Instrument Installation Requirements

AA REQ 673013

INSTRUMENT INSTALLATION REQUIREMENTS

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ISSUE 0 11 APRIL 2011

APPROVED COPYRIGHT

INSTRUMENT INSTALLATION REQUIREMENTS CONTENTS Page

1

Scope

4

2

Definitions

4

3

Standards and REQUIREMENTS

4

4

Safety, Health and Environment

5

5

Quality Requirements

6

5.1

Quality Control

6

5.2

Workmanship

6

5.3

Deviations

6

5.4

Equipment Storage

6

6

7

Battery Limits

7

6.1

Civil Works

7

6.2

Mechanical Works

7

6.3

Electrical Works

7

Erection

8

7.1

Order Quantities

8

7.2

Delivery Delays

8

7.3

Equipment

8

7.4

Drawings

8

7.5

Positioning

8

7.6

Mounting

9

7.7

Accessibility

9

For more information or to give feedback on this document, please contact M&T Risk and Assurance Tel 00 27 11 638 2815

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ISSUE 0 11 April 2011 COPYRIGHT

8

9

10

7.8

Installation

10

7.9

Steelwork

10

Cable Supports

11

8.1

Supply

11

8.2

Support Types

11

8.3

Installation

12

Cabling and Wiring

13

9.1

Cable Routes

13

9.2

Installation

13

9.3

Support and Strapping

14

9.4

Cable Glanding

15

9.5

Instrument Copper Cable

15

9.6

Local Termination Boxes

16

Tubing

17

10.1

Supply

17

10.2

Installation

17

10.3

Support

18

11

Labelling

18

12

Earthing

19

13

Painting Specification

19

14

Testing, Inspection and Commissioning

19

14.1

Initial Testing C1

19

14.2

Inspection C2

20

14.3

Commissioning C3

21

14.4

Certificates

21

14.5

Loop Packages

22

Appendix A: Referenced Documents

23

Appendix B: Record of Amendments

23

Appendix C: Index to Hook-Up Drawings

24

Appendix D: Hook-Up Drawings

26

For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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Appendix E: Photos of Correct Installation (Instrumentation)

81

Appendix F: Photos of Correct Installation (Electrical)

94


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1

SCOPE This specification covers the instrumentation aspect of the project with respect to; the supply, delivery, storage, fabrication, placing in position, erection, calibration, testing and commissioning of the instrumentation equipment specified as per project requirements and includes the maintenance of all instrumentation equipment until handover, to the client, with complete documentation. The supply of all free issued equipment as indicated on the bill of quantities is excluded from the scope of this document.

2

DEFINITIONS For the purpose of this requirement the following definitions shall apply:

3

BOQ

:

Bill Of Quantities

COW

:

Clerk of Works – the Client C&I Representative on site

CVT

:

Constant Voltage Transformer

IPDB

:

Instrument Power Distribution Boards

LOOP

:

A loop comprises all the equipment necessary to measure, monitor and control a process variable, including sensors, transmitters, I/O, actuators and all connecting wiring.

QCP

:

Quality Control Plan

RFI

:

Request For Inspection

SDQ

:

Site Design Query

SHE

:

Safety, Health and Environment

UPS

:

Un-interruptible Power Supplies

STANDARDS AND REQUIREMENTS This requirements shall be read in conjunction with the following documents: 

Hook-up drawings;



Bill of Quantities;



Mini bills;



Third party interface specifications;



Cable specifications;



Design office specifications;


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

Construction drawings; and



Specifications included with the enquiry document.

Compliance with the latest amendments of the following codes and standards shall be considered a minimum requirement. 

General Specification (Metric Edition) of the Ministry of Works and communications, Building Dept. of the Government of the Republic of South Africa.



South African Institute of Electrical Engineers Wiring Regulations.



South African Bureau of Standards.



British Standard Specifications.



British Standard Codes of Practice.



Mines and Works Act of South Africa.



Mines Quarries Works and Machinery Act and Regulations.



South African Chamber of Mines Safety Code.



South African Occupational Health and Safety Act.



The Electricity Supply regulations of South Africa.

In cases where relevant South African Bureau of Standard Codes of Practice or Standards does not exist, then the relevant British Standard Code or Specifications will apply. Any conflict between any of the documentation shall be brought to the attention of the Engineer for resolution.

4

SAFETY, HEALTH AND ENVIRONMENT The Contractor shall keep his working site clean and tidy at all times and shall ensure that safe and hygienic working conditions are provided. The Contractor shall conform to the site SHE requirements. A daily safety meeting shall be held to reinforce the safety requirements. The Contractor shall be responsible for the supply of all tools and equipment required to complete the project and will adhere to the site safety requirements. The Contractor shall be responsible for regular toolbox inspections to replace damaged or defective tools. A record shall be kept of the inspections and the results.

Any damage to equipment, caused by the use of either defective tools or incorrectly used tools shall be for the Contractor‟s account. No explosive type tools shall be used on site unless special permission is obtained from the Project Engineer. These are generally discouraged owing to safety considerations.


