A28 HBR 01 Gen Ins Spe 0003 Rev b1

HASSI BIR REKAIZ FIELD DEVELOPMENT
PHASE 1
FRONT END ENGINEERING DESIGN
INSTRUMENT INSTALLATION AND TESTING

SPECIFICATION
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A1 31/01/2017 NI Issued for Review PKL CKO
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AUTHORIZATION OF THE OWNER
PTT EXPLORATION AND PRODUCTION PUBLIC COMPANY LIMITED
HASSI BIR REKAIZ FIELD DEVELOPMENT

FRONT END ENGINEERING DESIGN
REV
Document Number :
HBR-01-GEN-INS-SPE-0003 B1
Hassi Bir Rekaiz Field Development
Phase 1
INSTRUMENT INSTALLATION AND TESTING SPECIFICATION
CONTENTS
CONTENTS ..........................................................................................................................2
HOLDS .................................................................................................................................5
1.0 INTRODUCTION ....................................................................................................... 7

1.1 General...................................................................................................................7
1.2 Purpose of Document ........................................................................................... 8
1.3 Definitions .............................................................................................................8
1.4 Terminology........................................................................................................... 8
2.0 DESIGN CODES AND SPECIFICATIONS ................................................................ 9

2.1 General...................................................................................................................9
2.2 Order of Precedence ............................................................................................. 9
2.3 Codes and Standards ........................................................................................... 9
2.4 Standards and Codes ........................................................................................... 9
2.5 Project Documents.............................................................................................. 11
2.6 Units of Measurement ......................................................................................... 12
3.0 GENERAL DESIGN DATA ...................................................................................... 14

3.1 Environmental Data............................................................................................. 14
4.0 GENERAL REQUIREMENTS .................................................................................. 16

4.1 Conditions ........................................................................................................... 16
4.2 Workmanship, Tidiness and Safety ................................................................... 16
4.3 Scope of Work and Responsibility ..................................................................... 18
4.4 Installation Drawings and Documents ............................................................... 19
4.5 Site Modifications................................................................................................ 20
4.6 Supply of Materials ............................................................................................. 21
4.7 Installation ........................................................................................................... 21
4.8 Equipment Protection and Storage .................................................................... 21
4.9 Instrument Equipment Mounting and Accessibility.......................................... 22
5.0 CABLE GLANDS .................................................................................................... 25
6.0 CABLING ................................................................................................................ 26

6.1 Segregation ......................................................................................................... 26
6.2 Installation ........................................................................................................... 26
6.3 Screens ................................................................................................................ 27
6.4 Junction Boxes and Terminations ..................................................................... 27
HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

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6.5 Cable Ladder Rack and Tray .............................................................................. 28

6.6 Markings .............................................................................................................. 29
7.0 TUBE FITTINGS (PNEUMATIC, PROCESS & HYDRAULIC) ................................. 30

7.1 Tubing and Tube Fittings.................................................................................... 30
7.2 Plugs .................................................................................................................... 31
7.3 Gauge Adaptors .................................................................................................. 31
7.4 Marking ................................................................................................................ 31
7.5 Packaging ............................................................................................................ 31
8.0 MANIFOLDS ........................................................................................................... 32

8.1 Instrument Manifolds (2 and 5 Valve) ................................................................ 32
8.2 Air Distribution Manifolds ................................................................................... 32
8.3 Air Filter Regulators ............................................................................................ 32
9.0 SUPPORT MATERIALS .......................................................................................... 34

9.1 Metal Frame Supports and Accessories ............................................................ 34
10.0 INSTRUMENT INSTALLATION............................................................................... 35

10.1 Mounting .............................................................................................................. 35
10.2 Locations ............................................................................................................. 35
11.0 QA ........................................................................................................................... 37
12.0 TESTING AND ACCEPTANCE CRITERIA ............................................................. 38

12.1 Mechanical Completion ...................................................................................... 38
12.1.1 Site Acceptance Testing (SAT) ...................................................................... 39
12.1.2 Pre-installation Testing and Calibration .......................................................... 39
12.2 Commissioning Acceptance .............................................................................. 39
12.2.1 Instrumentation .............................................................................................. 39
12.2.2 CSS & Telemetry ........................................................................................... 40
12.2.3 ESD System ................................................................................................... 40
12.2.4 Fire & Gas System (FGS) .............................................................................. 40
12.2.5 Interfaces to Management Computers/Historians/Data Recording Modules ... 40
12.2.6 Fiscal Metering Systems and Analysers ......................................................... 41
12.2.7 Package Control Systems .............................................................................. 41
12.2.8 Telecommunication Equipment Testing .......................................................... 41
13.0 DOCUMENTATION ................................................................................................. 42

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HOLDS
Hold No. Section Description

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GLOSSARY
The following terms may be referred to in this document and related Instrument
specifications:
AISI American Iron and Steel Institute

ANSI American National Standards Institute
API American Petroleum Institute
BDV Blowdown valve
BS British Standards
CA Contracting Authority
CE Conformité Européene
CSS Control & Safety System
EMC Electro-Magnetic Compatibility
EPC Engineering, Procurement, and Construction
ESD Emergency Shutdown
FGS Fire and Gas System
GH Gathering Hub (Phase 1)
GS Gathering Station
HBR Hassi Bir Rekaiz
HMI Human Machine Interface
ICC Instrument and Control Contrcator
I/O Input/Output
IEC International Electrotechnical Commission
IS Intrinsically Safe
ISA International Society of Automation
ISO International Standard Organisation
mA Milliamp
ONML Office National de Métrologie Légale (National Office for Legal
Metrology)
PTTEP PTT Exploration and Production
REB Rhourde El Baguel
RTU Remote Terminal Unit
SAT Site Acceptance Test
SDV Shutdown Valve

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1.0 INTRODUCTION
1.1 General
The Hassi Bir Rekaiz (HBR) permits consisting of Blocks 443a, 424a, 415ext and extending
to 414ext where it is located in the El Oued/Ouargla region, about 129 km to the east of
Hassi Messaoud base in Algeria.
The contract was awarded by ALNAFT to Consortium of PTTEP (Operator), CNOOC and
SONATRACH (SH) with the participation sharing of 24.5%, 24.5% and 51% respectively.
The current permits areas after the 2nd relinquishment comprise an area of 2,686.4 square
kilometer and the exploration activities are ongoing till May 25th 2017.
Figure 1-1: Project Location, Hassi Bir Rekaiz (HBR)
The Hassi Bir Rekaiz development project is an upstream project which Phase 1
development consisting of a number of oil wells, a gathering system and a Gathering Hub
(GH) with multiphase flow to Rhourde El Baguel (REB) via pipeline. In Phase 2, the
additional facilities, pipelines and related infrastructure will be installed in accordance with
full field development plan.

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1.2 Purpose of Document
This document defines the Instrument installation and testing specification to be adopted for
the Hassi Bir Rekaiz development project phase 1.
1.3 Definitions
For the purpose of this specification, the following definitions apply:
CONTRACTING JOINT OPERATING COMPANY

AUTHORITY OR “CA” (SONATRACH/CNOOC/PTTEP)
EPC Contractor or
The Contractor(s) appointed by the CA for the supply of
the equipment. Requirements of this specification shall
CONTRACTOR be enforced at all levels of the CONTRACTOR’S
procurement process. CA shall have access to all
CONTRACTOR’S suppliers to the same extent as
required of CONTRACTOR.
PURCHASER CA, or CONTRACTOR

The party(s) which manufactures and/or supplies
materials, equipment, technical documents/drawings
SUPPLIER/VENDOR
and services to perform the duties specified by
PURCHASER.
PROJECT Hassi Bir Rekaiz development project Phase 1
INDEPENDENT
Inspection Body or Authority appointed by the CA
VERIFICATION BODY
DPEM Algerian Ministry of Energy and Mines
L’Agence Nationale de Contrôle et de Régulation des

ARH Activités dans le domaine des Hydrocarbures
(Agency for Regulation of Hydrocarbons)
1.4 Terminology
The word “shall” is to be understood as a mandatory requirement.
The word “should” is to be understood as strongly recommended.
The word “may” is to be understood as an action to be undertaken at the PURCHASER’s

discretion.

