Stay dust & faa ama fatresta STANDARD SPECIFICATION FOR ERECTION TENDER 17.07.87 [ISSUED AS STANDARD SPECIFICATION Ge ov ua, Wher No. | DATE REVISION By, CHECKED | CONVENER |CHRTANAN (6.2) ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR |__SPECIFICATION | REV NEW DELHI ERECTION TENDER 6-52-60 Page 1 of 21 °be reproduced, ElL-1641-507 A4 210x297 ‘on the borrower's express agreement that they wi w property of ENGINEERS INDIA LIMITED. They ara ms by aw Format zt The ara copied 1.0 GENERAL 2.0 DEFINITIONS 3.0 SCOPE OF WORK CONTENTS 4.0 EXECUTION METHODOLOGY 5.0 DRAWINGS AND DOCUMENTS TO BE SUPPLIED FOR EXECUTION BY OWNER/ENGINEER-IN-CHARGE 6.0 DRAWINGS AND DOCUMENTS TO BE PROVIDED BY CONTRACTOR 7.0 MATERIALS SUPPLY 8.0 SCRAP AND EXCESS MATERIAL S ENGINEERS INDIA LIMITED NEW DELHI STANDARD SPECIFICATION FOR SPECIFICATION REV ERECTION TENDER 6-52-60 Page 2 of 211.0 GENERAL. 1.1 This specification, in gene: 1, covers the Scope of work, execution methodology, drawing 3 and document requirements, criterion for handling scrap and excess material, material supply requirements necessary to complete various works defined in this document, and other requirements which are required to be complied during the course of execution of instrumentation works. Be 1.2 Instrumentation works shall be performed in accordance with this technical specifications £8 and various other drawings and schedules supplied during the execution of work and 28 instructions received from Engineer-in-Charge or his authorised representative(s) from time Pg to time during the execution of this work. 2.0 DEFINITIONS 2.1 Manifolds 2.1.1 For close coupled instruments, wherein the distance of instrument is within 0.6 metre (2 feet) from the instrument tapping, “Manifold” shall mean complete piping of instruments from first block valve upto the instruments, 2.1.2. For remote mounted instruments, wherein distance of instrument is more than 0.6 metre 2 feet) from primary tapping such as orifice, “Manifold” shall mean the assembly of “nipples, valves and fittings around the instrument to form a block and bleed or pass manifold or drain manifold as the case may be. These shall be generally according to the installation standards enclosed with tender, Wherever the instruments are installed with built-in manifold (for example 2 valve-3 way manifold), this definition shall not be applicable as the built-in ma 2.2 First Block Valve Id forms part of the instrument. First block valve shall mean the valve/valves those are mounted directly on equipments, columns, vessels, pipes, standpipes etc, and shall be operated to isolate the instrument and interconnected instrument piping from the tp off point Supports {format are the property of ENGINEERS INDIA LIMITED, They ar merely loanad on the borrower ted way permit Supports shall mean the MS (mild steel) angles, flats, channels those are generally provided 5 to support the main cable ways, cable ducts, junction boxes, angle trays, perforated trays. 3 instrument impulse tubing/piping, signal tubing, instrument air supply lines ete.. at By specified intervals to keep all items firmly to protect the installation secured against 2 3 vibration, warping, bending etc. 5 ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR |_ SPECIFICATION bat NEW DELHI ERECTION TENDER 6-52-60 Page 3 of 21faned on tha borrower's exprase agreement that they fo the borrower for the intended use, EIL-1641-507 A4 210x297 GTENGINEERS INDIA LIMITED. Th The drawing, design and details given on thes format ara the proper 24 24.1 2.4.2 3.0 3 Scrap Salvageable Scraps Salvageable scrap shall mean lengths of tubes, pipes, multicables, other cables ete. that can be used one time or other at a later date. ‘This material is recovered from the cut-pieces of tubes, pipes, multicables, cables ete. Non Salvageable Scrap Non salvageable scrap shall mean the cut piece lengths of tubes, pipes, multicables, cables etc, and they are from cut pieces of tubes, pipes, multicables, cables etc. that cannot be used at all, at any time. Standards ‘The instrumentation erection, calibration and testing shall be carried out in accordance with various related national, international and Indian Standards. in instrumentation but not limited to the following. The Standards referred herein and mentioned below shall be of the latest edition prior to the date, of the purchaser's enquiry API Americagn Petroleum Institute MPMS - Manual of Petroljeum Measuring Standards RP - Recommended Practices BS-6739 Instrumentation in process control systems : Installation design and practice ISA Instrument Society of America Standards, Recommended Practices, and Technical Reports. RP 7.1 Pneumatic Control Circuit Pressure Test Is-5 Colours for ready mixed paints and enamels Is-2074 Ready mixed paint, air drying, red oxide-zine chrome priming 752-253 Duct fabrication details. 7-52-2083 Tubing Hook-up (Pneumatic) onwards 7-52-401 Instrumentation Installation Standards onwards (Process Hook-ups) - Instrumentation supports standards ~ Manufacturer's randards and practi SCOPE OF WORK Contractor scope of work shall include the following ; a) Complete instrument erection work with details as listed under “Schedule of quantities’ attached elsewhere in the tender document. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 0 SPECIFICATION REV Page 4 of 21ey wil not be reproduced for the intended use. EIL-1641-507 Ad 210x297 i lender to the bor 1d way permittad by a written consent given by ‘or used, exee 32 3.21 3.2.2 3.2.3 3.2.4 3.25 3.2.6 3.2.7 3.2.9 b) Supply of all hardware and residual activities not listed specifically in “Schedule of Quantities’ but are necessary to ensure proper execution and completeness of instrumentation work ©) Supply of all items specifically listed in the “Schedule of Quantities” with specifications attached else where in the tender document 4) As-built construction drawings and documents as detailed out in this specification ©) Arranging all necessary test and calibration equipment as per details provided in this specification 1) Any other work, not specifically listed, but necessary for the successful completion of instrumentation erection work defined in this specification ‘The various jobs covered under