SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

0
rev.

02-02-2002 Approved Issue

date Description/issued for prepared authorised client: ADWEA project: STANDARD SPECIFICATIONS FOR WATER WORKS title: SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

tender:

project:

document: W-I-SS-008

rev: 0

sheet: 1

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Table of Contents 1. 2. 3. 4.

page

SCOPE...................................................................................................4 STANDARDS & CODES .......................................................................4 SITE CONDITIONS................................................................................4 DRAWINGS & DOCUMENTS................................................................5 4.1 Piping and Instrument Diagram ...................................................5 4.2 Instrument Index List ...................................................................5 4.3 Instrument Schedule....................................................................5 4.4 Panel Layouts..............................................................................6 4.5 Technical Submittals and Filled-in Data Sheets ..........................6 4.6 Loop Diagrams ............................................................................6 4.7 Logic Diagrams............................................................................6 4.8 Circuit Diagrams ..........................................................................6 4.9 Wiring Terminal Layout................................................................6 4.10 Instrument Process Connection & Hook-up Details.....................7 4.11 List of Instrument Setting.............................................................7 4.12 Drawing List.................................................................................7 4.13 Nameplate List.............................................................................7 4.14 Instrument Installation Drawings..................................................7 4.15 Instrument Cable Schedule .........................................................7 4.16 Instrument Location and Cable Layouts ......................................7 4.17 Instruction Manuals .....................................................................7 4.18 Maintenance Manual ...................................................................8 4.19 Cause & Effect Schedule.............................................................8 4.20 I/O Lists .......................................................................................8 4.21 Alarm and Trip List ......................................................................8 4.22 Screen Display Drawings.............................................................8 4.23 Functional Specification Document .............................................8 4.24 Spare Parts Lists .........................................................................8 4.25 Control Philosophy Documents ...................................................8 4.26 PLC Logic Software.....................................................................9 4.27 Method Statements and Test Procedures ...................................9 GENERAL REQUIREMENTS ................................................................9 5.1 Workmanship...............................................................................9 5.2 Storage and Protection of Equipment..........................................9 5.3 Installation Instructions ..............................................................10 5.4 Coordination of Work.................................................................11 5.5 Clean Working Areas.................................................................11 CONSTRUCTION SPECIFICATION....................................................12 6.1 Field Instrumentation .................................................................12 6.2 Instrument Cabling ....................................................................16 6.3 Fiber Optic Cables.....................................................................19
Client Project: Title:

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ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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7.

INSTRUMENT CABINETS AND PANELS ..........................................24 7.1 System/Remote I/O Cabinets ....................................................25 7.2 Field Mounted Panels................................................................25 7.3 Remote Area Enclosures...........................................................26 IDENTIFICATIONS ..............................................................................26 8.1 Labelling and Name Plates........................................................26 8.2 Tag Numbers.............................................................................26 INSPECTION AND FUNCTIONAL TESTING ......................................27 9.1 Quality Plan ...............................................................................27 9.2 Field Instrumentation .................................................................28 9.3 Instrument Calibration ...............................................................28 9.4 Calibration Guidelines ...............................................................28 9.5 Field Inspection .........................................................................29 9.6 Loop Testing..............................................................................31 COMMISSIONING AND START-UP....................................................32 SITE ACCEPTANCE TEST .................................................................32

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9.

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Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

rev: 0

sheet: 3

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1.

SCOPE
This Specification covers the general requirements for the handling and installation of control system and instrumentation equipment as laid down in the design, drawings, technical specification, bill of quantities and all the other related documents. Handling includes storing, protecting, transporting, etc. required for the installation of the equipment. Installation includes the physical mounting, process connection, instrument air routing and connections, and cable routing and terminations, as required, to produce a complete functional instrumentation and control system as defined in the project drawings and documents.

2.