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Where the Project Engineer permits the use of explosive type tools, it shall be the Contractor's responsibility to keep a record of all such tools on site. All explosive tools shall be subject to a weekly check for safety and freedom from damage and the results recorded in the record book. An up to date list of all certified operators of such explosive type tools shall be kept in the record book.

5

QUALITY REQUIREMENTS

5.1

Quality Control The requirements of AA REQ 100 shall apply. The Contractor shall submit detailed résumés for all members of his project team to the Engineer for approval prior to installation work commencing.

5.2

Workmanship All installation work shall be carried out under the supervision of the Contractor's Site Manager, who shall have full charge of the work and who shall be appropriately experienced and qualified, in the erection and supervision of the work to be executed. The Site Manager shall be present, on site, for the duration of the project. In all matters relating to the installation of instrumentation equipment, the Contractor shall be responsible for ensuring that the workmanship, quality and suitability of his supply comply with the relevant standards and specifications. Any section of the work or materials supplied by the Contractor that is considered to be unacceptable shall be remade or replaced to the satisfaction of the COW. All marks and stains resulting from construction work shall be cleaned and repaired.

5.3

Deviations The Contractor shall acquaint himself with and follow all installation instructions provided for the project. If, for any reason, a deviation from the specifications, standards or drawings, does occur, the contractor shall formally apply for a concession prior to installation. The concession, on a formal concession request form, shall be submitted to the COW at least 48 hours prior to the planned installation. The Contractor shall ensure that the availability of all material and equipment intended for use on the project is assessed at the beginning of the project to ensure that the standard and type of material and equipment is consistent throughout the project.

5.4

Equipment Storage


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All equipment shall be stored in a dry and protected area, according to suppliers' specifications. The Contractor shall inspect all equipment on delivery for physical damage. The COW shall be notified, in writing, of any damage within 24 hrs of delivery. The Contractor shall be responsible for any damage or loss of goods handed over to him and will be required to replace, free of charge, any damaged or lost items.

6

BATTERY LIMITS

6.1

Civil Works Unless otherwise stated on the project drawing, all civil engineering works, including the cutting of holes through floors, walls or ceilings, the formation of pockets etc. will be carried out by the Contractor. Prior to commencement of breaking through, or using explosive bolts on civil installations the agreement of the Civil Engineer shall be obtained in writing. Where such action is found to be necessary, the Contractor shall make good the structure to the approval of the Civil Engineer.

6.2

Mechanical Works In-line instruments are to be supplied pre-calibrated, tested and tagged by the Contractor for installation. The Contractor will supervise the correct installation of in-line devices by the mechanical contractor. The mechanical contractor will be requested to provide the following connection points:

6.3



In service air lines - isolation valves



In process lines - flanged connections.

Electrical Works The termination of field bus cables in an electrical MCC may be completed by C&I personnel providing the cubicle in which the terminations are to take place contains no electrical equipment or cables. The electrical contractor shall terminate electrical MCC status signals. No work shall be performed by the C&I installation personnel inside an electrical panel.


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7

ERECTION

7.1

Order Quantities Contractor will be responsible for all material take off from latest revisions of the instrumentation drawings for ordering purposes. The Bill of Quantities and Schedules should only be used as a guideline. The quantities indicated in the schedules are provisional and neither any variation in quantities for individual items nor any variation in the relationship of these quantities one to the other as at tender stage and completion stage, will be considered as a basis for any claim whatsoever. Differences greater than 15% in planned lengths of cable and racking and actual installed lengths shall be reported to the COW.

7.2

Delivery Delays Any delay in the sequence of erection on site, for any particular section of the works, as a result of non or late delivery of any components or materials from Contractors, Suppliers or Subcontractors, will not automatically be considered a cause for delay in completing the works. The Contractor shall inform the Engineer in writing and in good time, of the impact that this shall have on the program and the related cost implications.

7.3

Equipment Where equipment is required that has not been specified, the Engineer shall approve the make and type of equipment, prior to purchase.

7.4

Drawings The Contractor shall keep one set of construction drawings separate from those used for installation purposes and these shall be marked up and stamped as-built drawings. The Contractor‟s responsible person must certify these drawings. These drawings shall be kept up to date with all deviations from project drawings, including omissions and additions to cable schedules. The Engineer may at any time request the inspection of the as-built drawings.

7.5

Positioning Groups of small items of equipment shall be logically grouped and mounted on common wall or floor mounting frames. Mounting positions are to be agreed with the COW prior to installation. The positioning of local control equipment shall be such as to give the best view of the driven machinery for reasons of safety and convenience. Local push-button stations etc. shall be mounted as close as practically possible to the driven items, but in any event shall not be mounted more than 1 meter from the equipment. Equipment shall not be situated in locations subject to leaks and spills. All components not


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otherwise protected from leaks or spills shall be mounted under a suitable shield or protective cover made from stainless steel with a sloped roof. Covers shall be made in accordance with the relevant hook-up drawing. All field mounted devices with digital displays, must be positioned in such a manner so that the displays are protected against direct exposure to sun-light.

