ANNEXURE – I1

Instrumentation specification for 10,000 MT Capacity Ammonia Storage Tank

ANNEXURE – I1

GENERAL INSTRUMENT SPECIFICATION

FOR
ERECTION CONTRACTORS

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INDEX

SR.
NO. TOPIC PAGE
1 Introduction 3
2a Removal of Instrument and Hardware of existing tank T 3
2b Instrument installation and Commissioning Schedule 3
3 Obligations of the Instrument Erection Contractor (IEC) 4
4 General Conditions 4
5 Standards 5
6 Workmanship, Tidiness and Safety 6
7 Scope of work and Responsibility 7
8 Basis /Detailed Scope of various Activities 9
9 Installation Drawings and Documentation 12
10 Supply of Material 13
11 Instrument Installation 14
12 Tubing/ Piping and Tubing Support 15
13 Instrument Cable Installation 16
14 Painting 18
15 Identification of Lines and Instruments 19
16 Testing 19
17 Loop Checking 21
18 Material reconciliation & wastage allowance 22

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1.0 INTRODUCTION

This specification and all additional documentation as listed under the appendices covers the
materials and methods to be followed by the Instrument Erection Contractor (hereinafter referred
to as IEC) when installing and testing instruments and associated cabling, tubing, tray work etc. in
the entire project. This will be the responsibility of LSTK bidder. Also various drawings/documents
pertaining to this section shall be approved by M/S GNFC, prior to final implementation.

2.a REMOVAL OF INSTRUMENT AND HARDWARE OF EXISTING TANK

T-

Bidder/IEC shall mobilize the site within 15 days from the date on which they have been issued
mobilization notice by M/S GNFC. This includes time required to set up facilities at site. Contractor
shall start work within 15 days from the date of notice.

IEC shall carry out following activities in existing single wall ammonia storage Tank.

a) Removal of existing instruments, junction box, cable, cable tray with hardware, tube, fittings,
Glanding, Canopy, etc.
b) Dismantling supporting structure of cable tray, junction box, and instruments.
c) Handover instrument, junction box, cable, cable tray with hardware, tube, fittings, gland to
GNFC with proper handling.
d) Refer Annex. for instruments list for removal.

2.b INSTRUMENT INSTALLATION, COMMISSIONING SCHEDULE

Bidder/IEC shall mobilize the site within 15 days from the date on which they have been issued
mobilization notice by M/S GNFC. This includes time required to set up facilities at site. Contractor
shall start work within 15 days from the date of notice.

Commissioning schedule shall be followed as agreed upon between M/s GNFC and BIDDER and it
shall be strictly followed. Various type of weekly, monthly progress and schedule review shall be
submitted by BIDDER as and when required by M/S GNFC.

3.0 OBLIGATIONS OF THE IEC

3.1 The obligations of IEC in fulfillment of the requirements of this specification are briefly
stated below (elaborated further in various annexure, appendices, and technical
documents).

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3.2 Instrument Installation work as per M/S GNFC’s specifications, drawings and good
engineering and construction practice.

3.3 Erection, checking, tests.

3.4 Preparation of testing/loop checking reports/records in specified formats.

3.5 Co-ordination (as and when required with M/S GNFC/other contractors/ agencies
working in the same area)

3.6 Providing guarantees for the work carried out/ materials supplied.

3.7 Submitting the bar chart, progress report on weekly basis for the work done during the
period, Tag wise status for all tags of instruments list of all complete section, manpower
and construction equipments, deployment details and such other activities as per
requirements of M/S GNFC. Submission of monthly material appropriation statement
for cables, cable tray, junction box, cable gland, tubing, piping materials fittings,
indicating the quantity issued and expended in standard Performa.

3.8 Providing proper tools and tackles, manpower (fully conversant with their job),
consumables required for carrying out and completing the job correctly and within the
scheduled time.

3.9 Receiving the material from M/S GNFC stores and transporting the same to IEC’s
stores/ work place. Returning balance material to the place as advised by M/S GNFC.

3.10 Keeping proper record of all free issue material received, used and balance and
submitting the material reconciliation statement at the end of the job.

3.11 Visual inspection of all free issue material and in case of any defect or shortage,
bringing it to the notice of M/S GNFC immediately.

4 GENERAL CONDITIONS

4.1 The contractor shall be provided with open space for the site office and shall be
provided with electrical supply from construction power feeder at one point within 100 m
from contractor’s office only. Further distribution, as required, shall be done by
contractors as per the rules/regulations given by M/S GNFC. It shall be contractor’s
responsibility to protect the area allocated to him.
4.2 The IEC shall keep on site during all working hours a site in charge thoroughly familiar
with the class and nature of the work to be performed under the terms of the contract.
This responsible person will be deemed to have full authority to receive and to pass on
to the IEC’s other employees all instructions relating to the work under the terms of the
contract.
4.3 Any instruction given by the M/S GNFC Engineer to the person shall be deemed to have
been given to the IEC/BIDDER.

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4.4 The IEC shall in the execution of his work use exclusively new material to the
standards laid down in this or any supplementary document given thereafter, any
inconsistency or ambiguity in the purchasers documentation shall be brought to the
notice of engineer –in- charge and shall be resolved before work commences.