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2.0 DESIGN CODES AND SPECIFICATIONS
2.1 General
The design, construction and supply of the equipment shall be in accordance with the latest
revisions of the following specifications, data sheets, codes and standards.
Where national Algerian regulations, codes and standards exist, their recommendations
shall always apply. Such national regulations shall therefore supplement or amend the
provisions of this document.
2.2 Order of Precedence
In the event of any conflict between this specification and the documents listed herein, the
decreasing order of precedence shall be:
1) Algerian Government Legislation

2) This Specification
3) Referenced Project Specifications
4) Referenced Codes, Standards and Regulations (latest edition)
2.3 Codes and Standards
Refer to HBR-01-GEN-INS-PHI-0001 Instrument, Control and Safety Systems Philosophy

for details of all applicable codes and standards including relevant Sonatrach and BRS
Philosophies.
2.4 Standards and Codes
• AGA GMM Gas Measurement Manual

• ANSI/FCI 70-2-2006 Control Valve Seat Leakage
• API MPMS Manual of Petroleum Measurement Standards
• API 607 Fire Test for Soft-Seated Quarter-Turn Valves
• API 6FA Fire Test for Valves
• API RP 520 Recommended Practice for the Design and Installation of Pressure
Relieving Systems
• API RP 521 Guide for Pressure Relief and De-pressuring Systems
• API RP 527 Commercial Seat Tightness of Safety Relief Valves with Metal to Metal
Seats
• API RP 551 Process Measurement Instrumentation
• API RP 552 Transmission Systems
• API RP 555 Process Analysers

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• API Spec 6A Wellhead Equipment

• API STD 526 Flanged Steel Safety Relief Valves
• API 670 Machinery Protection System
• ASME B16.5 Pipe Flanges and Flanged Fittings
• ASME B16.10 Face to Face and End to End Dimensions of Valves
• ASME B16.20 Metallic Gaskets for Pipe Flanges: Ring Joint, Spiral Wound, and
Jacketed
• ASME B31.3 Chemical Plant and Petroleum Refinery Piping
• ASME B40.100 Pressure Gauges and Gauge Attachments
• ASME PTC 19.3 Instruments and Apparatus. Part 3: Temperature Measurement
• ASME Boiler and Pressure Vessels Section VIII Division 1
• ASTM D323 Standard Test Method for Vapour Pressure of Petroleum Products
(Reid Method)
• BE EN ISO1461 Hot dip galvanized coatings on fabricated iron and steel articles.
Specifications and test methods
• BS 3463 Specification for observation and gauge glasses for pressure vessels
• BS 5308 Part 1 Instrumentation Cables. Part 1 Specification for Polyethylene
Insulated Cables
• BS 5346 ISO metric trapezoidal screw threads
• BS 5839 Fire Detection and Alarm Systems in Buildings
• BS EN 54 Fire Detection and Fire Alarm Systems.
• BS EN 837-1 Pressure Gauges
• BS EN 13849 Safety of Machinery - Safety Related Parts of Control Systems
• BS EN 61779 Electrical Apparatus for the Detection and Measurement of
Flammable Gases
• EU 94/9/EC - ATEX GUIDELINES. Approximation of the Laws of the Member
States Concerning Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres
• IEC 60079-0 Explosive Atmospheres Part 0 – Equipment General Requirements
• IEC 60079-1 Explosive Atmospheres Part 1 – Equipment Protection by Flameproof
Enclosures ‘d’.
• IEC 60079-2 Explosive Atmospheres Part 2 – Equipment Protection by Pressurised
Enclosures ‘p’.
• IEC 60079-6 Explosive Atmospheres Part 6 - Equipment protection by oil immersion
“o”.
• IEC 60079-7 Explosive Atmospheres Part 7 – Equipment Protection by Increased
Safety "e"
• IEC 60079-10-1 Explosive Atmospheres Part 10-1 – Explosive Gas Atmospheres.
• IEC 60079-11 Explosive Atmospheres Part 11 – Equipment Protection by Intrinsic
Safety ‘i’.

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• IEC 60079-14 Explosive Atmospheres Part 14 – Electrical Installation, Design, &

Erection
• IEC 60092.3 Cables (Construction, Testing, Installation)
• IEC 60331 Fire Resisting Characteristics of Electrical Cables
• IEC 60332 Test on Electrical Cables Under Fire Conditions
• IEC 60529 Degrees of Protection Provided by Enclosures
• IEC 60584-1 Thermocouples – PT 1 Reference table
• IEC 60584-2 Thermocouples – PT 1 Tolerances
• IEC 60751 Industrial Platinum Resistance Thermometers and Platinum
Temperature Sensors
• IEC 60754-1,2 Measurement / test on gas evolved during combustion
• IEC 61000 Electromagnetic Compatibility EMC Requirements
• IEC 61034 Measurement / test of smoke emission
• IEC 61508 Functional safety of electrical/Electronic/programmable Electronic safety
Related Systems
• IEC 61511 Functional safety, safety Instrumented Systems for process industry
sector
• IEC 61537 Cable Management – Cable Tray Systems and Cable Ladder Systems
• IP 15 Institute of Petroleum Model Code of Safe Practice Part 15
• ISA S5.1:1984 (R1992) Instrumentation Symbols and identification
• ISA S5.2 1976 (R1992) Binary Logic Diagrams for Process Operations
• ISA S18.1 1979 (R2004) Annunciator Sequences and Specification
• ISA S20: 1981 Specification Forms for Process Measurement and Control
Instruments Primary Elements and Control Valves
• ISA S 75-01.01: 2007 Flow Equations for Sizing Control Valves
• ISA S75-08.02: 2003 Face to Face Dimensions for Flangeless Control Valves
Bodies
• ISO 4406 Hydraulic Fluid Power – Fluids – Method for coding the level of
contamination by solid particles
• ISO 4126 Safety devices for protection against excessive pressure
• NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection
• NFPA 2001 Clean Agent Fire Extinguishing System
• NFPA 72 National Fire Alarm Code
• NFPA 750 Water Mist Extinguishing Systems
2.5 Project Documents
The following are related project documents:

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Document Number Description

HBR-01-GEN-INS-PHI-0001 Instrument and Control Philosophy
HBR-01-GEN-INS-SPE-0001 Control & Safety System (CSS) Specification
HBR-01-GEN-INS-SPE-0004 Instrumentation, Fire & Gas and Telecommunication Cable
Specification
HBR-01-GEN-INS-SPE-0005 Wellhead Control Panel Specification
HBR-01-GEN-TEL-SPE-0001 Telecommunication Systems Specification
HBR-01-GEN-TEL-PHI-0001 Telecommunication Philosophy
HBR-01-GEN-INS-DWG-0001 Overall Control and Safety System Architecture Drawing
HBR-01-BVX-INS-LAY-0001 Block Valve Station Local Equipment Room
HBR-01-GEN-INS-LAY-0001 Central Control Room and Equipment Layout
HBR-01-GH-INS-LAY-0001 Gathering Hub Local Equipment Room
HBR-01-GSX-INS-LAY-0001 Gathering Station Local Equipment Room
HBR-01-WSX-INS-LAY-0001 Wellsite Local Equipment Room
HBR-01-GEN-INS-TYP-0001 Typical Instrument Hook-up & Installation Details
HBR-01-GEN-TEL-DWG-0001 Overall Telecommunication Block Diagram
2.6 Units of Measurement
Parameter Unit Symbol

