SPECIFICATION NO.

PAGE

GS 301
REV. 2
REV.
NO.

BY

DATE

TR

10/16/00

1 OF 15
CHK

APP.

DATE

REMARKS

REWRITE ON MS WORD

GENERAL SPECIFICATION

INSTRUMENT INSTALLATION, CALIBRATION & TESTING

GS - 301

SPECS NO.
GS 301
REV. 2

GENERAL SPECIFICATION
INSTRUMENT INSTALLATION, CALIBRATION & TESTING
GS - 301

INDEX

1.0
2.0
3.0
4.0
5.0
6.0

SCOPE
CODES,STANDARDS AND COMPANY SPECIFICATIONS
GENERAL REQUIREMENTS
INSTRUMENT INSTALLATION
INSTRUMENT TESTING
INSTRUMENT CALIBRATION

PAGE
2 OF 15

SPECS NO.
GS 301
REV. 2

1.0

PAGE
3 OF 15

SCOPE
This specification covers the installation, calibration and testing of general
instrumentation for CNOOC SES Ltd. Jakarta, Indonesia.

2.0

CODES, STANDARDS AND COMPANY SPECIFICATIONS

2.1

2.2

3.0

Codes and Standards

2.1.1

ISA

Instrument Society of America

2.1.2

API

American Petroleum Institute

2.1.3

NEC

National Electric Code

2.1.4

ANSI

American national Standard Institute

General Specifications
2.2.1

GS-300

Instrument Standard Practices

2.2.2

GS-400

Electrical Standard Practices

2.2.3

GS-401

Electrical Installation & Testing

2.2.4

GS-200

Piping Standard Practices

GENERAL REQUIREMENTS
3.1

The purpose of this specification and its referenced codes, standards and
general specifications is to establish a minimum level of acceptable quality.
Alternate standard designs of equal or superior quality may be proposed,
provided all exceptions are listed, and written approval for all exceptions is
obtained from COMPANY.

3.2

In the case of conflict between documents, Vendor shall submit the

discrepancy to COMPANY for final resolution. In his Bid Document, Vendor
shall provide for the more stringent requirement unless otherwise instructed in
writing by the COMPANY.

SPECS NO.
GS 301
REV. 2

4.0

PAGE
4 OF 15

3.3

Installation of instruments not covered by this specification or drawings

supplied by the COMPANY shall be carried out in accordance with the
manufacturer's recommendations and shall be subject to COMPANY's
approval.

3.4

A contractor or Vendor supplying packaged instrument shall comply to the

requirements set forth in this specification.

INSTRUMENT INSTALLATION
4.1

General
4.1.1

Transmitters and other process connected instruments shall be located

as close as practical to the point of measurement while still being
accessible from the deck, permanent ladder or a platform. Transmitters
may be line mounted where line temperatures do not cause the
ambient temperature to exceed the manufacturer's recommendation
and where excessive line vibration is not present. If transmitters are
line mounted, special purpose clamp-on supports shall be used.
Welding to piping is not permitted.

4.1.2

Wherever possible, instruments requiring routine access shall be

mounted approximately 4 ft. - 6 inches above the deck or platform.

4.1.3

Locally mounted indicating instruments not requiring routine access

shall be located so as to be conveniently visible from the deck.

4.1.4

Locally mounted instruments shall be supported on brackets or

mounted on subplates, or placed on a suitable pedestal, pipe stand or
structural support. Pipe or structural stands shall be welded onto deck
plate or fixed to grating with 'J' bolts.

4.1.5

Instrument stands shall be located so that they do not interfere with

normal or emergency walkways, or access to equipment. Similarly,
tubing or conduit to locally mounted instruments shall not be routed
across normal or emergency walkways or interfere with access to
equipment.

4.1.6

No instrument stand shall be located or tubed-up until the COMPANY

on-site inspector has approved the Contractor's proposed location and
connection details.

4.1.7

Handrails shall not be used for supporting instruments or instrument

lines.

SPECS NO.
GS 301
REV. 2

4.2

4.3

4.4

4.5

PAGE
5 OF 15

Orifice Fittings
4.2.1

Orifice flanges or meter tubes shall be installed horizontally, near the

deck or a platform for ease of accessibility and safe changing of the
orifice plate.