5 STANDARDS :

5.1 The instrumentation installation and calibrations works shall be carried out generally in
accordance with various international and Indian standards listed below but not limited
to the following.

ii. API-RP-550 Manual on installation of refinery instruments and control system.

iii. ISA standards and practices for instrumentation.
iv. All engineering documents enclosed with this enquiry and those issued
subsequent to awarding of contract and during execution of contract.
v. Manufacturers’ standards and practices.

5.2 The IEC shall carry out the work in accordance with the documents /standards
/drawings listed herein, and in accordance with any local ‘Statutory Regulations’, client’s
requirements and supplementary documentation.

5.3 The IEC shall instruct his staff. Skilled and semi-skilled, in the standards required by the
purchaser and shall ensure that only competent persons are allowed to handle or work
on instruments or instrument systems.

5.4 All tools and tackles including welding sets, gas-cutting sets required for carrying out the
work uninterrupted shall be provided by the IEC. Tools and tackles shall be an
approved type.IEC shall furnish details of all calibration equipment, their makes, model,
calibration certificate etc. to M/S GNFC before commencement of work. Any
instrument without proper and valid calibration certificate from a recognized certifying
agency will not be allowed to be used.
5.5 The IEC shall arrange for the necessary staff, tools and tackles as and when required
for meeting the project schedule in consultation with engineer-in-charge.
5.6 The working hours, holidays, weekly off etc., shall be followed as per M/S GNFC’s rules/
regulations. However, if required IEC shall arrange their personnel to work extra after
office hours and / or in shifts and on holidays to meet project completion schedule with
the prior permission of M/S GNFC site In charge.
5.7 General Condition of Contract’ of M/S GNFC will be applicable and the contactor shall
be responsible for all arrangements with respect to workmen’s compensation, insurance
and any other local regulations covering the labor employed by him.
5.8 All rules & regulations pertaining to the ISO 14001 and ISO 45001 certification shall be
followed by IEC skilled/ semiskilled workman. IEC shall follow the guidelines given by
G.N.F.C. site in charge regarding ISO 14001, ISO 45001 and safety rules observed by
M/S GNFC.

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6.0 WORKMANSHIP, TIDINESS AND SAFETY

6.1 The IEC shall not allow rubbish and scrap material from his operation to lay above the
site. Such rubbish and scrap shall be collected daily and be deposited at a place
approved by the engineer in charge.
6.2 The IEC shall be responsible for protecting installed equipment from damage and
pilferage, and shall ensure that all covers, caps, screws and weather protections etc.
are replaced at the end of each working day.
6.3 Only the best construction and engineering practices are to be used, and all work must
be done to the satisfaction of M/S GNFC engineer who should be consulted on any
point requiring clarification. The IEC is free to suggest to M/S GNFC engineer
alternative methods for the execution of the work where this would result in
improvement.
6.4 The IEC shall take adequate precautions during use and storage of gas cylinders.
6.5 The IEC shall use, ELCB, with each power supply board required for the installation
work.
6.6 Upon completion of the work, the IEC shall promptly remove his equipment and return
to the relevant places and shall return any unused material supplied by the engineer-in-
charge. Finally the IEC must clear the site of all rubbish and scrap deposited by him to
the satisfaction of the engineer-in-charge.
6.7 The engineer-in-charge will with due reference to the relevant section of the conditions
of the contract lay down the safety regulations for the site and IEC shall ensure all his
personals understand and comply with this regulations. IEC shall make sure that
manpower deployed at M/S GNFC site for this job shall be issued Safety Helmet, Safety
shoes, safety goggles and any other PPE as instructed by M/S GNFC. For working at
height IEC shall provide safety belts, ladders, proper approach, scaffolding etc at its
own cost.
6.8 The IEC shall prepare a comprehensive schedule for carrying out the installation before
commencement of actual work.
6.9 The IEC shall arrange for the necessary staff as and when required for keeping to the
schedule in consultation with M/S GNFC.
6.10 The IEC shall submit the list of tools and tackles that will be provided by the IEC.
However additional tools and tackles shall be arranged by IEC to carry out work as per
specifications.

7.0 SCOPE OF WORK AND RESPONSIBILITY

7.1 The instrumentation erection work covers various jobs listed under the various
schedules. However to ensure proper execution and completeness of the
instrumentation work any or all of the following shall also form the part of the scope and
shall be covered in the quoted rates.
7.2 Fabrication of pipe nipples, including threading wherever required.
7.3 Back/seal welding of screwed fittings as required.
7.4 Laying of cable underground wherever required including excavation, sand filling, brick
laying and back filling.

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7.5 Connection of purging devices for instrument as per drawings.

