamp or U-bolts; they shall not be tack welded. Substantial hangers shall be provided for groups of conduits where it is not practicable to clamp directly into building walls or structural members.

Maximum distance between conduit supports : 1.5 m.

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1) The junction boxes shall be installed as indicated in typical block diagram for instrument interconnection and shall be permanently accessible.

2) Junction boxes shall be marked externally with suitable nameplates (corrosion - resistant).

3) Suitable corrosion-resistant cable glands shall be provided in order to house each cable.

4) All junction boxes shall be kept closed except when work is being performed upon them.

Cable inlets shall be kept closed until cables are installed. Spare inlets shall be sealed.

5) Terminals inside junction boxes shall be installed and marked as indicated on drawings.

6) Connections inside the junction boxes shall be aligned so as to allow easy access to any wire.

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1) Installation of multicore cables and multitubes shall not start before all necessary trenches, ladders, trays and trunking are completely ready.

In addition trenches shall be cleared from all foreign matter and a bottom layer of sand shall be applied.

2) The CONTRACTOR shall cut to size cables and multitubes, seal the end remaining on the drum and put a label on the drum indicating taken quantity.

3) Multicore cables and multitubes shall be handled carefully. No excessive pulling or bending forces shall be applied in order to avoid any damage. The CONTRACTOR shall keep in mind the minimum permissible bending radius when handling and installing cables.

4) In order to avoid any damage due to low external temperatures, no cable or multitube shall be installed when the air temperature is below 5°C or less if accepted by the cable manufacturer.

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Rev. 2 –14.09.09 Page 13 of 22

When it is absolutely necessary to pull cables when it freezes, they shall be heated up at suitable temperature before pulling.

5) Installation of cables and multitubes shall be consecutive and uninterrupted. In case of interruption of cable installation, the trenches shall temporarily be covered and cables shall suitably be protected against damage due to traffic or to installation work.

6) In order to prevent stress, cables and multitubes shall be laid with sufficient slack when trenches are excavated in soft soils.

7) Cables and multitubes shall be suitably fixed in ladders and trays by preformed saddles or plastic ties (e.g. Colson strips). This shall be done :

when changing direction,

every 1.5 m on horizontal runs,

every 30 cm on vertical runs.

If cables are clamped to conduits, pipes, etc. stainless steel cable ties shall be installed every meter in addition to plastic ones.

If cables are directly fixed to the structure, steel clips shall be used every 30 cm.

8) Marking of cables and multitubes shall be as follows :

at approximately 5 m intervals (or at intervals agreed by the OWNER’s REPRESENTATIVE) for underground cables and multitubes, by means of embossed strips of corrosion - resistant material.

at their termination point (outside of junction box where applicable) and in between at places where markers can be easily traced for above ground cables and multitubes by means of suitable label of engraved or embossed plastic. Cables shall anyhow be tagged at the inside and outside of building walls.

9) After completion of the installation of multicore cables and multitubes, all trenches shall be backfilled as mentioned in par. 6.3.1. and all trunking shall be covered.

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All electric signal lines shall be installed and connected as indicated on engineering drawings, taking into account the following requirements.

1) Plastic markers shall be provided on each side of each terminal for individual marking of all signal lines. Cross ferruling method shall be used.

2) Cable screens shall be interconnected in such a way that the screening is earthed only at the intended location.

3) Installation of special signal cables (e.g. coaxial cables) shall be performed as per manufacturer's recommendations.

4) Electric signal lines shall be laid in conduits or trays provided with supports at every 0.6 m maximum.

Supports shall not in general be attached to piping, nor be attached or supported from instruments or control valves, except supports which are designed for direct mounting on pipes.

Single pair cable shall be run on cable tray when more than 3 cables are run together. They shall be run as one single layer.

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Rev. 2 –14.09.09 Page 14 of 22

Where three cables or less are to be run (single circuit cables) from the main cable tray bank, these shall be run in straight lengths of conduit, size depending on number of cables. No conduit fittings shall be used, all angles, etc... are to be open. Alternatively the cables may be clipped in angle or channel section. Angle and channel shall be wire brushed and painted.

No cable shall be installed in the conduit until that part of the installation is complete. The conduit shall terminate away from angles to allow the permissible bend of the cable being installed. All conduits shall terminate away from instruments to allow for a loop of cable when terminating the cable.

5) No splicing of thermocouple extension cables is allowed. When absolutely necessary, connections shall be made in approved junction boxes.

6) Cables shall be suitably fixed in trays by plastic ties, every 25 cm on vertical runs and every 50 cm on horizontal runs.

7) Non isolated earthing cables laid on cable trays shall be isolated from the trays. Fixing bolts shall be stainless steel.

)+*)+.('/0/32.4-)1

Instrumentation cables (4-20 mA, mV signals, etc..) shall be adequately separated from power wiring and electrical equipment to minimize interferences. The physical distance between instrumentation cables and power cables in parallel routing shall be as follows :

Voltage (V) Min. distance (mm)

110 400 220/230 400 380/400 600 660/690 600 6000 1200

If required, the instrumentation cables shall cross the power cables at right angle and with a minimum distance of 300 mm.

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1) Cutting wire or cable to required lengths as it comes off a reel requires a location free from sharp objects.

A paved area is usually ideal, but if not available, a grassy or sandy area is adequate.

Crushed stone, muddy, and shelled areas shall be avoided.

Where traffic must cross wire as it is laid on the ground, temporary board ramps shall be provided to keep vehicles from damaging the wire.

2) The Instrumentation cable list gives an indication of the cable lengths for information only, not to cut cables.

3) A cable end preparation shall allow for the following :

terminate jackets and shield material without nicking insulation underneath,

protect cable ends against moisture infiltration prior to connecting the cable to its permanent terminations.

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Rev. 2 –14.09.09 Page 15 of 22

4) Stripping insulation from wire shall be done without nicking the conductor. Although this is of greater importance with solid wire than with stranded wire, it is a matter of concern with stranded wire also. The simplest way of avoiding nicks is to use stripping tools of proper design.

5) Insulated taper pins or spade lugs shall be used for all sizes of stranded wire. CONTRACTOR shall have proper tools to make these connections.

6) All wires or leads terminated at a connection shall have sufficient slack to reduce the effects of vibration. In application where multiple wires are routed from a common cable trunk to equally spaced terminals, the vibration bends shall be uniform in length to prevent stress on any one wire. Proper cable support is necessary to avoid having cable weight supported from wire terminations.

7) All cable or cable tray runs with entries into walls shall be sealed after installation of cables. To avoid any gas entering the control room(s) a special sealing box shall be installed in the wall of the control room(s).

8) Stainless steel kicking plates, sleeves or steel pipes shall be provided at least 500 mm above floor level where cables emerge from ground or from below steel structures.

9) In order to comply with the requirements for grounding at only one point, terminals are used to carry each shield through the junction boxes.

Accidental shorting or grounding of this shield within a junction box shall be avoided. This can be done by insulating both the shield end and the shield drain wire between the end on the cable jacket and the terminal strip.

Tubular heat shrink sleeves shall be installed on stripped pairs. The sleeves shall be applied immediately after stripping to prevent unravelling of the aluminum adhering mylar tape.

Since only one end of a shield is grounded, each cable has an ungrounded end. This cable end is finished with no ground, and insulation is applied over the trimmed cable end to avoid accidental grounds on any exposed shield or the shield drain wire. Each shield shall be grounded in the control room or in the instrument room.

Special care shall be taken to ground to the correct system, as indicated on the drawings.

10) Hot air heating equipment shall be provided to heat up the cables if connections have to be made when temperature is lower than 5°C.

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1) Single pneumatic lines shall be laid in trays, provided with supports at every 0.6 m maximum.

Supports shall in general not be attached to piping nor be attached or supported from instruments or control valves.

2) The single pneumatic lines shall be marked with the instrument tag number at the point of connection to the multitube.

3) Sufficient slack shall be provided in all air tubing to avoid strain on the instrument connections and to facilitate dismantling of the instruments (provide extra loop, 8 cm diameter).

4) When PVC covered copper tubing is used copper tubing ends shall be coated with PVC spray and plastic tape and all copper or brass valves and fittings with PVC spray.

The copper tubing shall be straightened and installed carefully to avoid kinking and unroundness.

5) In case the use of black polyethylene air tubing is specified (see air piping detail drawings) adequate tools shall be available for installation. Only careful handling of polyethylene tubing will result in a good installation. Elbow connectors shall be used for attaching the tubing with short bends to solenoid

Page 184 of 261


Rev. 2 –14.09.09 Page 16 of 22

valves, etc. to avoid that plastic tubing is bent with a small radius. Joints made with compression fittings shall have metal inserts to supports the tubing. Single polyethylene tubing shall be routed in open conduit.

6) Plastic sealing plugs shall be kept firmly fixed in air supply input, output and other connections, except during test and immediately before final plant connection.

7) Any air system, permanent or temporary used for energizing instrumentation shall be blown down thoroughly before making connections to the instruments and shall be from an oil free source.

Any connections between any air supply system and an instrument under test shall be via adequate filter and regulator. No temporary compressor shall be connected to the permanent instrument air distribution system.

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1) All cable entries inside control room shall be through MCT.

2) Actual sizing of MCT frame with blocks shall be the responsibility of CONTRACTOR based on actual no. of cables. While sizing MCT, CONTRACTOR to note that 50% spare block for each size / O.D. of cable shall be considered. MCT entries shall be closed with a thick CS plate which shall be removed by CONTRACTOR whenever the MCT shall be installed. The supply of MCT includes insert blocks, spare blocks, stay plates, end packing etc. For flexibility in engineering “ peel of sleeve” type design shall be used to accommodate certain range of cable O.D. in the same size of insert block.

3) MCT shall be installed by CONTRACTOR as per the recommended practice of supplier. No spare space shall be uncovered in the frame.

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Instrument installation work in control room and instrument rooms shall only start after completion of civil work (including air conditioning when applicable).

01(.--.('/0/32/0(*/-4/.*51.055)1:1

1) The control boards and/or desks shall normally be delivered to site completely piped and wired up to bulkhead plates and/or to terminal strips. The CONTRACTOR shall install them in the control room upon their arrival on site in order to minimize storage time.

If not possible, they shall be stored by the CONTRACTOR under suitable ambient conditions.

2) The CONTRACTOR shall duly protect front and back of control boards and/or desks during installation and all construction phases in order to avoid any possible damage.

3) Any damage to control boards and/or desks occurring during installation shall be repaired at CONTRACTOR'S costs.

4) The CONTRACTOR shall clean front and back of control boards and/or desks and shall be responsible for maintenance until plant turnover.

5) The CONTRACTOR shall, if required by the OWNER’s REPRESENTATIVE, make additional cut-outs on boards and/or desks after installation.

No flame cutting or welding is allowed on boards and/or desks.

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Rev. 2 –14.09.09 Page 17 of 22

Cutting shall be made using the most adequate tools so that board or desk finish be not damaged, and that cut-out will be neat and regular with smooth edges.

6) Any other authorized alteration that must be carried out to boards or desks shall be made in such a manner as to avoid shock or damage to instruments already installed.

7) If repairs have to be performed to the finishing of boards and desks, the procedure shall be submitted to the OWNER’s REPRESENTATIVE before to proceed with the work.

8) Any holes drilled in walls, floors or ceiling for the passage of cables shall be filled with the appropriate material to prevent the spreading of fires, etc...

01(.--.('/0/3'01(*,7)0(.('/0)?,'87)0('0'01(*,7)0(*//71

1) Racks, cross boards, control cabinets and auxiliary instruments shall be installed as shown on engineering drawings.

The CONTRACTOR shall provide all necessary protection during installation to avoid any damage and shall be responsible for maintenance and repair of possible damage until plant turnover.

2) Cable ladders, trays and/or trunking shall be installed as indicated on layout drawings.

They shall be firmly supported at sufficiently short intervals so as to avoid bending exceeding 0.5 % of span.

They shall be smooth internally in order to avoid any damage to cables.

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Power supply cables for instruments and analysers shall not be connected until complete tests have been performed on power distribution boards in order to avoid damages due to incorrect power supply or to avoid unsafe application of power supply.

Upon arrival of the equipment in the field and prior to storage or installation, the CONTRACTOR shall remove all accessories which have not been shipped separately, mark them with the identification number of the relative equipment and store them in the warehouse.

The same shall be done for spare parts.

The CONTRACTOR is also responsible for the following.

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1) To ensure that all instruments installed in the circuits are mechanically protected, until plant turnover, to prevent damages due to shocks.