4.2.2

It is not permitted to install an orifice meter such that the person

changing the orifice plate is required to stand directly over the top of
the fitting.

4.2.3

Full length upstream and downstream meter runs are required unless
the meter installation is specifically indicated on the P & ID's as a
reduced accuracy meter.

4.2.4

Orifice plates shall be installed after flushing the lines.

Positive Displacement Meters

4.3.1

A strainer shall be installed upstream of the meter.

4.3.2

Positive displacement meters shall be installed after hydrotesting, and

lines have been flushed.

Turbine Meter
4.4.1

A strainer shall be installed upstream of all turbine meters.

4.4.2

A minimum straight run of 20 x pipe diameter on the upstream and 5 x

pipe diameter on the downstream of the turbine meter shall be
provided.

4.4.3

Turbine meters shall be installed after hydrotesting, and lines have

been flushed.

Rotameters
4.5.1

The meter shall be installed vertically with the outlet connection at the
top and the inlet connection at the bottom.

4.5.2

Elbows, valves and other fittings shall not be closer than 5 pipe
diameters upstream.

4.5.3

The meter location shall be free from vibration and there shall be
sufficient clearance for the float removal.

SPECS NO.
GS 301
REV. 2

4.6

4.8

6 OF 15

Sight Flow Indicator

4.6.1

4.7

PAGE

The location of sight flow indicators shall be accessible from deck or a

platform.

Level Instruments
4.7.1

External displacer type level instruments shall have block valves on

both equalizing lines. These block valves shall be installed in the
vertical plane.

4.7.2

The equalizing lines on external displacer type level instruments shall

not be common with any other service. The minimum equalizing line
size shall be 1 1/2 inch.

4.7.3

Drain valves shall be provided to drain each displacer cage. This drain
shall be piped or tubed to the platform open oily drain system via a
conveniently located drain funnel.

4.7.4

External cage level instruments shall not be used for mounting other
instruments. Where multiple instruments are mounted to common
vessel connections, a single pipe column shall be used.

4.7.5

Vessel bridles or stand pipes for multiple level instruments shall be

used only with COMPANY approval. When used they shall be 4" Sch.
80 pipe minimum with block valves and 1" vent and drain
connections.

4.7.6

The lower equalizing connection for a pipe column shall not come
from the bottom of the vessel unless an internal stub-in with 90
elbow (looking downstream) is provided to prevent sediment
collecting in the pipe column.

Level Gauges
4.8.1

Level gauge connections shall normally be made directly to the vessel.

Level gauge connections to piping shall be permitted only when the
gauge cannot otherwise be installed at the proper elevation and then
only when the connection is to piping in which the fluid is normally
non-flowing, such as vessel drains.

4.8.2

All level gauges shall be provided with a 1/2 inch ball valve.

4.8.3

Multiple glass installations shall have 1" minimum visible gauge

column overlap.

SPECS NO.
GS 301
REV. 2

4.9

4.10

PAGE
7 OF 15

Temperature Instruments
4.9.1

Process sensing temperature elements shall be installed in suitable

thermowells.

4.9.2

Thermowell connections shall be 2" flanged with the same rating as

the piping or vessel in which they are installed.

Pressure Instruments
Locally mounted gages, unless otherwise specified, shall be supported directly
on the piping or vessel.

4.11

Shutdown and Control Valves

4.11.1 Where practical, control valves shall be installed in horizontal lines
with the operators above the valves.
4.11.2 Clearance shall be provided to allow inline maintenance of the valve.
Adequate clearance shall be provided above and below the valve to
allow removal of the valve operator and internal cage (trim) and valve
bottom plate as applicable.
4.11.3 Adequate clearance shall be provided around the shutdown valve
actuator for removal of the actuator rear cover plate without removal
of the actuator from the valve.

