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Engineering / Electrical
12 REV: C2
AREA: Norðurál Grundartangi Reduction Plant
SPEC No: 00/07/TS008
STANDARD TECHNICAL SPECIFICATION FOR INSTRUMENTATION
This Standard Technical Specification is subject to change without prior notice. The most current issue will at all times be located on the Nordural web site, www.nordural.is
REV C1 C2
BY HRY IMJ/TDS
DATE 01/03/1999 29.3.2004
CHK’D GP ÓJ
APPROVED TMS ÓJ
REVISIONS Issued for Construction Issued for Construction
NORÐURÁL - ENGINEERING
0 4.2004.3.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 CONTENTS SPECIFICATION PREFACE SHEET _________________________________________ 1 TECHNICAL SPECIFICATION__________________________________________ 3 1.0 5. REV.2 2.0 8.0 6.0 7.0 INSTRUMENT CABLE INSTALLATION _____________________________________ 8 PAINTING _______________________________________________________________ 10 IDENTIFICATION OF LINES AND INSTRUMENTS __________________________ 10 HEAT TRACING AND WINTERIZATION ___________________________________ 10 SPECIFIC REQUIREMENTS FOR PACKAGE EQUIPMENT ___________________ 11 MISCELLANEOUS________________________________________________________ 12 NORÐURÁL -2- 29. C2 .4 INTRODUCTION __________________________________________________________ 3 PIPING AND SUPPORTS ___________________________________________________ 4 GENERAL ______________________________________________________________________ AIR SUPPLY AND TRANSMISSION PIPING/TUBING _________________________________ PROCESS PIPEWORK ____________________________________________________________ PIPING AND TUBING SUPPORTS__________________________________________________ 4 5 6 7 3.0 2.3 2.0 2.1 2.
the Contractor shall by inspection confirm that it has been pre-tested in accordance with Clause 4..). solenoid valves etc. REV. Local instruments with the exception of those on lines and vessels shall be mounted with the centre line at approximately 1. NORÐURÁL -3- 29. Modifications to prefabricated panels must not be made without the written approval of the Engineer. Instruments shall not be bracketed directly off process lines except where specified by the Engineer.3.0 of the Instrument Installation/Commissioning Specification(NA/00/07/TS010) and Instrument PreCalibration Document (NA/00/80/40/07COM02) Issued to the Engineer. Throughout the construction period. The Contractor shall supply and fit these bags as required. and whose position is not previously specified shall preferably be rack mounted on slotted angle or similar framework. Owner: Norðurál hf (Nordic Aluminum Corporation Ltd. Local mounted instruments shall be bracketed.4 metres above the platform or floor in a position accessible for operation and maintenance. Wherever possible instruments shall be located so that they are protected from damage by passing or falling objects. from time to time to act on behalf of the Owner in the execution of the items covered by this Document. for any or all purposes provided in this Technical Specification.0 INTRODUCTION In this Document the following words and expressions shall have the meaning hereby assigned to them except where the context otherwise requires: Engineer: The Owner or any person or organization employed or engaged at any time by the Owner and authorized by the Owner. in writing. mounted in sub panels or placed on suitable pedestals. for mounting behind panels. instruments shall be protected adequately where necessary by covering with plastic bags of an approved type. an independent legal entity owned by Century Aluminum.2004. They shall where necessary be secured to the nearest suitable firm steelwork or masonry in a manner prescribed by the Engineer. Items such as miniature control valves. Before installing each instrument or equipment. C2 .NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 TECHNICAL SPECIFICATION 1. in whole or in any part.
for longer periods caps and plugs shall be used. joints should be systematically staggered and neatly off-set. NORÐURÁL -4- 29. eg for a period of up to one week adhesive tape may be used. All types of pipe and tube fittings supplied by the Contractor shall be approved by the Engineer before installation. There must be at least two pipes/tubes between adjacent joints. REV. Instrument panels shall not be used for earthing purposes. Where instrument pipes/tubing are run parallel to each other. but not connected. C2 . Pipes or tubes installed.3. 2.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 Handrails shall not be used for supporting instruments without prior approval from the Engineer.2004. The Contractor shall ensure that the specified thread and thread sealants are installed.0 PIPING AND SUPPORTS 2. Threaded fittings will have their threads specified in the Engineer's documentation.1 GENERAL Instrument piping and tubing to be installed must comply with Nordurál Standard Technical Specifications for Piping and can be classified in the following categories:(a) (b) (c) Air Supply Piping Transmission/Signal Tubing. Process Impulse Pipework. shall have the ends closed in an approved fashion to prevent the entry of foreign material. Where compression fittings are used the fittings shall be installed in strict accordance with the manufacturer's recommendation. All electronic instruments including control panels or instruments with electrical components shall be electrically earthed in strict accordance with the drawings.
