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App A - SOW
App A - SOW
Appendix A
Page 1 of 17
INDEX
1.0 INTRODUCTION
2.0 OBJECTIVE
12.0 SAFETY
13.0 COMMISSIONING
17.0 GUARANTEE
18.0 TRAINING
Appendix A
Page 2 of 17
ATTACHMENTS:
ABBREVIATIONS
BS : British Standard
CCR : Continuous Catalytic Reformer
Co60 : Radioactive material of Cobalt with isotope mass 60
Cs137 : Radioactive material of Cesium with isotope mass 137
CRCS : Catalyst Regeneration Control System by UOP
DCS : Distributed Control System
GM Counter : Geiger Mueller Counter
HSE : Health, Safety and Environment, QP Refinery
mCi : milli-Curie, a measurement unit for radioactive source activity
MoE : Ministry of Environment, Qatar
NOC : No Objection Certificate
OEM : Original Equipment Manufacturer
PTW : Permit To Work
RPO : Radiation Protection Officer, QP Refinery
SAT : Site Acceptance Test at QP Refinery
SER : Satellite Equipment Room
SPDT : Single Pole Double Throw, a type of Relay Contact
Appendix A
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1.0 INTRODUCTION
QP owns and operates a Refinery at Mesaieed, which is around 35 km. south of Doha
in the State of Qatar.
2.0 OBJECTIVE
The objective of this CONTRACT is to utilize the services of a competent, safety-
conscious and experienced OEM as CONTRACTOR to undertake the critical
replacement of radioactive level measurement and alarm systems in accordance with
this scope of work, specifications, standards and requirements specified herein on or
before SCHEDULED COMPLETION DATE to QPs Satisfaction.
Appendix A
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In radioactive level measurement and alarm systems, a radioactive source and
detectors are installed in the vessel by suitable mounting brackets. Power supply,
mono rack and transmitters are installed at remote location called Satellite Equipment
Room (SER 5).
The complete system comprising radioactive source, container, detector and electronic
units were supplied by M/s Endress + Hauser, Germany in the year 2000. Details of
the existing system in the CCR Unit 63 are provided in AttachmentI of this Appendix
A.
Discrete level alarm system is used to generate alarm at designated catalyst levels.
There are four (4) discrete level alarm systems at QP Refinery to generate level
alarms in Reactor (6301D), Dis-engaging hopper (6334F) and Lock Hopper Upper &
Lower (6338F) with tag names 63RLY002, 63RLY004, 63RLY008 and 63RLY009
respectively. Each system contains Cs-137 source and Scintillation/Geiger Mueller
(GM) counter type detector to generate alarm at desired catalyst level.
All discrete level alarm systems comprising radioactive source, container, detector and
electronic units were supplied M/s Endress + Hauser, Germany in the year 2000.
Details of the existing system in CCR Unit 62 are provided in AttachmentI of this
Appendix A.
All radioactive level detectors in CCR Unit 63 shall be replaced with latest type of
detectors. This will involve the replacement of old radioactive level detectors, power
supply, electronic units, cables, etc.,
Also, it is required to replace some old radioactive sources with containers as they
have decayed.
New radioactive level measurement and alarm systems shall be designed with a
useful life of minimum fifteen (15) years without any performance degradation. The
new system shall be designed with minimum source activity to the lowest extent
possible. The new system shall comply applicable Qatari and International Rules and
Regulations.
Appendix A
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Once the new level measurement and alarm system is installed and commissioned,
CONTRACTOR shall export all old radioactive sources either to OEM or to any
authorised company for appropriate disposal as per Qatari and International Rules and
Regulations.
6.1 The intent of this Appendix is not to specify completely the details of design,
engineering, procurement, supply, installation, testing, commissioning and
documentation of radioactive level measurement system at QP Refinery.
6.2 CONTRACTOR shall retrieve and review existing drawings and documentation and
shall carry out detailed WORKSITE survey to verify drawings are as-built before
proceeding with detailed design. In case of any discrepancy, CONTRACTOR shall
mark up actual as-installed details on drawings or documentation. QP is not
responsible for any difference between drawings or documentation and actual
WORKSITE installation. CONTRACTOR shall update existing drawings or
documentation related to the WORK.
6.3 All design data, drawings, specifications, and other information provided either directly
or indirectly by QP are for CONTRACTORs information and guidance only.
6.4 If a WORKSITE survey is required prior to bid submission, QP will make arrangements
upon CONTRACTORs request.
