SPECIFICATION SPECIFICATION FOR FOR MATERIAL, MATERIAL, INSTALLATION, INSTALLATION, TESTING TESTING AND AND COMMISSIONING

3 Conditions of Contract Conditions of Contract

5 Technical Technical Specification Specification

5.4 SPECIFICATION SPECIFICATION FOR FOR MATERIAL, MATERIAL, INSTALLATION, INSTALLATION, TESTING TESTING AND AND COMMISSIONING

COMMISSIONING

Materials supplied and workmanship shall be of the highest quality available and all work Materials supplied and workmanship shall be of the highest quality available and all work shall be carried out to meet the requirements of IS codes of Practice, I.E. Rules and to the shall be carried out to meet the requirements of IS codes of Practice, I.E. Rules and to the approval of

approval of the Engineer the Engineer and Local and Local Authorities. Authorities. The following The following specifications givespecifications give guidelines, but not limited to the quality and scope of work expected.

guidelines, but not limited to the quality and scope of work expected.

5.4.1

5.4.1 Lying & TeLying & Termination of rmination of Power, ContrPower, Control and Foundation ol and Foundation Fieldbus (FF) CFieldbus (FF) Cables.ables.

(i) Scope (i) Scope

This specification provides for laying, termination, testing and commissioning of Power, Control This specification provides for laying, termination, testing and commissioning of Power, Control

& FF Cables.

(ii)

(ii) Laying Laying of of CablesCables

The Contractor will unpack the drum if required and then transport it to a convenient spot near The Contractor will unpack the drum if required and then transport it to a convenient spot near the overhead tray so that lying of cable becomes easy.

the overhead tray so that lying of cable becomes easy.

Most important thing to bear in mind while laying cables is that there should not be any twisting Most important thing to bear in mind while laying cables is that there should not be any twisting while unwinding it from the drum, since this is likely to damage the insulation. Any while unwinding it from the drum, since this is likely to damage the insulation. Any repairing/replacement arising out of this negligence will be to the contractor's account.

repairing/replacement arising out of this negligence will be to the contractor's account.

Power, FF & Control Cables shall be laid between various equipment as per cable schedule Power, FF & Control Cables shall be laid between various equipment as per cable schedule (which will be given

(which will be given to the successful to the successful contractor). contractor). Tentative routes of Tentative routes of these cables have beenthese cables have been shown on the drawings.

shown on the drawings.

Adequate length of cables shall be pulled inside DCS panels, Control and FF junction boxes, Adequate length of cables shall be pulled inside DCS panels, Control and FF junction boxes, terminal boxes, etc. so as to permit neat termination of each core.

terminal boxes, etc. so as to permit neat termination of each core.

While laying cables parallel to buildings or utility pipelines, drainage, electrical cable tray etc.

minimum clearance shall not be less than 500 mm.

The contractor shall quote for laying of cables on 'per meter' basis which should include The contractor shall quote for laying of cables on 'per meter' basis which should include following parameters:

following parameters:

a) Laying Laying of of cables cables in in cable cable trays/ trays/ on on walls.walls.

b) Supplying Supplying and and providing providing of of cable cable ties ties clamps clamps of of required required sizes sizes to to hold hold the the cable cable firmlyfirmly to structure/tray.

to structure/tray.

Before the cable is cut, exact route length s

Before the cable is cut, exact route length shall be measured at site. hall be measured at site. Then allowing extra lengthThen allowing extra length of about 1.5m, or as directed by the Engineer, the cable is cut.

of about 1.5m, or as directed by the Engineer, the cable is cut.

Rollers and pu

Rollers and pulling socks slling socks shall be used hall be used while pulling while pulling the cable into the the cable into the trays. trays. This will beThis will be strictly enforced for larger size of cables and for long routes without which installation will not strictly enforced for larger size of cables and for long routes without which installation will not be permitted.

be permitted.

Bending radius of cable shall be minimum.

The cables shall be tested for insulation resistance with 1000 V megger, before laying. Cutting The cables shall be tested for insulation resistance with 1000 V megger, before laying. Cutting schedule for each drum to be prepared by contractor & approved by the Engineer prior to schedule for each drum to be prepared by contractor & approved by the Engineer prior to cutting.

cutting.