7.6

Mounting Where prepared foundations or supports have not been allowed for in the structural design, heavy equipment shall be mounted on the floor or on well-constructed and braced wallmounting frames. The mounting heights of equipment above the floor, unless shown otherwise on drawings shall be 1.8m to the top of the drip cover Allowance shall be made for a minimum of 25mm grouting when mounting instrument stands directly onto a concrete floor. Components specified for surface mounting may be mounted on a chassis plate attached to a wall, or on a vertical flat steel plate suitably supported by a column, stanchion or platform, or mounted with brackets. The Contractor shall provide for a re-enforced frame to support heavy weight equipment where installed on top of a false floor such as cubicles, UPS and CVT equipment. All clips, saddles or clamps for the securing of cables, pipes and tubes shall have smooth and rounded edges. The COW shall approve the types of saddle or clamp, before installation commences. Where conditions require the use of plastic or stainless steel strapping, appropriate references are made in subsequent sections of this specification. Precaution shall be taken to counter vibrations likely to be transmitted by the structure and/or plant machinery. As vibrations are unlikely to be fully evident until machinery is operating, checks for vibration shall be made during commissioning. Any unsatisfactory conditions detected shall be reported in writing to the Engineer for remedial action. All installation work shall be carried out with a view to minimising all anticipated detrimental effects of vibration, especially in the mode of erection of racking, conduit, plastic and copper tubing. No termination boxes or ancillaries will be mounted directly onto instrument equipment and valves, with the exception of proximity/limit switches, valve positioners etc.

7.7

Accessibility Field mounted equipment shall be installed so that they are readily accessible and protected from accidental impacts. Special care must be taken in the positioning of instruments e.g. instruments will not be installed under tank overflows, inside bund walls or drain sumps.

Special attention shall be given to the orientation of the device with regard to the access for For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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operation, maintenance, repair and calibration. Access provision should be made to all installed C&I equipment.

7.8

Installation All equipment shall be completely assembled, installed and connected in the location shown on the construction drawings and shall be fully prepared for operation unless it is stated elsewhere that this work or part of this work is to be done by others. All cable, piping, tubing and accessories required for the project shall be supplied and installed by the Contractor in accordance with the project installation requirements. To this end the Contractor will be assumed to have obtained from the equipment supplier and COW, full details for each erection, together with any handbook or drawings essential thereto. Should it be proven that any equipment be incorrectly installed the COW shall have the right to instruct the Contractor to re-install the items at his own cost. All field mounted devices, including the field I/O boxes will be a minimum rating of IP 65 and will be protected by stainless steel drip covers and rubber curtains where externally mounted. All cables or equipment shall be properly supported to relieve strain on connections and instruments. When installing instruments on rubber lined equipment, care shall be exercised not to damage lining. All nuclear and radio-active sources will be enclosed as per legal requirements. Where connections are to be made to a live or pre-commissioned installation, the Contractor must obtain a PERMIT TO WORK. The contractor shall submit an official Site Design Query (SDQ) when a contradiction between design, specifications and drawings occurs. These SDQ‟s must be submitted to the COW 48 hours prior to planned installation.

7.9

Steelwork All instrumentation steelwork requirements will be galvanised. Galvanising shall only be carried out after the completion of fabrication of the various components. The zinc coating shall have a minimum thickness of 87u for components with a thickness of 5mm or more and 44u for components less than 5mm thick. Small areas of damaged coating can be repaired in situ using an approved cold galvanising paint. Where holes are drilled in galvanised steelworks in order to fix support brackets, all such drill holes shall be treated with an approved cold galvanising paint within twelve hours of drilling.

All mild steel structures and equipment shall arrive on site sand blasted with a coat of primer For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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applied as per the paint specification. All site manufactured trays supports, racks, brackets or other metal work shall be painted according to the painting specification. The Contractor shall adhere to the project colour standards. Except with the prior written consent of the Engineer, cutting, welding or drilling on any vessels, any bin or piping or near any instrumentation is prohibited. All cutting, welding and drilling shall be neatly done to the satisfaction of the COW. Holes larger than 8mm in diameter shall not be drilled in structural steelworks without the prior consent of the Project Engineer. All incorrectly drilled holes into a structure or support steel will be paint treated and a „dummy bolt‟ installed. No other form of filler will be accepted. All component supports and mounting brackets shall be of ample strength and rigidity to ensure proper operation of the instrument. Careful attention shall be given to ensure that components are not mounted on handrails or attached to equipment or structures subject to vibration and process lines unless specifically designed for this purpose. The Contractor shall provide for two flat washers and one spring washer for each bolt installation and should be installed as per hook-up. The correct size washers shall be used at all times. Enlarging of the holes of the washers to suit the bolt size is prohibited. All bolts, nuts, washers and spring washers will be galvanised. Where stainless steel material needs to be installed stainless steel bolts, nuts, washers and spring washers shall be used. After tightening a bolt and nut assembly the length of the thread protruding from the nut will not be less than 2 threads, but not exceed 10 threads. Where a bolt is cut shorter, the cut will be treated as per paint specification.

8

CABLE SUPPORTS

8.1

Supply The Contractor shall include for the supply and installation of the necessary racks and supports which shall include straight lengths, bends, elbows, tees, reducers, brackets, fixing and fastening materials and touch-up paint.