Instrumentation erection work are detailed out in the schedule of quantities. However to ensure proper execution and completeness of works any or all of the following acti ities, as necessary, shall also form part of the vendor scope of work, The price of all such activiti shall be covered in the quoted rates Fabrication of pipe nipples as neces: ry including threading as per installation standards, Drilling of holes in blind flanges including cutting threads as per installation standards. Filling of seal pots filling liquids as per the instructions of Engineer-in-Charge al welding of screwed fit of Engineer-in-charge. This may involve welding of dissimilar materials using appropriate Back/s gS as required by standards or as per the instructions electrodes. Installation of purging devices tor i truments and instrument systems as per installation Standards. Civil works including the casting of foundation as required for instrument supports where paved surfaces do not exist. Minor civil works like chipping of pavement, grouting of instrument panels/supports/ stanchions on the pavement, laying of conduits below pavement afier chipping and refinishing of pavement as necessary. Sealing of cables/tube entries into the control room after laying and testing of all cables! tubes either by filling with sealing compound or by installing Multi-Cable Transit block (MCT) including fixing of MCT frame, routing of cables through cable blocks, tightening of cable blocks. Degre: 1g of handwheels of control valves, stud bolts, nuts of side and bottom flange of control valves, skid bolts and flanges of orifice plates/or other primary elements and degreasing of any other instrument as per manufacturers instructions or as required by Engineer-in-Charge. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 5 of 213 2 e 1 of ENGINEERS INDIA LIMITED mat are the prop way permitted by The draw borrower for the copied, ex 3.2.10 3.2.11 3.2.12 3.2.13 3.2.14 3.215 3.2.16 3.2.17 3.2.18 3.2.19 3.2.20 3.2.21 3.2.24 3.2.25 Degreasing of impulse lines, valves instruments and other instrument items in oxygen and chlorine service as per manufacturer's instructions or as required by Engineer-in-Charge, Rotation of top works of Displacer type level instruments wherever required Rotation of control valve bonnet wherever required Reversing the action of control valves either by replacement of actuator springs. accessories or positioner wherever required as per manufacturer's instructions or modification/repairs required to be carried out on the instruments namely. replacement of dial, glass for pressure gauges/temperature gauges or any other similar instrument, replacement of rotameter tubes and level gauge glass; replacement of damaged signal tubes on control valves; tapping of damaged threads on couplings, tees and other fittings; cleaning of nozzles and relays in pneumatic instruments Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts as per painting specification or as instructed by Engineer-in-Charge. Identification of instruments/impulse lines/manifold connected with alarm/trip circuit with approved colour of paint. Punching of tag numbers on items or tag plates wherever required as per instructions of Engineer-in-Charge. Fabrication and installation of pipe stanchion as per Instrument support standards including casting of concrete pedestal, grouting, welding etc. as necessary. Drilling holes for providing glands/grommets on panels, shut down cabinets, power supply cabinets, local control panels, pneumatic enclosures, junction boxes ete... wherever required for cables/mutitubes entry. Grounding of shields of shielded cables to respective instrument earth bus provided in the control room/local panel/thermocouple head etc. as required and instructed by Engineer-in- Charge. Laying and termination of earth cable at both ends between instrument earth bus provided in control room/local panel to instrument earth pits provided by other contractors unless specified otherwise. Grounding of one of the thermocouple lead in the head using 10 k @ resistance including of supply of resistance for grounded thermocouples Supply of all types of consumables required for the execution of the job without any exception. Sealing of safety valves with standard lead seals after final setting in the presence of Engineer-in-Charge Coordination during installation, precommissioning and commissioning with mechanical and other sub-contractors for proper installation of line mounted instruments like control ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR SPECIFICATION REV NEW DELHI ERECTION TENDER 6-52-60 ° Page 6 of 21That they will not be reproduced, ‘express agreama! The property of ENGINEERS INDIA LIMITED. They are merely loaned oF format The drawing, design and deta by the lender to the borrower for the inten way permitted by a written consont giv copied, exhibited or used, except in 3.2.26 3.2.27 3.2.28 3.2.29 3.2.30 3.2.31 3.2.32 3.2.33 valve, orifice assemblies, turbine meters, PD (positive displacement) meters, magnetic flowmeters, mass flowmeters etc., which involve removal of instruments, disconnection of tubes/cables; reconnection of same for alignment and proper installation. Coordination during precommissioning/commissioning with mechanical and other sub- contractor for proper installation of vessels/equipment mounted instruments like level transmitters, level gauges, level switches ete which involves removal of instruments, disconnection of tubes/cables, reconnection of the same for alignment and proper installation ete. Coordination with control system vendors (Distributed Control System (DCS)/ Programmable Logic Controller (PLC) /Analyser system/Terminal Automation ete), as necessary, during installation, loop checking and commissioning as per instructions of Engineer-in-Charge. Submission of monthly material appropriation statements for cables, tube, piping material and fittings, indicating the quantity issued and consumed in standard proforma. Incorporation of all information in owners drawings/document, as per the actual execution of work at site including preparation and submission of as-built drawings, Start-up and commissioning assistance as required and agreed upon with