Cables shall be neatly laid, with no crossing over of cables.

Cable ends after cutting shall be protected from dirt and moisture by wrapping with PVC Cable ends after cutting shall be protected from dirt and moisture by wrapping with PVC tapes/caps.

tapes/caps.

Any civil work or plastering work required as a part of cable laying work shall be done by the Any civil work or plastering work required as a part of cable laying work shall be done by the Contractor within the quoted rates. The quality of finish should be that of the other works or the Contractor within the quoted rates. The quality of finish should be that of the other works or the same will be redone by the Civil Contractor and the amount deducted from the Inst. Contractor's same will be redone by the Civil Contractor and the amount deducted from the Inst. Contractor's bill.

bill.

Any re-laying of cable required to be done due to wrong method of laying (for which Contractor Any re-laying of cable required to be done due to wrong method of laying (for which Contractor is responsible) shall be without any extra cost to the Owner.

is responsible) shall be without any extra cost to the Owner.

Engraved labels of SS 316 strip to match cable Tag no. of cable numbers shall be provided near Engraved labels of SS 316 strip to match cable Tag no. of cable numbers shall be provided near the terminal block in control room & cable identification tag number punched on SS 316. strip the terminal block in control room & cable identification tag number punched on SS 316. strip shall be provided on both ends nea

shall be provided on both ends near equipment.r equipment.

The Contractor shall supply and install coloured ferrules for multicore cable connections. The The Contractor shall supply and install coloured ferrules for multicore cable connections. The ferrule markings shall be identical to the tag numbers.

ferrule markings shall be identical to the tag numbers.

Cable Tray as supports:

(i)

(i) The The trays trays shall shall be be supported supported as as per per installation installation drawings. drawings. If If necessary, necessary, additionaladditional supports shall be provided. The supporting arrangement shall be approved by site supports shall be provided. The supporting arrangement shall be approved by site engineer.

engineer.

(ii)

(ii) Supports Supports shall shall have have same same treatment treatment as as per per trays.trays.

(iii)

(iii) Supply Supply & & Installation Installation rates rates for for supports supports shall shall not not be be included included in in the the rates rates for for cable cable traystrays but paid separately under rates for supply and fabrication of structural steel.

but paid separately under rates for supply and fabrication of structural steel.

5.4.2

5.4.2 Cable Cable Handling, Handling, DressingDressing

Presently the existing cables have been laid on trays, which are corroded and need replacement.

The cables shall be properly handled while dismantling of the cable trays/supports. Also the The cables shall be properly handled while dismantling of the cable trays/supports. Also the cables shall be placed in the newly installed cable trays. The cables shall be properly tied and cables shall be placed in the newly installed cable trays. The cables shall be properly tied and dressed as per

dressed as per the standard practised. the standard practised. Also the sAlso the segregation shall be egregation shall be done between pdone between power andower and low voltage instrument cables to the satisfaction of the HOCL.

low voltage instrument cables to the satisfaction of the HOCL.

5.4.3

5.4.3 Installation Installation of of TraysTrays

Prior to installation / fabrication, contractor to study each area and prepare “Method Statement”

and “Working sketches” for review a

and “Working sketches” for review and approval by HOCL.nd approval by HOCL.

5.4.4

5.4.4 Erection Erection material material supplysupply

•

• The Sub-contractor shall ensure and supply all erection hardware required for The Sub-contractor shall ensure and supply all erection hardware required for installation of all instrumentation, which form a part of the package unit. This installation of all instrumentation, which form a part of the package unit. This includes items like cables, cable glands, junction boxes, instrument valves, includes items like cables, cable glands, junction boxes, instrument valves, mounting accessories, impulse piping/tubing, pipe/tube fitting, pneumatic signal mounting accessories, impulse piping/tubing, pipe/tube fitting, pneumatic signal tubes, air line pipes, filter regulators, steam/electrical tracing, insulation tubes, air line pipes, filter regulators, steam/electrical tracing, insulation materials, cable trays, conduits, identification tags, structural material required materials, cable trays, conduits, identification tags, structural material required for instrument supports and trays etc.

for instrument supports and trays etc.