STANDARDS & CODES

Equipment, materials and services provided for this project must comply with all applicable local and national codes, standards, regulations and the like. The CONTRACTOR shall determine what codes, standards etc. apply to items within the scope of this specification. Specific applicable industry codes and standards to be used, are indicated in project specifications. Compliance with the applicable portions of all project specifications shall be the responsibility of the Contractor. Any conflicts between the referenced documents shall be identified to ADWEA/ENGINEER in writing for resolution. CONTRACTOR shall refer to all project-related drawings and documents to carry out the stated activities.

3.

SITE CONDITIONS
a) The site location of this project has a dust laden atmosphere. The temperature at night drops considerably, resulting in condensation. These conditions attack instrumentation electric terminals, contacts, etc. for which the CONTRACTOR must design protective measures. Any instrumentation not in an air conditioned atmosphere shall be supplied with waterproof, dust tight enclosures. In addition, local instrument cabinets shall also be weatherproof and equipped with space heaters. It is the CONTRACTOR's responsibility to design, furnish and install the instruments and control equipment to withstand and operate properly under the prevailing ambient conditions described in the project General Technical Requirements of this Contract. This Specification serves as a guideline to the CONTRACTOR. The CONTRACTOR shall make recommendations and include all the necessary equipment or protecting devices based on his previous experience on similar installations. All transmitters, electric/pneumatic converters, switches and other electrical devices which provide input signals to control systems must be housed in waterproof, insulated, dust-tight and heated (as required) local instrument cabinets to protect against corrosion, humidity and condensation. Sun shades shall also be provided and designed to protect cabinets from direct rays of the sun.
ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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d)

Special precautions shall be taken in the selection of materials and the design of enclosures to prevent failure and deterioration of mechanical and electrical components due to the prevailing humidity, high temperature and very corrosive atmosphere. As a minimum, all equipment mounted in control rooms shall be suitable for operation at 45C. Field mounted equipment shall be suitable for operation upto 52C and shall be provided with sun shields. The CONTRACTOR shall furnish, design and install all equipment in accordance with the requirements of the National Electrical Code. Special care shall be taken in areas classified as hazardous, such as areas near the flammables.

e)

4.

DRAWINGS & DOCUMENTS

The CONTRACTOR shall prepare and submit all the required drawings and documents for the instruments and control systems in hard copies and in soft copies (if required by ADWEA/ENGINEER). All drawings and documents shall be subject to approval of the ADWEA/ENGINEER, and shall be appropriately detailed and properly described in the English language. The set of instrumentation drawings and documents as well as instrumentation of package units shall include, but not be limited to the following:

4.1

Piping and Instrument Diagram

All instrumentation systems for measurement and control required for the project shall be shown on the Piping and Instrument Diagram (P&ID). All the basic functions of the instrumentation and control systems shall be shown. The symbols and identification numbers to be used for the graphical representation and identification of instruments shall be in accordance with ISA S5.1, or the latest standard.

4.2

Instrument Index List

This list shall show all instrument tag numbers, description, location, service and remarks.

4.3

Instrument Schedule
This list shall show all instrument tag numbers, drawing number on which the instrument is shown, location, description of the instrument, manufacturer name, model type, power supply type, adjusted range, set point operate range, material wetted parts. Process connection, field hook-up drawing and references of specification of instrument.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

rev: 0

sheet: 5

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4.4

Panel Layouts
These drawings shall show the inside and outside layout (to scale) of panels with instruments in outline dimensions, the indication of the tag numbers for each instrument, the numbering and main dimensions of panel sections and complete panel. The same requirements apply for the drawings of any auxiliary panel.

4.5

Technical Submittals and Filled-in Data Sheets

Technical Submittals shall be prepared for all components of instrumentation systems. Separate data sheets shall be filled-in for different type of instrument. All relevant process, construction and engineering data materials shall be incorporated on these data sheets. The technical submittals shall be provided with an index. The CONTRACTOR shall issue documentation of the selected equipment with the respective specifications to the ADWEA/ENGINEER in the approval stage in accordance with the requirements indicated in the General Technical Requirements.