7.6 Minor civil works like chipping of pavements & grouting on the pavements the
instrument panels/supports/stanchions, & chipping, refilling & finishing of the pavement
for conduits.
7.7 Sealing of cables at flange side of ammonia tank after lying and testing of all cables etc.
7.8 Rotation of control valve and / or bonnet wherever required.
7.9 Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts,
etc. as per painting specifications.
7.10 Identification with approved color of paint the instrument/impulse line/manifolds
connected with alarm / trips circuits. Also, punching of tag no on items shall be carried
out as per instructions of engineer-in-charge.
7.11 Coordination with mechanical and other sub contractors for proper installation of
lines/vessels/ equipments mounted instruments like control valves, orifice assemblies,
temperature Sensor, level transmitter, level transmitter chamber, level gauges, level
switches, flame arresters, breather valves etc., which involves removal of instruments,
disconnection of tubes / cables, reconnection for alignment and proper installation etc.
These instruments will be required to be uninstalled and reinstall before final installation
for flushing.
7.12 Junction box etc, for cables/ multi tubes/glands/ grommets.
7.13 Grounding of shield of all shielded cables to respective instrument earth bus provided in
the thermocouple head/ junction boxes.
7.14 Progress Reports: IEC will provide progress report on weekly basis for the work done
during the period. Tag wise status for all tags of instrument list of complete PROJECT
area shall be prepared. Submission of monthly material appropriation statement for
cables, tubing, piping materials fittings, indicating the quantity issued and expended in
standard Performa.
7.15 Completion of M/s GNFC’s drawings / documents, as per the execution of work at site.
7.16 Preparation and submission of “As Built” drawings (marked up copies) as required in
two sets.
7.17 Start-up and commissioning assistance, if required.
7.18 The bidder shall quote optionally for manpower supply rate on man-days basis for
services.
7.19 Submission of final material appropriation statements for all the materials issued by the
M/s GNFC.
7.20 Any other work not mentioned above, but required for the proper execution of the work
like working at height and scaffolding/proper approach provision shall be in the scope of
contractor.
7.21 Where requested by M/s GNFC/ engineer-in-charge or his authorized reprehensive, all
or any of the works detailed above and works as per various schedule shall also be
performed on package unit , local panels, cabinets, gauge board installed by M/s GNFC
or by others.
7.22 Sealing of switches with standard lead seals after final setting in the presence of
engineer-in-charge.
7.23 Installation and terminations of tubing, cables etc. For analyzers (from field to analyzers
house and within analyzer house) and its accessories like sample cooler etc.
7.24 IEC shall be responsible to draw free issue items from M/S GNFC’s store.
Transportation required to shift to site shall be arranged by IEC. IEC, shall check all

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material before it is shifted from store, any discrepancies or damage shall be reported to
engineer-in-charge immediately. IEC shall be responsible for the safe custody and
protection of this material until M/S GNFC representative accepts the installation. Any
loss or damage incurred during this period shall be chargeable to the IEC.
7.25 Fork lifts, jumbo etc. if required by IEC to carry out work, shall be arranged by them at
his cost. M/S GNFC may provide such equipments on chargeable basis, if same are
available.
7.26 The IEC shall be responsible for the supply of installation materials as detailed
elsewhere in this document.
7.27 The installation will be tested in accordance with the instrument installation testing
procedures given elsewhere in this specification. If, however, others carry out the
testing, the IEC shall ensure that instruments are adequately protected during flushing
and pressure testing.
7.28 The IEC shall be responsible for the supply and cost of all replacement material and
labor necessary to rectify faults which show up during instrument installation/ testing /
commissioning, provided such faults are due to faulty workmanship of faulty materials in
the IEC’s scope of supply.
7.29 The IEC shall be responsible for the expediting and inspection of all materials in his
scope of supply. However, the purchaser reserves the right to expedite and inspect
such materials. M/S GNFC reserves the right to reject any material supplied by the IEC
if not found technically acceptable or of specified/ required quality.
7.30 The IEC is expected to hand over a fully operable system and any defects of design
omission or discrepancies found which would impede this achievement must be brought
to the attention of M/S GNFC representative without undue delay.
7.31 The main instrument air header will (unless otherwise specified) be installed by others
as a part of piping up to and including the take off point (including the isolation valve) on
air header. Generally the IEC shall be responsible for the tubing downstream of a given
isolation valve and this valve together with all upstream pipe work will have been
previously installed and tested by others (as a part of piping work).
7.32 The installation of orifice plate assemblies, safety valves, breather valve, flame arrestor,
rupture disc, control / switching valves, mass flow meter, Rota meters, sample
connection points up to and including the first isolation valve for flow, pressure, analysis,
provision of flanged connection for temperature and any other in-line equipment will be
carried out as a part of piping work by a contractor or agency responsible for piping.
However this shall be supervised by IEC in consultation with site instrument engineer.
7.33 All welders deployed on the job by the IEC shall be approved by M/S GNFC. Any
expenses to be incurred for welders’ qualification as per requirement of M/S GNFC shall
be borne by IEC.

8.0 Basis / Detailed Scope for VARIOUS ACTIVITIES

8.1 Installation of the field instruments.

Installation of the field instruments such as electronic (Conventional / Smart) transmitters for
pressure, flow, level, D/P etc., GWR with process chamber, Non Contact Radar Level Transmitter,
,Magnetic Level gauges, pressure gauges, temperature gauges and temperature elements with
flanged/ welded thermowells for tank wall and process line shall include, but not limited to the

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- transportation of these items from the place of storage to the place of installation
- unpacking,
- physical verification,
- Installation (in accordance to the applicable Hook Up drgs.).
- All stud bolts, gaskets etc. as required for fixing the thermowells,
- All instruments shall have first isolation valve on the equipment installed by piping contractor.
Installation scope of the all instruments shall be from the downstream of first isolation valves.
- External chamber type level instruments shall include the assembly of loose items (such as
floats, Guided wave Radar LT, etc if these are dispatched separately to avoid transportation
damages).
- The IEC shall inspect the installation of all online instruments such as orifice plates, venture,
Rota meters, control valves, which will be installed by mechanical contractor.
- The contractor’s scope shall include plugging of all the unused (spare) cable entries in the
junction boxes and instrument.

