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    Inst.Installation QCP

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    6 views16 pages

    Inst - Installation QCP

    Uploaded by

    Suresh Pasumarthi

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 16
    Document Namber ‘SSGP-QcP-069-A4 PROCEDURE FOR Favor: © exteson INSTRUMENT SITE ACCEPTANCE TEST essen PA ote: [or maR 2013 Page 6 of 24 Commissioning Engineers Shall raport to the Commissioning Manager. Shall be responsible for execution and Implementation of all pre- commissioning and commissioning activities related to this procedure and prepare records. QN/QC Engineer? Shall report to QA/QC Manager. He shall be responsible for QC Inspector control and inspection of QC activities in line with this procedure, 6.0 METHopoLocy 6:4 INSTALLATION ‘8, Instrument Support Installation (2) The instrument supports shall be erected as per the AFC drawings. (b) The supports shall be fabricated at workshop or cast in ite, (6) The supports shall be checked for any transit damage prior to Installation. (2) The location of the supports shall Be marked as per the AFC drawings (PAID Hook up). (e) The supports shall be shifted to the erection location using the proper and safe method. (® The supports shall be fixed on its location using Anchor Botts after driling and tightened. bb. instrument Installation (0) Vendor calibrated cortfcates to be checkad and all the certificates will be submited to PCSB prior to Installation ofall instruments (©) The Installation of instruments shall be in accordance with AFC drawings (P40 Hook up). ©) Each instrument shall be checked for its tag number, voltage rating, working range ete prior to instalation. (@) Bench” testing checks. In accordance with client roguirements / specifations to be carried out at a certified lab before installation. alt certincates to be put into the dossier. Certincate for PSV's will be Submited atthe time of Installation as per the Doc number SSGP-O56- 6-RP-1003, 1 Pressure Instruments ~ Pressure Gauges: (©) Correct instrument tag number and location shall be confirmed as per {the locaton AFC drawing and PSTD, ee Bot." SBonachocoas * INSTRUMENT SITE ACCEPTANCE TEST Document Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: § | Category: FA Date: [or MAR 2013 Page 7 of2a o © @ © 0 @ 4.4. Pressure Instruments ~ Pressure & DP Transmitter @ o © © © © wm) Before installation geuges shall be checked for bench calibration with pret ranges. Manifold shall be fixed with correct ftings on instrument as per the Hook-up drawings and proper thread ssalant shall be used, Pressure gauge shal be Installed with proper thread sealant. ‘Wherever required, impulse tubing and vent tubing shall be completed a per the Rook-up drawing upon acceptance of hydro test / line pressure test /seal test « Gauges on vertcal Ines wll require an elbow Sr equal-tee as shovtn in the hook-up drawing s0 thet instrument ie ‘also readable in verte Pressure gauge shal be Installed for easy view from operating place. {solation valves must be provided for every pressure gauges maintenance and calibration provision. Correct instrument tag number and location shall be confirmed as per thelocation AFC drawing and 81D. ‘The instrument elevation and impulse tubing shall be as per the Hook- Lup drewings upon acceptance of hydro test/ line pressure test / seal test. Instrument steel supports and fixing devices shall be propery fabricated and fted without rough edges. Al driing shall be cared ‘out with the minimum tolerances. Steel work shall be used which 1s ‘adequately sized for the Intended load. All stel works to be painted according to Project specifications, Instruments shall be mounted so that they are as lose to the primary connection and also considering the Instument and process block Valve accessibility. The orientation and Instrument location shall be such that process connections can be made with minimum number of bends. ‘I installed support shall be inspected to ensure It is leveled, vertical ang the whole assembly secured. The transmitters shall be mounted above 1.3 meters from the operating flor level to centre line of the instrument. Instruments on main process line located more than 2.5, meters above grede or platform level shall be accessible by a permanent lsdéer or movable steps. Where supports are installed on pre-cast concrete foundations, the fxngs shall be checked to ensure they are tight and secured. Before Installation, Pressure transmitter shall be checked and Witnessed. for_dimensions and calibration paramaters based “an Instrument Data sheet ‘Bech SSaracr aes ae Document Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Ravn & INSTRUMENT SITE ACCEPTANCE TEST —— Date: [ex wan 20:3 Fane 378 (Cable glanding and termination shall be completed after the instrument final alignment completed. () Proper care shal be taken while connecting the HP & LP tubes to the ‘comect side ofthe intruments Temps 1.2. Temperature Instruments - Thermo-well ture Gauges, (2) Correct instrument tag number and location shall be confirmed as per the location drawing and PAID. (©) Before installation Thermo-wells and gauges shall be checked and ‘witnessed by QC for dimensional end