2) Cleaning and greasing, with lead free grease, of the instrument flanges and threads oxidized during transport or storage.

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1) Cleaning and greasing, with lead free grease, of block valve flanges and threads oxidized during transport or storage.

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Rev. 2 –14.09.09 Page 18 of 22

2) Replacement of stuffing in the stuffing boxes, wherever necessary.

/0(*/-*//7.05'01(*,7)0(*//71

The CONTRACTOR shall clean the control room and instrument rooms on a continuous basis. Dust shall be removed from equipment and racks. Rubbish shall be collected and dumped in suitable places indicated by the OWNER’s REPRESENTATIVE.

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Locking keys for control cabinets, cubicles, relay boxes, panels, switches, locking devices shall be clearly identified, removed from their locks and carefully stored until plant turnover.

Upon receipt of instruments, after completion of installation and prior to setting instruments to work, the CONTRACTOR shall carry out adequate calibration, verifications and tests in order to ascertain that all equipment and systems are suitable for the intended duty, have been correctly installed and are in operating conditions.

1) Contractor shall include a list of test and measuring instruments and quote in the price bid.

2) Equipment to be supplied in this contract shall include comprehensive built in diagnostic and test facility for system maintenance.

3) The contractor shall include a list of special purpose test instrument and simulators necessary for the testing, trouble shooting and system maintenance of the equipment and quote in the priced bid.

4) The Contractor shall include a list of all general-purpose test instruments necessary for the maintenance of the equipment and quote in the price bid.

5) Special tools and maintenance accessories such as Card Extenders cable assemblies, card extractors, wire wrapping and unwrapping tools etc. shall be supplied in the form of maintenance kits. The number of such kits shall be 1 (one).

6) It is to be noted that the contractor shall arrange all test equipment, tools, accessories required for the installation and commissioning of the system to be supplied against this contract.

1) Calibration, tests and verifications shall be carried out in accordance with a schedule to be established by the CONTRACTOR and to be approved by the OWNER’s REPRESENTATIVE.

For those calibration, verifications and tests, the CONTRACTOR shall make available, at his expense, all personnel and equipment needed.

2) The OWNER’s REPRESENTATIVE reserves the right to witness all calibration, tests and verifications and shall be advised with one week notice of such calibration, tests or verifications.

3) The results of calibration, verifications and tests shall be recorded on adequate documents by the CONTRACTOR.

Those documents, which shall be approved by the OWNER’s REPRESENTATIVE, shall indicate all works corresponding to calibration, verifications and tests.

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Rev. 2 –14.09.09 Page 19 of 22

After calibration, verifications and tests, the completed documents shall be transmitted to the OWNER’s REPRESENTATIVE.

4) The CONTRACTOR shall correct at his expense all faults found in his works.

5) Readjustment and/or repair that may be required to instruments, ancillary equipments, mechanical, pneumatic, steam or electrical connections due to damages incurred during test operations and attributable to the CONTRACTOR shall be made by the CONTRACTOR at no extra cost.

Instruments shall be calibrated before (or as soon as possible after) installation.

Calibration shall be carried out as follows.

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Zero and range test (0, 25, 50, 75 and 100 %, upward and downward).

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The calibration method shall be approved by the OWNER’s REPRESENTATIVE.

The CONTRACTOR shall perform the following verifications, using the latest revision of engineering documents.

1) To check, before installation, that instruments are in accordance with the technical specifications (correct tag number, range, size, type, rating, finish etc.).

2) To check all instrument and piping and associated fittings in order to ensure that they are installed in accordance with engineering drawings, are in perfect conditions and are fitted with necessary clamps.

Those checks cover mainly process impulse lines, tracing, insulation and air supply.

To check that all air sets are giving the correct air supply pressure.

3) Check of instrument location and orientation in order to ensure that they are accessible and easily readable.

A check of instrument reading shall also be made during the night and local plant lighting changes suggested to the OWNER’s REPRESENTATIVE, if necessary.

4) Check of all instrument block valves, drain and vent location for accessibility and from safety point of view.

Drain valves shall be located in such a way that they do not contaminate underlaying instruments, machinery or equipment and are not hazardous for personnel.

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Rev. 2 –14.09.09 Page 20 of 22

5) To check that the high and low pressure taps are connected to the correct side of the respective instruments.

6) Check of all cable ladders, trays, trunking, conduits, supports, junction boxes, local instrument panels and protection cabinets. Attention shall be paid to damage, rust, missing gaskets, screws, bolts, keys, locks etc.

7) Check of terminal connections for proper identification and polarity.

To check that spare wires are identified and properly connected to terminals or coiled inside the equipment.

8) To check that instruments, cabinets, boards etc. are properly earthed, wherever necessary.

9) To check that each instrument is suitably protected against adverse environmental conditions.

10) To examine all gaskets and valve stuffing boxes for tightness and replace if necessary.

11) To check connections for cable screening.

12) To check that correct power supply has been connected to instruments, analysers, relay boxes, control cabinets, control boards and other equipment and that suitable electrical protections are provided.

13) To check that cable entries to junction boxes are sealed and properly weather-proofed.

14) To check that temperature instruments are properly inserted inside thermowells.

The CONTRACTOR shall carry out the tests described in the following paragraphs.

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Each instrument process piping, including sampling and transport lines for analysers shall be pressure tested and leak-tested.

The testing fluid shall normally be water.

However OWNER’s REPRESENTATIVE shall specify the test medium which will be used.

The test pressure shall be 1.5 times the design pressure or equal to the maximum allowable pressure of the instrument whichever is the lower. After pressure testing, the instruments and associated process connection lines shall be drained and blown dry except in case where sealing liquid is used.

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Pneumatic transmission lines and air supply lines shall be leak-tested.

Test shall be performed as per ISA RP 7.1. "Pneumatic control circuit pressure test".

During hydrotest, instruments shall be isolated.

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All instrument wiring shall be checked out for insulation, shielding and grounding with megger test (500 volt range).

Page 189 of 261


Rev. 2 –14.09.09 Page 21 of 22

The test shall be made after the wires and cables have been installed but before connection to instruments and to control room termination cabinets or field mounted junction boxes.

Insulation shall not be less than 5 Megohm between wires, wire to shield and wire to ground.

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A control of continuity of pneumatic lines or electrical lines shall be made between field mounted devices and equipment located in control room and auxiliary room.

These tests shall also be used in order to check that each instrument is perfectly working.

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All electronic and pneumatic measurement and control loops shall be fully tested for proper operation.

Special devices such as selection relays, computing relays etc. shall also be adjusted.

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Alarm systems, safeguarding, sequential and control systems shall be fully tested for correct operation.

This includes a careful check of initiating devices and final elements (connections and operation).

All settings for initiating devices, time relays etc. shall be adjusted.

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A complete test shall be performed on electrical supply including automatic switch-over if applicable.

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After inspection and testing, all instrument loops shall be commissioned.

The CONTRACTOR shall make all necessary personnel available for repairs and modifications, which could be necessary during commissioning.

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1) The evaluation of the quantity of work performed, which has to be specified in the provisional work progress reports, shall be calculated by the CONTRACTOR and approved by the OWNER’s REPRESENTATIVE.

2) The works shall be paid as specified in the AGREEMENT.

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The CONTRACTOR shall work in close cooperation with the OWNER’s REPRESENTATIVE and other CONTRACTORS for necessary interfacing.

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Rev. 2 –14.09.09 Page 22 of 22

Every day during the erection period the CONTRACTOR'S representative on the site shall meet the OWNER’s REPRESENTATIVE'S in order to receive instructions and comments and to examine all problems in relation to the works.

The CONTRACTOR shall also attend the weekly meetings and any other meeting if required on urgent basis.

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Page 191 of 261

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GENERAL TECHNICAL

SPECIFICATION

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GENERAL TECHNICAL

SPECIFICATION

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SPECIFICATION

GTS 734 013

Rev. 9 – 14.09.09 Page III of V RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc

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Page 200 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013

Rev. 9 – 14.09.09 Page IV of V RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc

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Page 201 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013

Rev. 9 – 14.09.09 Page V of V RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc

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Page 202 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013

Rev. 9 – 14.09.09 Page 1 of 31 RL1 / 61 / e:\pradeep data\00_general technical specifications\gts revised 2009_gdf suez\inst 2009\soft\70000_734_gts_013__79300_859388934.doc

This specification covers the basic requirements for the design, the selection, the requisitioning and the installation of instrumentation and control systems associated with equipment purchased as a "Package Unit".

,-./.0.1/2

Subject to the requirements of the context, the terms (hereafter listed in alphabetical order) used in this specification are given the following meaning

AGREEMENT Designates the agreement concluded between the CLIENT and the CONTRACTOR, under which the latter undertakes to the former the GOODS and/or SERVICES according to the stipulations which are agreed and specified in the form of an order.

CLIENT Designates the purchaser of the GOODS and/or SERVICES which are the subject of the AGREEMENT.

CONTRACTOR Designates the individual or legal entity with whom the order has been concluded by the CLIENT. The term "CONTRACTOR" may be used indifferently for a supplier, a manufacturer, an erection contractor, etc.

DAYS - WEEKS - MONTHS Specify the number of calendar days, weeks or months and not of working days, weeks or months.

ENGINEER Designates the individual or legal entity to which the CLIENT has entrusted various tasks in relation with the carrying out of his PROJECT.

GOODS and/or SERVICES Designate, depending on the case, all or part of the drawings or documents, substances, materials, materiel, equipment, structures, plant, tools, machinery,... to be studied, designed, manufactured, supplied, erected, built, assembled, adapted, arranged or put into service by the CONTRACTOR under the AGREEMENT, including all the studies, tasks, works and services specified by the order. The Terms GOODS or SERVICES may by indifferently used one for the other as required by the context.


13,204/34532/3,647,89.5,:,/02

The design, construction, materials, testing of instrumentation and control systems shall be in accordance with the codes and standards mentioned in the present specification and in other applicable General

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GTS 734 013


Technical Specifications (GTS) and with the codes, standards and legal requirements listed in the Particular Technical Specifications for the PROJECT.

,;.,</3==51;47

Whenever CLIENT and/or ENGINEER review and/or approval is requested on a document to be submitted by the CONTRACTOR or before an action is implemented by the CONTRACTOR, such review and/or approval shall always be requested in writing by the CONTRACTOR to the CLIENT and/or the ENGINEER before any action subject of this review and/or approval is taken.

CLIENT and/or ENGINEER approval shall always be given in writing.

/2059:,/040.1/,5:./1716>

The terminology shall conform to ANSI/ISA S 51.1 "Process Instrumentation Terminology".

Instrument symbols and identification on P & I Diagrams shall be in accordance with the specification GTS/734/003 "Instrumentation symbols and identification".

,/,547

Instrumentation and control and monitoring systems of Package Units shall be in accordance with this specification and as defined in the P&I Diagrams.

The Package Units shall be supplied complete with all instrumentation, fully piped, wired and tested to ensure safe, reliable and effective operation as well as easy maintenance of the complete Package Units.

Protection and packing of all materials shall be suitable for shipment and protection on jobsite during storage prior to erection.

/2059:,/0,7,?0.1/

Instruments and instrumentation systems of proven reliability shall be used.

Selection of instrumentation shall be made from the approved Instrument Supplier Lists.

Any exception has to be justified and is subject to approval by the ENGINEER.

466./6

All instruments and instrumentation equipment shall be permanently identified by tags, labels and/or nameplates as defined in the drawing 7000/734/XX/7001 "Nameplates, tags and labels for instrumentation".

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4./0./6

Manufacturer's standard colours shall be used for all instrumentation equipment in control and instrument rooms, unless otherwise specified.

Field instruments shall generally be epoxy painted, unless otherwise specified.

54/2:.22.1/>20,:2

1) Transmission of the process variables shall generally be by means of electronic or low level signals.

The output signal for electronic instruments shall be 4 to 20 mA DC or digital.

As far as possible, a true two-wire transmission system shall be used.

2) Local control loops shall be pneumatic.

The standard analog signal for pneumatic instruments shall be 0.2 to 1 barg.

Each pneumatic instrument shall be provided with its own air filter regulator (air set).

3) No process fluid shall be piped into the control rooms or the instrument rooms.

/?71295,24/340,5.472

All instruments shall be suitable to withstand the environmental conditions specified for the plant location.

All parts subject to moisture, fungus growth or insect attack shall be suitably treated (tropicalisation).

Local instrument housings shall be weather-proof (IP 55 minimum or equivalent) and meet the electrical area classification requirements.

All parts of instruments exposed to process fluids shall be resistant to corrosion by the corresponding fluid.