6.6 CONTRACTOR shall ensure that the new system is designed, procured, installed,
tested, pre-commissioned and commissioned in accordance with QP and other QP
recognized national/international codes and standards.
6.7 Except as expressly provided herein, CONTRACTOR shall procure and supply all
materials including cables, testing devices, equipments, tools, consumable materials
and every other item of expense necessary for the execution of this CONTRACT.
CONTRACTOR shall install all items including cable laying, cable support, and
associated wiring/termination at the like as required. CONTRACTOR shall arrange
required specialists and labors as required.
6.8 Any deviation from QP specifications, standards, philosophies and codes of practice
shall be submitted by CONTRACTOR to QP for prior approval before any action is
taken on any deviation.
Appendix A
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6.9 CONTRACTOR shall advise QP of any design alternatives that may offer better
techno-economic solutions, if any.
All field equipments shall be suitably designed for outdoor use without any additional
protection. All electrical equipments exposed to direct sun light shall be provided with
permanent sun shades to avoid over heating and premature failure due to black body
radiation. Local climatic conditions are furnished below.
The scope of WORK to be performed by CONTRACTOR include but not limited to the
following and any other matter or thing necessary to bring the CONTRACT to
COMPLETION in accordance with requirements as specified in this CONTRACT. The
existing radioactive level measurement/alarm systems shall be replaced partly with a
state-of-art radioactive level measurement system. The various components, which
require refurbishment, replacement and/or services as a part of this CONTRACT are
described in following sections:
The existing radioactive level measurement and alarm systems shall be replaced with
latest state-of-art measurement system. The new system shall be capable of
measuring levels of solid catalyst in cylindrical metal vessels of different diameters and
wall thicknesses with radioactive source and scintillation type detection system.
Each system shall consist of a radioactive source of appropriate size, approved source
container, detector assembly, power supply, control unit and the like.
Appendix A
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In case of continuous level measurement system (Level Transmitter), the output of
detector shall be linear and proportional to the level of solids over a range of
measurement. In case of discrete level switching system (Level Switch), the output of
detector shall de-energize a relay at desired catalyst level.
The existing system have been exposed to ambient conditions for more than 15 years
and hence the integrity of radioactive source capsule and container shall be verified by
the CONTRACTOR during SITE SURVEY and shall recommend replacement.
Radioactive source containers supplied as a part of this CONTRACT shall have an in-
built shutter lock mechanism, which can be operated by a key. When the source
container is loaded with a radioactive source capsule of maximum activity for which it
has been designed and with the shutter or source control mechanism in the beam off
position, the radiation levels shall not result in an ambient dose equivalent rate or
directional dose equivalent rate, as appropriate, exceeding 1.7 Sv/h at any
accessible location on the gauge surface.
If the primary shielding material of radioactive source has a melting point of less than
800 Deg C then the system shall be designed in such a way that the radioactive
source container is entirely sealed within a durable metal vessel that has a melting
point of more than 800 Deg C; and maintain the required effectiveness of the primary
shield, if the shielding material is in a molten state.
Each source container shall be durably marked with a legibly stamped or engraved
label with the following information:
i) manufacturer name, model and serial number of the radioactive source and/or
container;
ii) name and address of the source supplier and/or manufacturer;
iii) name of the radioactive material;
iv) model and serial number of the radioactive source;
v) ISO class number of the radioactive source;
vi) original activity of the radioactive source and date the activity was measured;
vii) maximum radiation dose rate at one metre from the surface of the source
container (with all shutters closed) and date of this measurement.
CONTRACTOR shall perform radiation leakage tests for new source containers at
WORKSITE in the presence of Radiation Protection Officer (RPO) of QP Refinery. If
radiation leakage exceeds the recommended limit at any time within 12 months from
the date of Site Acceptance Test (SAT) then CONTRACTOR shall repair or replace
source container at free of cost.
Appendix A
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CONTRACTOR shall assess remaining life of radioactive sources and shall
recommend replacement, if the remaining life is less than 10 years. The size and
activity of new radioactive source shall be designed in such a way to generate only
adequate field strength to detect switching point depending upon the type of detector.
The OEM of new radioactive source capsules shall provide source certificates and
reacceptance certificate to take back the radioactive sources without any additional
cost for disposal from the end user (QP Refinery) once the radioactive source has
reached its end of useful life or is no longer required by QP Refinery.
All level switches are required to be operated when the level reaches switching point.
The detector and its electronics unit shall be capable of sending a signal to the
Catalyst Regeneration Control System (CRCS) to initiate defined action. In case of low
level switch, the normal level of catalyst is above radiation beam. In case of high level
switch, the normal level of catalyst is below radiation beam. During normal operation,
removal or addition of catalyst is continuous.