calibration with correct ranges 2 per the data chet. (©) Thermo-well shall be installed and tghtened with correct size, type and rating of gasket and nut bolts as per shall standard drawing (@) After thermo-well instalation, element entry shall be plugged with Sultabe plug tl the clement instalation. (©) Temperature Gauges shall be installed and Uightened properly on the thermo- well, (0) Ensure that element is touching the bottom ofthe therme-well (o) Temperature Gauges shall be installed for easy view from operating place. Gauges shal be any angle type so orientate accordingly 1.3 Temperature Instruments ~ RTD and Transmitters. (2) Correct instrument tag number and location shall be confirmed 2s per the location ‘AFC drawing and PBID. (©) Before installation RTD and Transmitters shall be checked and Witnessed by QC for Functional and ealbration with correc ranges a5 per the data sheet. (©) Head mounted flange type temperature transmitters shall be installed and tightened with correct size, type / rating of gasket and nut bolts. (@) RTD shall be installed on thermo-well and ensure that element Is touching the bottom of therma-wel. (@) Where transmitter is to be mounted separately, stee! supports and: fixing devices shall be properly fabricated and ‘ited without rough ledges. All crling shall be carried out with the minimum tolerances Steal work shall be used which Is adequately sized for the intended Toad. all steel works to be painted according ta Project. specications. {f) Instruments shall be mounted so that they are as lose to the Therma- well connection and also considering the instrument operation ‘and ‘maintenance sccesibilty. {@). The orientation and instrument location shell be such that the RTO) cable shall have the minimum length DoctteSSGROCb-Ieo.Ae a INSTRUMENT SITE ACCEPTANCE TEST Document Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: & | cgtegory fA Date: | 02 maR 2033 Page Sof 24 a 0 o « © co) o AA Level @ © © o © 0 A » Instruments shall not be mounted where temperature or vibretion from hydraules oF rotating. equipment will affect the operation of the Instrument. or cause damage to instrument and may affect the ‘accuracy of the instrument. Installed support shall be inspected to ensure it is levelled, vertical and the whole assembly secured. The transmitters shall be mounted approximately 1.3 metres from the operating floor level to centre line ‘of the instrument. Instruments on main process lines located more than 2.5 metres above grade or platform level shall be accessible by & Permanent ladder or movable steps. Where supports are installed on pre-cast concrete foundations, the ‘xings shall be checked to ensure they are tight and secured. Instrument shall be mounted on steel support with Its mounting brackets mounting bolts shall be tightened rigidly. ‘Supports bolted to structural steel shal be checked to ensure all bolts fete. are correctly Installed and securely fixed Upon completion of the installation, covering facials with polyethylene bags will protect the Transmitter assembly, Cable glancing and termination shall ba compte after the instrument Final alignment completed instruments ~ Level Gauges: ‘correct level gauge tag number and location shall be confirmed as per the location AFC erawing and & 1D. ‘Before installation, level gauge shall be checked for dimensions based fon Data Sheet. and checked with water, Level gauge tapping (nozzies) flanges centre-to-centre distance should match with level au9e. Level gauges shall be installed in such a way that Level gauge Indiations shall be readable from the floor level 0” adjacent platform, Suitable size, type and rating of gaskets and stud bolts shall be used for instalation and ensure that all stud bolts are tightened propery during level gauge installation. Level gauge vent & drain valve shall be installed as per the hook up drawings. After level gauge Installation final alignment and vericalty shall be checked. Magnetic type level gauges vertically and final allgnment shall be checked property 25 per vendors instruction. Also drain and vent valves Shall be Installed with sutable plugs. ‘Secha "eseracr ocr ne Document Number SSGP-QCP-069-n4 PROCEDURE FOR Po INSTRUMENT SITE ACCEPTANCE TEST Cosson FA Date: [01 MAR 2013, age 10 of 28 o /\ ° © 0 ‘Also ensure that magnetic level gauges measuring scale should be ‘xed properly which can show the upper end point and lower start polnt ofthe level ‘The wire rope from the level marker up to the float shall Be fod Faldly. In between pulley and "guides shall be xed as per vendor Installation procedures and witnessed by QC. Floats for Magnetic type level gauges shall nat be installed until hydro testing Is complete. The type of float (density or not) wil be checked - ‘care should be a taken to ensure that afloat can not be installed inthe ‘wrong gauge chamber. To avold this while removing the fost from the chamoer corresponding Instrument tag number shall be marked on ‘the float temporarly. After testing the same float should be installed fon the correct chamber. 