Engineer-in- Charge. Submission of final material appropriation statements for all the materials issued by the Owner. Any other work not specifically mentioned above, but required for the proper execution of the instrumentation erection work Where requested by Owner/Engineer-in-Charge or his authorised representatives, all or any of the works detailed above and schedule quantities shall also be performed on package units, local panels/eabinets/gauge board installed by owner or by others Work Excluded Installation of main panels, cabinets and consoles inside control room unless: specified otherwise. Installation of line mounted instruments like control valves, orifice plates and flanges. variable area flowmeters, magnetic flowmeters, tank level instruments etc. Installation of safety valves, breather valves, flame arresters, rupture discs. First block valve for instrument tapping points on piping and equipments Insulation of steam traced instrument primary impulse lines, Painting of impulse lines. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR SPECIFICATION REV NEW DELHI ERECTION TENDER 6-52-60 0 Page 7 of 214.0 EXECUTION METHODOLOGY 4.1 Instrument Impulse lines 4.1.1 All impulse lines shall be installed in the best workman like manner and shall follow installation standards in each case. Where there is no installation standard, the instruction of the Engineer-in-Charge shall be followed 4.1.2 Horizontal and vertical lines shall be installed using levels and plumb bobs. 4.1.3. Unless otherwise specified in the drawings, impulse lines shall have a slope of not less than 1 in 12 on the horizontal runs, 4.1.4 All welding shall be ried out as per welding procedures and codes with electrodes approved by Engineer-in-Charge. Only qualified welders approved by Engineer-in-Change shall carry out welding, Charges for non destructive testing like radiography. dye nded use, E1L-1641-507 A4 210x297 penetration tests, post weld heat treatment tests and stress relieving shall be worked out on the basis of actual man hours spent towards these works and manhour charges with cost =I on the bowwowar's express agroom of all materials, test equipments, etc., shall be used. However, any materials like electrode, equipments, testing charges for various tests etc., required for initial qualification of the welder/ welders shall be borne by the contractor. Wherever welding of dissimilar materials, 2 are envisaged for any process hookup, the contractor's scope includes these welding alongwith supply of weld materials, ne 4.1.5 Impulse pipes shall be bent using pipe benders only, hot bending will be totally rejected. Pipes shall be cut using pipe cutting device. Hot cutting will not be allowed. 4.1.6 — Piping/tubing for steam tracing shall be installed according to the standards without any pocket so as to avoid formation of the condensate pockets n consent given by the 4.1.7 All threaded joints shall be jointed with PTFE tape only. No other pipe jointing compound shall be used except on high temperature service where graphited sealing compounds shall erty of ENGINEERS INDIA LIMITED. They are merely I be used. 4.1.8 All impulse lines shall be properly supported at regular intervals of 1 metre, Wherever insert plates are not available, supports on concrete structures or on ceilings shall be fixed with a minimum of 10 mm expansion bolts. Angle supports shall be fabricated from 40 mm. a minimum x 40 mm x 5 mm MS angles, 42 PVC Covered/Bare Tube (Copper/SS/Alumi jum) 4.2.1 Single copper/SS/Aluminium tubes shall be laid as per standards on perforated steel plate The width of the trays shall be selected as per the number of tubes laid, Tubes shall be clamped to the trays at every 300 mm using clamps made of galvanised steel/aluminium led oF used, except strips, The practice of flattening tubes for clamping purposes shall not be permitted, In ease of PVC covered tubes, any exposed portion at ends and connection shall be neatly taped The drawing, design and detals give ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR |_ SPECIFICATION ne NEW DELHI ERECTION TENDER 6-52-60 Page 8 of 21z hey 297 rwer's express agreament tha ise. EIL 1641-507 Ad ENGINEERS INDIA LIMITED, Thay ara mere The drawing, design and datails givan on this format are the proper 4.2.2 4.2.3 43.3 43.4 43.5 43.6 44 441 44.2 to appropriate thickness. Open ends shall be covered to prevent ingress of moisture dust, vermin etc, Plugs should be removed only when final connection is made. Trays all be properly supported either from any rigid steel structure or concrete member as detailed under trays and supports as detailed in para 4.7.4 of this specification. All threaded ends of male/female tube connectors shall be installed with PTFE tape only Wdentification tag plates/terrules shall be provided on either side of copper tubing as per tubing/junction box schedules. Identification ferrules shall be single sleeve type with letters and numbers neatly printed. Installation of Multitubes And Multicore Cables Multitube/Multicore cables shall always be installed on ducts/trays and shall be properly clamped. At every vertical drop to junction boxes, they shall be clamped at more frequent intervals (maximum of 300 mm). They shall be connected inside junction boxes strictly according to the number system as mentioned in cable schedule. At bends minimum radius shall be maintained as per manufacturer's standard. The angle tray supports shall he fabricated from 40 mm x 40 mm x 5 mm angles, as a minimum Identification tags shall be provided on either end of multitube/multicore cables as per tubing/cable schedules. Engraved tag plates or PVC ferrules shall he used for identification of tubes/cables. All multitubes/Multicore cables shall be cut after the exact site measurement are taken between ends. The tube/cable drums shall be selected before cutting the lengths so as to avoid any wastage. All multicables and multitubes laid in ducts shall be properly dressed and tied with nylon wires of 3 mm diameter. In the field, the cables and tubes shall be laid in duets and trays as per layout drawings. Cables shall also be burried underground or taken in concrete trenches wherever required Inside control room all cables shall be laid in concrete trenches or below false flooring When laid below the false floor the cables shall be properly dressed and tied as per the instructions of Engineer-in-Charge. In other plant rooms like analyser room or local control rooms the cables shall be laid in concrete trenches, unless specified otherwise. Installation of Instruments All instruments shall be generally installed on supports as per installation standards, In each case all instruments shall be accessible, Receiver gauges shall be mounted on instrument supports itself, as far as possible, as per tubing hookup standards. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI SPECIFICATION REV ERECTION TENDER 6-52-60 ° Page 9 of 21That they will nol be reproduced sd use, EL 1641-507 £4 210x297 rider to the borrower for INDIA LINATED. 5 wed way poem ‘ven on this format are the property of ENGINEER sopied, exhibited or used, except in the The drawing, design and deta 443 45.2 4.6 4.6.1 4.6.2 47 47.1 4.7.2 473 4.74 4.75 Filter regulators shall be mounted on the instrument support below the instruments or on the control valve yoke, as tar as possible, Instrument Air Supply The main instrument air header in each area is laid by other contractor. Air supply trom the main air header take off valve to individual instruments shall he through either galvanised steel pipe or PVC covered copper tube or SS tubes. Individual take off valves shall generally be located on top of the main air header, Unions shall be provided at convenient locations. There shall be one isolation valve at each instrument end, The galvanised pipe shall be supported at a minimum interval of 1.5 metres with 40 mm x 40 mm x 5 mm MS angles. Final connection to the instrument shall be copper/SS tubing as per tubing hookup standards, Instrument Steam Tracing ‘The main steam header in each area is laid by other contractor. From the main steam header take off valve, steam to individual instruments shall be taken through carbon steel Pipes supported at regular intervals. Steam tracing around individual instruments shall be by copper tubes in general. After steam tracing, the line is connected to the drain funnel through individual steam trap/condensate return header/tapping point as the case may be. Electrical Tracing shall be done by others. Assistance, if required, shall be provided by the contractor as per instructions of Engineer-in-Charge. Cables Ducts/Ladder trays/perforated trays/angle trays and supports Galvanised main cable trays are generally prefabricated ladder type trays and shall be laid as per layout drawing. Closed ducts and ladder type MS angle type trays are generally fabricated as per the drawings and shall be laid as per layout drawings. Generally heavy structural supports tor cable ducts, ladder trays are provided by other agency. However, in critical areas, where additional supports are required to be provided in the opinion of the s te-in-charge the same shall be provided by contractor, ‘The perforated trays/angle trays shall be properly supported at a regular interval of maximum of 1 metre from insert plates or stee! structures. Wherever insert plates are not available supports on concrete structures and ceilings shall be fixed with minimum 10 mm diameter expansion bolts. Angle supports tor perforated trays/angle trays shall be fabricated trom 40 mm x 40 mm x 5 mm MS angles as a minimum. All supports shall be cut with hacksaw only. Any work executed by gas cutting for making holes or cutting pieces will be totally rejected. Free ends of angle support shall not have sharp edges and shall be properly rounded off @ ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 10 of 21Toy will not be reproduced, Wdod use. El. 1681-807 Aa 210x297 2 zg fat ae the property of ENGINEERS INDIA LI ‘ted way pormitted by a written consent given by the lender to the borrow mand detal exhibited of used, except in th The drawing, des 4.7.6 4.7.7 4.7.8 48 4.8.1 48.2 4.8.3 484 4.8.5 4.8.6 48.7 Perforated trays/angle trays shall be used for branch cables and tube trom main trays. Width of trays shall be selected according to number of tubes and cables. Trays shall be laid generally as per site conditions with the approval of Engineer-in-Charge No welding on galvanised trays/angles/pertorated trays shall be allowed in general, In specific cases where welding is unavoidable, this shall be carried out as per instructions from Engineer-in-Charge. For welding, if required, following procedure shall he followed as a minimum a) Remove galvanisation thoroughly from the portion to be welded b) After welding, clean the welded portion for any slug and sharp edge. ¢) Welded portion shall be painted as per procedure described under para 4.10. Main cable ducts, fabricated ladder type angle trays, MS perforated trays and their supports shall be painted as per painting specification detailed in para 4.10. Laying of Cables All cables shall be laid in accordance with installation drawings and cable schedules. Before laying, cable/multicable on drums shall be meggered and tested to ascertain the transit damages. All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficient amount for the final connection of the cable to the terminals on either end. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. Sufficient extra length of cable shall be kept at the termination points A detailed planning shall be submitted prior to cable laying, giving drum number, cable number, lengths which shall be approved by Engineer-in-Charge. Cables shall have complete uncut lengths from one termination to the other. All cables shall be indicated close to their termination point by cable number as per cable schedules/junction boxes schedules, PVC ferrule/tag plate shall be used and these identification tags shall be securely fastened to the cables. All cores of electrical cables shall be identified by their wire numbers by means of the PYC ferrules. Wire numbers shall be as per schedules. All temporary ends of cables shall be protected against dirt and moisture. For this purpose, ends of all PVC insulation cables shall be taped with an approved PVC or rubber insulating tape. The bending radius of cables shall be maintained as per manufacturers’ recommendation. Cables