8.2

Support Types Racks to be used shall include but shall not be limited to the following:  

Grid span basket tray racking for indoor use. O-Line 76 racking for outdoor use e.g. along conveyors.

Excessive brackets and support steel will be for the contractor‟s account. Angle-iron cable supports will be used where cables leave main racks to feed individual items, For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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subject to the following: 

The support will be galvanised;



No more than two cables may be run on a single angle-iron support;



The size of the angle iron support shall be such that no part of any cable projects beyond support; and



The minimum size angle iron support shall be 25 x 25 x 5mm

Where more than two cables run on the same route, 50 x 75 x 50mm grid span racking with 5mm strands may be used. Under no circumstances will any cable or cables run unsupported for a distance exceeding 300mm. No cable or instrument air tube will be strapped or supported to any instrumentation or equipment. An approved secondary runner or rack shall be provided. A mechanical wind load calculation will be done where the total span of external racking exceeds 1 meter.

8.3

Installation Racks or angle-iron supports shall be secured to structures by uni-strut brackets or approved equivalent such that there is no noticeable deflection of the rack/angle between support points. The maximum distance between support points for rack or angle-iron supports shall be 1.5 meters. A bracket shall be provided at every change in direction of racks or angle-iron supports. Racks/angle-iron supports shall be continuous and bends shall have radii not less than the minimum permitted for any cable or pipe there upon. Racks and angle-iron cable supports shall be installed in the plant as indicated in the project drawings. Horizontal, flat and face up rack installations to be limited to the minimum. Flat and face down horizontal cable rack installations are prohibited. The Contractor is required to check, prior to the installation of racks and supports that routes given in the drawings are: 

unobstructed, and



do not obstruct other reserved spaces

Holes for cables passing through a wall, partition, floor or ceiling shall be neatly made and finished off with plaster or filler as appropriate. Holes into air-conditioned rooms shall be sealed off so as not to affect the system performance.

No cable tray or support shall be fixed directly to the structure. A suitable bracket shall be fixed For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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to the structure and the cable tray or support fixed to the bracket. Under no circumstances shall any other equipment be fixed to any cable rack or secondary runner.

9

CABLING AND WIRING The cable sizes and types shall be as specified in the cable schedules in AA SPEC 673020, C&I Cables. Prior to delivery of any cable, the Contractor shall establish that its dielectric is sound, all cores are correct and continuous from end to end and that all cables are free of any visible defects. Any cost arising due to defects on cables, including installed cables, prior to hand over will be for the Contractor‟s account. The Contractor shall ensure that core colours / numbers are maintained throughout the installation to avoid confusion, and that colour coding conforms to the drawing requirements. Cable ends shall be sealed or capped immediately after cutting. This applies for the cable to be used as well as that remaining on the drum. Joints in cables are prohibited unless the route lengths exceed the maximum drum lengths manufactured. In this eventuality, approved proprietary types of junction boxes shall be used. Jointing will need approval from the COW.

9.1

Cable Routes The cable routes indicated on the drawings are indicative only and final routes shall be determined on site by the Contractor with approval from the COW. All cables shall be grouped and run according to the arrangements as shown on the project drawings. No installation of cables should commence without the prior approval of the COW in order to prevent the unnecessary crossing of cables, and to promote carefully planned routes. Should selected routes be found to be unsuitable because of prospective obstructions, spillage of solids or liquids, or excessive temperatures, prior approval for deviations shall be obtained from the COW. No cables shall be double-banked on racks, without the approval of the COW. Cables are to be installed in a planned manner to enable later additions and replacements. No cable shall be buried directly in the ground. Where instrumentation signal cables and power cables run on parallel routes greater than 5 meters, they shall be separated by a minimum distance of 300mm or a solid separation plate on the same rack.

9.2

Installation Where cables rise from a trench, or pass through a floor, they shall be protected against impact damage by 2mm thick galvanised pipes or other appropriate means which shall extend at least


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from 50mm below to 350mm above transition points. Holes for cables passing through steelworks shall be made smooth or bushed to prevent damage to the cable. Conductors shall not be carried over or bent around sharp corners or edges. All bends shall be to the cable manufacturers‟ specification. Conductors passing through holes in chassis or screens shall be fully protected by correctly fitted grommets or bushes. Conductors carried across a hinged portion of a chassis or door shall be flexible. Sufficient slack shall be provided to obviate tension. Sufficient slack shall be left at the conductor ends to allow the attached components to be removed for inspection and servicing, and to remake the ends. Cables shall enter an enclosure from below only, and shall be formed to relieve stress on the cable end. Exception to this shall be approved by the Engineer. Wiring shall be installed neatly in trunking, flexible conduit or in wire looms. Where this is not possible or practical, the cable loom shall be strapped together using plastic cable straps available for this purpose. Tightening of harness saddles or straps must not result in: 

Excessive pressure being exerted, which would result in a reduction of the conductor insulation diameter, or



Wear on the insulation, or



Excessive tension.

Unclamped leads shall be free of tension between points of connections.