4.5 Level Instruments ~ Displacer type level Transmitters: @ © o © © © @ o 0 Instrument tag number and location shall be confirmed as per the location AFC drawing and PB 1D ‘The instrument-incalled elevation shall be as per the approved level calealation and as specified in the Hook-up drawings. Instrument steel supports and fixing devices. shall be properly fabricated and fitted without rough edges. all driling shall be carried ‘out with the minimum tolerances. Staelwork shall be used which 1s ‘adequately sized for the intended load. All steel works to be painted ‘according to project specifications. Instruments shall be mounted so that they are as close to the primary ‘omection and also considering the instrument and process. block Valve seeassiblity. ‘The orientation end instrument location shell be such that process comections can be made with minimum number of tends. ‘All installed support shall be inspected to ensure its lovlled, vertical and the whole assembly secured. The OP-Type transmitters shall be ‘mounted approximately’ 1.3 metres from the operating floor level to centre line of the instrument. Instruments on main. process lines located more than 2.5 metres above grade or platform level shall be accessible by @ permanent ladder er movable steps. Instrument shall be mounted on steel support with Its mounting brackets and ai mounting bolts shalt be tightened rigidly Before installation, level transmitter shall be checked for dimensions and calibration parameters based on instrument Data sheet. Manifold, Impulse tubing and related accessories shal be installed as per the standard hook-up drawing Boca “SSergcrowsae Document Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: 6 : INSTRUMENT SITE ACCEPTANCE TEST ——_ ate: | 01 MAR 2013 Page fi of 34 () Cable landing and termination shall be completed after the instrument Installation completed. (K) Proper Care shall be token while connecting the HP & LP tubes to the comect side ofthe instrument. (Direct mountable instruments shall be Installed on the vessel nozzles ‘with sulable bolts and gasket 4.6 Flow Instruments ~ Primary Elements & Local Indicators: (2) Flow elements end other focal indicators shall only be installed when the lines have been hydro tested and fused out. Onifce plate shal not be installed during hydro testing. For other local Indicators spo! pieces shall be Installed during hydro testing. (©) Before installation these flow clemants and other local indicators flow direction upstream and downstream shall be checked and Installed a per the process flow diagram/PID. ‘The clmensional measurement shall be checked and recorded before installation, (©) Sultable size, type and rating Gaskets and stud bolts shall be used for instalng’ these items 35 per the pipe spec snd Hook-up drawing Ensure that all stud bolts are tightened properly during instalation. (2) Line mountable focal indicators shal be installed in such a way thatthe indication shall be viewed easily and accessible. (©) Ensure thatthe line mountable ocal indicators shall be install in such ‘2 way that the Instrument is having less vibration during operation, if rhecessary, damps oF supports shall be installed to avoid vibrations. (8 After instalation, instruments & detectors shall be cover with plast {or water and sand protection, 1.7. Flow Instruments ~ DP type Flow Transmitters: (@) Flow transmitter shall be checked and recorded before installation. (©) Instrumentinstalled elevation shall be ae per the approved drawing ‘and is above or below the process tapping points as specie in the Hook-up drawings, (©) Correct instrument'tag number and location shall be confirmed as per the lation drawing and P & 1D. (@) Instruments shall be mounted so that they are as close to the primary Connection and also ‘considering the instrument and process. block Valve sczessbity. (©) Ensure that there is provision for operation and maintenance access to main piping isolation valves. ‘Doni. S50>-0ch-055-N4 Document Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: & INSTRUMENT SITE ACCEPTANCE TEST Category: IFA ate: | 01 MAR 2013 Page 12 of 24 (0) Instrument steel supports and fixing devices shall be properly {abrcated and fitted without rough edges. All driling shall be carried ‘outwith the minimum tolerances, (9) Stootwork shall be used which s adequately sized fo the intended loa ‘il tee! materials to be patted as per the project specifications. (h) The orientation and instrument location shall be such that process comections can be made with minimum number of bend () struments shall not be mounted where temperature ar vibration from hyéraulies or rotating equipment wil affect the operation of the Instrument or cause damage to Instrument impulse tubing, ) Cable glancing and terminetion shall be completed after the instrument Installation completed. (K) Manifold, Impulse tubing ond related accessories shall be installed as per the ‘standard hook-up drawing. Vent and crain tall tubes with ‘minimum length of 300mm shell be connected on the drain and vent ports of the manifolds. This tll tubes shell be away from the operstor for reasons of safety. () Care to be taken while connecting the HP & LP tubes to the corect side ofthe Instrument and witnessed by QC. (mm) Ensure that primary flow elements have been installed before taking the instrument in to servic, 1.8 Control, Shutdown valve,On / off valve: (2) Factory Acceptance