4.12

Tubing Installation
4.12.1 The tubing installation shall be neat in appearance. Tubing shall be
run in either horizontal or vertical plane.
4.12.2 Tubing runs shall be grouped together where practical.
4.12.3 The use of short lengths of tubing in long runs shall be avoided to
reduce number of fittings.
4.12.4 Tubing runs shall be arranged so that couplings may be tightened
without distorting or bending the line.
4.12.5 Tubing shall be routed to prevent mechanical damage and present a
neat appearance. No pipe or tubing shall be subjected to mechanical
strain .
4.12.6 Tubing shall be bent with the correct size tubing bender. A tubing
cutter shall always be used to cut the tubing and it must be deburred
before being connected to the fittings.

SPECS NO.
GS 301
REV. 2

4.13

PAGE
8 OF 15

4.12.7

All pipe plugs shall be barstock with hex head.

4.12.8

On tubing to pipe connections and in making up screwed pipe joints,

teflon tape shall be applied to male threads. Thread compound,
SWAK, (manufactured by Cajon) may be used in accordance with
the piping specification if applied to male threads only. Compound
shall not be applied to tubing nut and ferrule.

4.12.9

All runs of tubing shall be continuously supported in a tubing tray,

channel or angle and be fastened to the support at 36 inch intervals.
Where it is impractical to continuously support single runs of tubing,
a waiver must be obtained from the COMPANY.

4.12.10

Tubing trays shall be reinforced fiberglass, supported at intervals of

not more than ten (10) feet.

4.12.11

Tubing tray brackets shall have holes drilled and finish coat painted
prior to installation.

Piping Installation
4.13.1

The differential and static pressure lines shall not exceed 20 feet in
length for direct connected or locally mounted instrument.

4.13.2

For gas services, where practical, the flow meter or transmitter shall
be installed above the orifice taps with impulse lines sloped such that
any condensation formed in the meter body or impulse lines will
drain into the orifice taps. Where this is not feasible, condensate pots
and drain valves shall be provided at the low point.

4.13.3

Flow instruments using orifice plates as the primary element shall

have a 316SS 3-Valve manifold near the instrument in addition to
the primary block valves at the orifice fitting.

4.13.4

The primary valves located at the orifice fitting shall be 1/2" full
opening and installed so as to permit cleaning the orifice connection.

4.13.5

Adequate instrument supply headers and branch lines shall be

provided for all operating areas. Take-offs for branch lines shall be
from the top of the main header with block valves equal in size to the
branch line. All low points shall have a 1/2" ball valve installed.

SPECS NO.
GS 301
REV. 2

4.14

5.0

PAGE
9 OF 15

Instrument Cable Installation

4.14.1

All electrical installation work and material furnished shall conform

to GS-400 Electrical Standard Practices and GS-401 Electrical
Installation & Testing.

4.14.2

Electrical signal wiring from electronic transmitters to receivers and

to final control elements shall be continuously shielded with the
shields grounded at the receiver end only. Cable shall be type MC
(metal clad) with an overall PVC jacket.

4.14.3

Wiring for thermocouples and resistance thermometers shall not be

run in the same conduit or cable with low voltage analog signals
(4-20 mA DC) or pulse signals from a flow meter. Pulse signals shall
not be run in the same conduit or cable with power wiring or
unshielded DC signal wiring.

INSTRUMENT TESTING
5.1

General
5.1.1

All testing and calibration shall be done by Contractor. The

contractor shall furnish all necessary test and calibration equipments.

5.1.2

The calibration and testing personnel shall be fully conversant with

the type of Manufacturer's equipment to be calibrated and tested.

5.1.3

The test and calibration equipment shall have better accuracy than
the Manufacturer's stated accuracy of the instrument to be tested.

5.1.4

Company reserves the right to reject any or all test and calibration
works of the equipment if they are not satisfactory to the
COMPANY.

5.1.5

Contractor shall submit a list of test and calibration equipment to be

used with all data e.g., test certificate, for COMPANY approval.

5.1.6

All errors or faulty workmanship discovered during testing, shall be

corrected to the satisfaction of the COMPANY.

SPECS NO.
GS 301
REV. 2

5.1.7

PAGE
10 OF 15

After completion of each test, a suitable tag, seal or marker

indicating the state reached shall be fixed to each instrument or
installation, e.g., a color coded label as follows :
-

blue

preinstallation tested

yellow

pressure tested

green

cable tested

This identification shall be shown on all components in the loop

installation, thereby making all personnel aware of the current status
of any loop.
5.1.8

Written test procedures shall be submitted by the Contractor for

COMPANY approval at least ten (10) days prior to commencement
of testing.