9.3

Support and Strapping Armoured cables shall be secured to racks or angle-iron supports by stainless steel cable ties with a ball locking mechanism that can operate in temperature range of “-80C to 539C“ (AISS 316 or 304). The span of strapping shall be such as to prevent sagging of cables. Un-armoured cables shall be secured to racks or angle-iron supports by cable ties of Polyamide 6.6. The cable ties shall be halogen free and UV resistant, constructed with buckles and design for use in outdoor areas subject to direct sunlight. The span of strapping shall be such as to prevent sagging of cables and in any event should not exceed 300mm. In areas not subject to direct sunlight such as electrical panels / boxes and general indoor installations, un-armoured cables shall be secured to racks or angle-iron supports by cable ties which shall be self-extinguishing, class V2 according to UL-94, constructed with buckles.

Cables running horizontally on racks mounted edgewise must be secured to the racks at 300mm intervals, to prevent sagging of cables. Cables laid flat in racks parallel with or slightly inclined to the ground or floor surfaces need not For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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be secured to the racks more often than is necessary to prevent the cables from walking as a consequence of expansion, contraction or vibration. Installation of open-ended, capped conduit may be used providing no other means of secondary cable support is possible.

9.4

Cable Glanding Cables shall be made off in situ and not made off and then moved into position. At the soonest practical opportunity before the commencement of terminating, the Contractor shall establish that the cables are sound (by testing insulation resistance and for the presence of moisture in the dielectric) and also that all cables are correct and continuous from end to end. All cables entering junction boxes or control panels shall be stripped to the inner sleeve only, where the end will be made off with transparent heat shrink sleeving for 20mm. Cable glands shall be as follows: PVC insulated cables – un-armoured. 

ENVIRO, fixed nipple compression gland, complete with retaining washer and neoprene compression bush.

PVC insulated cables - armoured. 

ENVIRO armoured, adjustable, mechanical cable gland.

The Contractor shall also include for the drilling of any gland holes required in gland plates and the supply of transparent heat shrink, strapping or other materials necessary to complete the termination. Special care shall be taken by the Contractor when drilling holes in the gland plates for cables to ensure maximum use of space on the area of the gland plate and not to have any unused holes which will affect the I.P. rating of the enclosures. All un-used gland holes shall be sealed off with proper Pratley Enviro gland stoppers which come with all the necessary accessories such as seals and nuts.

9.5

Instrument Copper Cable Terminations shall be made in a professional manner, with particular attention to the cleanliness of tools, materials and working site. A proprietary type of wire stripper must always be used. The stripping tool must be checked regularly and is subject to inspection by the COW. When the type of insulation is suitable, a hot wire stripper is recommended. No stranded conductors shall be fitted if any one strand has been damaged or broken. At terminations, cables shall be secured and connected in such a manner as to prevent undue


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mechanical stress on glands conductors or terminals. Spare cable cores are to be terminated such that the stripped length of the spare cores exceeds the stripped length of the longest used core. The contractor shall refer to the related hook-up drawings for the stripping of the cable inner sleeves and the type, colour and size of all the heat shrink to be used. Leads shall not be twisted together unless this is desirable for a design reason, i.e. to counter inductive effects. When stripping insulation from conductors, wires strands must not be nicked or cut. The insulation of a conductor shall not be stripped back further than or less than necessary to affect a secure joint. Wiring shall be arranged such that not more than two conductors are connected to one side of each terminal, with the understanding that the double up of conductors into one terminal should be avoided by using appropriate manufactured links. All conductors shall be terminated in an insulated double crimped lug of the appropriate type and size, using the proper crimping tool as recommended by the manufacturer of the termination. All crimping tools shall be of the ratchet type. Bare wire terminations will not be accepted. Pin lugs with attached 15mm sleeves for wire marking are to be used with terminal blocks in a strip format. Spade lugs with attached 23mm sleeves for wire marking will be used when terminating under a screw head. Where the space is limited inside any termination point, the contractor shall provide for the same type of lugs, but without sleeves attached to the lug. It shall be the Contractor's responsibility to ensure that lugs, tools and dies are of the correct size for the conductors. Enlarging of holes in lugs is strictly forbidden. The Contractor shall include for the supply and fitting of appropriate lugs and glands to all instruments (existing and new) and associated equipment. All instruments, control panels, switchboards and junction boxes etc. shall be wired in accordance with the project instrumentation wiring diagrams or hook up and shall be well planned and neatly arranged in the best possible manner. Cable screens shall be covered with transparent heat shrink sleeving and earthed where required by drawings. Unearthed screen wires are to be tied back. Under no circumstances may they be cut back. As a minimum the terminal block & cable connector installation specification will be adhered to.