! 7,?051/.?/2059:,/040.1/./"4@4531925,42

In hazardous areas, intrinsically safe instrumentation shall be provided.

If not possible or not practical, other protection concepts (flameproof equipment, increased safety, purging, ...) may also be used where applicable.

All electrical instruments to be installed in hazardous locations shall be certified to CENELEC Standards.

Contacts shall be encapsulated and, if used in intrinsically safe circuits, contacts shall be gold plated.

$ ::9/.0>

All instruments and control systems shall be immune from the effects of any R.F. interference that may occur at the plant location in accordance with IEC 801 "Electromagnetic compatibility for industrial-process measurement and control equipment".

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Equipment to be installed inside the European Community shall be in compliance with the European Community directive requirements, denoted by the "CE mark". This compliance shall extend to each relevant item.

% 7,?05.?47 1<,59==7>

The following electrical power supplies shall be used :

230 V, 50 Hz for control and monitoring system peripherals and for analysers, recorders, indicators, single loop controllers, instruments requiring a separate power supply,...

230 V, 50 Hz or 24 V DC for control cabinets and PLC cabinets,

24 V DC for transmitters, alarm and shut-down contacts, alarm systems, relay systems, switches, safety barriers,...,

24, 48 or 110 V DC for solenoid valves.

& .59==7>

The instrument air quality shall be in accordance with ISA S7.0.01 "Quality Standard for Instrument Air".

The minimum air pressure at any place in the plant shall be 4 barg.

The instrument air receivers shall have sufficient capacity for ensuring the entire instrument load during 15 minutes in case of air compressor failure.

54/2:.00,52

1) In general, transmitters shall be of the negligible displacement electronic type, except where such devices are not available or another type of device of proven superior performance is available for a specific measurement.

Pneumatic transmitters shall be equipped with an air input gauge as part of the supply air filter/regulator set.

2) Transmitter accuracy shall be ± 0.5 % of calibrated range or better. Repeatability shall be ± 0.1 % of calibrated range or better.

For metering stations, accuracy of transmitters shall be ± 0.1 % of calibrated range.

/2059:,/01//,?0.1/2

1) In general, process connections on instruments shall be 1/2" NPT. Adaptors shall not be used.

2) Pneumatic connections shall generally be 1/4" NPT. Larger sizes may be used for special applications, e.g. for high speed actuators.

3) Electrical connections on field instruments shall preferably be 20 mm ISO.

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,4295./6/.02

The metric SI system shall be used for all documents. The following units of measurement as well as their multiples and sub-multiples, shall be used :

71<

gas : Nm3/h (normal : 0°C; 1.01325 bara)

liquid : m3/h (at flowing temperature) l/h for flow lower than 0.1 m3/h

steam, condensate and mass flow : kg/h.

5,2295,

gauge pressure : barg

absolute pressure : bara

vacuum : mbar vacuum

differential pressure : bar

differential pressure for flow measurements : mbar

,;,7

0 - 100 % (Process)

m (Storage Tanks)

,:=,54095,

°C

/47>2,52

direct reading (as pH, % O2, ppm, µS, etc..)

0A,5:,4295,:,/02

Current : A or mA

Voltage : V or mV

Power : kW

Force : N

Mass : kg or t

Page 207 of 261

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Density : kg/m3

Time : d or h or s.

?47,2/3A4502

1) Temperature instruments shall have scales calibrated in °C.

2) Pressure instruments shall have scales calibrated in barg.

3) Absolute pressure and vacuum instruments shall have scales calibrated in bara or mbar vacuum.

4) Flow instruments shall have either 0 - 10 square root (local instruments) or 0 - 100 linear scales (control room instruments).

Scale multipliers shall be based on the measurement units defined in par. 4.13.1.

5) Level instruments shall have scales calibrated 0 - 100 %.

6) Charts for all instruments shall be 0 - 100 linear.

=45,4=4?.0>

Spare capacity is depending on the type of equipment and is defined in Appendix 1.

The documents and drawings to be prepared by the CONTRACTOR are listed hereunder. Further details are given in related PROJECT specification.

1?9:,/02

As a minimum requirement, the following documents shall be provided, when applicable.

/2059:,/02?A,397,

The schedule, in .dbf or compatible files, shall list all the instruments of all the loops using their tag numbers.

The schedule shall show, among others, the type of instruments, the range, the P&I Diagram number, the location and service of the instrument, the specification number, the purchase order number, the referenced installation drawing numbers, the loop drawing number, etc..

/2059:,/034042A,,02

The data sheets shall comprise all necessary technical data associated with the instruments. They shall include, as a minimum, the tag number, process data, range, settings, materials of construction, connection sizes and ratings, manufacturer's name and model number.

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47?9740.1/2A,,02

Calculation sheets for flow primary elements, control valves, safety relief valves, vacuum breakers, rupture disks, shall be provided.

=,?.-.?40.1/2-15:.?51=51?,2215B42,32>20,:2

The following documentation shall be provided by the CONTRACTOR for the Programmable Logic Controllers (PLC) and/or, if applicable, for the Process Control System (PCS) control cabinets.

1) Technical specification of the hardware structure.

2) I/O lists and arrangement in control cabinets.

3) Process specification documents (logic diagrams, sequence descriptions, description of control algorithms and interlocks, definition of mimics, instrument face plates, trending and reports).

4) Programming of PLC's with supply of commented listings of programs. Programming shall be performed in one of the following languages : Instruction List (IL), Structured Text (ST), Ladder Diagram (LD), Function Block Diagram (FBD) or Sequential Function Chart (SFC) (Grafcet). Programs shall be available on floppies.

5) Configuration for the PCS control cabinets (if applicable).

6) Hardware and software final manuals.

.201-4745:4/305.=2,00./62

That list shall show, for the concerned instrument, the tag number, the range, the P&I Diagram number, the setting of alarms and trips in process units and/or percentage.

/0,5-4?,3,2?5.=0.1/

The packaged equipment has to be inserted in the overall plant by the ENGINEER. The CONTRACTOR and the ENGINEER shall settle together the interface requirements :

utility consumption,

electrical compatibility of signals,

space required for local panel and/or equipment control panel,

junction box location on skids,

multicore cables (supplied by others) to the local panel remotely installed,

connection to other systems (type of signal, etc),

cause and effect charts interrelation,

remote control and monitoring requirements,

PCS and/or PLC interfaces (hardware and software).

Page 209 of 261

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GTS 734 013


Interfaces shall be defined by the ENGINEER and approved by the CONTRACTOR.

! ,50.-.?40.1/-.7,2

They shall contain copies of all electrical safety certificates and all documents applicable to the safety of electrical equipment installed in hazardous areas (e.g. intrinsically safe loop specifications).

54<./62

As a minimum requirement, the following drawings shall be prepared, when applicable.

9/?0.1/47711=354<./62

The functional loop drawings shall illustrate the process control philosophy.

16.?3.4654:2

Logic diagrams shall be prepared for all interlock and sequencing systems.

The symbols shall be in accordance with IEC 617-12.

4B7,7.202

The cable lists shall indicate details of the required cables (e.g. cable number, type, length, termination points, ...).

4B7,B71?C3.4654:2

The cable block diagrams shall show schematically an overview of the cable interconnections between panels, cabinets, racks, junction boxes and instruments.

4B7,74>190354<./62

The cable layout drawings shall show the main routing of instrument cables and the location of all instrument junction boxes and local panels.

/2059:,/074>190354<./62

The instrument layout drawings shall show the location of instruments, local panels, racks, control valves, junction boxes.

! .5./63.4654:2

The wiring diagrams shall show all cable termination details for junction boxes, crossboards, control cabinets, power supply cabinets, auxiliary cabinets, control panels, desks, etc..

Page 210 of 261

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$ ,74>3.4654:2

The relay diagrams shall show the connections between components of the relay system in a horizontal ladder format.

% 1<,529==7>3.4654:2

The power supply diagrams shall show, for each instrumentation power distribution board, the allocation and the rating of fuses or circuit breakers.

& 450A./6354<./62

The earthing drawings shall show the requirements of earth cabling up to the earthing systems.

11=3.4654:2

The loop diagrams shall show the connections between components of each loop with identification of terminals and cables.

4/,7?4B./,04/33,2C74>190354<./62

Those layout drawings shall show the front and rear arrangements and all the main sizes of panels, cabinets and desks. They shall include a schedule of instruments.

1/0517511:4/3./2059:,/0511:74>190354<./62

Those layout drawings shall show the location of panels, desks, cabinets, crossboards, racks, inside the control rooms and instrument rooms.

51?,22A11C(9=354<./62

The process hook-up drawings shall show installation details and tracing/insulation requirements for the various instruments, complete with a schedule of required material.

/,9:40.?4.529==7>354<./62

The pneumatic/air supply drawings shall show installation details for pneumatic loops and instrument air supply, complete with a schedule of required material.

/47>2,5A11C(9=354<./62

The analyser hook-up drawings shall show installation details and tracing/insulation requirements, complete with a schedule of required material.

Page 211 of 261

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GTS 734 013


.--,5,/0.47 5,2295,/2059:,/02

5.-.?,=740,2

1) Flow measurement shall normally be made using concentric square edged orifice plates with flange taps. In general, type 316 stainless steel orifice plates shall be provided.

Where the nature of the fluid is such as to require other material, it shall be suitable for the service.

If the fluid contains solids, eccentric or segmental orifice plate shall be used.

Quarter circle or conical entrance orifice plates shall be selected where Reynolds number is low.

2) The calculations, the dimensions and the installation of orifice plates, the "upstream" and "downstream" lengths, the tappings shall meet the requirements of ISO 5167.

The minimum upstream and downstream straight lengths required for installation of orifice plates are the values without parentheses ("zero additional uncertainty" values) given in Table 1 of ISO 5167.

3) Orifice plates in liquid service shall be furnished with vent holes flush with the top of the pipe and those in gas service shall be furnished with drain holes flush with the bottom of the pipe. Orifice plates for LNG service shall have a vent hole and a drain hole.

5.-.?,-74/6,24/3:,0,559/2

1) For line sizes up to and including 12", weld neck orifice flanges having flange taps and a minimum rating of 300 lb RF shall normally be used.

2) For line sizes 14" and larger, weld neck orifice flanges having flange taps and the standard line rating shall be used.

3) For accurate measurements, a holder shall be provided in order to fulfil the requirements of ISO 5167 concerning the concentricity of orifice plates.

4) Orifice plates in carrier rings, with integral corner tappings, shall be used where required by service conditions, and/or piping specifications.

5) Metering orifices shall not be installed in lines less than 2". If the line is less than 2", one of the following devices shall be used :

a) integral orifice type instrument,

b) swaged (2") meter run,

c) certified meter run with corner taps,

d) variable area flowmeter.

6) Metering orifices shall be located in horizontal lines. If not possible, the flow in vertical lines shall always be upward for liquids and downward for gases.

Page 212 of 261

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SPECIFICATION

GTS 734 013


71</1@@7,2,/095.09B,2

1) Flow nozzles or Venturi tubes may be used for measurement of slurries or suspended solids, or when low pressure loss is required in high velocity streams.

2) The requirements of ISO 5167 shall be applied for calculations, dimensions, "upstream" and "downstream" lengths, tappings.

The minimum upstream and downstream straight lengths required for installation of nozzles and Venturis are the values without parentheses ("zero additional uncertainty" values) given in Tables 1 and 2 of ISO 5167.

.01009B,2

Averaging Pitot tubes may be used for non-critical flow metering in large pipes and for applications where a low pressure loss is required.

/0,654715.-.?,0>=,./2059:,/02

For low flow rates in lines less than 2" diameter, integral orifice type instruments may be used.

,0,554/6,

1) The meter differential range shall be selected so that the d/D (Beta) ratio falls between 0.25 and 0.75. For custody transfer flow measurement, the d/D ratio shall be ≤ 0.6.

The standard differential range shall be 250 mbar.

If required, other differential ranges may be used (50 mbar, 125 mbar, 500 mbar).

For compressible fluids, the differential range in mbar, divided by the upstream pressure measured in bar absolute, shall not exceed 36.

2) The meter range shall be selected so that

the normal flow rate falls between 70 % and 80 % of the meter range;

the minimum and maximum flow rates fall between 30 % and 95 % of the meter range.

! .--,5,/0.47=5,2295,:,4295./63,;.?,2

The differential pressure produced by the primary flow element shall be measured by a differential pressure transmitter (differential capacitance type, inductance variation type or similar).

Transmitter process connections shall be 1/2" NPT.

For local measurement , bellows type displacement instrument may be used.