Where tubing is run in conduit or closed ducting.5 Bar. aluminium and plastic tubing will normally be jointed with alloy. Where the size of air mains has not been specified it shall be established in accordance with the following tables. as specified in the instrument hook-up drawings. All pneumatic signal tubing shall be cleaned by blowing through with filtered air before connection to instruments.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 Where stainless steel compression fittings are used.2004. Number of Users Line Size Metric Equivalent 1 2 to 5 6 to 20 21 to 50 51 to 100 101 to 200 ¼" NB ½" NB 1" NB 1½" NB 2" NB 3" NB 8 mm 15 mm 25 mm 40 mm 50 mm 80 mm NORÐURÁL -5- 29. consistent with good practice. based on a minimum pressure of 4. Any discrepancies between the materials/fittings specified and the materials/fittings provided shall be brought to the notice of the Engineer without delay.3. C2 . Single core tubing shall be run in such a manner as to give the maximum protection against mechanical damage. except at special junction boxes provided for this purpose. brass or plastic compression fittings. the Contractor shall ensure that stainless steel nuts and olives are fitted unless otherwise specified by the Engineer. Plastic lines run in conduit or closed ducting shall not have joints. The number of joints in pipework shall be kept to a minimum.2 AIR SUPPLY AND TRANSMISSION PIPING/TUBING PVC covered copper. REV. 2. the Contractor shall ensure that entry and exit of such enclosures are clean and smooth. Horizontal runs of pipes and tubes shall have pipes/tubes laid vertically one above the other as far as possible and shall be run with the minimum number of changes of direction consistent with good practice and neat appearance.
The minimum bending radius for each cable will be as stated. The slope of the impulse pipework shall be down from the tapping point for liquids.3. The Contractor shall pay special attention to the correct siting of vents and drains to ensure they are at the highest or lowest points of the piping run.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 Where permanent enclosures trunking or conduit etc. Special care shall be taken when multicore tubing is being installed in low ambient temperatures. NORÐURÁL -6- 29.3 PROCESS PIPEWORK All impulse piping shall in general be run with a slope of not less than 1 in 12 except where otherwise specified. Steel piping shall be joined by compression fittings. Impulse lines shall be kept as short as possible consistent with good practice and accessibility. steam and condensibles and up from the tapping point for gas service unless special provisions are made for venting and draining. Multicore tubing shall not be bent to radii less than the manufacturer's recommendation. socket welding flanges or by screwed connections depending upon the piping specification for the relevant project. are left with space for tubes to be pulled in at some future date. a galvanised draw wire of adequate size shall be left in the enclosure. REV. 2. Process piping or handrails shall not be used to support instrument lines unless the Engineer's documentation indicates that this is the preferred method or where approval is obtained from the Engineer.2004. C2 . The minimum radius and temperature limitation for bending tubing during installation shall be as stated. This will be shown on the Instrument hook-up drawing.
Supported.5 metre intervals to mild steel strip (not less than 16 SWG. Three or fewer copper or plastic tubes may in certain cases be secured by appropriate clips at 0.5 metres Size 25 6 ft 0 in 2. such routes must be approved by the Engineer. PVC covered or galvanised cable trays shall be used for continuously supporting four or more copper or plastic tubes and the tubes shall be secured to the tray at 0. C2 .6 mm)) or laid in small section angle bar.Supported.0 metres Size 40 to Size 50 9 ft 0 in 3.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 2. 6 in.4 PIPING AND TUBING SUPPORTS The following lists the maximum allowable distance between supports for various piping and tubing types:- SIZE IMPERIAL MAXIMUM DISTANCE BETWEEN SUPPORTS METRIC IMPERIAL METRIC Copper 3/8: OD and less 3/8" NB to 3/4" NB Steel.5 metre intervals.0 metres Multicore Tube Plastic Single Tube.2004.B. 1" N. NORÐURÁL -7- 29. (1. three or fewer plastic or copper tubes may be supported by clipping the tubes to the air header at 0.5 metre intervals. Steel.3.0 metres Continuously Continuously Supported. Size 10 to Size 20 4 ft. 1. REV. 1½" to 2" NB Steel Multicore Tube Plastic Single Tube Size 12 or less Continuously Continuously Supported. With the approval of the Engineer. 3 ft 0 in 1.