•

• The above broadly covers the items required for any typical plant, however theThe above broadly covers the items required for any typical plant, however the sub-contractor shall supply all necessary items to make the erection and sub-contractor shall supply all necessary items to make the erection and commissioning work complete in all respects, irrespective of whether erection commissioning work complete in all respects, irrespective of whether erection and commissioning is included in his scope or

and commissioning is included in his scope or not.not.

•

• The following are the minimum acceptable salient features of some of theThe following are the minimum acceptable salient features of some of the erection materials.

erection materials.

Analog signal cables Analog signal cables

•

• For FF connection special cables to be used for all analog signals, as per NSD-17For FF connection special cables to be used for all analog signals, as per NSD-17 specification to be supplied and erected.

specification to be supplied and erected.

Digital signal cables Digital signal cables

•

• Existing cables and cable routes will be used by erection contractor.Existing cables and cable routes will be used by erection contractor.

Ac 110Vac supply cables Ac 110Vac supply cables

•

• Existing cables and cable routes will be used by erection contractor.Existing cables and cable routes will be used by erection contractor.

Cable Glands Cable Glands

•

• Sub-contractor shall supply all cable glands required for glanding the aboveSub-contractor shall supply all cable glands required for glanding the above mentioned cables both at field instruments and at control room (local & main) / mentioned cables both at field instruments and at control room (local & main) / control room devices/junction boxes.

control room devices/junction boxes.

•

• All cables glands shall be of nickel-plated brass and they shall be doubleAll cables glands shall be of nickel-plated brass and they shall be double compression type suitable for armoured cables.

compression type suitable for armoured cables.

•

• Flame proof glands wherever required shall be supplied.Flame proof glands wherever required shall be supplied.

•

• For quantity of cable glands, refer in price schedule ‘D’.For quantity of cable glands, refer in price schedule ‘D’.

Junction Boxes Junction Boxes

•

• HOCL will supply junction boxes for HOCL will supply junction boxes for digital inputs and outputs as required.digital inputs and outputs as required.

•

• Contractor to supply and install 1000 nos of 2.5 sq. mm Din rail mounting typeContractor to supply and install 1000 nos of 2.5 sq. mm Din rail mounting type Clipon / Phonix make terminals to be fixed into existing digital junction boxes.

Clipon / Phonix make terminals to be fixed into existing digital junction boxes.

(Existing digital junction boxes to be

(Existing digital junction boxes to be used for digital inputs and used for digital inputs and outputs).outputs).

•

• Contractor to supply Foundation Fieldbus junction boxes.Contractor to supply Foundation Fieldbus junction boxes.

Instrument support/structural steel Instrument support/structural steel

•

• Sub-contractor shall supply instrument stand (stanchions and other structural steelSub-contractor shall supply instrument stand (stanchions and other structural steel material required for supporting the cable trays, impulse lines and instruments).

material required for supporting the cable trays, impulse lines and instruments).

gauge, flow switch, pressure gauge, pressure switch etc. shall be installed in such gauge, flow switch, pressure gauge, pressure switch etc. shall be installed in such a way that they have better readability and accessibility.

a way that they have better readability and accessibility.

•

• All capillary type instruments shall have the capillary tube supported properlyAll capillary type instruments shall have the capillary tube supported properly and shall have protection of capillary tube against mechanical damage.

and shall have protection of capillary tube against mechanical damage.

•

• All pressure, differential pressure instruments shall be provided with by-pass,All pressure, differential pressure instruments shall be provided with by-pass, drain/vent valves etc. as per the installation sketches, and shall have accessibility.

drain/vent valves etc. as per the installation sketches, and shall have accessibility.

•

• All primary piping/tubing (impulse lines) shall have a slope of 1/10 on theAll primary piping/tubing (impulse lines) shall have a slope of 1/10 on the horizontal run.

horizontal run.

•

• All welding shall be carried out as per the relevant code with proper electrodes.All welding shall be carried out as per the relevant code with proper electrodes.