Page 213 of 261

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GTS 734 013


45.4B7,5,471<:,0,52

1) Variable area flowmeters shall generally be used when wide rangeability (10 to 1), linear output or the measurement of very low flow rates is required.

2) Variable area flowmeters shall generally be used in pipes sizes 2" or smaller.

3) Variable area flowmeters are available as indicators, transmitters or a combination of the above, with or without alarms.

4) Variable area flowmeters range shall be selected so that normal flow falls between 50 and 60 % of the maximum scale.

5) Fluids containing solids shall be adequately filtered before entering the instrument interior.

6) Unless otherwise stated, material and rating shall be in accordance with the piping class.

7) Metal tube meters shall be used for process application or in hazardous service.

Glass tube meters shall only be used on low pressure service for small flows of liquid or gas for the measurement of purges to instrument tappings or analyser sample flows.

7,?051:46/,0.?71<:,0,52

Electromagnetic flowmeters are used for flow measurement of liquids having some degree of electrical conductivity.

They are mainly suitable for measurement of slurries, corrosive fluids or dirty fluids.

Vertical mounting is preferred.

95B./,,0,52

Turbine meters are used for accurate measurements and wide rangeability.

They are commonly used in custody transfer of light products or crude oils.

12.0.;,.2=74?,:,/0,0,52

Positive displacement meters are used when high accuracy over a wide flow range is required. They shall be installed in horizontal lines with an adequate upstream strainer.

They are commonly used in custody transfer, especially for heavy or viscous fluids.

150,D71<:,0,52

Vortex flowmeters are used in steam, liquid and gas services where large turn-down is required.

! 0A,571<:,0,52

Depending upon the application, the following flowmeters may be considered :

Page 214 of 261

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SPECIFICATION

GTS 734 013


target flowmeters,

ultrasonic flowmeters,

mass flowmeters (for mass flow and accurate measurement).

$ 71<<.0?A,2

Field mounted flow switches are only used for detection of a flow limit when no other flow measurement exists. Thermal type is preferred.

Variable area flowmeters with contact may be used as flow switches.

% /2047740.1/

Except for differential pressure elements, the different flowmeters here above listed shall be installed according to the manufacturer's recommendations.

! 54/2:.00,52

The pressure and differential pressure transmitters shall be of the capacitance type, piezoresistive type or similar.

If required by service conditions, other types may be used.


! 5,2295,496,2

Pressure gauges (mostly Bourdon tube type) shall have 100 mm dial, stainless steel pressure element and stainless steel case with blow-out disc.

Differential pressure gauges shall be of the bellows or diaphragm type.

Pressure gauge process connection shall be 1/2" NPTM.

Pneumatic receiver gauges may have a 1/4" NPTM connection.

! 5,2295,<.0?A,2

Pressure switches shall be snap acting type with dry SPDT contact. Switch differential shall be adjustable.

Internal setting adjustment shall be provided.

Process connection for pressure switches shall be 1/2" NPT.

Where pressure switches are not suitable, switching will be achieved by a trip amplifier using an analog signal.

Page 215 of 261

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SPECIFICATION

GTS 734 013


! 5,2295,4/6,2

1) Range shall be selected so that normal pressure be in the middle third of the span, if possible.

2) Suppressed ranges may be used to obtain better sensitivity where required.

! ;,5(4/6,/3/3,5(4/6, 510,?0.1/

1) Instruments shall have over-range protection to the maximum pressure to which they may be exposed.

2) Instruments exposed to vacuum shall have under-range protection to full vacuum.

! .2?,774/,192

1) Diaphragm seals shall be used for pressure instruments on slurries, viscous or highly corrosive fluids.

2) For all pressure instruments and gauges on the suction and discharge of reciprocating pumps or compressors, liquid-filled gauges or close coupled pulsation dampeners shall be used.

!! /2047740.1/

Due consideration is to be given to the installation of all pressure and differential pressure measuring devices to eliminate errors due to static head, condensation, gas, etc...

$ .--,5,/0.47 5,2295,,;,754/2:.00,52

Wherever possible differential pressure transmitters (differential capacitance type, inductance variation type or similar) shall be used for level measurements.

The transmitters shall be provided with elevation/suppression kit.


$ .2=74?,5>=,,;,754/2:.00,52

External displacer type level transmitters shall be used for liquid/liquid interface measurement. They may also be used for narrow measuring ranges up to 1524 mm. They shall be fitted with 2" flanges.

Internal displacer type level transmitters shall normally be supplied for open tanks and sump. They shall be fitted with a 4" flange.

$ 0A,5>=,2

Depending on the application, other level instrument types (internal displacement or ball float type, capacitance type, conductivity type, radioactive type, ultrasonic type, ...) may be used.

Page 216 of 261

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GTS 734 013


$ ,;,7<.0?A,2

Displacer or float type level switches are used for alarming or shut-down.

The external displacer or float type shall be fitted with 2" flanges and the internal displacer or float type with 4" flanges.

Vibrating fork type, ultrasonic type, capacitance type or conductivity type level switches may be used for specific applications.

$ ,;,7496,2

1) Magnetic type level gauges are preferred on hydrocarbons and organics and shall be used where application does not allow glass.

2) Gauge glasses shall be reflex type except for interface service and for liquids which may coat the inner surface of the reflex glass.

In the latter cases, transparent gauge glasses shall be used.

The gauge glasses shall be provided with gauge cocks.

3) The visible length of a level gauge must overlap the range of any associated level transmitter or controller.

4) Process connections shall be 1" flanged.

$ 4/C496,2

Storage tank level measurement shall normally be performed by float and tape type instruments (servo-gauges). For some applications, radar systems shall be considered.

For local tank level indication, a float type level indicator may be used.

$! 0.77./6,772

Stilling wells shall be provided inside vessels and tanks for internal displacer instruments and float type instruments.

The design shall include a retaining device to prevent loss of displacer or float.

The wells shall have vertically overlapping slots throughout their length.

% ,/,547

1) Temperature elements shall generally be installed in thermowells and be removable during plant operation.

Page 217 of 261

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GTS 734 013


2) The design of thermowells, temperature transmitters and temperature elements shall be in accordance with the ENGINEER specification.

% A,5:1<,772

1) Screwed thermowells (3/4" NPT) shall generally be used. They shall be drilled and machined from stainless steel bar stock.

They shall be foreseen for all temperature measurements except for thermocouples in concrete and for skin sensors.

Flanged thermowells shall be used when piping or vessel specification requires flanged connections.

2) Thermowell immersion shall be at least half of the nominal ID of the line up to and including 12" line size. In lines above 12", the thermowell immersion shall be 6" minimum.

For temperature measurements in vessels and tanks, the immersion length shall be 10" minimum.

3) Thermowells shall be provided with an extension when used on insulated pipes and vessels.

% ,2.204/?,,:=,54095,,0,?0152)*

Pt100 Resistance Temperature Detectors shall be used for remote temperature measurements.

They shall be specified for temperature from minus 200°C to plus 500°C.

RTD shall be 3-wire type and conform to IEC 751 grade 1.

% A,5:1?19=7,2

Thermocouples shall be used for temperature measurements above 500°C. They shall generally be NiCr-Ni (type K). Depending on the application, other types may be used.

The thermocouples shall conform to IEC 584.

% C./,/2152

Skin sensors shall be used for wall temperature measurement on tanks, vessels and pipes.

% ,:=,54095,54/2:.00,52

Temperature measuring elements (RTD or thermocouples) used in control loops shall be supplied with an industrial head housing including a two-wire transmitter.

%! 1?47,:=,54095,496,2

Temperature gauges shall be used for local indication and shall be bimetallic every angle type or filled system type. They shall be stainless steel and shall have 100 mm dial. They shall be fitted with a 1/2" NPT adjustable union for connection to well.

Page 218 of 261

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SPECIFICATION

GTS 734 013


All capillary tubing shall be stainless steel armored.

%$ ,:=,54095,<.0?A,2

Temperature switches shall only be used for alarming or shut-down when no other temperature measurement exists.

They shall be snap acting type with dry SPDT contact.

Switch differential shall be adjustable.

Internal setting adjustment shall be provided.

& 47;,,7,?0.1/

1) For general service, single seated globe type control valves (with heavy top, top and bottom, or cage guiding), shall normally be used. Double seated globe valves with top and bottom guiding or rotary shaft (eccentric rotary plug) type valves, may be used where required by process operating conditions.

2) Diaphragm, plug, butterfly, ball, or angle valves shall be used where required by line piping specifications.

Typically, butterfly valves shall be used for large volume flows at low shut-off differential pressures, and ball valves for large volume flows at high shut-off differential pressures. Angle valves shall be used to avoid solids accumulation and on erosive and flashing services. Diaphragm valves shall be applied for slurry service.

3) Self acting valves may be used for local control of utilities.

4) Control valve location, type, size and trim shall be carefully selected in order to avoid cavitation.

& 47;,40,5.472

The materials selected for the valve components shall be conform to the process requirements and shall be specified in the data sheets.

Steel valve bodies shall be forged (from 1 1/2" and below) or cast (from 2" and above).

Valves manufactured from rolled plates or from assembly by welding of cast parts are prohibited.

Asbestos and/or asbestos compound are not acceptable for packing. Teflon ring type packing shall be used up to 230°C.

& 47;,.@./6

Sizing of control valves shall be performed by using the flow equations given in ANSI/ISA - S 75.01 or by using the method recommended by the valve Manufacturer. The Cv of the valve shall be calculated on basis of 1.3 times the operating flow or of 1.1 times the maximum flow (the highest value is chosen).

Page 219 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


The calculated Cv value shall be corrected taking into account pipe reductions, cavitation and/or critical velocity.

& 1.2,

The noise level of control valves shall not exceed 80 dBa, as measured 1 meter downstream of the valve within 1 m radially from the pipe outside diameter.

& ?0940152

1) Wherever possible, valves shall be operated by spring return pneumatically operated diaphragm actuators.

2) Spring return piston actuators shall be used to provide longer strokes or greater thrust than is available from spring diaphragm units. They shall normally be sized to operate at an air supply of 4.0 barg.

3) Double-acting piston actuators which do not automatically fail to a safe position in the event of air failure shall be supplied with local air receiver, having sufficient capacity for at least three operations over the full travel of the valve. The use of such actuators shall not jeopardise plant safety.

4) Valve action on control signal or air failure shall be as indicated on P&ID. Shut-down valves shall move to a safe position on actuator power failure or on electrical signal failure.

5) Motor operated valve actuators shall have integral reversing starters and interposing relays.

The actuator shall be fitted with a torque switch, thermostat and space heater.

The actuator shall have position limit switches (open/closed) for stopping the motor at limit of travel.

6) Valve actuators shall be suitable for operating the valve with a differential pressure equivalent to the full upstream pressure.

& ??,2215.,2

& 12.0.1/,52

The control valves shall be fitted with electro-pneumatic positioners.

The positioners shall be provided with :

integrally mounted pressure gauge for air supply and positioner output air pressure,

air/filter regulators integrally mounted and piped by the manufacturer.

& .:.02<.0?A,2

Limit switches shall be of the inductive proximity type.

They shall be external to the actuator, not an integral part of it.

Exceptions have to be approved by the ENGINEER.

Page 220 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


& 17,/1.3;47;,2

Solenoid valves shall be suitable for the specified DC supply.

& 1120,55,74>2

Booster relays shall be fitted where necessary to ensure speed of response of valves and shall be close coupled to the valve actuator.

& 1?C(9=5,74>2

Lock-up relays may be used where process conditions demand and where they cannot give rise to a hazardous situation.

& /,9:40.?09B./6

Stainless steel 1/4" or 3/8" OD tubing shall be used for pneumatic connection between the positioner and the valve actuator.

Fittings shall be stainless steel compression type (two-ferrule type).

&! 1//,?0.1/2

1) Control valves shall have flanged connections. The flange rating and facing shall be in accordance with piping class. The face-to-face dimensions shall comply with ANSI/ISA S 75.03.

2) Except for cryogenic and gas applications, butterfly valves shall be of the wafer type designed to fit between piping flanges. Face-to-face dimensions shall be in accordance with ANSI/ISA S 75.04, where possible.

3) Connections for on-off valves shall be in accordance with piping class.

4) Pressure regulators may be of flanged type or of screwed type. Screwed type is subject to ENGINEER approval.

4-,0>,7.,-47;,2

1) Safety relief valves may be either of the conventional or balanced type. For specific applications, pilot operated relief valves may be considered.

For steam and high temperature service, open spring safety valves may be required.

2) Lifting levers shall be used on safety valves in steam generation service, on safety valves for air receivers and on other safety valves when required by codes or when specified.