9.6

Local Termination Boxes All field instruments (new and existing) shall terminate in a locally mounted approved termination box with a short length (1 to 2 meters) of flexible cable strapped to a proper


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supported angle iron secondary runner. The termination box can be a multiple-way unit to accommodate more than one associated circuit. No top entries are to be used. A suitably sized terminal strip shall be fitted inside the box. If access to a termination box is limited, the termination box must be mounted in such a manner so as to provide easy access. No termination box shall be fitted more than 5 meters away from the instrument without the prior approval of the COW. The contractor shall ensure that termination boxes for instruments with cast in fly leads shall suit the distance between the termination box and the instrument. Termination boxes are to be provided according to the relevant hook-up drawing. Where an instrument only provides for one gland entry, but with more than one cable or wire running to the instrument, flexible conduit must be used between the termination box and the instrument. Appropriate glands and seals must be used ensuring that the IP 65 rating is maintained.

10

TUBING

10.1

Supply The contractor shall provide for all fittings on Dekabon or Stainless Steel tubing air lines. These fittings shall be of the quick-release type and must be brass with a chrome coating or stainless steel if required as per manufacturer specification. Dekabon nylon tubing or Stainless Steel shall be used on all tubing installations and shall be included in the rate for associated equipment.

10.2

Installation The Contractor will ensure that all pipe cutting and bending tools supplied by him are in good condition. When installing tubing using compression type fittings, all the fitting manufacturer's instructions shall be followed exactly, which will include: 

Cutting of the tube



Cleaning of the tube



Installation of the ferrules



Correct torque applied to compression nut

PTFE tape shall be used for the installation of all threaded pipe fittings.

Sufficient slack shall be provided on all air tubing to avoid strain on instrument connections and to facilitate removal of the instrument. Where a straight union connector is used to extend air tubing, the joint shall be elevated above For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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the tubing route to allow access for leak testing. Every instrument air header shall be provided with a pressure regulator / filter and pressure gauge to suit the instrument air pressure range specified, unless stated otherwise on drawings. An individual shut-off ball valve should be supplied for each instrument. The contractor will ensure that shut off valves are installed in such a manner that operation of the valve is not restricted or hampered.

10.3

Support Tubing shall be supported in the same way as cabling.

11

LABELLING Each cable and conductor in the installation shall be labelled and identified according to drawings and schedules. Cables shall be marked for identification as per relevant cable schedules at each end and at 10m intervals along cable runs. The markers at each end shall be located at the cable glands and shall not be obscured in any way. The marker type shall be self-extinguishing (class V0 according to UL-94), UV resistant, chemical resistant and resistance against extreme atmospheric conditions. If the tag will be exposed to direct sunlight, the sleeve and the cable tie fastening the tag onto the cable must both be UV resistant. If the tag will not be exposed to direct sunlight, the sleeve and the cable tie must be selfextinguishing (class V2 according to UL-94). Individual conductors shall be numbered with sleeves attached to lugs and only if space is limited, will numbered slip-on ferrules with black writing on a yellow background be acceptable. Prior approval of the COW must be obtained. Each wire termination shall be fitted, at both ends, with crimp on ferrules with PVC sleeves attached to it. Plastic self-extinguishing (class V0 according to UL-94), UV resistant, halogen free tag shall be inserted into the sleeve with reference number printed on the tag. Tags to be black letters on yellow background and must correspond with the related schematic or wiring diagrams. All control panels, push-button stations, instrument termination box back plates, etc. shall be marked with screw on tags.

The tag, channel shape holder and transparent cover shall be halogen free, self-extinguishing (class V0 according to UL-94) and must be able to withstand temperature ranges of -50°C and


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+120°C. The labels must be approximately 70mm x 15mm in size and fitted in a suitable label holder with a transparent cover. The labels shall be provided by the Contractor and shall be as per hook-up drawing. All tubing shall be properly labelled at the point of entry at both sides of the approach to the equipment. This label should contain the equipment number of the equipment operated by the instrument air. The same label requirements apply as for cables. Temporary marking directly on any cable is not permitted unless done with a cable-marking pen approved by the COW. The Contractor will also ensure that after installation this marking is completely removed from cables. No stainless steel tags shall be used. Split, clip-on ferrules, non-self extinguishing tags or adhesive marking tape is not acceptable. The markings for horizontal runs shall be from left to right and for vertical runs from the bottom upwards.

12

EARTHING For Earthing details refer to AA REQ 673034, Earthing & Grounding.

13

PAINTING SPECIFICATION All galvanised steel will be paint treated as per paint specification with cold galvanise paint and a final coat of silver aluminium paint as a finish. For additional requirements refer to the applicable paint specification for the project.

14

TESTING, INSPECTION AND COMMISSIONING

14.1

Initial Testing C1 The Contractor shall include for the test equipment and trained personnel necessary to carry out acceptance inspections and tests, and no additional charges for such services will be accepted. When all the testing of an instrumentation loop has been completed, the Contractor shall notify the COW in writing and request inspection. Defects attributable to the Contractor found in the installation shall be rectified at the Contractors expense. The COW shall accept the loop from the Contractor in writing, but the Contractor shall retain responsibility for the loop until the complete area is handed over and accepted in writing by the COW.


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All instrument cables shall be tested for continuity and insulation resistance according to the following: 

Screen to screen

250VDC



Core to screen

500VDC



Core to core

500VDC

The minimum acceptable value of insulation resistance measured line to line or line to ground shall be infinity. Communication and field bus cables are to be tested in accordance with the instrument supplier's specification. Special attention shall be given to testing the shielding of cables and wires to ensure continuity of shield(s) and earthing. It is most important that all cable checks be performed with the instruments disconnected from the cable. The earthing location shall be exactly as shown on the relevant manufacturer's drawing. For detailed information refer to ATDP SS 20, Commissioning Procedure.

