SECTION 8 - INSTRUMENTATION

PT. GLOBAL POWER SERVICES

SECTION 8

INSTRUMENTATION

Rev. Date/Checked Dale/Approved Date/Issued Notes

Orig. Original Issue
Rev.A
Rev.B
Rev.C
Rev.D

PT. GLOBAL POWER SERVICES ©DOC2010 Page 1 of 14

SECTION 8 - INSTRUMENTATION

PT. GLOBAL POWER SERVICES

SECTION. 8 INSTRUMENTATION

Index Page

8.1 SCOPE OF WORK

8.11 GENERAL
8.12 DEFINITIONS
8.13 PROCESS CONTROL OVERVIEW
8.14 INCLUDED IN SCOPE
8.15 EXCLUDED IN SCOPE
8.2 INSTALLATION MATERIALS
8.3 TOOLS, EQUIPMENT AND CONSUMABLES
8.4 ADDITIONAL WORK AND DELETION'
8.5 INSTALLATION
8.6 WORKMANSHIP
8.7 RESPONSIBILITY FOR INSTRUMENTS
8.8 TAGGING PROCEDURES

PT. GLOBAL POWER SERVICES ©DOC2010 Page 2 of 14

SECTION 8 - INSTRUMENTATION

Section 8
INSTRUMENTATION

8.1 Scope of Work

8.11 General
The scope of work covered by this specification shall consist of the complete
installation of all instruments and control equipment supplied by the owner as listed
on accompanying documentation, except where specifically excluded by this
specification.
Complete installation means all instrumentation and control systems functional
and ready to operate as designed.

8.12 Definitions
The following words used in this instrumentation specification and on the
instrumentation drawings and documents shall have the meanings herein assigned:

"Instrument" shall mean any device for measuring, transmitting, controlling,

indicating, recording or operating and shall include final control elements such as
control valves, dampers and the like.
"Header" shall mean the main air, water, steam, etc. pipe lines called up on piping
drawings but not normally shown on instrument drawings.
"Branch Lines" shall mean air, water, steam, etc. lines from the header to groups of
instruments and to individual instruments.
"Air Tubing" shall mean tubing which either transmits signals between
instruments or supplies air to instruments.
"Impulse Tubing" or "Impulse Piping" shall mean tubing or piping which
connects an instrument to a part of the process such as a tap into a pipe line or a
tank.
"Signal Cable" shall mean low voltage multi-wire cable used for transmitting
analog or discrete signals between instruments or systems.
"Control Valve" shall mean any valve that is not operated directly by hand.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 3 of 14

SECTION 8 - INSTRUMENTATION

"Engineer" shall mean the instrument engineer or his representative appointed

by the owner.

8.13 Process Control Overview

Process monitoring and control will be accomplished by using a Bailey "INFI -
90" m i l l wide distributed control system connected to electronic Held
instrumentation.
Operations will be pcribrmed from one central control room and four satellite
control rooms. DCS I/O and equipment cabinets will be installed in rack rooms
located in the individual process areas.
Field instruments will bc'connccted to field junction boxes by single pair signal
cables run in conduit and/or tray. Separate junction boxes will be used for analog
and discrete signals. Virtually all discrete signals will be 24 VDC.
Signals to and from the field junction boxes will be transmitted via multi-core
cables, which arc routed in trays to the appropriate DCS cabinets situated in the
rack rooms.
The majority of the control valves will have pneumatic actuators interfaced to the
DCS with either electro-pneumatic positioners or solenoid valves, the remaining
control valves will have electric actuators.