8.2 Installation of cable trays/ducts

The scope shall includes, but not limited to the

- Transportation of the trays/ducts from the place of storage to the place of work,
- Lifting to the place of work
- Proper alignment and fixing/ clamping (SS clamp).
- The cable duct/trays shall be of Aluminum (perforated type for branch cable) as specified in
the detailed MTO. The cable trays shall be supplied in standard straight lengths of approx.
2500 mm.
- Any bends, elbows, risers, tees etc. as required for cable trays as per site conditions shall be
fabricated by the IEC from the straight run only. The coupler plates shall be used to join the
two trays.
- Cable trays for multi core cables from control room to JB is considered as main trays. Rest all
trays shall be considered as sub trays. Prefabricated perforated Aluminum sub trays/ branch
trays shall be used to run individual pneumatic signal / sample tubing/ electrical (signals not to
be mixed up) and shall be mounted on steel structure.
- The scope of work shall include fabrication, welding and installation of trays including supports
from structural and laying of various sizes sub trays in position.
- Sub trays shall be bolted to the supports. The scope work is also inclusive of the supply and
fabrication of all tray fittings such as bends, offsets, corners, and crossings etc., as per
requirements.
- Minor civil works like grouting, providing inserts, chipping the concrete, bricks etc shall be
included under the IEC’s scope of work.
- The sub trays shall be properly finished and laid to give neat appearance.
- All supports, clamps and other fixtures shall be painted with min. two coats of Red oxide and
two paint coats of epoxy paints as per M/S GNFC’s standard color codes.
- Welding of cable trays joints is permitted. However aluminum paints to be applied before
cable/ tube laying.

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- Support trays shall be run with the breadth of the tray in a vertical plane. Where the engineer
agrees that the breadth horizontal the tray must be provided with additional support prevent
sagging.

8.3 Installation of Impulse Lines:

Except for steam service instrument impulse lines, all other location shall be ½” OD SS tubes.
The thickness of impulse tube shall be 1.0 mm for ½” OD SS tubes and 0.8 mm for ¼” OD SS
tubes, unless otherwise specified. These thickness shall be followed as standard as a
minimum, except special case requirements for vary high pressure and temperature services.
The scope shall includes, but not limited to the

- Transportation of the all SS tubes from the place of storage to the place of work,
- Lifting to the place of work,
- Cutting (using the cutters),
- Bending,
- Fixing/Clamping(SS clamping)
- The scope shall include the installation of tubes using double compression fittings, laying of
separate trays for instrument tubes, clamping (SS clamps), supporting, pressure testing, leak
checking and leak arresting.
- Instrument air tubes shall be laid in separate perforated aluminum cable trays.

8.4 Laying of Cables

The scope includes but not limited to the

- Transportation of the cable drums from the place of storage to the place of work
- Cutting the cable to required length as per cable and drum schedules
- Laying and termination at both the ends.
- The scope shall include the installation, glanding and termination of cables using cable glands
at both the ends for all single pair cables.
- Supply of bootlace lugs, continuous ferrule sleeves, insulation tapes, Teflon tapes, etc.
- Lying of cables on trays, dressing, clamping, supporting, continuity checking, meager testing
and all related activities.
- IEC will supply all the consumable items & accessories for the grounding of junction boxes &
cable glands and other items shall also be includes in the scope of supply of IEC like
insulation tape, Teflon tape, Teflon paste, silicon rubber paste, bootlace ferrules, lugs,
earthing/shielding cable sleeves, of all types/size, etc.

8.5 Package Instruments

The instruments coming in the package items, apart from above all items mentioned at 8.1 to
8.4, additionally the IEC scope shall include the dismantling of all the instruments for the
calibration & re-fixing of the instruments at their respective location with proper electrical
connections.

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9.0 INSTALLATION DRAWINGS AND DOCUMENTATION

9.1 The list of drawings and documentation to be provided to IEC shall include

9.1.1 HOOK UP – DIAGRAMS

Schematic hook-up drawings, indicating the typical arrangement for air supply and
process impulse tubing for each instrument or group of instrument together with tag
numbers and installation materials.

9.1.2 INSTRUMENT PLOT PLANS

This drawing shows approximate location of relevant instruments, junction boxes,

cable tray layout and routing. As this will be only a schematic, the actual routing of
trays and location of instruments and junction boxes shall be decided by IEC as per
existing site conditions in consultation with M/S GNFC’s Engineer.

9.1.3 CABLE SCHEDULE

These schedules list all the cables, approximate cable lengths, sizes connection
points and relevant technical information.

9.1.4 BILL OF MATERIALS

This summarizes the quantities of Transmitters, Junction Boxes, tubes, valves, etc.
and other erection hardware required for the installation.

9.1.5 TERMINATION DRAWINGS

This document shall show the details of termination in the instrument, junction boxes,
controls racks etc.