4.6

Loop Diagrams
For each instrumentation system a loop diagram shall be prepared. This diagram shall show all components in one loop with their tag numbers, terminal strip numbers, cable numbers, relevant engineering data and connection to the instrument electrical supply system. The drawings shall clearly show the function of the various components. The location of components shall be clearly indicated, e.g. in areas for panel, back of panel, field, etc.

4.7

Logic Diagrams
For systems, such as interlocking systems, shutdown systems, emergency systems, etc., logic diagrams shall be prepared. The logic diagram symbols shall be in accordance with IEC 60117-15.

4.8

Circuit Diagrams
Circuit diagrams shall be made of electrical circuits and shall be in accordance with IEC 60117 and IEC 60113. All components such as switches, relays, timers, lamps etc. shall be provided with a tag number. The location of components shall be clearly indicated, e.g. for electrical panel, instrument panel, field, etc.

4.9

Wiring Terminal Layout

CONTRACTOR shall supply wiring terminal layout blocks with their tag nos. wire numbers with their incoming and outgoing destinations.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

rev: 0

sheet: 6

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4.10

Instrument Process Connection & Hook-up Details

Instrument process connections and hook-up material, take-off, thread, rating, standards etc. shall be shown on typical drawings common for particular type of instrument and shall be used at site by the CONTRACTOR. These typicals shall be accompanied by the list of auxiliary materials such as tubing for instrument piping, connectors, unions, valves, etc. Both drawings and material specifications are subject of ADWEA/ENGINEER approval.

4.11

List of Instrument Setting

This list shall show tag number, instrument range, switch point at required conditions, the equivalent setting of the relevant instrument, etc. This list shall be made before start-up of the installation subject to ADWEA/ENGINEER approval.

4.12

Drawing List
The CONTRACTOR shall prepare a drawing list, on which each drawing sheet is separately mentioned. The drawing list shall be combined with the drawing status report (monthly drawing schedule).

4.13

Nameplate List
This list shall show all nameplate inscriptions and dimensions including type of location, letter size, format, etc. fixing,

4.14

Instrument Installation Drawings

These drawings shall show, the instruments fixing brackets, stands, enclosures, shades, etc. materials, details of fixing, location etc.

4.15

Instrument Cable Schedule

This schedule shall show cable No., from, to, cores, sizes, type of cable, type of installation remarks etc.

4.16

Instrument Location and Cable Layouts

These drawings shall show approximately location of instruments, cable routing and cable numbers in detail.

4.17

Instruction Manuals
CONTRACTOR shall furnish all Instruction Manual covering all instruments and control systems as shipped. Revised manual pages shall be provided to show all changes made in the field by CONTRACTOR's Service engineer. The Instruction Manuals shall be furnished in accordance with the Project General Technical Requirements.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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sheet: 7

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4.18

Maintenance Manual
CONTRACTOR shall supply a complete set of maintenance manual covering all instrumentation and control systems.

4.19

Cause & Effect Schedule

Contractor shall submit a complete sets of all pumping station systems, protections and control function in a form of cause and effect schedule.

4.20

I/O Lists
Contractor shall submit a complete sets of input/output signals, digital and analogue which shall be used by the control system showing tag numbers, description, type of signal, rack number, addresses, panel numbers, slot, card, channel etc.

4.21

Alarm and Trip List

This list shall show all instruments tag numbers, description and type of indication (Alarm/Trip), stet point operation. ON/OFF delay time (if required).

4.22

Screen Display Drawings

These drawing shall show, the format of all the required HMI screens as per contract specification. The symbols and colours shall be as ADWEA standard and requirement.

4.23

Functional Specification Document

This document shall cover the explanations of all subject related to HMI screens including equipment status, system control, display items, alarming, real time and historical trending, system security, mimics, reports etc.

4.24

Spare Parts Lists

These documents shall cover all spare parts in relation to the instrumentation and the control systems.