5.1.9

In general, the test procedure shall be commenced as the following :

5.1.9.1 Preinstallation Test
This testing is to ensure that each instrument device
supplied has been calibrated in accordance with the
specification, functionally correct and in working order.
5.1.9.2 System Loop Test
This testing is to ensure that each instrument loop functions
correctly and is ready for start up.
5.1.9.3 Pressure Test
This testing is to ensure that instrument piping and tubing
has been correctly installed and pressure tight to a specific
working and testing conditions.

5.2

Preinstallation Testing
5.2.1

Instruments shall be subjected to preinstallation tests before being

installed on the line, vessel or equipments.

5.2.2

Instruments shall wherever possible be subjected to test and

calibration in accordance with its specification.

SPECS NO.
GS 301
REV. 2

5.3

5.4

PAGE
11 OF 15

5.2.3

Where practical, tests and calibration shall be performed to the design

process condition, by the use of manometer, potentiometers, resistance
bridges, dead weight testers, test pressure gauges etc., and utilizing
hydraulic, electric and pneumatic supply.

5.2.4

In general test and calibration of electric instruments shall not be

carried-out until an adequate warm up period has elapsed. Wherever
possible, the instrument shall be energized 24 hours before testing.

5.2.5

Control valves and operators shall be checked to ensure they stroke

through full range and to ensure specified failure position.

5.2.6

Shutdown valves shall be checked to ensure the proper action during

the emergency condition.

5.2.7

Level gages glass hold-down nuts shall be checked with a torque

wrench to ensure proper torque and even tension according to the
manufacturer's recommendation.

5.2.8

Instruments that use lubrication shall be checked and lubricated

wherever needed.

5.2.9

Tag nameplates shall be checked.

Loop Testing
5.3.1

Each instrument loop shall be checked for continuity, correct action of

the controller, valve and other devices.

5.3.2

Where practical, this test shall be accomplished by the introduction of

a spurious signal into the controller to simulate the actual process
condition. The controller shall be set at best predicted optimum
setting, for start up conditions.

Pressure Test
5.4.1

The pressure test for each instrument installation shall be done after
the instrument piping and tubing for that installation has been
completed and approved by COMPANY.

5.4.2

The pressure testing shall include the following:

5.4.2.1

Cleaning and blowing out all pipe and tubes to remove

scale, dust or other foreign material.

5.4.2.2

Blowing out all water used after hydrostatic testing of

process sensing lines.

SPECS NO.
GS 301
REV. 2

5.4.3

5.4.4

5.4.5

PAGE
12 OF 15

The instrument piping and tubing installation to be tested shall be

classified as follows :
-

Supply piping

Transmission and signal lines

Process Sensing Lines

Supply Piping Pressure Test

5.4.4.1

Each instrument air or gas supply line shall be disconnected

upstream of the individual air filter/regulator or instrument
port.

5.4.4.2

The lines shall be pressurized to 150 psig and then shall be

isolated from the pressure source. The pressure shall not fall
by more than 10 psig in 10 minutes.

5.4.4.3

If the leakage rate is more than 10 psig in 10 minutes, the

joints shall be checked with soap solution and corrected
wherever necessary.

5.4.4.4

The joints not previously proven shall be checked with soap

solution.

Transmission and Control Lines

5.4.5.1

Each individual transmission and control line shall be leak

tested by means of sight feed bubbler. Air consuming pilots,
if any, shall be disconnected prior to testing the line.

5.4.5.2

The tubing lines shall be pressurized and the test pressure

shall not exceed 20 psig. After pressurizing the bubble rate
shall be less than one (1) bubble in ten (10) seconds.

5.4.5.3

The joint not previously proven shall be tested with soap

solution.

5.4.6 Process Sensing Lines

5.4.6.1

Process sensing lines shall be disconnect from the

instrument and hydrostatically tested.

SPECS NO.
GS 301
REV. 2

5.4.6.2

PAGE
13 OF 15

The lines shall be pressurized to 1 times the maximum

working pressure and then isolated from the pressure
source.
The pressure in the lines shall be maintained without loss
for a period of ten (10) minutes.