installed above ground shall be run exposed on walls, ceilings, structures and shall run parallel or at right angles with beams, walls or columns, ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI SPECIFICATION REV ERECTION TENDER 6-52-60 ° Page 11 of 21"a they will nat be reproduced, iy loaned on the borrower's express agraarna rider to the borrower for the intended use, EIL-1841-507 Ad 210x297 ‘The drawing, design and details given an this format are the property of ENGINEERS INDIA LIMITED. They are rm copied, exhibited of used, except in the nd By a written consent given by the 48.8 48.9 48.10 4.8.11 4.8.12 4.8.13 48.14 4.8.15 Cables shall be rigidly supported on structural steel and masonry individually or in groups as required using PVC covered galvanised clips, multiple cable supports or cable trays, If drilling of steel must be resorted to, approval must be obtained and steel must be drilled Where the minimum of weakening of the structured wall result. Cable shall be supported at every 500 mm on vertical runs and every 100 mm on horizontal runs All special cables and power supply cables will be laid direct to the field instrument without any junction boxes, unless otherwise specified While laying cables in ducts/trenches or burying them, care shall be taken to ensure that Jew signal cables like alarm, analyser cables , special cables from turbine meters. compensating cable ete, are separated from other power supply cables Each underground cable (either in concrete trenches or burried) shall be provided with identitying tag of lead securely fastened every 30 m of its underground length with atleast one tag at each end before the cable leaves/enters the ground. Directly burried cables shall be laid underground in excavated cable trench wherever specified in layout drawings. Trenches shall have sufficient depth and width to accommodate all cables correctly spaced. Pipe sleeves. if required for eross overs other than road like drains etc. shall be provided by contractor as per the instru ions of Engineer-in-Charge. Before cables are placed the trench hottom shall be filled with 100 mm layer of sand and levelled, Each layer of cables shall be covered with 150 mm of sand ‘on top and sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall be placed flat on the final layer of sand and cable. The remaining portion of the trench shall be then back filled with soil compacted and levelled. On completion of every group of cable laying and before sand filling, every cable shall be given insulation test in the presence of Engineer-in-Charge. Any cable proved to be defective shall be replaced before the next group of cables are laid. Cable route markers indicating number of cables, depth and direction will be placed enroute, on crossevers/turnings ete. to mark the cable route. At each road crossings and other plac Where cables enter pipe sleeves, adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends after back filling. After laying, the pipe sleeves shall be sealed using sealing compounds. At the entry into concrete blocks at road crossings cable loops shall be provided at either ends to prevent any damage to cables. Each cable shall have one tag at each end before the cable enters/leaves conduit pipes. After laying of all the cables and multitubes, the cable entry to control room shall be Suitably filled and sealed so as to achieve a positive seal against the entry of gas/water ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR SPECIFICATION REV NEW DELHI ERECTION TENDER 6-52-60 ° Page 12 of 213 48.16 a 49 = 49.1 5 7 4.10 3 4.10.1 3 4.10.2 Be 4.10.3 Bs 4.10.4 33 Bi 4.10.5 £ 4.10.6 = 3 4.1 g aan a 4.112 ee 4.13 se at 4114 32 On completion of cable laying in concrete trenches, the trenches shall be filled with sand ‘and precast concrete slabs shall be placed on the trench. Earthing Earthing of junction boxes, local panels/cabinets, analysers etc as required. shall be carried out as per the documents and instruction from Engineer-in-Charge. Painting ‘This part of the specification is applicable to cable ducts, MS cable ways. angle trays. instrument supports/pertorated trays, all structural supports for the above items, ete The surface to be painted shall be thoroughly cleaned with wire brush, sand paper to remove all scales. After cleaning, the surface is painted with one coat of red oxide zine chromate primer conforming to 18-2074 and allowed to dry completely, Primer coated surface is painted with one coat of paint to the colour nearest to the final paint and allowed to dry. The colour number shall be specified from IS-5 Final second coating, shall be with the paint of desired colours and shall be selected from Is-5, It shall be noted that final second coating on external surfaces not covered hy cables, copper tubes etc. shall be applied just before handing over the plant or commissioning of the plant whichever is earlier ‘The name of manufacturer, colour and quality of all types of primer paint shall be subject to approval of Engineer-in-Charge. Testing Electrical cables for signal power supply alarms shall be checked for megger values and continuity before final termination and ferruling. ‘Testing shall be carried out after the Installation of instrument with primary piping complete in all respects and approved by Engineer -Charge. Primary piping shall be tested hydraulically/pneumatically to 1.5 times the operating pressure after isolating the instruments. Flushing of piping shall be carried out as per instructions of Engineer-in-Charge. Lines shall be blown atter hydro-testing. All external displacement/float type level instrument level gauges shall also be tested as per instructions of Engineer-in-Charge. Tubes and air line shall be tested with compressed air to 7 kg/cm? upto the filter regulator. The downstream side of the filter regulator shall be tested tor 1.5 kg/em?, The lines shall be blown with the instrument air upto the regulator for 15 minutes to remove any traces of oil, dust and moisture, All lines shall be checked with soap solution and bubbler unit for possible leak at joints. After pressurising, source shall be cut off and rate of fall in pressure shall be less than 1 kPa for every 4.4 metre (1 p.s.i. for each 100 ft) of