4.25

Control Philosophy Documents

These documents shall explain the control/protection and operation philosophy of all main and sub-systems, stating clearly if there are any deviations from the Contract Documents. The Contractor shall also explain his fall back strategy in case of SCADA Control System failure.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

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sheet: 8

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4.26

PLC Logic Software

The PLC Logic Software shall be submitted in ladder language program in hard copy and soft copy format. The Contractor shall provide the PLC programming software to ADWEA/ENGINEER for easy checking of the submitted program.

4.27

Method Statements and Test Procedures

The Contractor shall furnish all method statements and test procedures, subject to ADWEA/ENGINEER approval, before installation and testing of all project devices and equipment of the project, according to the Contract Specifications.

5. 5.1

GENERAL REQUIREMENTS Workmanship

Instrumentation and control systems installation work (the work) shall be performed in compliance with all contract documents, project specifications and drawings, and good construction practices. The work shall be performed, with good workmanship, by qualified personnel in compliance with established safety regulations. All work shall be performed using only the correct tools for the purpose. The work shall be performed so that the safety, integrity and quality of all systems are assured, including overall appearance and aesthetics. Defective work or works which does not conform to the contract documents, shall be corrected at the CONTRACTOR'S expense. Work in hazardous areas shall be carried out in accordance with the applicable regulations and safety procedures. Tie-ins to the existing facilities will be thoroughly reviewed with ADWEA/ENGINEER. Critical circuitry tie-ins will be subject to ADWEA's approval.

5.2

Storage and Protection of Equipment

Control Systems and instrumentation shall be properly stored and protected from damage at all times. Storage and protection shall be in compliance with manufacturers' recommendations and this specification, unless stated otherwise by ADWEA/ENGINEER in writing. Precautions for proper storage and protection shall include, but are not limited to, the following. a. Storage shall be inside a clean dry building or enclosed shelter, unless material can be stored outdoors without suffering damage. All equipment shall be stored in enclosed and environmentally controlled locations wherever recommended by the manufacturer.

b.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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c.

Valves with electronic instruments shall be stored indoors. Valves without electronic instruments may be stored outside on platforms or blocks at least 150mm above grade and covered with tarpaulins to protect them from the weather. Valves shall be stroked (operated) periodically in accordance with manufacturer's instructions. Ends of cable and air connections shall be completely sealed to prevent entry of moisture. All batteries shall be stored indoors in a dry environment. Batteries shall be visually inspected for cracks when they are received at the site. Batteries with crack damage shall not be installed. Batteries shall be covered or protected by other means to prevent accidental short circuits across terminals. All electronic instruments and panels containing electronic instruments shall be stored in an enclosed and environmentally controlled location. Protective finishes that have sustained damage during storage or installation shall be properly repaired. The material used and method of application shall be compatible with the original equipment manufacturer's finish.

d.

e.

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5.3

Installation Instructions
Each instrument equipment shall be provided with a three-ply phenolic nameplate (white/black/white) showing its identity and service. This nameplate shall be supplied and mounted by the CONTRACTOR unless otherwise supplied. Any proposal to deviate from the recommended installation methods, or from the project engineering documents and drawings shall be submitted to ADWEA/ENGINEER for approval. The approved documentation and procedures of the project shall be used, as reference, to authorize all such changes. The CONTRACTOR shall verify the exact locations for cable trays, panels, boxes, fixtures, pipes, branches, fittings, supports, etc., and shall be responsible to avoid interferences with each other and also with existing equipments/piping. The CONTRACTOR shall install any and all supplementary supports, brackets, hangers, etc., (in addition to those shown on the contract drawings) as required to complete the installation. Supports, brackets, hangers, etc., for equipment and materials shall be installed so as not to weaken the structure to which they are to be attached. Fastening hardware (bolts, nuts, screws, washers) shall be stainless steel. Supports for instrument pipe, conduit and equipment shall be hot-dipped galvanised steel. Conduits, fittings and angle shall have all burrs and foreign materials removed before installation. All unused conduit entries in fittings, junction boxes and equipment shall be plugged using manufactured threaded plugs or caps.
Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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sheet: 10