8.14 Included in the Scope

Without limiting the scope of Section 1.1, the contractors work shall
include the following: '
(a) Inspection, handling, transporting, mounting, and erection of all devices
shown on the instrument lists;
(b) any local gauges and indicators not on the instrument list but otherwise
shown on the P & I's and other documents.
(c) fabrication, transporting to and from sandblasting/painting contractor,
installation and grouting as required of all instrument stands, brackets,
fixtures, supports, etc. required for the complete instrumentation system
installation;
(d) Mounting of analog and discrete field junction boxes, (quantities listed in
appendix);

PT. GLOBAL POWER SERVICES ©DOC2010 Page 4 of 14

SECTION 8 - INSTRUMENTATION

(e) installation of conduit, tray, supports and single pair signal cables from field
instruments to field junction boxes. Termination and identification of all
such cables at both ends. Quantities to be taken off from the instrument lists.
Average length of 33 meters to be used for bid purposes;
(f) installation of conduits, tray, supports, and signal cables between field
instruments and sensors (e.g.: between temperature element and transmitter,
pH sensor and transmitter, etc.);
(g) termination and identification of all such cables at both ends. (Quantities to
be taken off from the instrument lists. Average length of 10 meters to be
used for bid purposes.);
(h) installation of branch cable tray runs between field junction boxes and main
cable tray runs. Average length of 30 meters to be used for bid purposes;
(i) installation of multi-core signal cables between field junction boxes and
DCS cabinets in rack rooms. Termination at junction box end and
identification at both ends of these cables. (Quantities and average lengths
listed in appendix.);
(j) installation, including supports, and connection of all impulse tubing and
piping which connects instruments to the process, taps. (Quantities to be
taken off from the instrument lists. Average length of 7.5 meters each to be
used for bid purposes.);
(k) installation of air supply branch lines and supports from air headers to each
control valve, other final control element or instrument as required. An
isolation valve shall be installed nearby each device. A short flexible tubing
or hose shall connect the device to the air supply isolation valve. (Quantities
to be taken off from the instrument lists. Average length of 15 meters to be
used for bid purposes.);
(l) installation of signal tubing and supports between pneumatic devices where
required; (e.g.: between solenoid valves and actuators, I/P transducers or
local controllers and valves, etc.);
(m) installation of purge air, water or steam branch line piping and tubing and
supports between the service headers and instruments as required.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 5 of 14

SECTION 8 - INSTRUMENTATION

(Quantities listed in appendix, average length of 15 meters to be used for bid

purposes.);
(n) mounting and connection of equipment vendor supplied instrument cabinets,
panels, junction boxes, etc. as detailed on vendor drawings;
(o) installation of primary measuring elements such as Temperature Sensors and
Wells, Analytical Probes, Pilot Tubes, etc. into pipe lines, vessels, etc.;
(p) installation of isolation valves between flange mounted level or pressure
transmitters and the flanged nozzle of the vessel;
(q) fabrication, mounting and connection of sample Pots, Coolers, Bubble Pipes,
etc. as required for Probes, Sensors or other instruments, (quantities listed in
appendix.);
(r) disconnection and reconnection of tubing, piping and cabling from control
valves. Mag meters and other inline devices which will be removed (by
others) from pipelines for Hushing and subsequently re-installed;
(s) manipulation of control valves, activators or other devices, either manually
or using temporary air supplies and/or power to assist in flushing
procedures;
(t) removal, transport to and from calibration shop and re-installation of
equipment vendor's pre-installed instrumentation;
(u) covering of field mounted instruments as necessary to protect them from
dust, dirt, paint spray, etc. and protecting them from mechanical damage;
(v) marking-up, for the owner, of one complete set of contract drawings during
the installation showing all "as built drawing" details;
(w) monitoring and advising mechanical contractors on proper installation of
control valves, mag meters and other in-line instruments;
(x) touch up painting of structural steel, etc. where damaged by mounting of
instrument supports;
(y) testing of all control loops as follows:
• Continuity testing of all signal lines.
• Visual inspection of all electrical, pneumatic, process and service
connections to confirm they are complete and correct.
• Tracing out, blowing clear and pressure testing of air supply and
signal piping and tubing.
• Pressure testing of all process impulse tubing and piping to 1 ½ times

PT. GLOBAL POWER SERVICES ©DOC2010 Page 6 of 14

SECTION 8 - INSTRUMENTATION

its service pressure. Testing procedures subject to approval by the

engineer.