copper (az) ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 13 of 21e ndad use. ElL-1641-507 A4 210x297 joaned on the borrower's express agreement that they willnt be reproduced. he the borrower fo ‘operty of ENGINEERS INDIA LIMITED. They hibited of Used, except inthe hs "The drawing, design and details given on this 4.115 4.12 4.121 4.12.2 4.123 4.12.4 4.12.5 4.12.6 4.12.7 4.12.8 4.12.9 4.12.10 4.1211 4.12.12 4.12.13 4.12.14 tubing for a test period of 2 minutes as per ISA RP 7-1 ‘Pneumatic Control Circuit Pressure Test’ All test results shall be recorded in the approved format, Calibration All instruments shall be calibrated strictly as per manufacturer's instructions prior to installation, The scope of calibration includes all field and control room instruments of all types namely, pneumatic, electronic, electrical etc Contractor shall use his own oil free instruments air compressor for calibration purposes Conversion from one unit to another for the purposes of calibration is not allowed, Procedure for calibration of different items are as outlined below, However, the detailed. procedure shall be submitted to Engineer-in-Charge tor approval betore proceeding with calibration. . All pressure and differential pressure transmitters all be calibrated to the settings as per Instrument data/specification sheets and instruction of Engineer-in-Charge All thermocouple receiver instruments shall be calibrated by generating millivolt signals suitable for span and type of thermocouple specified, Receiver instruments programmed shall be calibrated and aligned using test hook-up as per instructions from manufacturer/Engineer-in-Charge. All pressure and temperature switches shall be calibrated for 0%, 25%, 50%, 100% af range. These shall be set finally at the required values indicated on the data sheet Filled system instruments shall be calibrated for 0%, 25%, 50%, 75% and 100% range using standard thermo-oil Pressure transmitters shall be calibrated at 0%, 25%, 50%, 75% and 100% and vice versa of range using dead weight tester/hydraulic pumps with master gauges. DP transmitters shall be calibrated at 0%, 25%, 50%, 75% and 100% and vice versa of range using mercury, water column manometers and standard gauges Pressure transmitter hall be calibrated with dead weight tester and temperature gauges shall be calibrated with thermo-oil baths at 0%, 25%, 50%, 75% and 100% and vice versa of range Rotameter transmitters shall be calibrated by moving pointer to 0%, 25%, 50%, 75%, 100% and vice versa range and monitoring the output at the respective flow range The external displacer type of level instruments shall be dry calibrated as per manufacturer’s instructions or calibrated by filling the displacer chamber with water for level 0%, 25%, 50%, 75% and 100% and draining the water at 100%, 75%, 50%, 25% and 0% of ranges after applying table specific gravity corrections of the process fluid as per data sheets. & ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 14 of 21fo the borrowa OFENGINEERS INDIA LIMITED, Thay are merely lo ‘iven by the lender design and details 41215, 4.12.16 4.12.17 4.12.18 4.12.19 4.12.20 The internal displacer/float type level instruments shall be dry calibrated as per manufacturer's instruction or using calibration chamber fabricated out of steel pipes and filling the same with water after applying specific gravity corrections of process fluid as per data sheets, The level switches (external cage type) shall he set by filling the cage with water to the desired ala m/trip level. While setting the switches, it shall be ensured that the micro switches do not reset for full rated travel of the float. ‘Tank level indicators shall be calibrated by manually lifting the float at 0%, 25%, 50%, 75% and 100% and vice versa of ranges. Control valves and positioners shall be checked for hysteresis and linearity and shall be calibrated for rated strokes. Prior to calibration, valves shall be cleaned externally. The stem is than lubricated if required, and stroked few times to extreme positions of plug to ensure that movement is free from friction, The valve shall then be calibrated for rated stroke and linearity also, Subsequently the valves shall be checked for hysteresis to the accuracy of 1% full scale with positioner and 5% full scale without positioners. Stroke speed has to be evaluated for trip! shutdown valves as per safety requirements identified in-Charge ings shall be recorded in the enclosed format and submitted to Engineer- in-Charge for approval. Where significant deviations trom specifications are obtained, the matter shall be brought to the immediate notice of the Engineer-in-Charge for corrective action. Furnished hereunder is a list of recommended calibration and test equipments required as a minimum for calibration work. The contractor shall clearly state in his offer the complete list of calibration and test equipments alongwith the range, accuracy and quantity which he proposes to use for this job. Contractor should also ensure that any equipment not listed below but required at the time of calibration shall be made available at his own cost. All test equipments and kits shall be approved by NPL/IDEMI/ERTL authorities and shall have valid calibration report :~ a) Controller test stands Mfr. Standard b) _ Indicator/recorder test stands Mfr. Standard ©) Squeeze bulb (Flow calibrator) - Range : 0 to -10,000 mm H,O d) Dead weight testers (Budenberg or £0.1% equivalent for ranges upto 350 kg/em? ©) Gauge comparator for pressure gauges 40.2% Rating : upto 350 kg/cm? ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR SPECIFICATION REV NEW DELHI ERECTION TENDER 6-52-60 0 Page 15 of 21f) Oil bath for temperature instrument Mfr. Standard calibrations Max. temperature 350°C. g) Standard mercury in glass thermometers + 0.25% Range : -50 to + 50°C., 0 100°C (NPL certified) 0-250°C. agreement that they will not be reproduced, ‘written consent given by the lender to the borrower for the intanded use. EIL-1641.507 A4 210x297 h) Standard gauges for Ranges upto + 0.25% 350 kg/em? i) Ustube differential manometers/inclined + 1mm 3 tube manometer Static Pr. rating:7 kg/cm? z 3) Single leg manometers + 1mm g Scale : -1500 mm water 1500 mm hg. Static Pr. rating : 7 kg/cm? k) Decade resistance box Mir’s Standard 1) Multimeters £0.05 mV m) — Potentiometer/Direct digital calibrator - (capable of generating and measuring mV) n) — Meggers S00V / 1000V - 0) Air hydro pump/hydraulic pump - p) Vacuum pump - Instrument air compressor with filters - and regulators and deoilers. 