Detector electronics shall drive an output relay at designed switching point, which shall
change a SPDT or DPDT contact. CONTRACTOR shall furnish contact ratings of this
relay. The relay shall be de-energized when the solids are below the radiation beam
(Low level fail-safe). Fail-safe action implies that the design of the unit maximises the
probability that the unit will fail in the position specified. Details of existing level switch
wiring is shown in Attachment-IIA & Attachment-IIB of this Appendix A.
.
Set point drift caused by electrical and ambient variations shall not exceed 10 % of
designed field strength or count rate.
The response time specified in the document applies only to the direction of emptying
as indicated for each item. Response time in opposite direction is not critical to the
process and may be adjusted as necessary to optimize the primary response. The
response time specified shall include any time required for recovery of electronics from
the effects of high field strengths on the detector.
CONTRACTOR shall replace all radioactive detectors with latest type of scintillation
counter type detectors for all switching applications. This type of detector will
considerably reduce source size, source activity and increase accuracy of switching
point.
Appendix A
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catalyst path length. Details like vessel dimensions, process specifications, and the
like are provided in Attachment-IV of this Appendix A.
The level transmitter shall generate an output proportional to the level of solids over a
range of measurement. The output shall be 4-20 mA DC, which is compatible with
Honeywell DCS for process monitoring. The removal and filling rates of catalyst is
continuous. CONTRACTOR shall replace all detectors with new type of scintillation
type detectors.
Level transmitter systems shall have a point source and a linear detector.
CONTRACTOR shall provide latest scintillation type detector. CONTRACTOR shall
mention maximum height of measurement possible with a single detector with a point
source.
If one set of source and detector is not enough to cover required range of
measurement then CONTRACTOR shall supply provide two detectors. Wirings and
configuration shall be carried out accordingly to accommodate two detectors. Similarly,
if one source cannot cover entire length of measurement then two sources shall be
provided. Sources shall be tilted in order to cover active length of detectors.
CONTRACTOR shall supply and install remote display unit for all Level Transmitters at
appropriate location at the same plat form.
New detectors shall operate with 24 VDC power supply. QP will provide redundant 110
VAC, 50 Hz single-phase power supply at one location in SER5. CONTRACTOR shall
install a redundant 24 VDC power supply units in SER5 and shall distribute power
supply to all control units/radioactive detectors. CONTRACTOR shall keep a provision
to isolate any instrument independently.
All equipments to be installed at field and SER5 shall be suitable for hazardous area
classification Zone 1; Gas Group IIC; Temperature T4 as defined in BS 5345. Field
equipment shall be explosion proof and a copy of typical explosion proof certificates
issued by competent authorities shall be submitted along with bid. All field equipment
shall be weather proof IP66, NEMA 4X or higher.
7.7 Cable
Appendix A
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CONTRACTOR shall check suitability of existing signal cable between field detector
and electronics located at SER5. The existing cable may be used for signals from new
radioactive detectors. If existing cable is not suitable then CONTRACTOR shall
replace the same with suitable cable. If cable tray or support is required for any new or
existing cable then CONTRACTOR shall supply and install the same. CONTRACTOR
shall supply/install cables and any other materials to hook-up new control unit and
power supply units, which will be installed in SER5.
If the new detector require external power supply (4 wire system) then QP will permit
the CONTRACTOR to use existing Junction Box (24VDC) between SER5 and CCR
platform. It is the responsibility of CONTRACTOR to provide necessary branch cables
(2C X 2.5 Sq.mm) from junction box located at CCR platform to each radioactive
detector. Contractor shall supply/install cables, cable glands, cable tray/support and
any other materials to power new radioactive detectors from SER5.
All power cables shall be flame retardant type conforming to BS 5467 with outer
sheath colour black. Core colours shall be Red (Positive) and Black (Negative).
If the weight of the new system is heavier than existing system then CONTRACTOR
shall inform QP in order to verify vessel support and additional support/reinforcing
requirements.
Cooling jacket shall be provided for all detectors as they are exposed to high
process/ambient temperature.
Cooling water supply is provided for each detector. But it may be plugged or not
effective. Hence, CONTRACTOR shall check and confirm existing cooling water
system can provide adequate cooling.
Appendix A
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Wherever cooling water system is not effective, CONTRACTOR shall provide
independent vortex cooler for each radioactive detector. QP will provide instrument air
connection at nearest location depending upon availability. CONTRACTOR shall
provide necessary stainless steel tubings, fittings, isolation valves, regulators,
pressure gauges and support for vortex coolers.