14.2

Inspection C2 The COW shall inspect and approve all instrumentation installations. All instrumentation installations, including equipment fabricated on site or in the workshop of the Contractor is subject to inspection and tests that shall be carried out in the presence of the Engineer or COW. Defective items shall be re-inspected and re-tested after rectification. The contractor shall submit an official Request for Inspection (RFI) at least 48 hours in advance to the COW. The contractor shall include all the relative loop packages with the RFI. The client will reject an incomplete RFI package. RFI's shall consist of small, manageable loop quantities, in order to prevent undesirable practices being continued should a fault be found. All rework costs are for the contractors account. All monitoring/control equipment comprising the installation, including the wiring, housing and other details, shall be inspected to ensure that it conforms to the drawings, diagrams and other information supplied. The checks shall include for all terminations and connections in accordance with the loop diagrams.

All equipment shall be inspected to ensure that it is properly identified. The contractor shall be solely responsible for ensuring that the correct instrument is installed in its location. For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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Only the Engineer and the COW will have the authority to sign any acceptance or hand over certificates. All punch list items shall be completed within a reasonable period of time and resubmitted to the COW for inspection and acceptance. At the completion of each package, the Contractor shall provide acceptance certificates for signature by the COW. For detailed information refer to ATDP SS 20, Commissioning Procedure

14.3

Commissioning C3 The Contractor shall provide particulars of the daily rates for superintendent, supervisor, foreman, charge hand and artisan grades, as it is envisaged that assistance from such staff will be required as extras to the Contract, particularly during the cold and hot commissioning of the plant. No equipment shall be commissioned until it has been authorised by the Engineer and COW who, thereupon, will become responsible for the safety of the affected equipment and all personnel having access thereto. All field equipment shall be checked in respect of electrical and mechanical operation of all moving parts, tightness of connections etc. Check and set power supply voltages and air supply pressure. Configure, check and calibrate all analogue signals for correct operating range and span. Perform functional check of loops by simulating plant conditions where possible. MCC control circuits shall be tested with live control bus-wires for correct operation of control push-buttons, interlocks, trip switches, pre-start alarms, contactors retaining circuits, indicators, etc. Precaution shall be taken to ensure that the main bus bars are not energised during the testing operations. Check of pneumatic tubing for tightness of joints, including leak test (Bubble test) For detailed information refer to ATD P SS 20, Commissioning Procedure.

14.4

Certificates The results of all calibrations, tests and reservations are to be recorded on an appropriate form, approved by the COW, which shall be meaningfully filled in.

All deviations of the installation shall be marked up on the supplied documentation to accurately reflect the as-built status of the plant on completion. The above information shall be made available to the Engineer when requested and shall be For more information or to give feedback on this document please contact M&T Risk and Assurance 00 27 11 638 2815

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placed into the loop packs.

14.5

Loop Packages A sample loop handover package, per loop type, shall be submitted to the Engineer for approval and shall consist of the following: 

Main index;



Sub indexes;



Client approved “C1” hand over certificate;



Contractor‟s QCP;



Related installation checklists;



Calibration megger and loop test certificates;



Contractor‟s punchlist;



Client‟s punchlist; and



As-built drawings certified by the Contractor‟s Quality Control Inspector.

These samples shall form the basis of all loop packs and all loop packs shall comply with them. A loop package shall be compiled, to the satisfaction of the COW, before any loop checks are done. The loop packs shall include all test certificates relevant to the associated loop in order as described in the index. The final loop document will only be signed off if and when all the documents are in place and the final loop check has been completed. No loop shall be considered complete if the documentation is incomplete. No loop pack shall be signed off unless all punch items have been cleared and signed off.


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APPENDIX A: REFERENCED DOCUMENTS AA_REQ_673013, Instrument Installation

AA REQ 100

:

Quality Requirements for Suppliers of Critical Equipment.

AA REQ 673034

:

Earthing and Grounding

AA SPEC 673020

:

C&I Cables

ATDP SS 20

:

Commissioning Procedure

APPENDIX B: RECORD OF AMENDMENTS Issue 0

:

New document based on AA STD 673013 Rev 1 (April 2011)


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ISSUE 0


11 April 2011 COPYRIGHT

APPENDIX C: INDEX TO HOOK-UP DRAWINGS DRAWING No

SHEET

DESCRIPTION

REV

DATE

001

AUDIBLE ALARM WITH LENS

A

2002/12/08

002

AUDIBLE ALARMS (TYPICAL)