Test gags shall not be provided.

3) Orifice area calculation shall be made in accordance with ASME VIII and API RP 520.

Page 221 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


4?99:5,4C,52

1) Vacuum breakers shall be of the diaphragm type pallet seating design.

2) Pallets shall have drip rings to eliminate condensate collecting at seats.

9=095,.2?2

Rupture discs may be used, alone or in conjunction with a safety valve, as protective devices against over-pressure or vacuum.

! !

/47>2,52

1) The analysers shall be furnished, when required, with pre-assembled sampling system and calibration system.

2) Analyser selection shall be made according to the following criteria :

principle of operation for use in the application,

type of output signals for data transmission,

serviceability,

reliability,

ease of installation,

utilities required,

simplicity of design.

4:=7./6/347.B540.1/>20,:2

1) Sampling systems shall comprise all necessary equipment to extract from the process a sample that truly represents the process fluid characteristics, to deliver it to the analyser at the required temperature, pressure and flow rate, to dispose of spent sample and wastes, and to provide a means of calibrating the entire system.

2) Means shall be provided for checking the calibration of the analyser.

3) Analyser sampling and calibration systems shall be in accordance with API 555, "Process Analyzers".

/47>2,5>20,:/2047740.1/

Suitable protection shall be provided for ensuring reliable, accurate and safe operation of the analyser systems.

When the analyser case is not sufficient to provide the required protection, a housing is required.

Page 222 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


The type of housing (cabinet, shelter, house) will depend on the analyser, the environment in which it will operate, the sample line length, the ease of maintenance and the economics.

!

=,540.1/471/0517 A.7121=A>

The main control and monitoring functions will be carried out by a Process Control System (PCS) which will act as the operator interface for the whole plant.

The tasks covered by the PCS will be related to continuous loops, on/off devices control, sequencing control, recipe handling, …, and to operator interface requirements like real time and historical trending, alarming functions, interactive mimics, ...

1/0517/31/.015./6>20,:215A, 4?C46,/.02

1) The monitoring and remote operation of the Package Units shall be carried out from the main control room by means of the PCS in three possible ways.

Type 1 : All safety functions, sequences, control functions are achieved by the PCS and/or the Emergency Shut-Down (ESD) system foreseen by the ENGINEER;

Type 2 : All safety functions, sequences, control functions are achieved by systems provided by the CONTRACTOR.

Supervisory functions and remote controls (start-stop) are achieved by the PCS if required;

Type 3 : Safety functions and sequences are achieved by systems provided by the CONTRACTOR.

Control functions, supervisory functions and remote controls are achieved by the PCS.

The type of control and monitoring system is defined in the Particular Technical Specification for the PROJECT.

The CONTRACTOR shall be responsible for :

the complete engineering and detailed design for the Package Unit instrumentation, control cabinets and local control panel (if required); interface terminal blocks shall be submitted to the approval of the ENGINEER,

the connections to the skid mounted junction boxes and to the Package Unit control cabinets or local control panels if mounted in the vicinity of the equipment,

the detailed design of cables and wiring from instrumentation or skid junction boxes to Package Unit cabinets or Package Unit control panels mounted remotely or in instrument rooms.

2) If applicable, the CONTRACTOR shall supply a programmable controller (PLC) in order to perform the functional sequences, controls, interlocks, safeguardings (non critical shut-downs) associated with the Package Unit.

Page 223 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


The PLC will be interfaced to the PCS by serial link, or in case of a small number of exchanged information by discrete I/O's.

The serial link type and the communication protocol shall be as agreed between the CONTRACTOR, the ENGINEER and the PCS manufacturer.

3) When specifically required, the CONTRACTOR shall provide, as an alternative to PLC, a PCS control cabinet which shall be integrated in the overall plant control system.

4) Local panels shall be provided, if necessary, for the minimum local operation and monitoring of the equipment requested by the CONTRACTOR. Those panels shall contain push buttons, switches, lamps, indicators, annunciator lamp boxes and pneumatic instruments (if any).

1?47745:2/3A90(1</1/3.0.1/2

1) Visible annunciator systems shall generally be of the solid state back-lighted nameplate type. The system shall be provided with common "acknowledge" and "test" push buttons. Twin lamps shall be provided for each window.

The alarm sequence shall be in accordance with ISA S18.1. It shall include a first-out feature of sequence number F3-A-3 when applicable.

2) Contact initiating alarms or shut-down shall be closed in normal operation and shall open in case of fault conditions.

The shut-down actuators (solenoid valves, relays, ...) shall be energised under normal operation and de-energised for shut-down.

3) The shut-down functions shall be carried out by the PLC associated with the Package Unit, but emergency shut-down conditions shall be implemented using safety relay logic and/or safety PLC.

??,22.B.7.0>

1) The installation of instrumentation shall be such as to minimise the effects of fire, solar radiation, vibration, heat from process equipment, condensation, spillage, rain, and maintenance activities, etc.

2) Instruments and their connections shall always be accessible from ground level, floors, platforms, walkways (2 m above or 1 m either side of).

/2059:,/01//,?0.1/2/ .=./6/3,22,72

Instrument connections on piping and vessels shall be as indicated in Appendix 2.

Connections for items such as analysers, and those required in ducts, heater stacks, etc., shall be determined to suit each type of application.

The location of flow and pressure instruments connections on horizontal pipes shall preferably be as indicated in Appendix 3.

Page 224 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


/2059:,/0 51?,22 .=./6

1) The instrument impulse lines shall include facilities for isolation, maintenance, protection, testing and calibration.

2) The primary isolating valves shall meet the piping specification requirements.

The requirements for double block valves shall apply to primary piping or vessel connection only.

3) Vent and drain facilities, as required for maintenance and/or test and calibration, shall be fitted with valves.

4) The instrument impulse lines shall be designed to compensate the expansion or contraction of the process pipes due to temperature variations.

5) Flow and pressure transmitters and pressure switches in gas service shall be mounted above the tapping points.

In liquid and steam service, they shall be mounted under the tapping points.

In cryogenic service, all flow and pressure transmitters and pressure switches shall be mounted above the tapping points and the level transmitters above the top tapping point.

/2059:,/0.59==7>

1) Air supply headers and sub-headers shall be sized as follows :

Number of consumers Nominal pipe size

4 1/2"

10 3/4"

25 1"

80 1 1/2"

150 2"

300 3" 2) Main line take-offs for sub-headers shall be from the top of the line and shall be fitted with isolating.

Drain valves shall be provided at each low point on the sub-headers.

3) Each pneumatic instrument shall have its individual air supply line equipped with an isolating valve and an air filter or an air filter-regulator.

5,?0.1/15C2

The installation, calibration, checking and testing of instrumentation shall be performed by the CONTRACTOR, except otherwise specified.

If the erection works are performed by others, the CONTRACTOR shall provide supervision and remains responsible for the erection works until completion.

Page 225 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


/2047740.1/40,5.47

/2059:,/0=51?,22=.=./6

316 stainless steel tubing, compression fittings, manifolds and valves shall be used for instrument process piping connected to the isolating valves on process lines and equipment, unless process conditions require another material.

/2059:,/04.5=.=./64/309B./6

a) Galvanised carbon steel pipes, fittings and valves shall be used for the main air distribution.

b) For pneumatic signals and individual air supply lines, copper tubing PVC covered and brass compression fittings and valves shall be used.

If required by environmental conditions, 316 stainless steel tubing and fittings will be used.

0A,5./2047740.1/:40,5.47

The other instrumentation installation material (junction boxes, marshalling cabinets, auxiliary cabinets, power distribution cabinets, cable glands, push-buttons and lamps, protective housings, supports, cable trays and ladders, cable conduits, etc…) shall comply with the ENGINEER specifications.

!

The supports for instruments and junction boxes shall be in accordance with the standard drawing 70000/734/XX/7002 "Standard supports for instrumentation".

$ /2059:,/0 510,?0.1/

Weather protection and, when applicable, mechanical protection shall be provided.

The method of protection shall be carefully selected in function of the fluid properties, toxicity and hazard.

Fragile instruments shall be supported independently of equipment which may generate nuisances (e.g. possible damage by mechanical vibrations).

,/,547

1) All field mounted electrical and electronic instruments shall be connected by means of individual cables to field mounted junction boxes.

2) The field mounted junction boxes shall be provided for the connection of multicore cables and of individual cables to local instruments.

Different types of signals shall be segregated into separate junction boxes :

Page 226 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


analogue signals,

RTD signals,

thermocouple signals,

frequency signals,

logic signals,

solenoid valves,

power supply.

A further segregation shall be made between intrinsically safe and non-intrinsically safe signals.

3) Multicore cables shall be used between each field mounted instrument junction box or panel and the marshalling terminations in the instrument rooms or in the control rooms.

4) All field cable runs shall be designed to prevent ingress of moisture. Side or bottom entries to instruments or junction boxes should be used to ensure this. Cables shall have drip loops.

5) Spare capacity to be provided in multicore cables is defined in Appendix 1. This spare capacity is applicable to the as built situation.

6) The cables shall be installed above ground on cable trays and/or ladders made of heavy duty galvanised steel. Cable runs shall be designed to avoid all possible fire hazards. Where this is not practical, cable runs shall be fireproofed using metal trunking, mineral wool and galvanised cladding.

7) The numbering system for cables, junction boxes, crossboards, panels, cabinets, consoles, shall be specified by the ENGINEER.

8) All cables and wires shall be numbered. All cables shall be marked at each end. Each wire shall be labelled (terminal strip reference).

9) Where field cables are run in areas with little available means of support (e.g. structural steelwork), cables shall be laid in trenches.

10) All cables shall pass through a compression type cable gland before being terminated.

Glands shall meet the requirements of the area in which they are installed and certification shall be required where applicable.

4B7,2

The instrumentation cables shall be selected in function of the application on basis of the ENGINEER specification.

,5:./40.1/2

1) Screw clamp type terminals shall be used. Conductor ends shall be fitted with crimped end-sleeves.

Only one wire shall be connected to each terminal side.

Page 227 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


Terminal straps shall be used for bridges between terminals.

2) Sufficient slack cable shall be left neatly coiled or looped at terminals to allow for the re-making of terminations, additions and testing.

3) Attention shall be given to the location of terminal rails in junction boxes, etc.., in order to provide sufficient space to install field cables without bunching or congestion. All cable and terminal numbers shall be clearly visible.

4) All spare wires of instrument cables shall be terminated to terminals in junction boxes, local panels, cabinets, control room panels, etc..

,65,640.1/-4B7,2

Instrumentation cables (4-20 mA, mV signals, etc.) shall be adequately separated from power wiring and electrical equipment to minimize interferences. The physical distance between instrumentation cables and power cables in parallel routing shall be as follows :

Voltage (V) Min. distance (mm)

110 400

230 400

400 600

690 600

6000 1200 If required, the instrumentation cables shall cross the power cables at right angle and with a minimum distance of 300 mm.

450A./6

Earthing of instruments, panels, consoles, shall be carried out in accordance with the applicable code requirements.

?5,,/./6

Screens on instrument cables carrying 4-20 mA and on-off signals (low level, low impedance signals) shall be interconnected and earthed at one point (preferably in the instrument room).

Exception shall be done for cables carrying digital (serial) signals, high frequencies, etc. In those case, the screens shall be earthed at both ends to prevent against electromagnetic interferences caused by HF radiations.

! +9/?0.1/1D,2

Junction boxes shall be of approved design with components to meet the requirements of the area classification.

Page 228 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


In this specification reference is made to the following documents.

"

734/003 Instrumentation symbols and identification.

70000/734/XX/7001 Nameplates, tags and labels for instrumentation.

70000/734/XX/7002 Standard supports for instrumentation.

"

IEC 584 : Thermocouples

IEC 617-12 : Graphical symbols for diagrams - Binary logic diagrams.

IEC 751 : Industrial platinum resistance thermometers sensors.

IEC 801 : Electromagnetic compatibility for industrial - process measurement and control equipment.

)*

ISO 5167 : Measurement of fluid flow by means of pressure differential devices

Part 1 : Orifice plates, nozzles and Venturi tubes inserted in circular cross section conduits running full

Part 2 : Diaphragms or nozzles installed at the inlet of a conduit.

API RP 520 : Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries.

API 555 : Process Analyzers.

ANSI/ISA S7.0.01 : Quality standard for instrument air.

ANSI/ISA S18.1 : Annunciator sequences and specifications.

ANSI/ISA S51.1 : Process Instrumentation terminology.

ANSI/ISA S75.01 : Flow equations for sizing control valves.