9.1.6 Piping and instrumentation diagrams

9.1.7 Instrument JB schedule, Air Manifold Schedule, Loop wiring diagram.

9.2 Drawings and Documents to be provided by IEC.

9.2.1 The drawings for materials that is included in IEC’s supply and erection scope.
9.2.2 The detail engineering drawing wherever such work is assigned.
9.2.3 Two sets of lay out drawing, interconnection diagrams, cable schedules etc duly
incorporating the changes/ modifications carried out during the course of execution of
works for approval of M/s GNFC.
9.2.4 Final material appropriation statement for all “free issue”, materials indicating shortages,
if any, in the Performa duly approved by engineer-in-charge.

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10.0 SUPPLY OF MATERIALS

The responsibility of IEC for the supply of all materials will unless otherwise specified be as
follows, but not limited to the

10.1 Materials to be supplied by the IEC at his own cost, as part of these specifications.
10.2 The supply of consumables like Teflon tape, insulation tape, welding rods, gas cutting
sets, piping compound, nitrogen in cylinders etc.
10.3 SS Bolts and nuts for supports, U bolts with nuts, SS clamps for tubes and pipes,
expansion bolts of various sizes( all nut/bolts, washers, etc. shall be of SS304 MOC) for
fixing to concert structure.
10.4 All industrial gases like oxygen, acetylene or inert, and all types of electrodes, brazing
rods, flux etc for welding purposes, with necessary facilities for testing the welded joints.
10.5 Paints (in various colors as required), primers, rustoline, TCE and other solvents.
10.6 All structural supports (size and quality of all MS channels, angels, flats, etc. shall be as
per I.S.) for instruments (including 2” pipe with SCH40 as a min.) and GWR process
chamber, Temperature Element of Tank Wall, JB’s, Trays etc. Including their supply
and fabrication including painting shall be in scope of IEC.
10.7 All materials for minor civil work like grouting etc.
10.8 Installation materials such as number ferrules, continuous ferrule sleeves, tag no. plates
of aluminum MOC, SS clamp for securing the cables/tubes and all other clamps, SS
MOC Nut/bolts/fasteners etc. required for installation of instruments as
specified/approved by M/S GNFC. IEC shall use gold plated lugs for RTD loop
terminations.
10.9 Accessories like tees, bents, crosses, bolts, supports etc as required for instrument to
JB,
10.10 Spool pieces and blinds for testing wherever required.
10.11 Lubricating oil, silicon oil, grease, soap solution.
10.12 Silicon carbide paper, painting brushes, yellow cloth, waste cotton for cleaning, wire
brushes, paint brushes, etc.
10.13 Neoprene rubber sheets, asbestos sheets,
10.14 Nozzle cleaning wires
10.15 Ferrule Machine with spare cartridge, Ferrule Tube.
10.16 Araldite, M-seal, Locktite, quick fix, rubber compound, silicon rubber tube.
10.17 GE make HRC fuses, glass fuses (ISI approved).
10.18 Any other items not specified, but required for completion of the job.
10.19 Materials approved by M/S GNFC‘s representative shall always be used. The IEC shall
submit in sealed pockets of all consumables like bolts, nuts, lubricants, ferrules lugs,
Teflon taps, Teflon paste, insulation taps, etc for approval from engineer-in-charge
which form the standards for erection works within the one week of placement of LOI.
10.20 The IEC shall procure the various installation materials from reputed vendors and such
materials shall be of good quality. M/S GNFC reserves the right to inspect and approve
such materials.

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11.0 INSTRUMENT INSTALLATION

11.1 Each instrument, erection hardware, or accessory to be installed by the IEC shall be
inspected visually for any damage.
11.2 The IEC shall then take it from where it is stored, lift it into position and ensure it is
leveled, plumbed and firmly secured.
11.3 The IEC shall be responsible for transporting equipment to be installed by him from the
store to the place of installation. Once the instrument is issued, loss or damage shall be
to IEC’s account.
11.4 Throughout the construction period, instrument shall be adequately protected wherever
necessary, by covering with suitable plastic bags. The IEC shall supply and fit these
bags as required.
11.5 Instruments shall not be bracketed directly off process lines except where specified by
engineer-in-charge.
11.6 Local mounted instruments shall be bracketed, mounted in sub-panels or placed on a
suitable pedestal. They shall, wherever necessary, be secured to the nearest suitable
firm steelwork in a manner prescribed by M/S GNFC. Wherever possible, instruments
shall be located so that they are protected from damage by passing or falling objects.
11.7 Local instruments with the exception of those on lines and vessels shall be mounted
with the centerline at approximately 1.2 meters above the platform or floor in a position
accessible for operation and maintenance.
11.8 Handrails shall not be used for supporting instruments.
11.9 All electronic instruments or instruments with electrical components shall be electrically
earthed in strict accordance with drawings. Steel panel board shall not be used for
earthling.
11.10 Instrument shall be installed in accordance with the appropriate hook-up diagrams or as
per the manufacturer’s recommendations, wherever hook diagrams are not available.
The IEC is not permitted to deviate from these diagrams with prior written approval from
engineer-in-charge. Instruments, JBs shall be installed strictly as per the installation
drawings provided for the projects.
11.11 All cable entries to instruments shall be preferably from bottom. If bottom entry is not
possible due to any reason, the cable entry shall be from side.
11.12 The instrument already mounted on the equipment shall be removed by the IEC for the
calibration check and re-fix back after consulting with M/s GNFC.
11.13 The case of the Instrument shall be earthed by earthing wire to the nearest earth bus
bar provided by others for the safety reasons.
11.13 The prefabricated (designed as per M/s GNFC site requirement) CANOPY of 2 mm
aluminum plate shall be installed for all the instruments and junction box except control
valves. The fabrication & supply of the canopy with installation hardware is in IEC
scope.