A

2002/12/08

004

TYP. ON/OFF ACTUATED VALVE WITH PROX. SWITCH

A

2002/12/08

005

TYPICAL FILTER/REGULATOR INSTALLATION

A

2002/12/08

006

SOLENOID VALVE ON PINCH VALVES

A

2002/12/08

007

TYPICAL DRG. FOR DRIP COVERS

A

2002/12/08

008

CLAM SHELL & RADIAL GATE PROXIMITY SWITCH

A

2002/12/08

009

CABLE & TUBING SUPPORT METHOD

A

2002/12/08

010

VIBRATING LEVEL SWITCH FOR UNDERPAN

A

2002/12/08

011

MODULATING CONTROL VALVE

A

2002/12/08

012

CAPACITANCE LEVEL SWITCH E&H

A

2002/12/08

013

BELT ALIGNMENT SWITCH

A

2002/12/08

014

BELT SLIP MONITOR (TYPICAL)

A

2002/12/08

015

MOUNTING BRACKET FOR BELT ALIGNMENT SWITCHES

A

2002/12/08

016

PROXIMITY POSITION SWITCH (TYP.) RADIAL GATES

A

2002/12/08

017

FLOW SWITCH: IN-LINE TARGET TYPE.

A

2002/12/08

018

FLOAT SWITCH FOR FLOOD ALARMS

A

2002/12/08

019

TILT SWITCHES (TYP) FOR VERTCAL MOUNTING

A

2002/12/08

020

FLOAT SWITCH FOR SUMP CONTROL

A

2002/12/08

022

TEMPERATURE SWITCH (TYPICAL)

A

2002/12/08

023

VIBRATING FORK LEVEL SWITCH (TYPICAL)

A

2002/12/08

024

PRESS. GAUGE DIRECT MOUNTED

A

2002/12/08

025

PRESS GAUGE FOR LIQUID SERVICE DIRECT MOUNTED

A

2002/12/08

026

HAND SWITCH / CONTACT POINTS

A

2002/12/08

027

ULTRASONIC TRANSDUCER - CLOSED TANK (TYP.)

A

2002/12/08

028

PRESS SWITCH ON PINCH VALVE

A

2002/12/08

029

ULTRASONIC LEVEL TRANS. TYP. FOR OPEN TANKS

A

2002/12/08

030

MICROWAVE BLOCKED CHUTE DETECTION (TYPICAL)

A

2002/12/08

031

DENSITY SENSOR (NUCLEAR)

A

2002/12/08

032

ELECTROMAGNETIC FLOW METER

A

2002/12/08

033

METAL DETECTOR

A

2002/12/08

034

HUMIDITY TRANSMITTER (TYPICAL)

A

2002/12/08

035

INLINE SOLENOID OPERATED ON/OFF VALVE (TYP)

A

2002/12/08

036

CAPACITANCE LEVEL PROBE (TYPICAL)

A

2002/12/08

037

MASS METER (LOAD CELLS FOR BINS) (TYP.)

A

2002/12/08

038

PRESSURE DIFF TRANSMITTER ORIFICE PLATE

A

2002/12/08

039

SINGLE INSTRUMENT STAND

A

2002/12/08

040

DOUBLE INSTRUMENT STAND

A

2002/12/08

041

LASER TRANSMITTER MOUNTED VERTICALLY

A

2002/12/08

042

THERMOCOUPLE/RTD WITH INTEGRAL TRANSMITTER

A

2002/12/08


STATUS

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ISSUE 0


11 April 2011 COPYRIGHT

DRAWING No

SHEET

DESCRIPTION

REV

DATE

044

PRESSURE SWITCH

A

2002/12/08

045

SINGLE SOLENOID VALVE WITH PRATLEY BOX

A

2002/12/08

046

NUCLEAR LEVEL SWITCH

A

2002/12/08

047

DOUBLE SOLENOID VALVE WITH PRATLEY BOX

A

2002/12/08

048

WEIGHTOMETER

A

2002/12/08

049

TYPICAL TERMINATION BOX INSTALLATION

A

2002/12/08

050

JB AND INSTRUMENT LABELS

A

2002/12/08

051

DOPPLER TYPE FLOW SWITCH

A

2002/12/08

052

CABLE MAKE-OFF HEAT SHRINK DETAIL

A

2002/12/08

053

MAKE - OFF CABLES IN BOXES AND PANELS

A

2002/12/08

054

CAPACITANCE LEVEL SWITCH FOR UNDERPAN

A

2002/12/08

055

PRESSURE TRANSMITTER

A

2002/12/08

056

THERMOCOUPLE/RTD WITH REMOTE TRANSMITTER

A

2002/12/08

058

PHOTO ELECTRIC SWITCH

A

2002/12/08

059

HYDRAULIC RAM POSITION TRANSMITTER

A

2002/12/08


STATUS

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APPENDIX E: PHOTOS OF CORRECT INSTALLATION (INSTRUMENTATION) The following photos illustrate the correct installation of cable racks, control panels, junction boxes, relay and solenoid panels, IPDBs, PLC panels, Remote I/O panels, valves and other instruments. Also included are the correct cable routing, strapping, marking, glanding and termination.


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APPENDIX F: PHOTOS OF CORRECT INSTALLATION (ELECTRICAL) The following photos illustrate the correct installation of cable racks, motors, emergency stop push buttons, etc. Also shown are the correct cable routing, spacing and strapping as well as the cable laydown areas.


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Instrument Installation Requirements

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