Page 229 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


ANSI/ISA S75.03 : Face-to-face dimensions for flanged globe style control valve bodies (ANSI classes 125, 150, 250, 300 and 600).

ANSI/ISA S75.04 : Face-to-face dimensions for flangeless control valve bodies (ANSI classes 150, 300 and 600).

!

ASME section VIII : Boiler and pressure vessel code - Pressure vessels.

S S S

Page 230 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


APPENDIX 1 TO THE SPECIFICATION GTS/734/013 - SPARE CAPACITY

Spare capacity is depending on the type of equipment and is defined in the following table.

ITEM DESCRIPTION SPARE

1 PLC and PCS I/O cabinets

installed spare components 5 %

spare space for future extensions

(with prewired connections)

10 %

2 Multicore cables

spare cores (all cores have to be connected to the terminals of junction boxes, marshalling racks or any other terminal strip)

20 %

3 Cable ladders and trays

spare room for additional cables

30 %

4 Alarm systems

installed spare electronic cards 5 %

spare slots for additional electronic cards with prewired connections

20 %

non-engraved spare annunciator windows with prewired connections

20 %

5 Marshalling racks

spare poles for additional cables 20 %

spare room for additional crossboard terminals or modules

10 %

6 Power distribution cabinets

spare miniature circuit breakers connected to the power supply

10 %

spare room for additional miniature circuit breakers

10 %

Page 231 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


APPENDIX 2 TO THE SPECIFICATION GTS/734/013 - INSTRUMENT CONNECTIONS

Type of instrumentation Connections Notes

Piping Vessel or equipment

Temperature 3/4" threaded 3/4" threaded

2" flanged 2 flanged (1) (2)

Pressure 1/2" threaded 1/2" threaded

3/4" flanged 3/4" flanged (1) (2)

2" flanged 2" flanged (2) (3)

F

L

Orifice flanges, Venturis, nozzles, 1/2" threaded (NPT) -

O

W

Averaging Pitot tubes as per manufacturer recommendation -

Differential pressure 1/2" threaded

type transmitter 3/4" flanged (2) (4)

L Diagram type transmitter 3" or 4" flanged (2) (5)

E External displacer type 2" flanged (2)

Internal displacer type 4" flanged (2)

V Level switch external float 2" flanged (2)

E

Level switch internal float 4" flanged (2)

L Level switch, ultrasonic, capacitance, conductivity, …

2" flanged (2)

Level gauge 1" flanged (2)

2" flanged (2) (4)

Notes

(1) For plastic or lined vessels and piping,

(2) Rating and facing as per piping or vessel specification,

(3) For instruments with diaphragm seal,

(4) For plastic or lined vessels,

(5) 3" for flush diaphragm type and 4" for extended diaphragm type.

Page 232 of 261

GENERAL TECHNICAL

SPECIFICATION

GTS 734 013


APPENDIX 3 TO THE SPECIFICATION GTS/734/013 - LOCATION OF FLOW AND PRESSURE

INSTRUMENT CONNECTIONS

ON HORIZONTAL PIPES

Fluid Location of instrument connections Notes

Gas Vertically upward (2)

Steam Horizontally

Liquid From horizontal centre line down to 45° below horizontal centre line

(1) (2)

Notes

(1) For slurry and corrosion service, connections must be on top of piping.

(2) For cryogenic gas and liquid, see Piping Standard Assemblies.

S S S

Page 233 of 261

QAP NoDatePrepared by MAApproved byProjectClientConsultant

M Contractor'sTPI

General Finish Job Card

Verification of- Modal No.- Serial No.- Calibration Range- Material of construction- Customer Tag P R/W- Certification Lable- Process connection- Asscessories

- Calibration Critical Electrical Calibration Procedure& Job Card

CalibrationProcedure & Job

Card- Calibration / Accuracy / Range

- Load Variation Test

- Power Supply Variation Test

- Reverse Plolarity Test

- Accessories Major Visual As per Model As per Model - Communication with HARTCommunicator

- Verfication of Model & Tag No.

- Over range Pressure Test Critical Visual 100% Product Data Sheet Product DataSheet

M P PerformC W/R Witness

TPI W/R Witness of Test / Review of Certificates & Documents as per QAP

Witness Test / Inspection

Procedure & JobCard

Procedure & JobCard Comliance Report

2

Critical Electrical

Critical

ARSJHPLGAIL

W

P W

Calibration Procedure& Job Card

100%

Remarks

100%Electrical

Visual

Type of Check

PTest & CalibrationReport

Acceptancenorm

Inspection ByFormat OfRecords

Third Party Inspection Agency

ManufacturerConsultant /Owner

P.013312-D-11013-201 Rev.017.07.19

TE-IN

Checked : SHD

INTERNAL TEST / INSPECTION1

Job Card & ProductData SheetMajor

CalibrationProcedure & Job

Card

Legend

100%

QUALITY ASSURANCE PLANPRESSURE & TEMPERATURE TRANSMITTER

Sr.No Description Characteristic Class Quantam of

CheckReferenceDocument

Page 1 of 1

Page 234 of 261

QAP NoDatePrepared by MA Checked by :Approved byProjectClientConsultant

Sr. No. Component Operation Charactristics Checked Category Type/Method ofCheck Referrence Document Acceptance Norm Format of Plan Remarks

P W M TPIA C

Raw Material a) Dimensions MA Mechanical 100% 100% PO approved PO approved TC P R W/R

b) Chemical Analysis MA Chemical Sample _ Spec/Drg. Spec/Drg. TC P R W/R

c) Marking, Tagging MA Visual 100% 100% Approved Spec/PO Approved Spec/PO TC P W W/R

2 Routine test Accuracy HystresisRepeatability CR Measurement 5

Points 100% 100% EN 837-1 EN 837-1 Calibration Report P W W/R

Over range protection CR Visual 100% 100% EN 837-1 EN 837-1 Test Report P W W/RAccessories (If applicable) 1) Chemical Analysis MA Chemical Sample TCGuage Saver in SS 316 2) Dimensions MA Measurement 100% 100% Work Certificate

3) Leak Tightness CR Hydrotest 100% 100% Test Certificate

3 IRN P R

Note: 1) Material and Type shall be as per tender specification / datasheet.

Category: CR - Characteristics affecting safety of equipment and personnelMA - Characteristics affecting safety of PerformanceMT - Charactristics affecting safety of Appearance

M-ManufacturerTPIA-Third Party Inspection AgencyC-Client/ Counsaltanr

P-Perform

W-Witness

R-Review

Extent of Check Agency

QUALITY ASSURANCE PLANFOR PRESSURE GAUGE

P.013312-D-11013-202 Rev.021.06.19

ARSJHPLGAILTE-IN

SHD

Approved/POspecs/Datasheet/Drawing

Approved/POspecs/Datasheet/Drawin

g

1

W W/RP

Page 1 of 1

Page 235 of 261

QAP NoDatePrepared by MA Checked : SHDApproved byProjectClientConsultant

Sr. No. ComponentOperation Characteristics Checked Category Type/ Method of check Extent of check Reference document Acceptance norm Format of plan Remarks

M Contractor'sTPIA

a) Accuracy Test MA Testing 100% IEC751/DIN43760 IEC751/DIN43760 LOGBOOK/Computerized

P W

b) IR at AMB & at 500VDC * * 100% STD TO STD LOGBOOK/Computerized

P W

c) Hot IR at 320 Deg c & 500VDC

* * 100% STD TO STD LOGBOOK/Computerized

P W

d) N2 Test * * 100% STD TO STD LOGBOOK/Computerized

P W

e) Response Time test * * 10% STD TO STD Test Reports P W

f) Dimensions/Connection * Measurement 100% Applicable Specification/Drawing

to ApplicableSpecification/Drawings

Design P W

g)Weather proofness test MA/CR Testing Sample of design IP 65 IS 13947 IP 65 IS 13947 Testing certificates P WThermowell

1 Raw materials ofthermowell

Chemical Composition MA analysis _Applicable Specification To applicable specifications

Test Reports P R

a) dimension MA measuring 100% Applicable Specification to Applicable Log book test report P Wb) hydro test MA testing 100% Applicable Specification No leakage Log book test report P Wc) bore concentricity test MA/CR go- no gauge 100% Applicable Specification/ within 10% of walll Log book P Wd)visual MA/MT observation 100% Co. Std. To Co. Std. Log Book P We)workmanship/finish MA/MT observation 100% Co. Std. To Co. Std. Log Book P Wf) Spec/ tagging MA visual 100% Applicable Specification/

Drawing to Applicable

Specification/DrawingsLog book P W

g) threading MA thread gauge 100% STD TO STD Log book P Wh) surface finish MT visual 100% STD TO STD Log book P W

3 IRN P

Note:1) Material and Type shall be as per tender specification / datasheet.Note:M-Manufacturer P-PerformTPIA-Third Party Inspection Agency R-ReviewC-Client/ Counsaltanr W-Witness

Agency

RTD Assemblies

The results loggedin the log book

would be issued inthe form of test

certificates as perDIN

2 thermowell

No leakage at 40kg/cm2

1 RTD assemblies

QUALITY ASSURANCE PLANFOR RTD AND THERMOWELL

P.013312-D-11013-203 Rev.017.07.19

ARSJHPLGAILTE-IN

Page 1 of 1

Page 236 of 261


S.No Activity Description Description of Test TestFrequency

Ref. std &Cl.no.

Procedure No. AcceptanceCriteria

Document /Report

Manufacturer TPI agency Remark

A1 Core ( Mode Field) Diameter

a) @1310 nmb) @ 1550 nm

Geometry Test 100% ITU-T-G652 Vendor tospecify

As per PTS Vendor to specify P W

2 Cut of Wavelength on 2 metersample of fiber (In Cable)

Spectral Test 100% ITU-T-G652 Vendor tospecify


3 Attenuation Co-efficient@ 1310@1550@1625

Attenuation Co-efficient Test

100% ITU-T-G652 Vendor tospecify


4 Chromatic Dispersiona) 1285 - 1330 nmb) 1270 - 1340 nmc) 1550 nmd) 1625 nme) Zero Dispersion wavelengthf) Zero Dispersion Slope

ChromaticDispersion



5 Geometrical Parametersa) Primary Coating Diameterb) Cladding Diameterc) Clad non Circularityb) Mode Field Concentricity error

Geometrical Tests 100% ITU-T-G652 Vendor tospecify


6 Fibre PMD Maximum Individualfibre

PMD Test 100% ITU-T-G652 Vendor tospecify


7 Fibre Proof Test Fibre Proof Test 100% ITU-T-G652 Vendor tospecify


FOR FIBRES CABLE

SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19

ARChecked :SHDQUALITY ASSURANCE PLAN

(24 F) ARMOURED OPTICAL FIBER CABLE

1 of 6Page 237 of 261



Ref. std &Cl.no.


Document /Report


SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19



8 Fibre Curl Fibre Curl Test 100% ITU-T-G652 Vendor tospecify


9 Attenuation Vs Wavelength@1285 - 1330 nm@ 1525 - 1575 nm

SpectralAttenuation Test



10 Attenuation with bendinga) 100 turns on a mandrel of 60mmdiameterb) 1 turn on mandrel of 32mmdiameter

Attenuation test 100% ITU-T-G652 Vendor tospecify


B

1 Visual Inspectiona) Cable lay up and fibreidentificationb) Identification and lengthmarking on outer jacketc) Colour contrast of the markingwith the outer sheath of the Cablesd) Overall diameter of the cablee) Length

Visual Tests &Dimentional test

5% GR 409 -CORE

Vendor tospecify


2 Tests for Moisture barriera) Thickness of layersb) Extent of overlappingc) Electrical Continuity of metalliclayerd) Water swellable tape on powere) Water immersion

Moisture barriertests

a) 5%

b) 5%

c) 100%d) 100%e) 5%

GR-20-CORE

IEC - 60793 -1 - 53

Vendor tospecify


FOR FINISHED CABLES (armoured)

2 of 6Page 238 of 261



Ref. std &Cl.no.