(z) providing four technicians per mill process area, whose qualifications shall be
satisfactory to the engineer, to assist the owner's loop checking and
commissioning teams;
(aa) providing regular weekly reports of completed installation work so that the
owner can check the progress of the work;
(bb) attending regular meetings as scheduled by the owner to discuss all aspects
of the work;
(cc) coordinating the installation work and co-operating with other contractors to
minimize conflicts and to conform with all Mechanical, Electrical and
Instrumentation schedules; and
(dd) following the tagging procedure described in section 9.

8.15 Excluded from the Scope

The following items arc specifically excluded from the contractors work:
(a) installation of the Bailey Distributed Control System hardware, cabinets, consoles,
computers, peripherals, system cables, data highway cables and accessories;
(b) termination of signal cables at the DCS I/O cabinets;
(c) mounting of control valves, orifice plates, mag meters and other such inline
instruments into pipe lines;
(d) shop calibration of instruments;
(e) process taps from the process pipe or equipment up to and including the first isolation
valve;
(f) 220 VAC Power Supply Wiring to field instruments requiring such power;
(g) couplings and other such connections on process pipes or vessels required for
installation of primary elements such as Temperature Wells, Pitot Tubes,
Analytical Instrument Probes, etc.; and
(h) main cable tray runs.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 7 of 14

SECTION 8 - INSTRUMENTATION

8.2 Installation Materials

The owner shall supply all instruments and installation materials required for the
complete instrumentation system erection.
8.21 Installation materials supplied by the owner shall include but not be limited to the
following:
• All materials required for fabrication of instrument stands, brackets,
supports, etc.
• Piping, pipe fittings, manual valves.
• Tubing, tube fittings, tubing tray.
• Cable tray, conduit, conduit fittings.
• Multi and single pair signal cables, cable connectors and glands.
• Cable/wire markers, wire lugs and terminals.
• Nuts, bolts, washers, fasteners, gaskets, paint.

8.22 The contractor shall maintain detailed records of material quantities and cable lengths
used during the installation work. These records shall be available to the engineer
for inspection and shall be turned over to the owner on completion of the work. The
records shall clearly indicate where the materials were used.
8.23 Maximum 5% waste is allowed for small bore pipes, tubing and fabrication materials.
The accepted measurement for cable pulling is the length between connection points
plus 2 meters.
Material wastage in excess of the 5% allowance will be back charged to the
contractor.
8.24 All materials remaining in the contractor's stock when the work is complete shall
be the owners property.
8.25 The contractor shall ensure that there is always sufficient installation materials on
hand so that installation work iS not delayed due to the lack of materials. He must give
sufficient advance notice (2 months minimum) of his requirements to the owner so
that stock may be purchased and delivered before it is needed for installation.
8.26 Installation materials shall be initially received and stored by the owner. The
materials shall be available to the contractor upon written request. He shall sign for the
materials upon receipt and assume full responsibility for them.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 8 of 14

SECTION 8 - INSTRUMENTATION

8.27 Installation materials, prior to installation, shall be stored in a clean, dry (where
applicable) and secure enclosure acceptable to the engineer.

8.3 Tools, Equipment and Consumables

All tools, equipment and consumables required to complete the installation, as described
in the scope of work, shall be provided by the contractor.

8.31 Tools and equipment shall include but not be limited to the following:
• Hand tools
• Power tools
• Pipe threaders
• Tube benders
• Cable pulleys, Reel Jacks, etc.
• Welding machines
• Cutting torches
• Ladders and scaffolding
• Hoists, lifts, vehicles, etc. as required to handle and transport instruments
and materials.
• Safety equipment

8.32 Consumables shall include but not limited to the following:

• Welding rods
• Acetylene
• Oxygen
• Pipe thread compounds and tape
• Thread cutting lubricants
• Bolt thread compounds
• Sealants

8.4 Additional Work and Deletion

Any additional work or deletion of work requested by the owner, which is beyond the
+/- 5% lump sum variance in scope, shall be covered by unit prices, where applicable,
or by separate agreement in writing. The work in either case shall be the subject of a
separate order.
8.41 The bidder is requested to supply unit prices on the attached forms based on the
typical installation drawings and design standards included in the appendix.
8.5 Installation
The instrument installation shall be in accordance with the typical installation
drawings and design standards included in the appendix.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 9 of 14