12.0 Instrument Tubing:

12.1 Instrument tubing to be installed can be classified in the following categories:

A) Air supply tubing
B) Transmission/ signal tubing
C) Process impulse line tubing

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12.2 Pipes/ Tubes shall be bent using pipe / tube bender; any hot bending will be totally
rejected. These shall be cut using pipe / tube cutting devices. Hot cutting will not be
allowed. Cutting of the tubes/tubing by hacksaw shall not be acceptable.
12.3 Pipes or tubes installed, but not connected, shall have the ends closed in an approved
fashion to, prevent the entry of foreign material. For a period of up to one week,
adhesive tape may be used, for a longer period caps or plugs shall be used.
12.4 Where instrument tubing is run parallel to each other, joints should be systematically
staggered and neatly offset. There must be at least two pipes / tubes between adjacent
joints.
12.5 Threaded fittings will have their threads specified in the purchaser’s documentation. All
threaded joints shall have Teflon tap as sealing medium
12.6 Where compression fittings are used, the fittings shall be installed in strict accordance
with the manufacturer’s recommendation. Due care shall be taken while handling the
compression fittings to avoid loss of ferrules.
12.7 Where stainless compression fittings are used, the IEC must ensure that stainless steel
nuts and olives are fitted unless otherwise specified by engineer.
12.8 Any discrepancies between the materials / fitting specified, and the material / fittings
provided shall be brought to the notice of the engineer-in-charge without delay.
12.9 The number of joints in the tubing shall be kept to a minimum consistent with good
practice and also to keep the wastage to the minimum.
12.10 Sufficient flexibility shall be provided in meter leads, air supply and tubing lines to allow
for movement (e.g. expansion, of the lines or the equipments to which connected.)

AIR SUPPLY AND TRANSMISSION TUBING

12.11 Horizontal runs of pipes and tubes shall have pipes / tubes laid vertically one above the
other as far as possible and shall be run with the minimum number of changes of
direction consistent with good practice and neat appearance.
12.12 All pneumatic signal tubing shall be cleaned by blowing through with instrument air prior
to installation.
12.13 Single tubing shall be run in such a manner as to give the maximum protection against
mechanical damage.
12.14 Where permanent enclosure trunking or conduit, etc., are left, space for tubes to be
pulled at some future date, a galvanized draw wire of adequate size shall be left in the
enclosure.

PROCESS TUBING

12.15 Impulse lines shall be kept as short as possible consistent with good practices.
12.16 All impulse tubing shall, in general, be run with a slope of not less than 1 in 12 except
where otherwise specified. The slope of the impulse tubing shall be up from the tapping
point for gas service unless special provisions are made for venting and draining.
12.17 S.S. tubing shall be joined by double compression fittings, or by screwed connections as
shown on the instrument hook – up drawing.

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PIPING AND TUBING SUPPORTS

12.18 Instrument air and signal tubing shall be adequately supported wherever possible to
prevent any mechanical damage.
12.19 Angle iron or 50 mm perforated trays shall be used for continuously supporting four or
more SS tubes and the tubes shall be secured to the tray at 0.5 meter intervals by
suitable U-clamps (SS).
12.20 The tray must be provided with suitable supports to prevent sagging.

13.0 INSTRUMENT CABLE INSTALLATION

13.1 The IEC must ensure that whenever an electrical cable specification is issued the
appropriate sections shall be read in conjunction with these specifications and any
omission or ambiguities should be resolved with the engineer-in-charge.
13.2 The cable installation drawings and documentations provided by the engineer will
normally specify or incorporate regulations for the electrical noise pick up. However
following general rules apply,
13.3 Parallel runs of the instrument cables and power cables should be avoided where
parallel runs must be made cable spacing specified in the documentation must be
maintained.
13.4 Where instrument and power cable cross in close proximity the cross shall be made at
right angle.
13.5 Single core / Single pair cables shall be cut after the exact site measurements are taken
between ends. The cable drum schedule shall be followed before cutting the length to
avoid any wastage.
13.6 Joints shall only be made at terminals in instruments or approved equipment. No
intermediate joints shall be made on cable tray or in conduit. Cables must be run in
accordance with the purchaser’s documentation.
13.7 All cables shall be terminated at junction boxes and instruments by proper glanding,
using proper size crimping lugs of approved design and with appropriate crimping tools.
13.8 Qualified electrician who is well experienced in this type of work shall do the junction
box or instrument wiring connections in an approved manner.
13.9 Where conduit terminates at cabinets, terminal box trunking or ducting, it shall be
secured with a lock nut, brushed and ferruled in an approved manner. Sharp edges
shall be removed and conduit not otherwise connected shall be terminated in smooth
brushes.
13.10 Cables shall properly be laid in perforated trays of suitable size aluminum MOC.
13.11 All cable shall be tagged with permanently punched strip of aluminum and identified as
given in cable schedule. The cable tag shall be on instrument side, junction box side.
The aluminum strips shall be securely fastened to cables using SS wires. Cable
identification tags shall be provided as following:

A) At an interval of 10 mtrs for cable laid above ground.