test (includes Hydrostatic Test, Seal Leak test, Funetional/operational, Dimensional /veual tet) for the Cantral, Shut down Valves wil be done inthe factory by vendor prior to shipment to Site. A” vendor document which furnishes the “dats of factory ‘acceptance test wil be submitted to PCSB. (©) After installation of the Control, Shut Down valve, OrVOfT valve whase functional Operational Check 1s. already “done by vendor only Functional and Loop check wil be performed at ste (©) To carry out Operational check / Functional Check wil be done as per the operation manual which is mentioned ip the “document number 'SSGP-40-46-GN-3005, Select the relevant test equipment, suitable for the instrument range, as speciied within the instrument data sheet. (@) Record the test equipment certificate reference na, on the calibration test sheet: Remove the shipping stops. (©) Connect a sutable regulated air supply with @ test pressure geuge to the dlaphregm case connection. Inereace the prescure to load the Aliaphragm and check the valve spindle postion rom the valve stem positon indicator. The travel should be checked at the following Document Nomber ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: 6 INSTRUMENT SITE ACCEPTANCE TEST Category: IFA bate: | on mar 2013 Page 13 of 24 positions 0, 25, 50, 75, 100 percent of the valve stroke, Where necessary, adjust the valve spring tension nut to obtain the correct Start point and re-test (9) whore tight shut of s speci, atest rig will be fitted comprising af blind Range ited with a bleed pipe and a sultably rated Isolation valve. ‘The open end of the bleed pipe should be Immersed in water so that discharge bubbles can be observed. The valve inlet should be ‘connected to 2 pressure source equal to te valve shutoff pressure (a) The specited signal pressure corresponding tothe valve closed position, Under ‘normal operating conditions should be applied to the valve fctustor and where necessary adjustments made fo the valve unt the leakage bubble rate fe within the spectied tolerance. The seat leak test {operational leak test are done as per the vendor document number ‘SSGP-40-46-QP-7008. (H) The test results shall be recorded on the relevant test sheet and signed by the technician. The instrument shall then be referenced with the relevant sticker to highlight ts status. (For installation correct valve tag number and tocation shall be confirmed as por the location AFC drawing and PRID. (0) Control, Shutdown and Self Regulating valves shall be installed so that they are readily accessible for maintenance purposes. () Ensure that the valves are Installed in correct orientation for the Upstream and down stream flow. (1) Pneumatic tubing connection shall be completed as given in the Hook- {p drawings upon acceptance of hydro test / line pressure test / seal tect ater the fina installation of valves. (m) Unused pneumatic prts shall be plugged with suitable plugs. (s) All accessories like Solenoid valves, Air regulators, Exhaust ‘ters, Positioner and limit Switches etc shall be Installed as shown in the ‘Supplier General Arrangement Drawing (0) Cable shall be supported property near valve to avoid mechanical damage during vaive maintenance work. (©) Cable glanding and terminations shall be done. (@) Unused gland holes shal be plugged with suable pug. (8 Earthing connections for SOV and limit switches shall be completed as per the approved Termination Drawing. (5) Control valves are to be dropped out of test while during hydro test of, pipaines, ‘Bech "SSceneco sens rand Dacument Number ‘SSGP-QCP-069-A4 PROCEDURE FOR Revision: © | category: FA INSTRUMENT SITE ACCEPTANCE TEST Date: | 01 MAR 2023 Page 14 of 4 6.2 FIELD INSTRUMENT SITE ACCEPTANCE TEST ‘Aer installation of the field instruments which are already calibrated by the vendor based on bench calbration procedure, the loop checking and ‘Unetional test wil be carried. out and witnessed by QC according to the report format SSGP-QCP-127-RF- (O1-06).The test procedure for the instrument ls based on the vendor document number SSGP-042-46-QP- 7000 for PT end DPT whereas SSGP-042-46-QP-7003 for TT and TW, Field instrumentation shall be marked with predetermined identieation tag numbers In accordance with the project specifications, as identified within the instrument index. ‘The Instrument tag plate shall contain the insteument tag number and its service for both operations and maintenance ease of reference. The Service cescription, whien shall appear on the Instrument tag pate, shall be {an approved abbreviation or short name service description a eppraved By the clent ll instrument teg plates shell have @ white coloured background with black taxt of eight 30 mn 6.3 FIRE AND GAS DETECTORS (2) Correct instrument tag number and location / elevation shall be confirmed 3s per the location AFC drawing. (©) Instrument. steel supports and fixing devices shall be properly fabricated and fitted without rough edges, All driling shall be caried fut with the minimum tolerences. Stee! work shall be used which i adequately sized for the intended load. all steel works to be painted Becording to Project specifications. The vendor mounting arrangement

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