SECTION 8 - INSTRUMENTATION

•
8.51 Local codes and standards having jurisdiction over any part of the work covered in
this specification shall apply.
8.52 Where manufacturer's specifications are provided, installation of instrumentation
equipment shall conform to those specifications, except where such specifications are
less stringent than this specification, then this specification shall govern. Should
manufacturer's specifications conflict with this specification, the engineer shall
decide which one will govern.
8.53 Where standard codes and specifications are referred to on the drawings or specification,
the reference shall mean the latest edition there of.
8.54 Instruments or components not specifically located on detail drawings, but illustrated on
P & 1's, schematics or typical drawings shall be field located as directed by the engineer.
8.55 Locations of all instruments or components specifically identified on location or
other detail drawings arc subject to confirmation by the engineer.
8.56 Instruments and components shall not be attached to vibrating equipment, but shall be
mounted onto a solid structure.
8.57 Welding onto machinery, equipment or structural steel is not allowed without
permission of the engineer. Cutting of structural steel is forbidden.
8.58 Before a mounting stand is attached to a concrete floor the surface of the concrete to
be in contact with grout shall be roughened and cleaned of all dirt, oil, grease and loose
material.
8.59 Installation of cables and trays:
a. The cable trays shall be supported at intervals not exceeding the maximum distance
specified by the manufacturer.
b. The location of cable tray droppers and/or conduits to field-mounted items will not be
shown on the installation drawings. The Contractor shall observe that when
locating these, he shall not restrict future maintenance and operation of the equipment,
nor block transport or walkways. He shall also try to utilize the same droppers for the
requirements of the electrical installation, where practical.
c. The Contractor shall cooperate with other trades regarding the location of cable tray
supports and droppers in order to avoid any interferences.
d. The Owner reserves the right to request the Contractor to relocate any drop-out

PT. GLOBAL POWER SERVICES ©DOC2010 Page 10 of 14

SECTION 8 - INSTRUMENTATION

which in his opinion does not comply with general practice of the trade without extra
cost to the owner. No horizontal sections of the drop-outs shall be located lower than
2.1 m above walking floor level.
e. Where cable tray pass under or over steam lines, asbestos barriers shall be installed
between the tray and the steam lines. A minimum of 150 mm clear space between
cable and surface of pipes of pipe insulation shall be allowed.
f. Cables shall run on the trays to which they are assigned in the layouts and cable lists.
g. The estimated length of each cable will be shown on the cable schedules provided by
the Owner. The Contractor shall inform the Owner if there is a difference between the
estimated and installed length.
h. Cables shall be run straight and parallel within the tray.
i. Where there is only one tray for both power and control cables, they shall
be clearly separated. Proper barrier inserts shall be installed when
stipulated by the engineer.
j. Ties shall be used for securing cables on ladders as follows:
i) All cables shall be tied on bends.
ii) Larger cables shall be spaced and shall be tied at intervals that will ensure
maintenance of the spacing called for in the standards.
iii) On horizontal runs, spaced cables only shall be tied. However, on vertical runs
all cables shall be tied. Maximum distance between ties shall be 60 cm.
iv) All cables shall be secured within 60 cm of terminating boxes or apparatus.
k. All cables and wires shall be installed in continuous lengths from one end of the circuit
to the other if not otherwise specified.
1. Cables and wires shall be numbered at both ends in accordance with the cable
identification standard included in the appendix.
m. The contractor shall drill all gland plates as necessary to accept the correct size cable
gland.
n. All cables to field-mounted equipment shall enter from below.
o. Where non-armored cables leave trays or boxes outside electrical rooms, they shall be
run in galvanized welded steel conduit or otherwise mechanically protected.
p. All cables passing less than 1.5 m above ground shall be protected from mechanical
damage.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 11 of 14

SECTION 8 - INSTRUMENTATION

q. All wiring shall be terminated using crimp on style spade or pin type lugs as appropriate
for the terminal.