Any testing (non destructive) like DP test on root weld and final weld shall be Any testing (non destructive) like DP test on root weld and final weld shall be carried out as applicable. All consumable like paint, ferrules, lugs shall be part of carried out as applicable. All consumable like paint, ferrules, lugs shall be part of sub-contractor’s scope of supply. Any pre/post weld treatment as required by the sub-contractor’s scope of supply. Any pre/post weld treatment as required by the codes shall be carried out.

codes shall be carried out.

•

• All threaded joints shall be jointed by Teflon tapes only.All threaded joints shall be jointed by Teflon tapes only.

•

• All impulse lines shall be supported at regular intervals.All impulse lines shall be supported at regular intervals.

•

• Instrument drain/vent connections shall be piped to safe area or above pipe racksInstrument drain/vent connections shall be piped to safe area or above pipe racks to avoid accumulation of hazardous fluid in the plant atmosphere.

to avoid accumulation of hazardous fluid in the plant atmosphere.

•

• All tubes/cables shall be properly laid on cable trays, which shall be supported atAll tubes/cables shall be properly laid on cable trays, which shall be supported at regular intervals with identification tags.

regular intervals with identification tags.

•

• Separate routing or physical separation minimum 300mm shall be maintainedSeparate routing or physical separation minimum 300mm shall be maintained between signal cables and shut down/power cables.

between signal cables and shut down/power cables.

•

• Wherever intrinsic circuit system cabling is employed the minimum separation of Wherever intrinsic circuit system cabling is employed the minimum separation of 150mm. shall be adhered to between IS and non IS signal cables.

150mm. shall be adhered to between IS and non IS signal cables.

•

• The cases of instruments shall be earthed by earthing wire to the nearest earth busThe cases of instruments shall be earthed by earthing wire to the nearest earth bus bar provided by others, for safety reasons.

bar provided by others, for safety reasons.

•

• In case the cables are to be buried or laid in concrete trench the same shall beIn case the cables are to be buried or laid in concrete trench the same shall be carried out by sub-contractor with prior intimation to client.

carried out by sub-contractor with prior intimation to client.

•

• Painting of angle trays, instrument supports & all structural supports shall be asPainting of angle trays, instrument supports & all structural supports shall be as under:

under:

•

• The surface to be painted shall be thoroughly cleaned with brush/sand paper toThe surface to be painted shall be thoroughly cleaned with brush/sand paper to remove all scales. After cleaning, one coat of zinc chromate primer shall be given remove all scales. After cleaning, one coat of zinc chromate primer shall be given conforming to IS-2074 and allowed to dry. One coat of final when paint shall be conforming to IS-2074 and allowed to dry. One coat of final when paint shall be applied. The paint selected shall be epoxy type :

applied. The paint selected shall be epoxy type :

5.4.6

5.4.6 Testing Testing and and CalibrationCalibration

•

• All impulse lines shall be properly flushed after isolating both the instrument andAll impulse lines shall be properly flushed after isolating both the instrument and the vessel/piping.

the vessel/piping.

•

• All impulse lines shall be tested hydraulically at 1.5 times the maximumAll impulse lines shall be tested hydraulically at 1.5 times the maximum operating pressure. Ensure that instrument and vessel/piping is isolated during operating pressure. Ensure that instrument and vessel/piping is isolated during this test.

this test.

•

• In case of special conditions where hydrotesting is not permitted due to serviceIn case of special conditions where hydrotesting is not permitted due to service conditions, the impulse lines testing shall be carried out by using air or nitrogen.

conditions, the impulse lines testing shall be carried out by using air or nitrogen.

•

• All external cage type level instruments shall be tested up to 1.5 times operatingAll external cage type level instruments shall be tested up to 1.5 times operating pressure by using nitrogen only.

pressure by using nitrogen only.

•

• After pressure testing all these impulse lines shall be drained and dried with dryAfter pressure testing all these impulse lines shall be drained and dried with dry air to remove any moisture.

air to remove any moisture.

•

• Instrument airlines will be service tested only for any leak after pressurising andInstrument airlines will be service tested only for any leak after pressurising and

In document Technical Bid (Page 47-58)