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Indoor circuit breakers shall be provided with a typed circuit directory sheet that correctly lists the circuit associated with each circuit breaker. Instruments and equipment shall be installed in conformance with manufacturer's instructions. Interface wiring to electrical equipment shall be connected in accordance with contract documents and manufacturer's instructions. Doors on panels shall be kept closed and locked except when erection of the equipment requires them to be open, or when access is required to work/inspect panel internals. Equipment enclosures, panels and cubicles shall be levelled by shimming before bolting to the prepared foundations. Travel and shipping stops shall be removed prior to the installation of an instrument. Cable and air entries of all equipment shall be made weathertight as soon as they are mounted in the field. Vents open to atmosphere shall be protected against ingress of foreign matter. Unprotected openings should have a gooseneck or equivalent to protect against falling particles. Unless furnished by the equipment supplier, the CONTRACTOR shall install an austenitic stainless steel bug screen in instrument air vents and breather ports.

5.4

Coordination of Work
The CONTRACTOR shall be responsible to check other discipline drawings for coordination to eliminate conflicts prior to installation of materials or equipment. Failure to perform this check will imply that the CONTRACTOR bear all relocation costs, including labour, equipment and material, at no cost to ADWEA. All conflicts with other disciplines shall be brought to the attention of the ADWEA/ENGINEER for authorisation to change or modify location of instrument/ equipments.

5.5

Clean Working Areas

Working areas shall be kept clean and free of debris to the maximum extent possible. Working areas shall be cleaned on a daily basis. Sand and dust ingress shall be kept to a minimum, especially during cable pulling. Computer floor tiles shall be removed only from those areas where access for installation and cable routing is necessary.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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sheet: 11

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6. 6.1
6.1.1

CONSTRUCTION SPECIFICATION Field Instrumentation

Instrument Mounting and Hook-Ups
The installations shall be designed in such a way that all instruments, their measuring point and their process connections are safely and permanently accessible. All instruments shall be installed, unless otherwise stated, so that they: a) are not subject to excessive vibration or to mechanical stress and not exposed to extreme high temperatures and direct sun radiation. can be easily read. can be easily mounted and removed. provide a accurate representative measurement of the process condition (IP rating). are sufficient weatherproofed (IP rating).

b) c) d) e)

For pipelines the branch nipple and isolating valve shall form part of the process piping and shall comply fully with the relevant piping specifications. Instrument piping starts at the first detachable connection (screw thread or flange) st downstream of the 1 isolation valve, except for connections installed in control valves and displacement chambers for level instruments, if applicable. All instrument process connections for instrumentation shall be provided with valves with straight through trim to allow rodding out of plugged connections. Type and material of instrument valves shall be ball or gate valve and AISI 316 respectively. Process connections on the surge vessel shall be made by means of 1" flanged branches with minimum ratings ASA 300 lbs, depending on the standards which are applied; stiffened when necessary for strength, branches shall be fitted with isolating valves for the connection of instrument piping. Different connections may be allowed to suit level instruments provided, but require specified ADWEA/ENGINEER's approval. Welding is not allowed on instrument piping and connections. The process connection shall normally terminate in a DN 15 lapped joint flange unless other sizes are dictated by the size of connections on the connections on the instrument. Size and material of instrument piping shall be " and stainless steel AISI 316L/Ti. All pressure instruments shall be installed at the pressure source with a block valve and a vent to facilitate zero checking and to enable the system to be depressurised prior to removal of the instrument. When the pressure instrument is located at a distance from the process