8.510 Instrument Air Branch Lines.

8.510.1 Instrument air branch lines from air headers are not shown on drawings and
shall be field run. They shall be well supported in accordance with good piping
practices and be sized as follows:
No. of Control Valves supplied from one branch:
Branch Line Branch Line Size
1-4 12mm (l/2")diam. pipe
5-8 18mm (3/4") diam. pipe
9-16 25mm (1") diam. pipe
Each control valve or pneumatic device shall have it's own air supply isolation
valve (1/2") in close proximity.
8.511 Stainless steel air tubing and process impulse tubing shall be well supported in
accordance with good installation practices. Compression type tube fittings
shall be tightened in accordance with the manufactures specifications.
8.512 Instrument purge water and purge steam branch lines are not shown on
drawings and shall be field run. They shall be well supported in
accordance with good piping practices and be made from 12mm (1/2")
diam. pipe. '
8.6 Workmanship
The work shall be done in a workmanlike manner with workmanship of the
best quality appropriate to the trade and in strict conformity with the provisions
of this contract, in accordance with good engineering practices, and to the
satisfaction of the engineer.
8.6.1 Careful attention shall be paid to workmanship. Any work which in the opinion
of the engineer is badly arranged or poorly executed or not in accordance with
the contract specification shall be redone in a proper manner by the contractor at
no expense to the owner.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 12 of 14

SECTION 8 - INSTRUMENTATION

8.62 The contractor shall give assurance that he has experience in this type of
installation work for similar industrial developments and, as such, is able to
anticipate the type of work which he may encounter while carrying out this
contract, even though all the detailed information may not be fully covered in the
specification drawings.
8.63 The contractor shall use skilled staff for the installation work. His foremen shall have
detailed knowledge of, and experience with the type of installation work included
in this inquiry.
8.64 The contractor shall keep all his areas of the workplace in a clean, tidy and
organized state. Failure to comply with written clean-up requests will result in
the owner performing the tasks and back charging the contractor.
8.65 Before starting the installation work the contractor shall examine the conditions
with other contractors so that the cables, trays, instrument supports, etc. can be
installed properly and appropriately, taking into consideration the installation of
other equipment.
8.7 Responsibility for Instruments
Instruments shall be initially received, tagged, stored and calibrated by the owner.
8.71 Instruments held in the owners stores shall be available to the contractor after
calibration and upon written request. The contractor shall give sufficient
advance notice of his requirements so as to allow the owner enough time for
handling and calibrating the instruments prior to handing over to the contractor.
8.72 The contractor shall perform any inspection or checks he deems necessary to insure
he is receiving undamaged instruments. Any damage shall be reported to the
engineer in writing immediately after inspection and before signing for receipt.
8.73 Immediately upon assuring himself the instruments are in good order the
contractor shall sign for receipt, and assume full responsibly for the
instruments. Any subsequent damage will be to the contractors account. The
contractor shall keep a detailed record of all instruments in his care.
8.74 The contractor shall ensure that, prior to installation, the instruments are stored in a
clean, dry and secure enclosure acceptable to the engineer.
8.75 The contractor shall ensure that the vendor's I.D. tags and the owners check-out

PT. GLOBAL POWER SERVICES ©DOC2010 Page 13 of 14

SECTION 8 - INSTRUMENTATION

tags remain attached to the instruments at all times.

8.76 Responsibility for the instruments shall revert to the owner when they are
signed off as operational by the engineer.
8.8 Tagging Procedures
The installation of instrumentation shall follow the stages described below, which
conform to the stages set out in the check out tag, a preliminary copy of which is
included in the appendix.
8.81 Stage 1

Receive and inspect by Gpos

8.82 Stage 2

Shop calibrate by Gpos.

8.83 Stage 3

Receive and inspect by contractor.

8.84 Stage 4

Installation by contractor.

8.85 Stage 5

Testing by contractor.

Following completion of the above stages, there will be loop check out and

commissioning stages carried out by the owners teams with assistance from the

contractor.

PT. GLOBAL POWER SERVICES ©DOC2010 Page 14 of 14