2
Area square metres m
3
Mass Concentration milligrams per cubic metre mg/m
parts per million (molar) ppm
3
Density kilograms per cubic metre kg/m
Elevation metres m
Electrical Current milli-amp, amp mA, A
Electrical Potential volt, kilovolt V, kV
Electrical Power watt, kilowatt, megawatt W, kW, MW
Electrical Resistance ohm ohm
Energy megajoule MJ
Enthalpy and Head (gas) kilo joule per kilogram kJ/kg
Mass Flow kilogram – moles per hour kgmol/h
3
Oil/NG Liquid Flow cubic metres per hour m /h
(barrels per day) (bbl/d)
Illuminance Lux (Lumens per square meter) lx
3
Liquid Volumetric Flow cubic metres per hour m /h
(barrels per day) (bbl/d)
3
Gas Volumetric Flow cubic metres per hour m /h
3
Standard cubic metres per day Sm /d
(million std cubic feet per day) (MMscfd)
Power / Heat flow kilowatts kW
o
Specific Heat kilojoules per kilogram – per degree C kJ/kg- C

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Parameter Unit Symbol

2 o
Heat Transfer Coefficient watts per square metre – per degree C W/m - C
3
Heating Value megajoules per cubic metre MJ/m
megajoules per kilogram MJ/kg
Length kilometres km
metres m
millimetres mm
Level Metre or millimetre (or % of range) m or mm or %
Liquid Head metres m
Mass kilogram kg
tonne t
Quantity of Substance Kilogram-moles kg mol
3
Volume cubic metres m
Gas Volume Fraction mole percent mol %
Liquid Volume Fraction volume percent vol %
Flow Velocity metres per second m/s
Wind Velocity metres per second m/s
Dynamic Viscosity centipoise cP
Kinematic Viscosity centistokes cSt
Pressure bar absolute bara
(pounds per square inch absolute)* (psia)
bar gauge barg
(pounds per square inch gauge)* (psig)
Sound Pressure decibels dBA
o
Temperature degrees Celsius C
o
Thermal Conductivity watts per metre – per deg. C W/m- C
Rotational Speed revolutions per minute rpm
Supplement Unit (in parentheses)

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3.0 GENERAL DESIGN DATA
3.1 Environmental Data
Blocks 443a, 424a, 415ext and 414ext are located in the Sahara desert which is
characterised by maximum hours of sun exposure, high temperatures, low humidity and a
very low rainfall. The climate is considered to be relatively constant throughout the year.
The following environmental data shall be used for design purposes:
Location:
Country Algeria
Altitude 110-172m (CPF @ 132 m)
Climate Dry, sandy desert, environment
Air:
Design minimum temperature -5°C
Design maximum temperature 55°C
Design Temperature (maximum) for Turbo
Machinery Rating 45° C
Design temperature maximum for air coolers in 50°C
critical process service (eg oil rundown)
Design temperature maximum for air coolers in 45°C
non-critical process service
Design Temperature For Electric Motors 50°C
Black Bulb Temperature, Equipment Exposed to 90°C
Direct Sunlight
Average Medium Temperature – Winter 15°C
Average Medium Temperature – Summer 29°C
Medium Temperature - Annual 22°C
Typical Diurnal Temperature Range 27°C
Typical Rate of Change of Temperature 10 ºC / hr
HVAC Design Dry Bulb Temperature – Summer 50°C
HVAC Design Dry Bulb Temperature – Winter 0°C

Maximum humidity 97%
Minimum humidity 9%
Max. Soil Temp. 29°Cat 1.0 m below grade
Min. Soil Temp 15°Cat 1.0 m below grade
Site atmospheric pressure 1028.7mbar (maximum)
Rainfall:
Maximum monthly 57 mm
60 minutes max. 20 mm
24 hours max. 45 mm
Local Contamination:

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Dust High
Saline Air Low
Sandstorms High
Wind:
Maximum wind speed (for structural design) 50 m/s
Normal wind speed (for equipment/machinery 38 m/s
operation)
Annual Medium 3.3 m/s
Prevailing wind direction Predominantly from the East
Seismic Design Criteria: Seismic Zone 0
Lightning: High concentration of direct lightning
phenomena during seasonal storms

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4.0 GENERAL REQUIREMENTS
4.1 Conditions
The CONTRACTORCONTRACTOR shall employ a competent representative whose name
shall have been communicated previously in writing to the Purchaser, who will superintend
the carrying out of works on the Site.
The said representative shall be present on the site during working hours and any orders or
instructions which the Purchaser shall give to the CONTRACTOR’s representative shall be
deemed to have been given to the CONTRACTOR.
The CONTRACTOR shall in the execution of his work use exclusively new material to the
standard laid down in this or any supplementary document. Any inconsistency or ambiguity
in the Purchaser’s documentation shall be resolved with the Purchaser before the work
commences.
The CONTRACTOR shall carry out the work in accordance with the standards listed and
referred to herein, and in accordance with any local statutory regulations and
supplementary documentation.
The CONTRACTOR shall instruct his staff, skilled, semi-skilled and unskilled, in the
standards required by the Purchaser and shall ensure that only fully trained competent staff
handle or work on instruments, instrument systems, packaged equipment instrumentation
and telecommunication equipment.
The CONTRACTOR shall set up and maintain a quality assurance system. To ensure that
all equipment is supplied and installed and/or work is carried out in full accordance with the
project specification and complies with the requirements of the relevant parts of the quality
systems standard ISO 9000.
The CONTRACTOR shall ensure that his personnel have been trained to perform the
various specialist tasks associated with the installation, testing and pre-commissioning of
the equipment identified in the document, including the CONTRACTOR’s scope of supply,
such as, compression fittings and cable glands. The CONTRACTOR shall submit up to
date evidence of this expertise.
4.2 Workmanship, Tidiness and Safety

The following clauses state the minimum requirements for workmanship, tidiness and
safety in the absence of more specific information.

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The CONTRACTOR shall not allow rubbish and scrap materials from his operations to
remain on the site or be retained in any piece of finished work. Such rubbish and scrap
shall be collected daily and be deposited in places approved by the Purchaser.
The CONTRACTOR shall be responsible for protecting installed equipment from damage
and pilferage and shall ensure that all covers, caps, screws and weather protection, etc.,
are replaced at the end of each working day.
Particular attention shall be paid to some types of fire & gas detectors, which shall not be
exposed to atmosphere or contamination, until ready for loop energisation.
Materials and equipment not immediately required shall be adequately protected and stored
at approved storage locations until required.
Only the best trade practises shall be used, and all work shall be performed to the
satisfaction of the Purchaser who shall be consulted on any point requiring clarification. The
CONTRACTOR is free to suggest to the Purchaser alternative methods for the execution of
the work where this would result in improvement.
Upon completion of the work the CONTRACTOR shall remove his equipment promptly and
return to the relevant place any unused materials supplied by the Purchaser. Finally, the
CONTRACTOR must clear the site of all rubbish and scrap deposited by himself to the
satisfaction of the Purchaser.
The CONTRACTOR shall ensure that adequate precautions are taken during the use and
storage of gas cylinders and cylinders left unattended are isolated at the main stop valve.
All safety regulations and site instructions regarding the handling and storage of gas
cylinders shall be observed.
Before commencing work, the CONTRACTOR shall ensure that the areas in which he is
working are adequately illuminated. The CONTRACTOR shall be responsible for the
provision of weather protective covers, if required, to maintain continuity of work.
The Purchaser will lay down the safety regulations for the site and it shall be the
responsibility of the CONTRACTOR to ensure that all his personnel understand and comply
with these rules.
The CONTRACTOR shall, at all times, observe and comply with any appropriate National
Safety regulations.

