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INSTRUMENT INSTALLATION
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INSTRUMENT INSTALLATION
AAA/RPT
JAIL
JAI
JPL
JPL
JPL
EDLO/JLFL
ASO
ASO
ASO
ASO
ASO
6
5
4
3
2
1
15/03/11
18/06/07
NOV.2005
11.98
2.84
5.77
APPROV.
CHECKED.
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DATE
REVISIN GENERAL
REVISADO POR CAMBIO DE RAZN SOCIAL
REVISIN GENERAL (Incluidos comentarios de Construccin)
REVISIN GENERAL
REVISIN GENERAL
EMISIN
DESCRIPTION
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INDEX
1
OBJECT ................................................................................................................... 4
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
Control Valves................................................................................... 15
7.1.6
7.1.7
Analyzers .......................................................................................... 15
7.1.8
7.1.9
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1 OBJECT
The object of this specification is to establish the requirements and conditions that the
Contractor should meet regarding the execution of the works included in the instruments
installation and control equipment.
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In the connections specified as threaded, the thread will be executed carefully, using PTFE
tape as joint element. Should the process requires, welding seal will be also made.
Pipes, trays, etc., will be settled so that they allow a clearance in height of two and half
meters onto platforms or walkways.
In those points that, during the installation, any anticorrosive finish of a material may result
damaged due to reasons such as by cutting, bending activities, etc., the damaged surface
must be painted and protected to ensure a complete anticorrosive coating.
All instruments which situation is not determined in the documentation will be located in
accessible places for their easy calibration and maintenance and also in accordance with
the instructions of the work supervision.
As the calibrations and instruments tests are being carried out, the instruments will be
labeled indicating their check status. The Contractor will be able to present a report at every
time, indicating the status of the tests performed and remarking the possible anomalies that
might arise.
During the erection, Contractor will be responsible to preserve of rainwater, dew, dust and
other contingencies to all equipment that must be kept open, and to provide provisional
protection in case the items could have water for any reason, and to dry and clean them
properly.
It will be Contractors responsibility to maintain the work area properly clean, and he will be
in charge of unpacking the instruments, local panels, distribution panels, consoles, cabins,
etc., and to deposit the packing in the waste collecting point.
4 SCOPE OF WORKS
The Contractor has the obligation of transmitting the content of this specification for general
knowledge of all his employees.
Contractor will be responsible for the installation of all the instruments indicated in the
material requisitions (MR), following drawing indications, and also instructions and
recommendations of the manufacturer. This information will be given by Engineering and
Contractor will be in charge of the in situ verification of the viability of the location of the
different elements of the installation.
In the case that there were any equipment or material not possible to install according to
forwarded drawings, its installation will be carried out according to the good practice of this
discipline, but always with the previous approval of the Work Supervision.
In the case of those instruments directly installed on the process line, the erection will be
carried out for others; notwithstanding, the Contractor will be responsible for verifying the
correct installation. As an example, these instruments could be the following:
- Control, on-off, self-regulating and motorized valves.
- Safety valves, rupture discs, pressure-Vacuum valves.
- Displacer type levels, Magnetic and glass level gauges, flotation type switches, ServoGauge Transmitters.
- Thermowells and associated items, such as thermometers, Thermocouples, etc.
- Orifice Plates, venture tubes, restriction Orifices, calibrated tubes, rotameters.
- Mass-Flow transmitters, Vortex type, Magnetic, turbines.
- Any other instrument assembled directly on a line or recipient.
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Installation battery limits will be defined in detail on the hook-up drawings forwarded by
Engineering.
Contractor will be responsible for the supply, unload, transportation and storage of its own
material.
Contractor will be responsible for providing the necessary means to unload, transport and
to locate in provisional and/or final place all cabins, consoles, panels and analyzer shelters.
The general warehouseman will supply to Contractor the materials provided by others when
required for the advance of the installation. The transportation of materials from the general
warehouse to the Contractor laboratory or the Plant will be carried out by staff and by
means of Contractor.
Once material has been delivered to the Contractor, it will remain under his custody, and he
will be responsible for any defect, damage or loss, as well as for the replacement of any
damaged or stolen element of the installation.