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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connection, an additional block valve and a vent valve shall be placed adjacent to the instrument. For ease of removal of alignment, pressure gauges shall be screwed into unions and not directly into valves or sockets. Pressure piping to instrument shall be such that under no circumstances vapour locks or traps formed, and that piping is completely "full of liquid". Pressure gauges on pump suction and discharge lines shall be easily visible from the relevant pump starter switch as well as from the suction and discharge valves, the gauges should preferably be installed close to the discharge valves. When measuring pulsating pressure, suitable dampening methods shall be provided (dampening devices in the process connection etc.). Where pressure gauges are installed on liquid measurement, allowance must be made for the static head in the instrument line. Pressure transmitters shall be suitable for field mounting and be connected with the process via block and bleed valves. Magnetic flow elements shall be mounted strictly according to the manufacturer's instruction. The flow meter must be oriented with the electrodes in a horizontal line. Precautions must be taken to ensure that the metering tube is filled at all times during measurement. The sensor should be mounted away from turbulence generation components (e.g. valves, elbows, tsections) whenever possible so that the upstream distance shall be min. (5 to 10) X pipe dia. and the downstream distance shall be min (2 to 5) X pipe dia. In case of using a remote transmitter unit then the cable type and length shall be according to Vendor recommendations and specifications. Magnetic flowmeters and their converter shall be protected against direct sun radiation. Level gauges shall be installed with a shut-off valve in both the top and bottom process connections. The float for the level switches shall be mounted in an external float chamber which shall be installed with a shut-off valve in both the top and bottom process connection. All liquid level instruments shall be provided with drain valves and vent valves. The ADWEA/ENGINEER reserves the right to direct the removal and replacement of any work which, in his opinion, does not present an orderly or reasonably neat workmanlike appearance, provided that such work can be properly installed in an orderly way by usual methods. Such removal and replacement shall be carried out solely at the CONTRACTOR's expense.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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Instruments shall not be installed until heavy construction work adjacent to instruments has been completed to an extent that there can be no damage to the instrument installation by this construction work. After installation suitable guards for the protection of panels, local instruments and enclosures shall be provided to prevent damage during other construction activities.

6.1.2

Instrument Locations
CONTRACTOR shall verify the location of each field instrument prior to installation using, as a reference, instrument location plans and installation details. Instruments shall be installed in accordance with the approved project instrument installation details. Instruments shall be orientated so that the display faces the direct access approach to the equipment with which they are associated. Instruments shall be located with due regard to maintenance activities, vents, drains and filling points to minimise the impingement of process fluids on housings and cables. Care shall be taken to ensure that no passage ways or access to other plant equipment, electrical panels, other instruments etc., are obstructed. Indicating instruments shall be orientated to permit viewing from walkways or platforms. Instruments shall generally be accessible for adjustment or maintenance without the use of ladders. Each instrument shall be provided with a support as detailed in the approved hook-up diagrams. No instrument support shall be welded to a vessel, pipe or any other equipment. No instrument shall be installed so that it depends for support or rigidity on the impulse piping or electrical connection to it. Instruments shall not be supported from process piping, unless specifically shown on drawings. Handrails shall not be used for mounting or supporting instruments, nor shall any instrument or support be located within 150mm of the top handrail. Local mounted instruments shall be bracketed or sub-panel mounted on the nearest steelwork or masonry, or on a piping stand. All instrument locations shall be finalised in consultation with ADWEA/ENGINEER and prior approval obtained.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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sheet: 14

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6.1.3

Instrument Process Tubing

All impulse lines shall be run with a slope of not less than 1:12 except where otherwise stated. The slope shall be down from the tapping point for liquid and condensibles, and up from the tapping point for gases. The CONTRACTOR shall ensure that vents are sited at the highest point of the installation and drains at the lowest. Impulse lines shall be kept as short as possible consistent with good construction practice and accessibility and the number of joints in the impulse lines shall be kept to a minimum. Joints made in adjoining tubing shall be such that the joints are not adjacent at the same level. All screwed connections shall be sealed off with a sealing compound compatible with the fluid within the tubing. PTFE tape shall not be used. Tubing shall not sag. Adequate support shall be provided at 1 m intervals. insulating spacer shall be supplied to separate the tubing from the supports. Thermally

Tubing shall run with a minimum number of changes of direction consistent with good practice and neat appearance. Tubing shall not be supported from handrails. Tubing shall not be supported from process lines. Due regard shall be given to hot service installation that is subject to expansion, to ensure that sufficient flexibility is allowed for expansion. Where stainless steel tubing with compression fittings is installed, CONTRACTOR shall ensure that the correct procedures, as specified by the fittings manufacturer, are followed. This shall include, but not be limited to, the following: Proper cutting of the tube. Only approved cutting tools shall be used. Proper installation of the ferrules. Checking that the tube is round and free from burrs and distortions.