B) At an interval of 5 mtrs. For cable laid underground.

13.12 Shield, drain wire, terminated in junction boxes or earthling strips shall be provided with
PVC sleeve cover. This shall be supplied by IEC.

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13.13 Yellow color continuous Ferrules sleeve (with black font) of proper size shall be
provided for each terminated wire as per termination drawing. Double cross ferruling
philosophy shall be used at all locations, which indicates source/destination side detail
at each end.
13.14 Spare wires shall also be ferruled / tagged and neatly dressed.

13.15 Cables shall not be bent to radius less than the manufacturer’s recommendations (i.e 10
times the cable O.D).

13.16 All copper cables shall be terminated at junction boxes and instruments by proper
glanding with PVC hood covering.

13.17 Clips and saddles securing to steelwork or tray shall be of aluminum. These clips shall
be spaced at 0.5-meter intervals.

13.18 The cable laid on the cable tray shall be properly dressed in such a manner that the
crossing of cables shall be minimized. The cable on the cable tray shall be clamped with
SS strip at every 0.5 mtrs in vertical tray & 2 mtrs in the horizontal cable tray.

13.19 No cable laying cables in the cable trench or to be buried in concrete trench

14.0 PAINTING

14.1 All ferrous materials for brackets and supports supplied by the contractor and other
material not already protected in an approved way shall be cleaned and primed before
erection with primer as per painting specification given by M/S GNFC.
14.2 Painting of instrument supports, cable tray supports, all structural, all structural supports
shall be as under

14.2.1 The surface to be painted shall be thoroughly cleaned with wire brush/ sand paper to
remove all scales.
14.2.2 After cleaning, one coat of red oxide zinc chromate primer shall be given conforming to
IS-2074 and allowed to dry.
14.2.3 One coat of final red oxide shall be applied prior to first coat of paint.
14.2.4 Final coat of color shall be given before handing over the plant / commissioning.
14.2.5 The two coats of primer & two coats of final paint shall show DFT ad 25 microns (min)
respectively. The painting shall have total DFT as 100 microns (min).
14.2.6 The primer & final paint shall be of first class quality & shall confirm to the following.

Primer : Red oxide Zinc Chromate Primer

Type : Single pack Composition Modified phenolic alkyd
Pigmented with red oxide & zinc chromate.
DFT : 25 microns / coat (min)
Finish coat :Epoxy Paint (Chemical Resistant)
Type : Single pack Composition Phenolic medium
pigmented with superior quality pigments.
DFT : 25 microns / coat (min)

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The paints shall be confirm to the specifications given above & first class quality in their
products range of any of the following manufactures

1) Asian Paints
2) Bombay Paints
3) British Paints
4) Johnson & Nicholson
5) Shalimar

15.0 IDENTIFICATION OF LINES AND INSTRUMENTS

15.1 All site mounted instruments, cables, junction boxes, air header isolation valves,
tubing’s and wiring termination, shall be labeled or tagged in a manner approved by M/s
GNFC. Material for tag plate and tie wire shall be SS.

15.2 The engineer-in-charge will provide a table of label and other details for labels within
IEC supply.

15.3 All cable termination shall be identified by ferrules. The ferrules shall be continuous
sleeve type, white or yellow PVC with black lettering. IEC shall supply ferrules of
different sizes based on the cable sizes.

15.4 Air stations and local instruments shall have their reference numbers neatly marked on
them.

16.0 TESTING

All the necessary test equipments for performing the following tests shall be provided by the
instrument installation contractor. The instrument installation contractor shall furnish a list of test and
calibration equipments with make / model no that will be provided by him. This list should include
instrument listed at annexure-I as a minimum. However, other types of test equipment shall be
provided by contractor, if required in order to carry out work as per specifications. M/s GNFC shall
check the calibration of the test equipments of contractor.

16.1 All pneumatic signal lines shall be disconnected and blown through with instrument air
for 15 minutes to remove traces of oil, dust and moisture. Air manifolds shall also be
blown with instrument air after installation.
16.2 All instrument air mains shall be isolated from the instrument and pressurized
pneumatically, 1.5 times maximum working pressure and isolated from the source of
pressure. The pressure shall not fall by more than 0.1kg/cm2 in ten minutes. Also leak
test by soap solution shall be performed in presence of M/S GNFC on each joint, which
are to be leak tested.
16.3 All impulse lines shall be isolated from the instrument and hydraulically tested to 1.5
times the working pressure and isolated from the source of pressure. The pressure
shall not fall by more than 0.1 kg/ cm2 in ten minutes.

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16.4 All thermocouple, electric, power, and electronics instrument wiring shall be tested for
resistance between conductor and earth and for insulation between conductors with a
potential of 500V /1.1KV DC. This test shall be carried out with all conductors
disconnected except from the test instruments. The resistance shall not be less than 10
M ohm. Electrical continuity of cable armoring or braiding, conduits and any associated
flexible tubing, earthing conductor and / or equipment enclosures are to be checked for
compliance with the appropriate clause of IS-3043.
16.5 Transmitter connection to the correct receivers and polarity shall be checked.
16.6 Correct connection and electric switches shall be checked.
16.7 The written results of the test in duplicate for retention by M/s GNFC/ Engineer in
charge shall be approved by the engineer in charge.
16.8 The instrument installations contractors are responsible for supplying the necessary test
equipment and reasonable evidence of the satisfactory condition of this shall be
provided, if required.