The Contractor will consider in his offer all necessary requirements for a complete and
correct installation, including both personnel and materials required for a good organization
of the work. As an example, but non restrictive, the following obligations must be
considered:
-
The Contractor will submit, based on the schedule of works, a construction program for the
works of his responsibility which will be subjected to approval during the bidding and
execution phase.
The Contractor will carry out monthly progress and site construction program reports during
the execution phase.
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The cable bending radius will be as a minimum 10 times of their nominal external diameter.
The entry of the cable through the cable gland must present no curves and it has to be
foreseen a pigtail of 20-30cm with the cable.
All the cable shields will maintain the continuity and they will be isolated from the instrument
housing and from the junction box. As a general rule, they will only be connected on earth
at the side of the control room.
The cable armour will be put to earth by its cable gland, except in the cabins at the control
room, in which it will be connected to the earth bar by means of copper pigtails supplied by
the Contractor.
All the cables will be identified in their ends with a stainless steel plate, supplied and fixed
by the Contractor.
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In case of installation with air tree manifolds, the Contractor will provide and install all the
valves of the manifold and a stainless steel plate to identify the corresponding consumer's
tag.
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Within the scope of unit prices it is included the lifting of the false floor (assembled by
others) for the installation of trays, cabinets, and lying of cables.
It is also included the cutting and necessary manipulation of the tiles for the final
conditioning of the floor and the covering of it, till it is in perfect conditions for usage.
the
will
the
the
The results of the tests done will be registered in the corresponding reports and the failures
found will be immediately communicated to Site Supervision.
The pre-calibrations works will be the following:
- It will be observed that the equipment is labeled with their corresponding tag, in case of
not having identification plate, the Contractor will supply it and has to placed in the
instrument.
- Lubrication of the control valves when necessary.
- Filling of the instruments with sealing liquid when necessary.
- Adjustment of air filters.
- When the instrument has mobile parts, it will be verified the correct operation of them.
- Checkout of all the joints and packing to ensure sealing.
The calibration works will be as follows:
- In general, all ranges, alarms, zero point and the values of minimum four points will be
proven and adjusted in all the instruments. The Contractor will be responsible for the
calibration even for the instruments already installed by others, such as package units
like boilers, compressors, etc.
- For the calibration of any instrument, the manufacturer's instructions will be followed.
- In the case of safety circuits and alarms, all signals will be checked and adjusted. The
checkout will include switches, lamps, solenoid valves, relays and alarms, simulating
different possible conditions.
- The air for the calibration of pneumatic instruments must be clean and dry, if it is not
available during the period of instrument calibration, the Contractor will have to provide
his own bottles of dry air or nitrogen.
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7.1.1
Temperature Instruments
7.1.2
Pressure Instruments
The pressure transmitters, differential pressure and gauges will be tested and calibrated
at zero, 25%, 50% and 100% of the range.
The pressure transmitters with sealing diaphragm will be tested and recalibrated with
heated diaphragm at process temperature, when it is higher than 100C, using for this
purpose controlled temperature immersion.
The pressure switches will be calibrated at a workshop with a pressure indicator, being
adjusted the setpoint, the differential and checking the commutation action.
7.1.3
Level Instruments
The level instruments such as radar, ultrasounds and capacitive will be tested and
calibrated at zero, 25%, 50% and 100% of the range, according to the manufacturers
indications, whenever it is possible.
The level instruments of displacer type will be calibrated by filling the chamber with clean
water and measuring the level with a transparent plastic tube connected to the lower
drainage. After the calibration, the density will be adjusted to the service conditions.
In the switches float-type, vibration, capacitive and conductive, the commutation points will
be tested considering the measure principle, adjusting them and checking their action.
Regarding the glass and magnetic levels, it will be tested the perfect condition of the
instruments in each case, the sheets and their action, the glasses, valves and illuminators
in case there are some.
7.1.4
Flow Instruments
For all the flow instruments in which the measure is through transmitters of differential
pressure, the instruments will be tested and calibrated at zero, 25%, 50% and 100%.
For such instruments as coriolis, vortex, thermal-mass, magnetic, etc, the checkout and
calibration will be carried out once they have been assembled, following the
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manufacturer's instructions. In case that, together with them, any remote local indicators
have been supplied, it will be checked the range for which they have been calibrated.