Document /Report


SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19



3 Tensile Performance(Tensile load of 9.81 W Newton or2700 N whichever is higher ,Where W = weight of 1Km Cablein Kg)

Tensile Test 5% IEC - 794 - 1 -E1

Vendor tospecify


4 Crush(200Kg of load to be slowly placedand held for 60 sec)

Crush Test 5% IEC - 794 - 1 -E3

Vendor tospecify


5 Impact(Mass of 5 Kg to fall freely from500mm height on the cable sample10 times repeatedly with a gapbetween 1 impact to anotherapprox. at 60 sec)

Impact Test 5% IEC - 794 - 1 -E4

Vendor tospecify


6 Torsion(Weight of 7.5Kg attached to thestationary chuck and shall besubjected to 10 cycles)

Torsion Test 5% IEC - 794 - 1 -E7

Vendor tospecify


7 Bend(To be performed preferably withprocedure 1(of IEC) with a mandreldiameter of 20 D , where D is thediameter of the cable and testingshall be done with 4 turns of cablewrapped and then unwrapped for10 complete cycles)

Bend Test 5% IEC - 794 - 1 -E11

Vendor tospecify


8 Snatch(With a load of 10 N)

Snatch Test 5% IEC - 794 - 1 -E9

Vendor tospecify


3 of 6Page 239 of 261



Ref. std &Cl.no.


Document /Report


SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19



9 Kink(Radius: 10 x Cable Diameter)

Kink Test 5% IEC - 794 - 1 -E10

Vendor tospecify


10 Temperature Cycling Tested on 200mCable length withtemperature cycle asfollows:-a) At room temperature: 1 hrb) At 0°C: 12 hrsc) At 65°C: 12 hrsd) From 65°C to room: 1 hr temperature

5% IEC - 794 - 1 -F 1

Vendor tospecify


11 Water Penetration Water PenetrationTest

10% IEC - 794 - 1 -F 5

Vendor tospecify


12 Water Immersion Water Immersiontest

5% IEC - 60793 -53

Vendor tospecify


14 Sheath Integraty (Spark test) As Per PTS OneClosure

GR.No. G/OJC -01 / 01 AUG

Vendor tospecify


4 of 6Page 240 of 261



Ref. std &Cl.no.


Document /Report


SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19



15 1. Polarization Mode Dispersion2. Abrasion Test3. Flexural Rigidity Test on theoptical fibre cable4. Test of Figure of 8 (Eight) on thecable5. Cable Aging Test6. Check of easy removal of sheath7. Effect of aggressive media on thecable surface (Acidic and Alkalinebehavior)8. Check of the Quality of theLoose Tube (Containing OpticalFibre)9. Drainage Test for Loose Tubeand Drip Test on the Cable

As Per PTS 5% GR.No. G/OJC -01 / 01 AUG92

Vendor tospecify


C

1 Water Ingress Test As Per PTS OneClosure


Vendor tospecify


2 Impact Test As Per PTS OneClosure


Vendor tospecify


3 Drop and Topple test As Per PTS OneClosure


Vendor tospecify


4 Pulling Test As Per PTS OneClosure


Vendor tospecify


5 Static Load Test As Per PTS OneClosure

GR.No. G/OJC -01 / 01 AUG92

Vendor tospecify


LEGEND :

FOR JOINT CLOSURES

5 of 6Page 241 of 261



Ref. std &Cl.no.


Document /Report


SJHPLGAILTE-IN

P.013312-D-11013 204 Rev.017.06.19



R : ReviewW : WitnessP : PerformWR : Vendor WitnessTPIA : Third Party InspectionAgency

Notes :1) The above mentioned testing and acceptance criteria are minimum requirements for Optical Fiber Cable complying ITU-T 652specifications, however , supplier shall ensure that the product also comply to the additional requirements as per technical specifications anddata sheets.2) The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative andTPIA. Any item deemed to have been left out may also be included in the QAP of the vendor.3) TPIA shall have right to inspect minimum 10% of all manufacturing activities on each day or as apecified above.4) TPIA along with Owner / Owner's representative shall review / approve all the documents related to QAP / Quality manuals Drawings etc.submitted by supplier.5) TPIA shall also review the test certificates submitted by the manufacturer.6) Supplier shall in coordination with sub vendor shall issue detailed production and inspection schedule indicating the dates and the locationsto facilitate Owner / Owner's representative to organise Inspection.7) Supplier shall submit their own Detailed QAP Duly Signed and Stamped.

6 of 6Page 242 of 261

QAP NoDatePrepared by MAApproved byProjectClient

Consultant

S.No Activity Description Description of Test Test Frequency Ref. std & Cl.no. Procedure No. Acceptance Criteria Document / Report Manufacturer TPIagency Control Authority

1 Dimension Dimensional outsidediameter wall thickness

As Per Table 1 of GR /CDS - 08 / 02 NOV2004

GR / CDS - 08 / 02NOV 2004

Vendor to Specify As Per PTS andGR / CDS - 08 / 02 NOV2004

Vendor to Specify P W W / R

2 Ovality Dimensional outsideDiameter


GR / CDS - 08 / 02NOV 2004



3 Tensile Strength Tensile ElongationProperty


GR / CDS - 08 / 02NOV 2004



4 Reversion Test Shrinkage As Per Table 2 of GR /CDS - 08 / 02 NOV2004

GR / CDS - 08 / 02NOV 2004



5 Environmental Stress CrackResistance

Chemical Property ofProduct


GR / CDS - 08 / 02NOV 2004 & ASTM D- 1693



6 Impact Strength Impact Strength Test As Per Table 2 of GR /CDS - 08 / 02 NOV2004

GR / CDS - 08 / 02NOV 2004



7 Crush Resistance Test Deflection of Duct As Per Table 2 of GR /CDS - 08 / 02 NOV2004

GR / CDS - 08 / 02NOV 2004



8 Mandrel Test Internal Dia of Duct As Per Table 2 of GR /CDS - 08 / 02 NOV2004

GR / CDS - 08 / 02NOV 2004



9 Oxidation Induction Test Oxidation of HDPEmaterial


GR / CDS - 08 / 02NOV 2004



10 Hydraulic Characteritic Test Leakage , Swelling ,Weeping and Brust andCrack in test duration


GR / CDS - 08 / 02NOV 2004



11 Internal Co- efficient of friction Co-efficient of frictionHDPE material


GR / CDS - 08 / 02NOV 2004



12 Ash Content Ash content of finishedproducts

As Per PTS andGR / CDS - 08 / 02NOV 2004

GR / CDS - 08 / 02NOV 2004



SJHPLGAIL

TE-IN

QUALITY ASSURANCE PLANPLB - HDPE DUCT

P.013312-D-11013-205 Rev.0

Checked :SHD17.07.19

AR

1 of 2Page 243 of 261

QAP NoDatePrepared by MAApproved byProjectClient

Consultant

S.No Activity Description Description of Test Test Frequency Ref. std & Cl.no. Procedure No. Acceptance Criteria Document / Report Manufacturer TPIagency Control Authority

SJHPLGAIL

TE-IN

QUALITY ASSURANCE PLANPLB - HDPE DUCT

P.013312-D-11013-205 Rev.0

Checked :SHD17.07.19

AR

13 Maximum Pulling Strength Pulling force on coupler As Per PTS andGR / CDS - 08 / 02NOV 2004

GR / CDS - 08 / 02NOV 2004



14 UV Stabiliser of content of Resin Identification of UVadditive


GR / CDS - 08 / 02NOV 2004



15 UV Stabiliser of content of Duct As Per PTS As Per PTS andGR / CDS - 08 / 02NOV 2004

GR / CDS - 08 / 02NOV 2004



16 Fading of colour of Duct GR / ASTM D - 1712 As Per PTS andGR / CDS - 08 / 02NOV 2004

GR / CDS - 08 / 02NOV 2004



17 Bending Radius As Per PTS andGR / CDS - 08 / 02 NOV2004


GR / CDS - 08 / 02NOV 2004



18 Thickness of inner lubricant As Per PTS andGR / CDS - 08 / 02 NOV2004


GR / CDS - 08 / 02NOV 2004



19 Density of finished product As Per PTS As Per IS 7328 As Per IS 7328 Vendor to Specify As Per PTS Vendor to Specify P W W / R

20 Melt flow rate of finished duct As Per PTS As Per IS 2530 As Per IS 2530 Vendor to Specify As Per PTS Vendor to Specify P W W / R

21 Change in MFR As Per PTS AS Per GR / CDS - 08 /02 NOV 2004

GR / CDS - 08 / 02NOV 2004

Vendor to Specify As Per PTS Vendor to Specify P W W / R

LEGEND :R : ReviewW : WitnessP : PerformTPIA : Third Party InspectionAgency

Notes :1) The above mentioned testing and acceptance criteria are minimum requirements , however , supplier shall ensure that the product also comply to the additional requirements as pertechnical specifications and data sheets.2) The supplier shall submit their own detailed QAP prepared on the basis of the above for approval of Owner / Owner's representative and TPIA.3) TPIA shall have right to inspect minimum 10% of all manufacturing activities on each day or as apecified above.4) TPIA along with Owner / Owner's representative shall review / approve all the documents related to QAP / Quality manuals Drawings etc. submitted by supplier.5) TPIA shall also review the test certificates submitted by the manufacturer.6) Supplier shall in coordination with sub vendor shall issue detailed production and inspection schedule indicating the dates and the locations to facilitate Owner / Owner's representative toorganise Inspection.7) Supplier shall submit their own Detailed QAP Duly Signed and Stamped.

2 of 2Page 244 of 261

QAP NoDatePrepared by MA Checked by : SHDApproved byProjectClientConsultant

SL. No. Component/Operation Charachteristics Type of Check Quantum of

Check Reference Doc Acceptance Norms

1 Raw MaterialInspection

Manifacturer/Vendor

Contractor'sTPIA Remark

1. Surface Finish Visual2. Diameter/Dimension Physical3. Resistance Electrical4. Chemical property (Persulphatetest for tinned copper ) Chemical

5. Annealing Test Physical1. Tensile & Elongation before &after ageing Visual

2. Type of compound Visual3. Thermal Stability Physical1. Oxygen Index Enviro Min. 30%2. Temperature Index Enviro Min 250deg C1. Surface Condition Visual2. Uniformity of Zinc Coating Chemical3. Tensile strength & elongation Physical4. Torsion/ Winding Physical

2 Process Inspection1. Type of Material Visual2. Thickness of Insulation (Avg.Min.) Physical

3. Core Identification Visual4. Surface Finish Visual5. Spark test Electrical6. Volume Resistivity Electrical1. Sequence of laying Visual2. Continuity of conductor Electrical3. Continuity of common pair Electrical4. Dimension Physical5. Lay Length Physical1. Tape thickness Physical2. Tape overlap Visual3. Drain wire size Physical

Setting &During Process

BS 5308(P-2) & RelevantStandard as perSpecification


P R

P R

Pair/Triad- laying

Insulated core2.1

Pair/Triad screeing &Overall screeing

2.2

2.3

Armour-Galvanisedsteel round wire/strip1.3

P R

P R

Copper / Aluminiumwire (As Applicable)

Insulation & Sheathingcompound1.2

FR Test for FR PVConly

1.1

One sample perbatch

IS 3975/ BS 5308(P-2)Relevant Standard as per

Specification


Specification

P R

R

QUALITY ASSURANCE PLANFOR

INSTRUMENT CABLES

P.013312-D-11013-206 Rev.017.07.19

ARSJHPLGAILTE-IN

Each setting &during run of

M/c

Inspection Agency

100% SampleIS 8130/ BS 5308(P-2) &Relevant Standard as per

Specification


Specification

One sample perbatch


Specification


Specification

ASTM-D2863

P

1 of 4Page 245 of 261





INSTRUMENT CABLES

P.013312-D-11013-206 Rev.017.07.19

ARSJHPLGAILTE-IN

Inspection Agency

1. Type of PVC Visual2. Dimension Physical3. Thickness of Inner Sheath Physical4. Surface finish & Colour Visual5. Embossing/ Printing/SequentialMarkingon outer sheath Visual

1. No. of strips/wires Visual2. Dimension of strips/wires Physical3. Direction of lay Visual1. Make up VisualNo. of strands counting2. Size/Dimensions Physical3. DC Resistance at 20deg C ElectricalAnnealing (Before stranding) forcopper Physical

1. Conductor Resistance Electrical 100% DrumsIS 8130/ BS 5308(P-2) &Relevant Standard as perSpecification

IS 8130/ BS 5308(P-2) &Relevant Standard as perSpecification

P W

2. Mutual Capacitance Electrical 10% Drums

3. Capacitance between core & screen Electrical 10% Drums

4. L/R Ratio Electrical 10% Drums5. HV Testa) Core to coreb) Core to shield/Armour

Electrical 100% Drums

6. Spark Testa. Coreb. Sheath

BS 5308(P-2) / BS 5099& Relevant Standard asper Specification

Relevant Standard as perSpecification P W

7. Test for rodent & termite repulsion P W

1. HV Testa) Core to coreb) Core to shield/Armour

Electrical 10% Sample BS 5308(P-2) & RelevantStandard as perSpecification


2. Conductor Resistance Electrical 10% SampleIS 8130/ BS 5308(P-2) &Relevant Standard as perSpecification


WP

P R

P R

P R

100% spools atstart & end

Routine Test3

2.6 Conductor

Inner sheath and outersheath2.4

Armouring2.5




IS 8130/ BS 5308(P-2)Relevant Standard as perSpecification

Each setting &at the running

of M/c

Starting of M/c& duringprocess

2 of 4Page 246 of 261





INSTRUMENT CABLES

P.013312-D-11013-206 Rev.017.07.19

ARSJHPLGAILTE-IN

Inspection Agency

3. Continuity test Electrical 10% Sample4. Insulation Resistance (Before &After HV)a. Individual Conductorb. Individual Screens