The radioactive level measurement system shall be capable of detecting solids of 1.6
mm spheres with a bulk density of 560 kg/m3. The tangent angle of repose is
approximately 0.5. Mechanism of addition and removal of catalysts has been designed
in such a way that the shape of the cone formed by catalyst will not be disturbed.
CONTRACTOR shall provide a list of all spare parts with part number and budgetary
price in order to order and maintain all new hardware for uninterrupted operations after
commissioning.
Appendix A
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containers, detectors, if required. Also, CONTRACTOR shall check effectiveness of
cooling water system.
Also, CONTRACTOR shall check remaining life of radioactive sources and shall
replace any sources, if the remaining life is less than 10 years.
CONTRACTOR shall provide list of items with model number and other technical
details to QP for review before releasing PURCHASE ORDER for procurement.
CONTRACTOR shall check and report any damage in the packing or container of new
radioactive sources upon receipt of material at WORKSITE.
CONTRACTOR shall unpack and check materials against packing list. Any damage
shall be reported to QP and damaged items shall be replaced without any additional
cost to QP. CONTRACTOR shall keep all radioactive sources in safe storage room at
QP Refinery until installation at WORKSITE.
CONTRACTOR shall provide original source certificates with distinct serial number of
capsules for all new radioactive sources. Also, they shall provide a letter of
Appendix A
Page 13 of 17
reacceptance by OEM to take back old radioactive sources after end of useful life or is
no longer required by QP Refinery.
New Radioactive sources shall be kept in a special storage room for radioactive
sources at QP Refinery until installation.
After replacement, old radioactive sources shall be kept in storage room until export.
Movement of radioactive sources shall be carried out strictly under the supervision of
Radiation Protection Officer (RPO) of QP.
Once new level measurement and alarm systems are installed and commissioned,
CONTRACTOR shall export old sources for authorised disposal. Available source
certificates would be provided by QP. CONTRACTOR shall obtain necessary
documents including acceptance letter from the OEM of old radioactive sources to
obtain export license in Qatar.
Appendix A
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12.0 SAFETY
CONTRACTOR shall follow all local and international safety rules and regulations for
personnel and radiation safety. CONTRACTOR shall ensure that all CONTRACTOR
PERSONNEL shall have undergone necessary safety training as required by QP
procedures as well as statutory requirements and shall provide records to substantiate
the same.
12.1 No work shall be carried out without necessary Permits to Work (PTW).
CONTRACTOR shall adopt and follow the PTW system in all QP restricted and
unrestricted areas.
12.3 CONTRACTOR shall keep first aid accessories and shall immediately report
any accident or near miss incident to QP.
12.4 CONTRACTOR shall conduct a detailed investigation and identify all hazards
that arise of any incident and submit the intended corrective actions to QP.
Based on frequency of incidents, CONTRACTOR performance will be subject to
review and where necessary, WORK shall be stopped until corrective measures
are in place.
13.0 COMMISSIONING
CONTRACTOR shall ensure that all equipments and cables are properly installed and
terminated before commissioning the system.
CONTRACTOR shall carry out preliminary checks and required loop testing prior to
commissioning of the system.
It may not be possible to empty or fill catalyst to required level. Hence, new radioactive
level measurement and alarm systems shall be commissioned on-line. CONTRACTOR
shall simulate catalyst before putting the new system in service. The system will be
kept under observation for at least four weeks after successful commissioning.
Appendix A
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CONTRACTOR shall inspect all hardware upon receipt for any transit damage.
CONTRACTOR shall inspect hardware installation, cabling, termination, grounding,
and the like before power-on.
The SAT shall include complete performance and functional testing of the installed
equipments. Some of the SAT activities may co-exist with commissioning.
CONTRACTOR shall submit radioactive source sizing calculation along with bid.
CONTRACTOR shall submit three (3) hard copies and one (1) soft copy sets of final
drawings and documentation to QP within four (4) weeks from completion of SAT.
18.0 GUARANTEE
Appendix A
Page 16 of 17
All WORK including supplied hardware/instruments shall be guaranteed by
CONTRACTOR/OEM for a period of twelve (12) calendar months from the date of
SITE ACCEPTANCE TEST.
19.0 TRAINING
The normal working week consists of five (5) days, 06:30 A.M. till 2:30 P.M., eight
hours a day, Friday and Saturday are week ends.
Appendix A
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