1) Current generator (Instrument checker) - 4-20 mA DC(Yokogawa make or equivalent) iy of ENGINEERS INDIA LIMITED. They are meraly loaned on the Barra with 24 V DC power source. 4.13 Loop Checking 4.13.1 Loop checking shall be pertormed after calibration, interconnection and leak testing of signal lines is carried out for all instruments. Loop tests are conducted to check the functional performance of all elements comprising the loop, thereby ensuring proper inter- connections and operations. 4.13.2 Before proceeding for loop checking, the calibration results of individual elements shall be is given on this format are tha props recorded on the proforma and shall be approved by Engineer-in-Charge for correctness of z : installation, measurements and calibration results. z i 4.13.3 Loop testing for all control loops shall be generally by simulating process conditions for gs at least 0%, 25%, 50%, 75% and 100% of full scale inputs. Detailed procedure shall be ? = submitted to Engineer-in-Charge for approval before proceeding with the loop checking. 5 ENGINEERS INDIA LIMITED| STANDARD SPECIFICATION FOR |__SPECIFICATION | REV NEW DELHI ERECTION TENDER 6-52-60 0 Page 16 of 21tbe reproduced, fed use, ElL-1681-507 Ad 210x297 19 the borrower fo e 2 E & ed by a written consent given by th 4.13.5 4.13.6 In case of shutdown systems, field/receiver switches are simulated for abnormality by isconnecting the wires at terminals. Function of all associated systems are checked including performance of solenoid valves, On/Off type control/shutdown valves including proper functioning of limit switches and other accessories. Adjustment of limit switches, wherever necessary also form part of checking of loop performance. Performance of individual loops shall be accepted for an overall accuracy of +1.5% Where deviation is found to exist more than specified limit, contractor shall recalibrate the instruments which shall also form part of loop testing, at no extra cost Afier the loop test is complete, the contractor shall connect back any terminations and connections removed for loop checkin; A loop shall be considered as handed over only after measurements in that particular loop are completed and certified by Engineer-in-Charge, in addition to loop sheets heing duly filled in all respects, approved and accepted by Engineer-in-Charge and Client.In case of loops in which certain it struments of the loops are calibrated by other agency, loop checking shall be performed in coordination with the agency involved. If a detect in the calibration of the instruments in contractor cope is observed, same shall he rectified to the satisfaction of the Engineer-in-Charge. However, if detect is detected in the calibration of the instruments in the scope of other agency, same shall be rectified by the agency involved. After the calibration has been rechecked by other agency/agencies, the loop checking would be performed to the satistaction of Engineer-in-Charge. This is part of the contractor scope of work. Final certified loop sheets shall be submitted n 4 copies and one transparency to the Engineer-in-Charge. Whenever the installation of central control system like Distributed Control System/Programmable logic controllers/Terminal automation system etc in control room is carried out by any other agency, contractor scope of work for the loops connected to these system shall include the following :- a) Laying of all related cables upto the designated panel/cabinets/console, dressing of cables including inside control room, identification of cables and cores/pairs of each cable coordination with control system vendor during glanding and termination b) Calibration of all field instruments independently. ©) Providing all assistance to control system vendor during loop checking. This shall include providing signals trom the field instruments and checking valve operation with the output provided from control system to enable control system vendor to oop performance. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 17 of 21T they will not be reproduced, EIL-1641.507 A4 210x297 joaned on the borwower's oxpross agres operty of ENGINEERS INDIA LIMITED. They 5.0 ae 4) — Coordination with control system vendor to meet loop checking schedule. It shall be contractor's responsibility to demonstrate/prove measuring signal levels of field strument output in control room in the respective identified pair in case of any problem ©) Rectification/recalibration of field instruments if found defective during loop checking. However, the termination of field cables, checking of interconnection between instrument/equipments inside control room, ferruling/tagging of interconnecting cables inside control room and performing loop checking with coordination of contractor shall he in the scope of Control system vendor. It shall be contractors responsibility to complete all entries in the “Loop Sheet’ related to field instrumentation including calibration, installation checks, interconnection of tubing and cabling, hydrotest etc. and get it duly signed by the Engineer-in-charge. All loop sheets duly filled and signed shall be handed over to control system vendor for overall loop checking records. It shall be control system vendor's responsibility to complete the loop check column in loop sheet after Engineer-in-charge accept the loops and hand over the sheets in 4 copies to client. All field related assistance shall be provided by contractor during all these activi DRAWINGS AND DOCUMENTS TO BE SUPPLIED FOR EXECUTION BY OWNER/ENGINEER-IN-CHARGE. General layout plan for all units, showing all information like position of field instruments junetion boxes, indicative routes of cables, main duct/cable trays. Cable schedules for alarm/signal/shutdown/power supply cables, pneumatic tubes.earthing guide lines etc. Termination details/drawings for connecting at control room end Individual instrument specifications. Bill of Mater Installation standards/hook up. Manufacturers hand books with instruction for installation and calibration wherever necessary for reference. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 18 of 215 2 E This format are the property of ENGINEERS INDIA LIMITED. = ited way permitted by a written consent given by the lender nthe ted oF used, except 6.0 6.1 64 7.0 7 TAA 7A 713 74 TAS 716 TAT 718 72 124 DRAWINGS AND DOCUMENTS TO BE PROVIDED BY CONTRACTOR ‘The drawings for materials that are included in their scope of supply namely local control panel, junction boxes local cabinets ‘The detailed engineering drawings wherever such work is assigned. ‘Two sets of As-built with originals layout drawings, instrumentation index, standards, bill of materials, cable schedules ete. duly incorporating the changes/modification carried out during the course of execution of works. The drawings/documents shall be provided by the owner for the above purpose. Final material appropriation statement for all the free issue materials indicating shortages if any in the proforma duly approved by Engineer-in-Charge. MATERIALS SUPPLY Materials To Be Supplied By The Owner Free Of Cost All pipes, tubes and piping materials such as fittings, steam traps, valves, flanges, gaskets. bolts and nuts for flanges necessary for primary piping, air supply and steam tracing. Tubes, tube fittings, polyethylene tubes and fittings. All field mounted instruments like pneumatic, electronic and analyser instruments. pressure gauges, temperature elements, dial thermometers, thermowells, switches. and accessories like air filter regulators, receiver pressure gauges, solenoid valves ete Pneumatic and electric junction boxes for field mounting, Single pair/Single triad/multi-pair/multi triad shielded cables/Thermocouple extension cables for signal/alarm/temperature signals and any other special cable specifically indicated in ‘Schedule of Quantities” Two core/three core power cable. Alll electrical conduits, fittings, cable glands and cable accessories unless otherwise specifically indicated. Local panels. Materials to be supplied by the contractor at his own cost, as part of this specification ‘The procurement and supply in sequence and at the appropriate time of all materials and consumables except. for the materials specifically enlisted under Owner’s scope of supply shall be entirely the contractor's responsibility and his rates for execution shall be inclusive for all these items, These are as ,but not limited 0, the following :~ a) All industrial gases like oxygen, acetylene or inert gases, compressed air and all types of electrodes, brazing rods, flux etc. for welding purpose, with necessary facilities for testing the welded joints. ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 0 SPECIFICATION REV Page 19 of 21hey wil not be reproduce Ba zs 722 7.23 724 7S 3 5 8.0 7 8.1 E 8.2 as 83 33 b) PTFE tape and other pipe jointing compounds for threads and material for sealing of cable entries to control room, local panels, insulation tapes, sealing compounds for flame proof conduit fittings. c) Bolts and nuts for supports, U-bolts with nuts, clamps tor tubes and pipes. anchor bolts tor panels, expansion bolts (pinch anchor/raw1 bolts) of various sizes fur fixing to concrete structures. Polythene bags tor protection of instruments against rain 4) Paints, primers and solvents. ©) Plastic tags for identifications of tubes/wires at panel junction boxes. 1) All materials for minor civil works like grouting ete 2) — Structural steel, MS Plates, GI plates, flats, pipe ete. required tor fabrication or instruments supports and tray supports wherever required h) All accessories for electrical wiring like cable lugs, ferrules tor identification ete Prefabricated main cable ducts and perforated/ladder trays with necessary accessories like tees bends, crosses etc. as specified in Schedule of quantities. Mounting accessories tor the above like bolts, supports etc. Spool pieces and blinds for testing wherever required. Any other item not specified, but required for the completion of the job. Note: The contractor shall submit in sealed cellophane packets samples of all consumables like bolts, nuts, lubricants, ferrules lugs and any other material included in their scope of supply for approval of Engineer-in-Charge which then forms the standards for erection work, SCRAP AND EXCESS MATERIAL Every month, the contractor shall submit an account for all the materials issued to him by the Owner in the standard proforma prescribed for this purposes by the Engineer-in- Charge On completion of the work, the contractor shall submit ‘material appropriation’ statements, for all materials sued by the Owner in the proforma prescribed by the Engi Charge The following scrap allowances are permissible Length below 0.5 metres Non salvageable Unaccountable Steel pipes, 8S tubes 2% 0.5% Length below 2.0 metres Single pair, Single triad, two core/ three core 0.5% ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI ERECTION TENDER 6-52-60 SPECIFICATION REV Page 20 of 21(or be reproduced we properly of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower" 84 ength below 20 metres Multitube, Multicables 2% 0.5% All excess materials and scrap shall be returned after duly accounting for, to the storage points designated by the Owner, Where materials are to be weighed before return, the contractor shall be responsible for making the necessary arrangements for weighing ete. The contractor shall not use scrap section obtained during the course of construction tor fabricating temporary supports or other items without prior permission of the Engineer-in- Charge If the contractor fails to return the surplus material as aforesaid, the owner will charge the contractor for such unreturned material at panel rates, which will be deducted from whatever amount is due to the contractor. In case any material issued by the owner deteriorates during storage by the contractor, new material will be issued to him at panel rates, but the delay in procuring such materials will be at the contra ENGINEERS INDIA LIMITED | STANDARD SPECIFICATION FOR NEW DELHI SPECIFICATION REV ERECTION TENDER 6-52-60 Page 21 of 21