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4.3 Scope of Work and Responsibility

The CONTRACTOR shall be responsible for the supply of such installation materials and
for the installation of all instruments and systems as detailed in the Contract documents
and as listed in the related appendices.
The CONTRACTOR shall be responsible for the expediting and inspection of all materials
in his supply. However, the Purchaser reserves the right to expedite and inspect such
materials.
The CONTRACTOR shall be responsible for the transportation on the site of all
instrumentation and materials, and for the provision of adequate labour and facilities to
carry out this function.
The CONTRACTOR shall ascertain whether all materials received by him are in good
working order and shall report any defects immediately to the Purchaser. Thereafter, the
CONTRACTOR shall be responsible for the safekeeping and protection of this material until
the purchaser accepts the installation. Any loss or damage incurred during this period shall
be chargeable to the CONTRACTOR.
Where instruments have been removed from the panel for transportation, the
CONTRACTOR shall replace these in the panel and re-connect where necessary, unless
this function is part of the panel fabricator’s responsibility.
The CONTRACTOR shall ensure that the equipment suppliers’ recommendations for the
preservation and maintenance of all equipment are implemented immediately the
equipment is received. Where equipment may remain crated for an extended period, the
equipment supplier shall be advised to ensure that adequate preservation materials are
provided.
The CONTRACTOR shall be responsible for reviewing equipment manufacturer’s

information as necessary in order to be completely familiar with the equipment to be
installed.
The CONTRACTOR shall ensure the presence of the equipment manufacturer’s

representative, as deemed necessary under the purchase order, at the job site throughout
all stages of final positioning, alignment and pre-commissioning.
The CONTRACTOR shall ensure that the installation is tested in accordance with the
correct equipment specification unless specified otherwise. If, however, the testing is to be
carried out by others, the CONTRACTOR shall ensure that instruments are adequately
protected during flushing and pressure testing.

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The CONTRACTOR shall hand over fully operable systems. Any defects in design,
omissions or discrepancies found which would impede this achievement must be brought to
the Purchaser’s attention without due delay.
4.4 Installation Drawings and Documents

The CONTRACTOR shall maintain a drawing register on the plant site. Only the latest
revision of drawings shall be used to perform the works. The installation drawings and
documents provided will be as listed in the drawing schedule. Typically these documents
shall compromise, but not be limited to, the following:
• Instrument Index – lists all instrument items by tag numbers and provides an index
to the applicable purchase order requisitions, datasheets and specifications.
• Hazardous Area Schedule – listing all instrument items by tag numbers and
providing an index to hazardous area requirements and applicable certification. Any
equipment supplied by the CONTRACTOR shall be incorporated into this document
by the CONTRACTOR.
• Telecomms Schedule – lists all telecommunications equipment by tag numbers and

providing an index to the applicable purchase order requisitions, data sheets and
specifications.
• Instrument/Telecomms Layout/Location Drawings – area layout drawings on which

are shown the approximate location of instruments (e,g. Transmitters, control
valves), panels, air manifolds, junction boxes, local panels, Fire and Gas detectors,
telecoms equipment, etc.
• Instrument Installation Details – standard or special hook-up drawings showing

piping, tubing and mounting arrangements for the various instruments, with an
itemised material list for each arrangement.
• Termination Diagrams – drawings showing terminal layout in panels and identifying

wiring connections, terminals, cable and core numbers for instrument/telecoms field
cables.
• Room Layouts – showing locations of instrument/telecoms panels/consoles and

auxiliary racks in control rooms, communication rooms and equipment rooms, and
the routing of connecting cables and/or tubing.
• Cable Racking Layouts – overall plot plan showing the routing of the cable racking
for instrument/telecoms cables, and approximate locations of the main junction
boxes. Where applicable, cable/tubing tray layouts are also shown.
• Junction Box Termination Drawings – drawings giving details of individual junction

boxes, by tag number, showing the cable connections, terminal details and
identification.

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• Cable Schedules – lists all instrument/telecoms cables with lengths, sizes,

connection points, gland details, core identification and relevant technical
information.
• Cable Block Diagrams – drawings showing schematic representation of cable

routing from control rooms, communication rooms and equipment rooms to field
junction boxes.
• Installation Material Summary – details the material quantities required for the
installation of each instrument and total quantities ordered together with the relevant
order numbers.
• Instrument Specifications/Data Sheets – defines the technical specification and

design data for each instrument.
• Telecommunication Specifications/Data Sheets – defines the technical specification

and design data for equipment in each telecoms system.
4.5 Site Modifications

Any modifications, exceptions or additions to the Purchaser’s documentation shall be
agreed and confirmed in writing by the Purchaser, and a price agreed before the
CONTRACTOR commences such work.
The CONTRACTOR shall provide a set of red-line marked-up as-built documentation,

which shall be completed by others at the end of the Contract. The CONTRACTOR shall
keep a set of prints of all documentation, which shall be marked up as and when changes
are agreed.
The CONTRACTOR shall be responsible for correcting, free of charge, any part of the
installation that is found not to be in compliance with the Purchaser’s documentation. The
CONTRACTOR shall also replace at his cost any material required to bring the installation
in line with the Purchaser’s documentation.
The CONTRACTOR may with prior approval of the Purchaser, make slight deviations from
the drawings that result in a more economical or efficient installation. The CONTRACTOR
shall keep a record of all changes and notify the Purchaser so that the drawings can be
updated.
Where detail design is by the CONTRACTOR instruments must be located approximately in

the positions shown on the instrument layout drawings. If the detailed design requires the
relocation of an instrument extending the cable tray more than 50 meters or in another fire
area this must be approved in advance by the Purchaser.

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4.6 Supply of Materials

CONTRACTOR shall be responsible to supply, install, test and commission all instrument
and telecommunications systems to complete the project requirements.
The CONTRACTOR shall also provide the engineering services and all support
documentation required to complete the installation and testing activities.
4.7 Installation
Before any equipment is installed, the CONTRACTOR shall ensure that all necessary
platforms and support steel work are in place.
All dimensions shall be checked to ensure that they are in accordance with the general
arrangement drawings and are compatible with the design drawing.
All equipment shall be located in the correct position on the deck and supporting steelwork.
The CONTRACTOR shall ensure that equipment is aligned in an approved manner.
All instruments to be installed shall be stated on the Instrument Schedules.
All telecommunications equipment to be installed shall be stated on the

Telecommunications Schedules.
Particular attention should be paid to the handling, installation and alignment of the fire &
gas detectors. Sufficient access shall be provided to enable testing of fire & gas equipment.
All instruments shall be installed as specified on the relative design documents, e.g. hook-
ups, mounting details, area layout, etc., In accordance with the manufacturer’s instructions
and good practices.
All telecommunications equipment shall be installed as specified on the relative design

documents, e.g. mounting details, area layout, etc., In accordance with the manufacturer’s
instructions and good practices.
Locally mounted instruments and manual call points shall be mounted at a suitable working
height from floor or platform (i.e. 1.5m in an accessible position and give clear access for
maintenance). All access/escape routes shall be kept clear.
Earthing systems shall be in compliance with HBR-01-GEN-ELE-SPE-0009 Earthing &

lightning Protection Specification.
4.8 Equipment Protection and Storage

Equipment and materials that cannot be installed upon delivery must be housed in a
properly constructed and heated store, and protected from dust and damp. Completion of