Electrical One sample perlot

5. Tensile Strength & Elongation forInsulation & sheath before ageing Physical 10% Sample

6. Dimension Visual 10% Sample7. Cable Capacitance between core &screen & L/R ratio test Electrical 10% Sample

8. Spark Testa. Coreb. Sheath

BS 5308(P-2) / BS 5099& Relevant Standard as

per Specification

Relevant Standard as perSpecification

9. Test for rodent & termiderepulsion. Chemical One sample per

lot " "

10. Uniformity of zinc coating onarmour Chemical " " "

11. Oxygen Index test as perASTMD:2863 Chemical " " "

12. Temperature Index test as perASTMD:2864 Chemical " " "

13. FR test as per IS:10810 Thermal " " "14. Overall finish & drum length Visual " " "1. Oxygen Index Enviro Min. 30%

2. Temperature Index Enviro Min 250deg C

3. Flammability test Fire IEC 332-1 Shall Pass

4. Smoke Density As Applicable ASTM 2843

5. Acid Gas Generation As Applicable IEC-754-1

6. Swedish Chimmney Test As Applicable As per Relevant Staandard

P W

P W



One sample perlot

ASTM-D2863

Acceptance Test4

Flammability Test forFRLS PVC only5

3 of 4Page 247 of 261





INSTRUMENT CABLES

P.013312-D-11013-206 Rev.017.07.19

ARSJHPLGAILTE-IN

Inspection Agency

6 Type Test

1. Conductor Resistance ElectricalIS 8130/ BS 5308(P-2) &Relevant Standard as perSpecification


P R

2. Annealing Test on Cu PhysicalBS 6360 & RelevantStandard as perSpecification

BS 6360 & RelevantStandard as perSpecification

P R

1. Tensile strength Physical2. % Elongation Physical3. Torsion/Winding Physical4. Wt. of zinc coating Chemical5. Dimensions Physical6. Uniformity of coating Chemical

6.3 Thickness of Insulation& Sheath Thickness of Insulation & Sheath Physical One sample per

lot



P R

1. Elongation & T. S. Before & AfterAgeing Physical

2. Ageing in Air oven Physical3. Shrinkage test Physical4. Hot Deformation Physical5. Heat Shock Physical6. Thermal stability Physical7. Flammability Test Physical8. Loss of Mass Physical

6.5Insulation Resistancetest at room & ratedtemperature

Volume resistivity Electrical One sample perlot



P R

6.6 H.V. test at roomtemperature H.V. test at room temperature Electrical One sample per

lot



P R

6.7 Noise Test Electrostatic noise rejection ratio test Electrical One sample perlot



P R

Finish

Marking on drum

C: Critical M-Manufacturer,W: Witness P-Perfomer,LEGEND:

R: Review of Docs B: Major RW-Random witnessA: Minor TPIA-Third Party Inspection Agency H-HOLD

As per Relevant Standard100% As per Relevant Standard P R

One sample perlot



P R6.4Physical tests onInsulation & OuterSheath

packing in drum7

One sample perlot

One sample perlot


P RBS 5308(P-2) & RelevantStandard as perSpecification

Visual

Tests For Conductor6.1

6.2 Test on Armourwire/strip

4 of 4Page 248 of 261


Manifacturer/Vendor TPIA Client

1

1.1Material Identification, Visual,Pressure test on castings forhazardous area Junction boxes.

100% P R R

2

2.1 Visual, Dimensions 100% P R -

3

· Visual, dimensional, clearance& Paint shade check for all items.

JB TAG no. Plate· Verification of Terminal Nos.,sizes and no. of entries· Bill of material verification.· Warning plate for junctionboxes and marking on cableglands, Adapters, Plugs etc.· Pressure test on casting forflameproof junction boxes.· High Voltage and insulationresistance test.· Air leak test report onpneumatic JBs.

W/RSupplier’s Test Records /Relevant Standard as per

SpecificationWP

Machining of components

Final Inspection

Material Test Certificates /Lab test certificates

/Relevant Standard as perSpecification

Test Records / RelevantStandard as per Specification

Material Inspection

Incoming materials likeCastings, Terminals etc.

In process Inspection

Remark


JUNCTION BOX

P.013312-D-11013-207 Rev.017.07.19

ARSJHPLGAILTE-IN

Sl.No Description Characterisitc Quantum ofCheck Record

Inspection Agency

3.1 100% bySupplierFinal Inspection

Page 1 of 2Page 249 of 261



Remark


JUNCTION BOX

P.013312-D-11013-207 Rev.017.07.19

ARSJHPLGAILTE-IN

Sl.No Description Characterisitc Quantum ofCheck Record

Inspection Agency

4

4.1 Pre treatment, primer, final paintshade, thickness 100% P R R

5

· Certificate from authority likeBASEEFA, FM, PTB, ATEX, UL,CIMFR etc. for use in specifiedhazardous area.· Statutory approval certificatesfor instruments from CCOE/PESOfor use in specified hazardousarea.· Degree of protectioncertificate for instrumenthousing.· Traceability of record.· Suppliers Internal TestRecords

LEGEND: C: Critical M-Manufacturer,

W: Witness P-Perfomer,

R: Review of Docs

A: Minor H-HOLD

B: Major

TPIA-Third PartyInspection Agency

RW-Random witness

R

Suppliers Internal TestReports

R5.1

Prototype fortype tests /100% for

others

P

Documentation and IC

Documentation and IC

Statutory ApprovalCertificates / Type TestCertificates / SuppliersInternal test records

Painting

(Painting of JBs prior toassembly)

Page 2 of 2Page 250 of 261

QAP NoDatePrepared by MA Checked by SHDApproved byProjectClientConsultant


1.0 Material Inspection

1

Incoming materials like Gasdetectors, Gas monitors /Controllers, Portable gasdetectors, System cabinets,Power supply units, Hooters,Beacons, Data loggers,Junction boxes etc.

Visual 100% Approved Datasheet / Job Specification

ApprovedDatasheet / Job Specification

Manufacturer’stest Certificates P R R

2.0 Final Inspection

2.1 Final Inspection Visual 100% Approved Datasheet / Job Specification


P W

Visual /electrical 100% Approved Datasheet /

Job Specification


P W

Visual /electrical 100% Approved Datasheet /

Job Specification


P W

Type ofCheckSL. No.

Functional Check

Make, Model Number

CharacteristicsComponent /Operation

2.3

Calibration check of gas detectors including alarm,repeatability, response time.- Redundancy check for power supply units-Functional check of gas monitors / controllers with gasdetectors.

Functional check of portable gas detectors- Functional check of portable purge calibrators.-Functional checks of GD system with PCs, Data loggers,Printers, Hooters, Annunciators, Beacons etc.-Verification of system diagnostics, System and applicationsoftware including Graphics (if configured), Interface withthird party devices.-Performance test as per standard specification

P.013312-D-11013-208 Rev.017.07.19

ARSJHPL

Visual , Dimension check- Bill of Material- Tag Plates- Wiring check of cabinets with all accessories


GAS DETECTION SYSTEM

Inspection Agency

GAILTE-IN

Format ofPlan

AcceptanceNorm

ReferrenceDocument

Quantum ofCheck

Page 1 of 2

Page 251 of 261

QAP NoDatePrepared by MA Checked by SHDApproved byProjectClientConsultant


Type ofCheckSL. No. CharacteristicsComponent /

Operation

P.013312-D-11013-208 Rev.017.07.19

ARSJHPL


GAS DETECTION SYSTEM

Inspection Agency

GAILTE-IN

Format ofPlan

AcceptanceNorm

ReferrenceDocument

Quantum ofCheck

2.4 Certification / Documents Visual

Prototype foreach model

100 %

Statutory ApprovalCertificates/Type TestCertificates

Statutory ApprovalCertificates/TypeTest Certificates

P R

3 Packing Visual 100% Packing List P R

NOTE:

LEGEND: R: Review of Docs C: Critical B: Major RW-Random witness

A: Minor W: Witness TPIA-Third Party Inspection Agency H-HOLD

Visual check and Proper packing to prevent entry of foreignmaterial

Certificate from testing agency like BASEEFA, FM, PTB,CIMFR etc. for instruments for gas detectors, portabledetectors, junction boxes etc. for use in specified hazardousarea- BIS approval for gas detectors, junction boxes etc.manufactured indigenously for use in specified hazardousarea.- Statutory approval certificates for instruments fromCCOE/PESO for use in specified hazardous area.- Degree of protection certificate for instrument housing.- Electromagnetic & Radio frequency compatibilityrequirements for gas detectors, gas monitors/controllers.-Test certificate for calibration gases

ALL TESTING AND MEASURING EQUIPMENTS/INSTRUMENTS SHALL HAVE VALID CALIBRATION WITH CALIBRATION CERTIFICATES & TRACEABILITIES.

M-Manufacturer,

P-Perfomer,

Page 2 of 2

Page 252 of 261



1.0 Material Inspection

1 Incoming sheet steel forpanel fabrication Visual 100% Approved Datasheet /

Job Specification


Manufacturer’stest Certificates P R R

2.0 Final Inspection

2.1 Final Inspection Visual /electrical 100% Approved Datasheet /

Job Specification


P W R/W

2.2 Certification / Documents aspplicable Visual

Prototype foreach model

100 %

Statutory ApprovalCertificates/Type TestCertificates

Statutory ApprovalCertificates/TypeTest Certificates

P R R

3 Packing Visual 100% Packing List P R -

4 Documentation andinspection certificate Visual 100%

Supplier testrecords/Inspectioncertificate



P R R

NOTE:

LEGEND: R: Review of Docs C: Critical B: Major RW-Random witness

A: Minor W: Witness TPIA-Third Party Inspection Agency H-HOLD

P.013312-D-11013-209 Rev.017.07.19

ARSJHPL

Visual , Dimension check- Bill of Material- Tag Plates- Wiring check of cabinets with all accessories- High Voltage test and insulation test- Functional check of instruments and accessories, shutdown & interlock system by simulation- Earthing check- component layout arrangement.- Easy accessibility for maintenance/replacement ofcomponents


LOCAL CONTROL PANEL

Inspection Agency

GAILTE-IN

Format ofPlan

AcceptanceNorm

ReferrenceDocument

Quantum ofCheck

ALL TESTING AND MEASURING EQUIPMENTS/INSTRUMENTS SHALL HAVE VALID CALIBRATION WITH CALIBRATION CERTIFICATES & TRACEABILITIES.

M-Manufacturer,

P-Perfomer,

Type ofCheckSL. No.

Review of internal test reportCertificates for all bought out componentCalibration test certificate for all instrumentInspection certificate issuance

Certificate from testing agency like BASEEFA, FM, PTB,CIMFR etc. for instruments use in specified hazardous area- Statutory approval certificates for instruments fromCCOE/PESO for use in specified hazardous area.- Degree of protection certificate for instrument housing.- Electromagnetic & Radio frequency compatibilityrequirements

Visual, Surface Finish, Dimensions, Chemical treatment.

CharacteristicsComponent /Operation

Visual check and Proper packing to prevent entry of foreignmaterial

Page 1 of 1

Page 253 of 261

of 261

At the helm of the Energy Transition, Tractebel provides a full range of engineering and advisory servicesthroughout the life cycle of its clients’ projects, including design and project management. As one of the world’sleading engineering and advisory companies and with more than 150 years of experience, it's our mission toactively shape the world of tomorrow. With about 5,000 experts and presence in more than 70 countries, we areable to offer our customers multidisciplinary solutions in energy, water and urban.

TRACTEBEL ENGINEERING PVT. LTD.Intec House 37Institutional Area, Sector 44122 002 - Gurgaon - INDIAtractebel-engie.com

Antik ROYtel. + 91 124 469 8500fax + 91 124 469 [email protected]

LAYING AND ASSOCIATED WORKS FOR …tender.tractebelindia.com/GAIL/8000014928/Technical Vol...DESIGN...

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