cable spacings specified in the documentation shall be maintained. 3. In such cases the trunking etc. the breadth shall revert to the vertical plane at the earliest possible point. shall be supported to the satisfaction of the Engineer. However. Where the Engineer agrees that a short section must be run with the breadth horizontal. Cable trays supporting tubing shall be run with the breadth of the tray in a vertical plane. All cables to instruments shall be flexible (high temperature where NORÐURÁL -8- 29. The cable installation drawings and documentation provided by the Engineer will normally specify or incorporate regulations for the elimination of electrical noise pick-up. nominally 15 x cable external diameter. If run in the horizontal plane the tray shall be provided with additional supports to prevent sagging. Trunking or conduit may be used to replace cable tray under certain circumstances. REV. C2 . All static cabling on furnaces shall be Mineral Insulated and terminated in approved junction boxes.5 metre intervals. Multicore cables shall not be bent to radii less than the manufacturer's recommendations.2004.3. the following general rules apply.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 Capillaries of filled systems shall be run independently of all other lines and shall be supported continuously by using mild steel angle with clips at 0. Parallel runs of instrument cables and power cables should be avoided but where parallel runs must be made. Thermocouple cables shall be run completely independently of other instrument cables with a minimum separation of 150 mm and with "cross overs" at right angles. All installations shall be in accordance with the Norðurál Electrical Specifications.0 INSTRUMENT CABLE INSTALLATION The Contractor must ensure that whenever an Electrical Specification is issued the appropriate sections shall be read in conjunction with this Specification and any omissions or ambiguities should be resolved by the Engineer. Where instrument and power cables cross in close proximity the cross shall be made at right angles.
all runs shall be mechanically and electrically continuous. Conduit shall not be fixed by hook bolts unless agreed by the Engineer. Where conduit is installed. Care must be taken when PVC conduit or ducting is used that it is not run adjacent to plant equipment operating at elevated temperatures. Where hook bolts are used they shall be properly performed. No For metallic conduit. Cable trays supporting cables shall be run with the breadth of the tray in a vertical plane. the breadth shall revert to the vertical plane at the earliest possible point. terminals box. REV. PVC items shall not be subjected to temperatures in excess of 80°C. it shall be securely locknutted. NORÐURÁL -9- 29. intermediate joints shall be made on cable tray or in conduits.2004. Sharp edges shall be removed and conduit not otherwise connected shall be terminated in smooth bushes. bushed and ferruled in an approved manner. the entry and exit shall be smooth and free from burrs. Joints shall only be made at terminals in instruments or approved equipment. C2 . All threaded joints shall have a minimum of 5 complete threads for non hazardous areas and 7 complete threads in hazardous areas. trunking or ducting. Running threads shall not be permitted.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 necessary) and the connections to the rigid cable installation shall be via approved local junction boxes. Cable interfaces between static and moving equipment shall be via flexible cables with approved junction boxes at each end. Where the Engineer agrees that a short section must be run with the breadth horizontal. Clips and saddles securing cables to steelwork or tray shall be metallic and plastic covered. all exposed threads must be primed after screwing with an approved aluminium anti corrosive heat resistant paint. If run in the horizontal plane the tray shall be provided with additional supports to prevent sagging. Where conduit terminates at a cabinet. Conduit or mineral insulated metal sheathed cables shall be run horizontally or vertically or parallel to structure and steelwork. Cables shall be pulled into such conduits in a way that ensures there is no damage to the cable.5 metre intervals. Clips shall be spaced at 0. Where cables are run through electrical conduits.3.