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control/equipment rooms should be programmed to permit the installation of panels

immediately upon receipt and so minimise handling. If the heating system for the
control/equipment rooms is not in operation, temporary heaters must be installed to ensure
that the panels and instruments are kept dry and warm.
Equipment and materials not required for immediate installation shall be adequately
protected and stored in dry heated storage at an approved location. In all cases all special
precautions advised for unpacking and preservation shall be in accordance with the
manufacturer’s recommendations.
Field devices not provided with housings shall be adequately protected, throughout the
construction period, by covering with heavy-duty plastic bags of an approved type,
containing silica-gel bags if specified or by applying more robust protection where
necessary. Protection of instruments and provision of covers, etc., shall be the
responsibility of the CONTRACTOR.
During the following equipment installation the CONTRACTOR shall ensure that no
damage or deterioration occurs to the installed equipment.
Where instruments are liable to impact damage such as resulting from rigging, scaffolding,
etc., the instrument shall preferably be removed. If not, adequate protective wooden or
similar temporary protection shall be installed. In all cases, the CONTRACTOR shall be
totally responsible for repair/replacement of damaged instruments.
Any equipment removed after initial installation for reasons of protection against damage,
shall be re-packed in the original carton, packing or equal and identified by a tag number.
4.9 Instrument Equipment Mounting and Accessibility

The CONTRACTOR shall ensure that all floors, plinths, fixings and access ways are
suitable for the equipment to be installed. Plinths and fixing points shall be dimensionally
checked against the item of equipment, and any discrepancy shall be resolved by
CONTRACTOR before installation is done.
All panels shall be mounted in the correct order and sequence as shown on approved
drawings and all designation labels checked for correct identification.
Instruments shall be located, so far as possible, so that they do not obstruct access or
walkways and shall be afforded protection from damage by passing or falling objects. They
shall also be clear of drainage points for condensate, water and process fluids from
adjacent plant equipment.

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All indicating instruments and instruments requiring adjustments shall be accessible for
servicing from floor level, walkways, platforms or permanent ladders. Orifice plates, line
mounted flow transmitters, temperature elements, etc., may be accessed by temporary
means provided they are less than three meters above floor level. Above 3 meters they
shall be provided with permanent access.
All indicating instruments shall be mounted and oriented so as to be easily read from an
adjacent working level. Where indicators are associated with control valves or transmitters,
or are utilised for setting up control operations, the indicator shall be positioned and
orientated so that they can be read from the relevant instrument or control point. The
indicator may be a direct mounted process indicator or the repeat signal indicator from a
transmitter.
Pedestal mounted instruments shall be located at a height of between 1.4 and 1.6 meters
above floor level or permanent platforms, unless site conditions dictate otherwise (e.g.
where vibration could be a problem, a shorter pedestal may be desirable).
All indicating instruments shall be readable from floor level or permanent platforms. Gauge
glasses shall be visible from access ladders and, preferably, from any control valve which
controls the vessel level.
When locating pedestal-mounted flowmeters for liquid, steam or gas service, care must be
taken to ensure that the elevation of the orifice installation is suitable so that sufficient slope
in the impulse line is obtained.
Control valves, shutoff valves and relief valves shall be located in accordance with the
piping isometric drawings and, in general, should be accessible from floor level or
permanent platforms. Clearance should be provided above the valve to allow for servicing
of the actuator and below for servicing the valve internals, where applicable. Suitable
clearances should also be provided to give access to hand wheels and valve positioners.
Care shall be taken in locating instruments so as to keep the impulse lines as short as
possible, at the same time enabling control instruments to be mounted as close as possible
to their control valves.
Mounting materials shall be selected to avoid electrolytic corrosion by avoiding the use of
dissimilar metals in contact with each other. Where the use of dissimilar metals cannot be
avoided, then insulating materials shall be inserted between them.
Field instrument supports/stanchions shall be carbon steel hot dip galvanised to BS729,
and field instrument mounting plates, brackets, bolts and nuts shall be 316SS.

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Holes for mounting and brackets shall be prefabricated for ease of installation of panels in
the field. Junction boxes shall be bolted to their mountings with at least 12mm diameter
bolts.
Where corrodible materials are used in supporting steelwork or cable trays are cut or
drilled, the exposed surfaces shall be suitably protected. Securing screws or bolts/nuts shall
be non-corrodible and if cut shall be treated to prevent corrosion.
Care shall be taken to ensure that the expansion of piping or vessels will not damage
impulse piping or instruments.
All pressure instruments fitted with blow-out vents shall be mounted with a clearance equal
to at least one blow-out vent diameter between the vent and nearest obstructing surface.
Analysis instruments shall be installed/housed in accordance with the specifications and

drawings.

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5.0 CABLE GLANDS

The cable glands shall be suitable for cables as specified in the Instrument Cable
Specification to be provided by the Purchaser. The Purchaser shall ensure that cable gland
dimensions are compatible with the project cable types.
Outdoor cable glands, shall be certified Ex’de’ and weatherproof to IP65, with PCP cable
shrouds. Brass glands shall be used for outdoors and areas requiring hazardous area
certification. All brass components shall be Nickel plated.
Brass earth tags or star washer shall be used on all unthreaded entries to ensure proper
earthing. A plastic ring or integral O-ring shall be fitted between the gland and instrument /
junction box to maintain the IP rating
All cable glands shall be in metric sizes with ISO thread connections. Cable gland for
transmitters shall be M20 size.
Gland adapter material shall either be the same material as the gland or as the instrument.
Each gland shall provide the facility for cable armour inspection and easy removal from
equipment.

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6.0 CABLING
All electrical equipment and cable installation shall meet or exceed the requirements of
Algerian Regulations for Electrical Installations.
6.1 Segregation
Signal segregation shall be maintained within multicore, transmitter and package skid
wiring and within dedicated junction boxes for different circuit types, i.e. separate boxes for:
• Control, shutdown and FGS;

• Analogue and digital;
• IS and Non-IS.
Electrical power cables shall not be run in the same tray/trunking or trench as instrument
and telecommunication signal cabling.
Should the parallel installation of electrical power cables with instrument or

telecommunications cables be unavoidable then the following segregation distances shall
be applied:
• 300mm for 230 Volts

• 600mm for 400 Volts
• 1000mm for 5.5 kVolts and above
6.2 Installation
Cables shall be routed such that the following apply:
• they do not obstruct traffic through the plant or interfere with accessibility to or
removal of process equipment
• they avoid hot environments and potential fire risk areas
• they are not exposed to mechanical abuse
• they avoid areas where spillage is likely to occur from overflowing tanks, near
condensate drains, etc
• they avoid areas where escaping vapour or corrosive gases are likely to be
present
• they avoid process piping and are installed with sufficient clearance from pipe
work, which may require lagging/insulating
• they are fully supported on a suitable cable support system. Junction box cable
entries shall be generally in the bottom for multipair cables and in the side for
single pair or single triple cables
• Where cables enter and leave equipment, the appropriate type of cable gland (at
least equivalent to the equipment certification) shall be fitted.
• Cable transits shall be used on all break throughs and penetrations.

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6.3 Screens
Instrument cables shall be protected from the effect of EMC as follows:
• 2-core analogue signal cables shall have an overall screen

• Multicore analogue signal cables shall be overall screened
• 2-core digital signal cables shall have an overall screen
• Multicore digital signal cables shall have an overall screen
• Individual Instrument screens on field instruments shall be left floating, i.e.,
terminated to insulated earth bar within the field termination junction box in order
to maintain continuity via the multicore screens where they will be terminated at
the marshalling cabinets instrument earth bars.
6.4 Junction Boxes and Terminations

Size and layout of all cable entries into gland plates for field items and equipment racks
shall be the Suppliers responsibility.
All fixing bolts, nuts and washers etc., shall be ISO metric threaded and 316 SS.
All field cables shall generally be terminated using cable glands. Cables run to panels,
cabinets and consoles located in equipment rooms shall be terminated in accordance with
the installation drawings.
It shall be the CONTRACTOR’s responsibility to select the correct size of gland to suit the
cable.
In general cable armour shall be earthed at both ends to comply with EMC guidelines.
All terminations shall be made with approved tools, which shall be tested periodically at a
period to be agreed with the Purchaser. Tools used for a particular installation should be
traceable. Crimped type terminations shall be used for stranded conductors. Where
instruments are fitted with flat-headed screw type terminals, wire ends should be fitted with
crimped spades having a retaining lip. Stranded conductors up to and including 2.5mm2
shall be fitted with insulated sleeve pin crimps and terminated directly into ‘Klippon’ type
terminals .
System cable interconnection between marshalling and system cabinets shall be as per
vendor/manufacturer recommendations and ELCO plug/pin shall be used for the system
cable connections between cabinets.
Sufficient slack wire shall be left neatly looped at terminals to permit re-making
terminations, additions and testing.