16.9 All errors all faulty workmanship discovered during this testing or during subsequent
testing and commissioning shall be corrected by the instrument installation contractor at
his cost.
16.10 All test results shall be recorded in the approved formats.
16.11 All cable connections at field instruments and junction box terminals shall be checked
for:

 Correct polarity
 Correct Numbering
 Proper jointing / termination using copper lugs and PVC sleeves
 Cable continuity check: This check shall be done from junction box to individual
instrument under supervision and as per the instruction of M/S GNFC.

16.12 All cables shall be checked for proper clamping (SS) / support and shall be neatly
dressed.

16.13 Solenoid Valves shall be checked for operation by energizing them and checking their
operation. Suitable power source (as per the voltage value and type of voltage
specified on the nameplate of the solenoid valve.) and suitable voltmeter shall be
arranged by IEC for this purpose.

16.14 Temperature Elements shall be checked for continuity and resistance / milli volt value
(at 0%, 25%, 50%, 75%, 100% of the range and vice versa) using a suitable
temperature bath. Temperature transmitters (if any) shall be checked for operation.

16.15 The level switches (external cage type) shall be set by filling the cage with water to the
desired alarm / trip level, while setting the switch, it shall be ensured that the micro
switches do not reset for full rate travel of the float.

16.16 The IEC shall be responsible to keep proper record of all the tests performed and these
shall be approved by M/s GNFC. These records shall be finally submitted to M/s GNFC.

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17.0 LOOP CHECKING

Being a job, to minimize down time on account of loop simulation work, the whole
activity is to be carried out stage wise as follows.

Stage-I : When plant is running: Loop simulation from DCS marshalling cabinets to field
instruments like transmitters and control valves etc.

Stage-II : During Shutdown: Loop simulation from Junction Box to field instrument like
transmitters and control valves etc.

17.1 Loop test shall be performed after calibration of all instruments and leak test of signal
lines. Loop test are conducted to check the functional performance of all element
comprising the loop, thereby ensuring proper conditions and operations. All the control
room equipment namely DCS, PLC, and other peripherals are supplied, installed and
commissioned by DCS supplier/M/S GNFC.. The loop testing shall be done by IEC in
presence of M/S GNFC Engineers / Technicians.

Loop testing for all open/closed loops shall be generally by simulation of process
condition and shall fix points namely 0%, 25%, 50%, 75%, 100% of full scale inputs.
Detailed procedure shall be submitted to Engineer in charge for approval before
proceeding with the loop testing.

After the loop testing is completed, the contractor shall connect back any terminations
and connections removed for loop test./ marking shall be done on “loop checked”
instruments.
A loop shall be considered as handed over only after all the tests are over in that
particular loop are completed and certified by Engineer in charge, in addition to loop
sheets being duly filled in all respects and approved and accepted by Engineer in
charge.

In case of loop, in which certain instruments of the loops are calibrated by other agency,
the loop testing shall be performed in coordination with agency involved. If any defect in
the calibration of the instruments in contractor’s scope is observed, it shall be rectified to
the satisfaction of the engineer in charge. However, defect in calibration in the
instruments in the scope of other agency, it shall be rectified by other agency involved.
After the calibration has been rechecked by other agency, the loop checking would be
performed to the satisfaction of Engineer in charge, and this part is covered under the
scope of the contract.
Final certified loop sheet should be submitted in two copies to M/S GNFC and two
copies to consultant.

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18. MATERIAL RECONCILIATION & WASTAGE ALLOWANCE

Every month IEC shall submit an account for all the material issued to him by the M/s
GNFC in the manner prescribed for this purpose by the engineer-in-charge.
On completion of the work, the IEC shall submit a statement in 4 copies giving details of
all material / instruments received by him and material/ instruments erected and balance
items returned to M/S GNFC. .
The following wastage allowance shall be permitted. In case the wastage is more than
permitted allowance, the cost of such wastage shall be recovered from IEC.

ITEMS WASTAGE ALLOWANCE

- Compression fittings, valves, NIL 2%

Cable Glands

- Other fittings NIL 0.5%

Multi tube, multi cables Length below 2.0 mtr Non-salvageable

Unaccountable

18.4 All excess material and scrap shall be returned after duly accounting for, to the storage
points designated by the M/s GNFC.

18.5 Where materials are to be weighted before return, IEC shall be responsible for making
the necessary arrangement for weighing.

18.6 IEC shall not use scrap obtained during the course of construction for fabricating
temporary support or other items, without prior permission of engineer-in-charge.

18.7 If the IEC fails to return the surplus materials as aforesaid, the M/s GNFC will charge
the IEC such non returned at penalty rates which shall be deducted from whatever
amount that is due to IEC.

18.8 In case any material issued by the M/s GNFC deteriorates/lost during storage by IEC,
new materials may be issued to him at penalty rate and the delay in procuring such
material will be to the IEC’s account only unless timely replacement is arranged by the
IEC.

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