0 HEAT TRACING AND WINTERIZATION A schedule of installations that require heat tracing will be provided by the Engineer and will include:(a) (b) (c) (d) (e) (f) Instrument tag number and type.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 Conduit pull boxes shall be provided at distances not exceeding three random lengths of 3 metres. tubing and wiring terminations. cable armourings. General information.0 IDENTIFICATION OF LINES AND INSTRUMENTS All site mounted instruments. air header isolation valves. Designing and Installations 4. Seal used. NORÐURÁL . junction boxes. The Engineer will provide a schedule of the label details for labels within the Contractor's supply. shall be labelled or tagged in a manner approved by the Engineer.2004.0 PAINTING Brackets and supports supplied by the Contractor and other materials not already protected in an approved way shall be primed and painted in accordance with the Norðurál 00/03/TS001 Standard Technical Specification for Surface treatment and Painting 5. Heat tracing may utilize steam or oil heating or electrical heating. 6.10 - 29. REV.3. C2 . Special care shall be taken to correctly earth all conduits. Process fluid and minimum required temperature. cable trays and all enclosures by the use of approved bonding accessories in accordance with Norðurál Electrical Specification NA/00/06/TS013 Electrical Specification for General Electrical Engineering. cracking etc. with regard to the possibility of boiling off. Not more than two right angle bends occurring in one pull. Type of tracing insulation and housing. Associated vessel or pipeline identification.
20 mA etc) and digital communication cables shall be screened. 7. limit switches. indicators. All low level instrument transmission signals (4 . the Contractor shall ensure that all instrument lagging is installed correctly.1. REV.0 SPECIFIC REQUIREMENTS FOR PACKAGE EQUIPMENT This section of the specification covers the requirements for the cabling of instrumentation equipment supplied with the main equipment. All flexible cables shall be adequately supported and protected using either a closed or open GI conduit system. Siemens OZOFLEX Type HO7RN of the correct size for the equipment. transmitters may be mounted in housings. The Contractor shall pay special attention when connecting tracing to such items as control valves with heated bodies and d/p cells with trace heating bolts.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 The medium to be used shall be specified. Manufacturer's recommendations shall be followed.2004. Twisted pair and Full floating balanced.3.11 - 29. In general. However. NORÐURÁL . They will not normally be mounted in housings. This lagging will be done by others. All field devices and junction boxes shall have an enclosure rating of IP56 or above. These housings will normally be provided by the Engineer. and controllers which require tracing shall be mounted in heated housings. Locally mounted pressure gauges shall where necessary be protected by steam tracing. All sensors. All field devices and instruments shall be tagged with an alphanumeric identification number in accordance with ISA 55. Field mounted recorders. actuators and the like shall be cabled using flexible cables. the Contractor shall ensure that all instrument tracing is installed correctly. However. all heat traced equipment and lines shall be suitably lagged or insulated. C2 . The main control cable routes shall use multicore cables to be specified by the supplier. Steam or oil heating will normally be installed by the Contractor but electrical heating is usually installed by others. Where specified. All flexible cables shall be terminated in a field junction box or boxes.
Any PLC programme shall be written in a structured format in a logical progression. The working programme shall not be stored in the RAM. All these units will be included in the supply and shall comply with the technical specifications for electrical equipment. except in the case of blocks containing dynamic data.2004. shall be performed within the junction boxes or panel. but will be provided and installed by others in accordance with the suppliers installation instructions. desks or programmable controller (PLC) racks will be similarly tagged using the Engineer's cable numbers. The installation shall be immune from Radio Frequency interference from portable hand held radios operating at frequencies of 140 MHz and 1000 MHz at 4 watt power level from a minimum distance of 0.0 MISCELLANEOUS In addition to equipment directly attributed to control and instrumentation it is anticipated that general electrical equipment such as circuit breakers.3. will be required to complete the system. 8. selector switches etc. Any cross wiring etc. As far as possible the programme should enable conversion to "Ladder" logic. SFC (Sequencial Function Chart) and CFC (Continuous Function Chart) although it may be initially written in "Statement List". consoles. Following the commissioning of any PLC system the complete programme where applicable shall be stored in internal ROM in the CPU or written on an EEPROM which shall be installed in the CPU.12 - 29. All cable cores shall be tagged and terminated consecutively on I/O terminals. The control panels and racks shall be fitted with incandescent lamps controlled by door switches.5 meters. fuses. In the case of junction boxes the Contractor may provide separate I/O terminals to facilitate cross wiring. All main cable runs from junction boxes to control panels. REV. All cables to control panels. NORÐURÁL . consoles. Cable numbers will be issued on request. All multicore cables shall be PVC/PVC and shall be specified by the supplier. desk or PLC racks will be bottom entry. lamps.NORÐURÁL NORDIC ALUMINUM STANDARD TECHNICAL SPECIFICATION 00/07/TS008 All field device cables shall be tagged with the corresponding device tag number. C2 . All I/O terminals shall be suitably located to permit easy access for cable glanding and termination.
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