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Where termination is made to a measuring element, which has to be withdrawn (e.g.

thermocouple) sufficient length of flexible cable shall be allowed, if possible, for the element
to be withdrawn without electrical disconnection.
Co-axial and other special cables shall be terminated in accordance with the
manufacturer’s instructions.
Cables and terminals shall be ferruled and identified in accordance with the project
drawings. Identification shall be clear and wires shall contain ferrules bearing the same
number as the terminal identification. Cable core marking shall identify each core with its
appropriate terminal number.
The supporting of cables shall be such that a gland takes no weight and the cable
armouring is properly finished within the compression gland.
Straining of cables at cable glands is to be avoided, and cables are to be perpendicular to

the gland plate for a minimum of 150mm before entering the gland.
Where cables are specified with spare cores, the spare cores shall be terminated into spare
terminals as designated on the design documents.
Junction boxes and remote I/O cabinets shall be securely mounted either individually or in
groups and insulated from both frame and steel supports. All junction boxes shall be pre
cabled, glanded, terminated and tested.
6.5 Cable Ladder Rack and Tray

Ladder racks and trays shall be secured to secondary steelwork supports or proprietary
support system, utilising the tray manufacturers standard fixings.
Clash checking of major routes will be done at the detail design stage. Any site clashes that
are discovered shall be resolved such that the integrity of the route is maintained and
further clashes eliminated.
Site run rack or tray shall be installed to minimise cable lengths and shall be clash checked
prior to installation. A computer model shall be utilised where ever possible for clash
checking.
If, after completion of the ladder rack and tray installation, it is apparent that additional
supports will be required, e.g., at bends or risers, then these shall be designed on site and
installed as required.

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Individual site run routes shall be minimised, wherever possible, by grouping cables running
in common areas.
Burrs and sharp edges formed on the cable tray or racks when cut shall be removed so that
the exposed edge will not cause damage to cables or cause injury to personnel.
Cable tray shall be perforated heavy duty, return flanged cable tray and accessories, hot
dipped galvanised (HDG) mild steel to an average thickness of 83microns to BS EN
ISO1461 “Hot dip galvanized coatings on fabricated iron and steel articles. Specifications
and test methods”. Material shall be 1.5mm or 2.0mm thick mild steel dependent on the tray
width. Reference the requirements of IEC 61537 Cable Management – Cable Tray Systems
and Cable Ladder Systems.
Protection against mechanical damage and solar radiation, e.g., cable tray covers, shall be
provided.
The structural steel work and other metal items, such as cable tray, cable ladders, etc.,
shall be supplementary bonded to provide equipotential bonding and to reduce the risk of
static charge build up.
Cable trays shall be supported on structural members and not process lines. For up to 3
cable runs, UNISTRUT SS channel (or equivalent) or angle iron may be used in lieu of
cable trays.
6.6 Markings
All cables shall be identified by their respective reference numbers as indicated on the
cable schedule.
Permanent cable markers shall be located at each end of the cable and at both sides of
cable transits, bulkheads or splices using stainless steel or aluminium labels. Buried cables
shall have surface markers fitted every 10m and 1m each side of bends and
junctions/crossover.
Cable markers shall be clearly visible from the direction in which the cables would be
normally inspected.
Core identification shall be provided in accordance with the design drawings and be
readable in the terminated position. Core identification shall be terminal reference/wire
numbers and be of a proprietary printable type.

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7.0 TUBE FITTINGS (PNEUMATIC, PROCESS & HYDRAULIC)
7.1 Tubing and Tube Fittings

Tubing shall be imperial size, minimum 316L stainless steel, unless superior material is
required for the process medium. (For corrosive service Monel tube to ASTM B 165 and
Monel fittings shall be used.)
Tubing shall conform to ASTM A 269, seamless, bright annealed, with minimum
molybdenum content of 2.5% and maximum hardness of RB-90. Tubing shall meet ASTM
A269 supplementary requirement S4 and supplied with certified test report per ASTM A 450
/ A 450M section 26.
Tube fittings shall be Swagelok, 316SS, (unless superior material is required for the
application), imperial size, double compression type.
Tubing minimum wall thickness shall be as follows:
1/4” OD : 0.035”
3/8” OD : 0.049”
1/2” OD : 0.065”
3/4" OD : 0.065”
1” OD : 0.083”
Only 1/2” OD tubing shall be used for process connections. Process tubing shall have block
and drain valves.
Fusible plug loops shall use 3/8” OD tubing.
All tubing instrument lines and pipe shall be bent, assembled, tested and inspected, in
accordance with this specification, the design drawings, and ASME B31.3.
When construction or testing is interrupted all pipe ends or open parts shall be plugged and
covered.
Impulse lines shall be kept as short as possible and slope to the tapping point.
• Upward for liquid

• Downward for gas
Tubing joints shall be staggered and separated or covered to avoid dirt and corrosion traps.
Tubing shall be cold bent using proper bending tools. Misformed or wrinkled bends are not
acceptable. Re-bending of tubing is not permitted (rejected bends shall be scrapped).

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Tubing shall be continuously supported with 316L stainless steel edgewise up tray or
ladder. Up to 3 runs of tubing can be supported on UNISTRUT SS Channel (or equivalent)
or angle iron. Tubing shall be attached to supports using 316SS accessories or as an
alternative STAUFF clamps (or equivalent) may be used. Tubing shall not be run in the
same tray as cables.
7.2 Plugs
Forged stainless steel to ASTM A182F316L hexagonal head plugs (Rating shall be as per
piping specification or higher). Threaded NPT to ANSI B1.20.1
7.3 Gauge Adaptors

Stainless steel to ASTM A182F 316L swivel gauge adaptor. Threaded NPT to ANSI
B1.20.1
7.4 Marking
All components shall be marked with the following details:
• Manufacturers Name
• Material of manufacture
• Material traceability number
• Manufacturers part number
• Tube diameter where applicable
7.5 Packaging
All fittings shall be provided as a complete assembly in suitable packaging to prevent
damage. Threads shall be fitted with plastic protectors. Packages shall be clearly marked
with manufacturers’ name, fitting reference number, material of construction and the total
quantity contained.

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8.0 MANIFOLDS
8.1 Instrument Manifolds (2 and 5 Valve)

Manifolds shall be manufactured from solid AISI 316L stainless steel bar. Manifolds shall be
suitable for direct or remote mounting. Bonnet assembly shall be 316 stainless steel
incorporating a non-rotating 316L stainless Steel stem, flexible gland packing and be
suitably locked to prevent detachment from valve body.
Manifolds shall be provided with 2” pipe mounting bracket suitable for independent
mounting in order to support the instrument which shall be directly bolted to the manifold.
The functions and open/closed positions of the valves must be clearly and permanently
identified.
Thread form shall be NPT in accordance with ASME B1.20.1. Process connections shall be
threaded ½” NPT female. Vent connections shall be threaded ¼” NPT female. Valve rating
shall be 6000 psig.
8.2 Air Distribution Manifolds

10 ways air distribution manifolds shall be supplied complete with 10 off isolating ball
valves. The manifold body shall be fabricated in 316L stainless steel from either extruded
section or all welded construction in 1½" nominal bore pipe.
Flange material shall be forged stainless steel to ASTM A182 F316L. Flange surface finish
shall be to ASME B46.1 (125 – 250 RA).
Inlet connection shall be 1½" flange Class 150lb Raised Face to ANSI B16.5.
Outlet connections shall be as follows:
• ½” Isolating ball valves

• Stainless Steel body to AISI 316
• Ball and stem to 316 stainless steel
• KEL-F seats and Teflon seals
• Outlets to be plugged ½" NPT female
Drain connection shall be ½" NPTF ball valve – specification as above.
NPT threads to ANSI B1.20.1.
8.3 Air Filter Regulators

All instruments requiring an air supply shall be provided with an air filter regulator.
Air filter regulators shall be a combination filter regulator, die cast aluminium body, spring
case and drip well complete with compatible 50mm diameter gauge.