5.4.6.3

5.5

The joints not previously proven shall be checked with soap

solution.

5.4.7

The hydraulic tubing lines to wellhead downhole valves (SCSSV)

shall be hydrostatic tested to a pressure of 5000 psig.

5.4.8

Attention is drawn to the fact that various tests are carried out by
others on process piping, e.g., hydrostatic tests, flushing, etc. During
hydrostatic test on the process piping the instruments shall be
disconnected to ensure that initial isolation valves are leak proof.

Testing of Instrument Wiring

Testing of instrument wiring shall be in accordance with General Specification,
GS-401 Electrical Installation and Testing.

5.6

Shutdown and Alarm Function Test

Alarm and shutdown circuits shall be checked for correct functional operation
of equipment and devices.

5.7

Documentation
5.7.1

Contractor shall prepare the Test Record which shall include, but not
limited to the followings :
5.7.1.1
5.7.1.2
5.7.1.3
5.7.1.4
5.7.1.5
5.7.1.6
5.7.1.7
5.7.1.8
5.7.1.9
5.7.1.10

5.7.2

Description of the test to be performed

List of equipment to be tested
List of test equipment
Sheets for recording data (when appropriate)
Time and Date of the test
Time and date of Retest (if retest required)
List of instrument loops
List of individual instruments
Name and signature of the technician performing the test
Name and signature of COMPANY witness

All completed and accepted test record shall be submitted to

COMPANY within 48 hours after the test completion.

SPECS NO.
GS 301
REV. 2

5.7.3

6.0

PAGE
14 OF 15

COMPANY shall be notified fourty-eight (48) hours in advance of

any test.

INSTRUMENT CALIBRATION
6.1

6.2

General
6.1.1

Complete loop calibration (i.e., calibration of each loop instrument in

situ) shall be carried out after the instrument loop has been completed.

6.1.2

Removal, replacement and transportation of any instrument to

facilitate calibration and any costs arising therefrom, shall be the
responsibility of the Contractor.

6.1.3

COMPANY shall be allowed free access to inspect work and all items
of test equipment at all times.

6.1.4

Calibration work carried out on the platform may be required when

plant is in the commissioning stage or where process fluids are
present. Safety rules and relevant permits to work in the particular
location shall apply to all calibration, testing and check-out work.

6.1.5

Personnel employed for calibration work shall be qualified and

thoroughly conversant with the types of instrumentation installed.

Technical Requirements
6.2.1

Instrument calibration shall comprise calibration of individual loop

components followed by functional and calibration check of
completed loops after completion of installation.

6.2.2

The calibration techniques and equipment used shall ensure

verification of the instrument manufacturers specified accuracy and
performance. The calibrations shall verify the span, mid range and
zero.

6.2.3

The removal of instruments for calibration is optional unless good

practice dictates otherwise; e.g., positive displacement type
accounting flowmeters, shall not be removed for calibration.
If any instrument is removed from its installed position for calibration,
the reinstallation shall be pressure and leak tested and polarity
checked for correct operation.

SPECS NO.
GS 301
REV. 2

6.3

PAGE
15 OF 15

6.2.4

After calibration, each instrument shall be clearly marked as having

been checked, including names of Contractor and COMPANY
witness, date of test, by means of adhesive tape labels. The checking
of complete loops shall be indicated by marking the control room
panel instrument or other appropriate instrument for field loops.

6.2.5

After calibration, all instrument primary elements that are in contact

with process fluids shall be isolated from the process at the first
isolation valve. Torque tube displacer chambers shall be drained after
calibration and then isolated from the process.

Documentation
6.3.1

All calibration results shall be recorded on special forms, the format of

which shall be approved by COMPANY. It shall be the responsibility
of the Contractor to develop an acceptable form.

6.3.2

The Contractor shall complete calibration certificates for individual

instruments and loops, keeping the documentation up to date on a
daily basis.

6.3.3

Upon final instrument loop acceptances, each individual instrument of

the calibrated loop shall be labeled with name of calibrator, date of
calibration, calibration set points, and signatures of COMPANY
witness.

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