7.1.5
Control Valves
All the control valves actuated by diaphragm or piston will be pneumatically auctioned
checking that the action, stroke and range of the spring meet the characteristic shown on
the nameplate.
The positioners will be calibrated according to the characteristics plate, checking the air
failure and linearity.
The butterfly-valves will be checked working freely the internal disk and being sure that
the stroke indicator marks the correct position.
For the motor operated valves their operation and the motor spin direction will be tested.
All the accessories (manual remote control, booster, solenoids, proximity switches, etc.)
will be functionally tested.
7.1.6
Safety Valves
According to the nameplate and data sheet provided, it will be checked the orifice size,
process connections and set point.
It is included in the unit price the transport from the general warehouse to the workshop,
where the operation, setpoint and leakage of the valve will be checked, as well as the
transport from the workshop to the warehouse again or to its final location. The test will be
carried out on a homologated test bench with the presence of an authorized quality
Inspector and Site Supervision.
In the event the test is not correct, the valve will be adjusted. The cost associated to this
valve re-setting shall be out of the Contractor's scope.
In the rupture discs it will be checked that their nameplate meet the specifications required
in the data sheet.
7.1.7
Analyzers
In simple analyzers like Ph-type, conductivity, disolve oxygen and similar, the Contractor
will be in charge of checking and calibrating the equipment in his workshop, according to
the manufacturers instructions and documents, with appropriate equipment for this task.
Regarding more complex analytical equipment, such as gas detectors, chromatographs,
and those in cabins or shelters the calibration and start-up proceedings shall have been
contracted to the analyzer supplier. The Contractor's scope will be to support the
representative of the analyzers in the calibration and start-up of the analyzers according to
his instructions and under his direction.
7.1.8
Control Panels
The Contractor will check according to the specifications and manufacturers drawings all
the labels on instruments and panels, to be sure they were not lost or damaged during the
transport and installation, and he will also check the functionality of the assembled
elements on them, push-buttons, lamps, selectors, etc.
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Especial Instruments
All instruments not detailed in this specification, will be calibrated according to vendors
instructions. If the project particular specifications would request the technical support of
the instrument vendor for calibration and start-up, the Contractor will assist the
representative person of the equipment supplier to carry out the works under his
instructions.
8 INSTRUMENTS INSTALLATION
In general, all instruments assembled on pipes and on equipments directly, will be
installed by others, although this does not exclude the Contractor to supervise it, checking
the correct installation.
Within the scope of the unit prices, it is included the verification of the location in the
process line, considering the Engineering diagrams.
All installations will meet the requirements shown in the diagrams and specifications, and
be installed considering their easy access.
The Contractor will supply, manufacture and install all necessary supports for the correct
fixation of the instruments, so that the installation provides enough rigidity and no stress
on the instruments connection. The supports will have to be approved by the Site
Supervision before they are manufactured and they will be painted according to the
painting specification that applies for the project.
Once the custody of the instruments have been given to the Contractor in the warehouse,
he will be responsible for protecting them against possible damages that may occur
before, during or once installed, and with this purpose the Contractor will protect them
against weather inclemency or any other possible damages. Any damage the equipments
may suffer will be under Contractor responsibility and Contractor will run with the costs.
Thermocouples/RTD/Integrated Transmitters
Bimetallic and Bulb thermometers
Skin points
Temperature transmitters
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Control valves
Motorized valves
On-Off Valves
Solenoid Valves
Pressure regulating Valves
Temperature regulating Valves
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The analyzers and its sample conditioning routing will be mounted by the Contractor
based on the hook-up provided by Engineering.
In the case of the gas detectors, the Contractor will be the in charge of the equipment
installation. The documentation about the location and the installation drawings of the
equipment will be provided by Engineering.
Regarding the analyzers located inside cabinets or in shelters, their price includes also the
installation of the equipment in their locations according to the drawings supplied by
Engineering and the necessary connections of the service collectors according to the
hook-up provided by Engineering.
For the analyzers cabins or shelters it will be in the Contractor's scope to collect, to
transport and to position them as indicated in the layout drawings. The cable layout and
the associated bed plate is excluded from this unit price.