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The main valve shall be moulded neoprene on stainless steel stem. The relief valve shall
be brass. The main valve spring shall be a carbon spring steel. The diaphragm shall be
nylon reinforced nitride. The filter shall be 40 microns maximum porous stone or equivalent.
The exterior finish shall be epoxy resin based paint.
The connections shall be NPT female to ANSI B1.20.1.
Maximum inlet pressure (body rating) shall be 10.5barg.

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9.0 SUPPORT MATERIALS
9.1 Metal Frame Supports and Accessories

Metal channel cable support systems shall comprise channels, channel combinations,
cantilever arms, brackets, fittings, nuts, bolts and washers all in accordance with BSEN
ISO1461.
Channel, channel combinations, cantilever arms and support brackets shall be fabricated
from a minimum 2.5mm thick steel to EN10025, Grade 430A, hot dipped galvanised to an
average thickness of 47 microns to BSEN ISO 1461.
Fittings shall be flat plates, base plates, angles, V and Z shape and beam clamps
fabricated from a minimum 6mm thick steel to EN10025, Grade 430A, hot dipped
galvanised to an average thickness of 80microns to BSEN ISO1461.

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10.0 INSTRUMENT INSTALLATION
10.1 Mounting
No instrument shall be mounted on hand railing or any structure that is liable to be removed
for maintenance purposes. No instrument (other than direct mounted pressure gauges)
shall be installed such that it depends for support or rigidity on the impulse piping or
electrical cabling connection to it.
Capillaries of filled systems shall be run independently of all other lines and shall be
continuously supported on steel angle or similar and clipped at intervals of no greater than
500mm.
Locally mounted instruments shall be mounted on suitable instrument stands or shall be

suitably bracketed and surface mounted on the nearest suitable firm steelwork. Surface
mounting pressure gauges with blow-out pressure release devices at the rear, shall be
mounted at least 20mm away from the mounting plate by means of distance pieces.
All transmitters, pressure gauges, etc., shall be installed in accordance with approved
process hook up drawings with regard to line slopes and relative positioning of
components. Where necessary, the process pipe work and instrument impulse tubing shall
be heat traced and insulated.
Process connection nozzles for instrumentation shall be extended, if required, to ensure

that primary isolation valves and process hook up or instrument connections are accessible
outside the main process pipe work insulation.
Actuated valves, whether modulating or on/off type, will generally be provided with
associated ancillaries (e.g., I/P positioners, filter regulators, solenoid valves, etc.,) already
piped and mounted on the valve/actuator assembly.
Where such ancillary equipment is supplied loose, it shall mounted on a suitable instrument
stand local to the valve and install interconnecting tubing as required.
Materials for instrument brackets and mounting stands shall be selected, or suitably
insulated, to avoid electrolytic action.
10.2 Locations
Approximate locations of field instruments, local panels and junction boxes shall be shown
on the instrument location and routing diagrams. For the exact locations of in line
instruments and valves and on line instrument isolation valves refer to the piping general
arrangement drawings and isometrics developed during detail design.

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Exact locations of secondary instrumentation items such as transmitters, local panels,

junction boxes, etc., shall be determined during construction and installed in accordance
with the installation specification and its referenced documents.
In general, instruments shall be visible and accessible, from grade, platform or permanent
walkway, to allow adjustment and maintenance (e.g., instrument data plates, gauges, zero
and span adjustments and valve manifolds) without the use of ladders or scaffolding.
Instruments shall be located at a practical height (normally 1200mm above grade).
Instruments shall be located away from heated surfaces (at least 600mm) and installation
protected from heat damage.
Instruments shall be located above grade or platform as indicated on the layout drawings
and shall be positioned so as not to cause obstruction to access ways.
Where practicable, instruments shall be close coupled to the process tapping. Excluding
remote mounted applications, instruments shall be mounted as near as practical to the
process connection.
Where instruments are required to be installed remotely from its associated process
tapping isolation valve, the length of impulse lines shall be kept to a minimum consistent
with speed of response and the possibility of blockage and mechanical damage. Heavy
equipment such as large control valves, relief valves and flow meters shall be provided with
adequate free space for maintenance and removal.

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11.0 QA
The Purchaser shall maintain an effective quality system that complies with the
requirements of the CA quality requirements specification and BS EN ISO9001.

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12.0 TESTING AND ACCEPTANCE CRITERIA

The CONTRACTOR shall be responsible for completing the following testing and
acceptance activities:
12.1 Mechanical Completion

Conduct any non-operating checks to ensure instrument operability, e.g., remove shipping
stops, verify instrument capability to measure, operate and stroke valves in the direction
and manner required by the process application.
Clean all transmission and control tubing by blowing with cooled and filtered clean air
before connecting to instrument components.
Clean all air supply headers by blowing with clean air and check for tightness.
Leak test pneumatic control circuits in accordance with the latest edition of ISA
Recommended Practice 7.1, Pneumatic Control Circuit Pressure Test.
Check piping from instruments to process piping for tightness.
Install and connect all system components and verify their conformance to specifications
and design criteria for function and range using dummy transmission signals as required.
Check all electrical signals and alarm wiring for continuity, correct source of power, and
polarity.
Check thermocouples for proper joining of wires, position of elements in wells, proper
polarity, and continuity of receiving instruments.
Identify orifice plates by tagging. Check and record bores of orifice plates and install after
completion of flushing operations.
Isolate or remove, if necessary, in line components such as control valves, positive

displacement meters, and turbine meters for pipework pressure testing. Reinstall these
items after testing the systems with the components removed or isolated.
Isolate or remove components for flushing operations and reinstall them on the completion
of these operations.
Conduct all flushing and cleaning operations for hydraulic systems, e.g., at gas production
wellheads, etc.
Install any sealing fluids, as required.
Fully pressurise and energise the transmitting and control signal system(s) by opening
process connections at primary sensors and final regulators and by making control mode
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settings for automatic operation of equipment as the process unit is charged and brought
on stream.
12.1.1 Site Acceptance Testing (SAT)
The main Instrumentation and Telecommunication systems shall be installed in

accordance with the equipment installation details and equipment layout drawings.
On completion of each system installation the equipment shall undergo a SAT in
accordance with the Approved Site Acceptance Test procedure.
On completion of the SAT and the removal of any punch list items the SAT
Procedure shall be accepted and signed off and then handed over to the
CONTRACTOR’s Mechanical Completions team.
Instrument and Telecommunications system that shall undergo an SAT shall
include, but may not be limited to the following:
• CSS, including PCS, ESD, FGS and RTU systems
• Telephones PABX
• Radio Systems
12.1.2 Pre-installation Testing and Calibration
Calibration certificate and calibration report of the instrument shall be verified for
validity and suitability prior to installation of the instrument. 5 points field calibration
shall be performed for instrument with invalid calibration certificate.
Smart instrument transmitters shall not be subjected to pre-installation testing
unless specifically requested by CA. Supplier Instrument documentation shall be
checked against each Tagged instrument prior to installation.
Non-smart instruments shall be subjected to a pre-installation test unless agreed in
writing with CA and this test shall commence as soon as practicable after the
receipt of the instrument on site. Tests and adjustments shall be performed in
accordance with the manufacturer’s instructions. In general tests shall simulate as
closely as possible design process conditions, by the use of manometers,
potentiometers, resistance bridges, dead weight testers, test pressure gauges, etc.
12.2 Commissioning Acceptance