8.7.1 Oxygen Analyzer
8.7.2 Humidity Analyzer
8.7.3 Analyzer of Oil in Water (Water-cut)
8.7.4 Analyzer of Water in Hydrocarbon (BSW)
8.7.5 Ph Analyzer
8.7.6 CO2 Analyzer
8.7.7 H2S Analyzer
8.7.8 Dissolved Oxygen Analyzer
8.7.9 Corrosion Analyzer
8.7.10 Gas Detectors
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9 LOOP TESTS
After all the instruments have been calibrated and installed, there will be a functional test
of the control loops including the following operations:
- Zero Confirmation. All the loop components should be set at zero within the accuracy
specified.
- Functional Test. Each loop must be operated simulating its operation from the
transmitter to the final element. The perfect operation of the complete loop has to be
tested (Close Loop test), or that of each individual component (Open loop test) and
the control action according to the project specifications.
It will be held a record of the tests, fulfilling the corresponding protocol. The Owner and
the Site Supervision will be previously informed in order they can be present when
performing the tests.
The calibration, installation and testing works will not be considered as concluded until the
instrumentation supervisor has issued the written approval.
The tests according to the instrument type will be as follows:
Thermocouples
Each thermocouple will be checked sending a mV signal from the field, which will be
received in the operator station. This signal will be equivalent to the range of operation of
the item. Afterwards, when connecting the thermocouple to the head, it will be checked
that the indication on the operator station corresponds to the environmental temperature.
Electronic transmitters
It will be injected in the instrument the signal corresponding to 0%, 50% and 100% of its
range. It will be checked in the control room the correct reception of the signal and the
indication on the operator station.
Final Control Elements
From the control room or local panel the signals corresponding to 0%, 50% and 100% of
the range will be sent, and it will be checked that the final element is set in the required
positions.
Instrument Contacts in the Field
It will be simulated in the field instrument the conditions caused by changes (for example,
in a pressure switch it would be injected the set pressure to cause the state change) and
the position will be observed on the operation station.
Output from Control Room to Field
The output to solenoids or other final elements will be forced from control room and it will
be checked in the field the correct operation of the instrument and other elements affected
by it (for example, control and on-off valves, hydraulic actuators, lamps )
Special Devices
For all the instruments not describe above, (for example: analyzers, special valves,
Coriolis, etc.) the loop test will be carried out by injecting the corresponding signal in the
equipment and checking its indication on the operation station.
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Electric Equipment
For the tests of the electric equipment, panels, SAI, electric groups and pump motors, the
corresponding signals will be simulated from the equipment and the indication will be
verified on the operation station when having a digital input.
Regarding a digital output, a signal from the system will be forced and it will be checked
that the electric equipment executes the required operation.
10 TRENCH CONDITIONING
The Contractor will be responsible for the conditioning of trenches for cable laying and
instrumentation ducts as well as the closing of them. The erection of the trenches will be
executed by others.
During the instrumentation erection until the complete covering of the trench, the
Contractor will be in charge of keeping the trench totally clean of dirt and of any other
object or material.
Before laying the cables in the trench, its bottom will be conditioned and properly leveled
and compacted. The cables will be disposed in the trench separated by inner separators
according to the documents provided by Engineering. When in the same trench several
layers of cables should be installed, these will be separated from each other by means of
a layer of clean sand. The supply of this sand will be within the Contractor's scope.
If the trench is located in a paved area, its covering will be carried out placing concrete
slabs and sealing them to avoid dirt penetrating inside.
The opening of existing trenches to make instrumentation works, will be the Contractors
responsibility, including in his unit price the removal, covering and correct sealing of the
trench, once the works are finished.
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The installation of consoles, cabins and cabinets will be certified per unit, in relation with
their dimensions, including conditioning and final fixation. The supports and bed plates are
excluded of the unit price.
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The entries of cables and ducts to rooms will be certified by square meter, including all the
necessary elements for their proper final installation.
11.9.3
Technical Floor
The certification of the technical floor will be done per square meter, including all the
works required for its complete conditioning after the conclusion of the works performed in
the rack or control room.