The following is for guidance only. Detailed commissioning and acceptance procedures
shall be provided by the Purchaser.
12.2.1 Instrumentation
Verify final instrument operation, valve stroking, orifice plate installation, relief valve
installation and certification.
For all systems, the CONTRACTOR shall maintain a log of all temporary ‘overrides’
including a risk identification and mitigation, software modifications or electrical
circuit modifications that have not been defined within the design (including
jumpers, etc). At the end of the project the CONTRACTOR shall be required to
demonstrate that all mechanical, hard wired and software overrides have been

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removed or incorporated as a permanent modification and recorded in the design

documents.
“Overrides” can be defined by any temporary arrangement, inhibit or link and
implemented by either an electrical or mechanical means.
12.2.2 CSS & Telemetry
The ICC shall perform a 100% loop check from the field device to the CSS HMI.
Prove all loop controllers control within range and to a set point, change range of
transmitters as necessary, tune all controllers using on line tuning equipment,
monitor all loops for a period for stability, prove complex loops, split range, etc.,
monitor controller performance over entire range. Alarm function shall be tested
and verified display correctness.
Ensure all special control schemes including APC and optimisation control
schemes operate correctly and prove their control algorithms during process
operations.
Prove communications to all compressor and turbine package control systems, well
sites, intermediate field manifolds, PMS, MCCs, and metering.
Verify all telemetry communications, response times and data mapping on a 100%
I/O basis.
Set up a long term automatic data collection & statistical performance test of
telemetry system. Verify that the system meets the specification and any faults are
rectified.
12.2.3 ESD System
Prove the ESD system at each ESD Shutdown level by initiation of all inputs and
verification of the correct outputs per the ESD C&E.
Verify all output loops including stroking of ESDV & BDV and shutdown of electrical
drives.
Verify that all ESD output devices operate within a specified time and prove overall
shutdown is within design requirements.
Verify the sequence of events time stamping.
Verify the blow down pressures & temperatures versus time is within specification.
Demonstrate the plant remains operationally stable under each ESD condition.
12.2.4 Fire & Gas System (FGS)
Prove the FGS at each level by initiating each detector and checking the outputs
operate correctly as per the FGS C&E.
12.2.5 Interfaces to Management Computers/Historians/Data Recording Modules
Prove that every input has the required accuracy, frequency and is correctly
recorded. Prove that data recording is occurring in an uninterrupted fashion without
communication or data validity errors. Prove that the storage space and archiving
functions are working and are capable of supporting long term data retention.

Revision : B1
Date : 25/04/2017
Page : 40 of 42
Phase 1
12.2.6 Fiscal Metering Systems and Analysers
Prove fiscal metering system measurements including 100% check of data

repeated to the CSS. Demonstrate the metering streams computation accuracy
against CA and ONML acceptance procedures.
Prove any stand alone analysers operate correctly to specification.
12.2.7 Package Control Systems
Prove control functionality of each Package Control System.

Prove Package Control System interfaces to the CSS and ESD System. Verify that
data is displayed on the CSS correctly. Alarm function shall be tested and verified
display correctness.
Prove all Package Control System loop controllers control within range and to a set
point, change range of transmitters as necessary, tune all controllers, monitor all
loops for stability, prove complex loops like split range, etc. Monitor controller
performance. Ensure all special controllers operate correctly, prove control
algorithms in operation.
Prove communication of all package serial I/O to CSS, hardwired I/O to/from ESD
and any control interfaces with CSS.
12.2.8 Telecommunication Equipment Testing
All telecommunication equipment shall be subject to function testing at the

Vendor’s works.
All individual pieces of equipment shall be tested for functionality and operability
within the central system, this includes all hand held radios and remote stations.
All function testing certificates shall be made available to the site commissioning
team.
All cable systems for telecommunication equipment shall be tested for continuity.
All cable tests shall be carried out prior to connection of the equipment.
Pre-commissioning and commissioning shall be carried out on all
telecommunication systems to ensure full functionality according to the
requirements of the vendor specifications and the CA specifications. All tie-ins to
associated telecommunications shall be fully tested. All systems shall also be
subject to a full function test including verification of the complete system on all
locations.

Revision : B1
Date : 25/04/2017
Page : 41 of 42
Phase 1
13.0 DOCUMENTATION
The Contractor shall develop inspection and test reports which record that the materials
and equipment have been correctly installed and are ready for operation.
These checks will be undertaken by the Contractor and verified by the CA during the
completion phases of the project.
All test and inspection record sheets shall be signed by the qualified technician and
CONTRACTOR supervisor, and if witness testing is required the CA representative
signature shall also be included.
Punch Lists will be produced to identify non-conformance, incomplete and/or outstanding

work.

Revision : B1
Date : 25/04/2017
Page : 42 of 42

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HASSI BIR REKAIZ FIELD DEVELOPMENT

FRONT END ENGINEERING DESIGN

INSTRUMENT INSTALLATION AND TESTING

B1 25/04/2017 NI Issued for Approval PKL CKO

PTT EXPLORATION AND PRODUCTION PUBLIC COMPANY LIMITED

HASSI BIR REKAIZ FIELD DEVELOPMENT

1.0 INTRODUCTION ....................................................................................................... 7

2.0 DESIGN CODES AND SPECIFICATIONS ................................................................ 9

3.0 GENERAL DESIGN DATA ...................................................................................... 14

4.0 GENERAL REQUIREMENTS .................................................................................. 16

5.0 CABLE GLANDS .................................................................................................... 25

6.0 CABLING ................................................................................................................ 26

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

6.5 Cable Ladder Rack and Tray .............................................................................. 28

7.0 TUBE FITTINGS (PNEUMATIC, PROCESS & HYDRAULIC) ................................. 30

8.0 MANIFOLDS ........................................................................................................... 32

9.0 SUPPORT MATERIALS .......................................................................................... 34

10.0 INSTRUMENT INSTALLATION............................................................................... 35

12.0 TESTING AND ACCEPTANCE CRITERIA ............................................................. 38

13.0 DOCUMENTATION ................................................................................................. 42

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

Hold No. Section Description

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

AISI American Iron and Steel Institute

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

Figure 1-1: Project Location, Hassi Bir Rekaiz (HBR)

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

1.2 Purpose of Document

For the purpose of this specification, the following definitions apply:

CONTRACTING JOINT OPERATING COMPANY

PURCHASER CA, or CONTRACTOR

DPEM Algerian Ministry of Energy and Mines

L’Agence Nationale de Contrôle et de Régulation des

The word “shall” is to be understood as a mandatory requirement.

The word “should” is to be understood as strongly recommended.

The word “may” is to be understood as an action to be undertaken at the PURCHASER’s

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

2.0 DESIGN CODES AND SPECIFICATIONS

2.2 Order of Precedence

1) Algerian Government Legislation

2.3 Codes and Standards

Refer to HBR-01-GEN-INS-PHI-0001 Instrument, Control and Safety Systems Philosophy

2.4 Standards and Codes

• AGA GMM Gas Measurement Manual

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

• API Spec 6A Wellhead Equipment

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

• IEC 60079-14 Explosive Atmospheres Part 14 – Electrical Installation, Design, &

2.5 Project Documents

The following are related project documents:

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

Document Number Description

2.6 Units of Measurement

Parameter Unit Symbol

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

Parameter Unit Symbol

Supplement Unit (in parentheses)

HASSI BIR REKAIZ Development Project Document : HBR-01-GEN-INS-SPE-0003

3.0 GENERAL DESIGN DATA

3.1 Environmental Data

The following environmental data shall be used for design purposes:

HVAC Design Dry Bulb Temperature – Winter 0°C