6.1.4

Piping and Tubing Supports

Piping and tubing shall be kept free from vibrating structures or equipment. Trays shall be used to support four or more tubes. The tubes shall be secured to the tray at not more than 0.5 metre intervals.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

rev: 0

sheet: 15

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6.2

Instrument Cabling
Field runs are classified as follows: Main Runs Main runs are cables, (multicores, pairs or triads) that run between control room and field junction boxes, local panels or instruments. Local Runs Local runs are cables, (pairs or triads) that run between instruments and junction boxes or local panels.

6.2.1

Installation Methods
Cables run between the control room and the field junction boxes, local panels etc, shall be routed as per approved project drawings and specifications. Multicore cables shall be terminated at suitably positioned junction boxes and connections to field instruments completed by individual cables routed overhead on cable ladder rack and/or cable tray. Instrument cables shall be routed separately from electrical power and lighting cables. The physical separation of signal and power cables on parallel runs shall not be less than that shown below. Minimum Separation Instrument Cables and Power Cables 125V or 10A 50V or 50A 440V or 200A 5kV or 500A 11/33kV or 800A 500mm 600mm 750mm 1250mm 2000mm

Cross overs that bring power and signal cables into close proximity shall be made at right angles, with a minimum separation distance of 300 mm. The above may be relaxed on entries to instruments and panels. Instrument cables carrying more than 10 Amps shall be treated as power cables. All instrument cables may be combined in the same tray/ladder but cables of a particular category/functionality shall be bundled together such that the maximum separation can be achieved between high level signal wiring and low level signal wiring.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

rev: 0

sheet: 16

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6.2.2

Overhead Cable Tray and Ladder Racking

Ladder/tray bends shall conform and comply with the minimum bending radius recommended by the cable manufacturer. Proprietary earth bonding straps shall be installed at all joints of ladder rack/cable tray systems. The tray shall be of adequate width, perforated with turned edges for extra strength. Site fabrication bends may be used, for nonstandard bends, the support fixing shall be either side of the bend or in the centre. The bend shall conform and comply with the minimum bending radius recommended by the cable tray manufacturer. Tray shall be supported at not more than 1m distances unless supported by a mild steel angle section racking. Supports shall be welded to steelwork, prior to painting. No Instrument/ Tray supports shall be welded to vessels or pipework. Tray shall be fixed with Galvanised nuts, bolts etc. Individual cable runs near to terminal point e.g. an instrument, may be run in MS angle section only, No conduit shall be used. All support steelwork shall be painted prior to cables being installed. Painting shall be as per ADWEA Specifications. All cable trays shall be located to avoid obstructions. With the exception of pre-wired package units; routing and fixing of all trays, angles, shall be determined on-site by the CONTRACTOR, subject to approval by ADWEA.

6.2.3

Cable Fixing
Cables shall be fixed by performed saddles or by PVC covered stainless steel strapping. Strapping shall not support more than 12 single pair cables, or 5 multipair cables depending on their overall size. Cable fixing shall not be more than 250mm apart on vertical run tray and 500mm on horizontal run cable tray/ladder.

6.2.4

Cable Transits
Where cables enter buildings which require positive sealing against fire, positive pressures, moisture or gas ingress, then a cable sealing system of approved multicable transits shall be used. Cables shall be tagged/numbered at both sides of the sealing system.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

tender:

project:

document: W-I-SS-008

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6.2.5

Cable Sheath Identification

All local run cables shall be identified with cable marker at each end i.e., instrument and junction box, or Junction box and Marshalling cabinet end (control room). All signal conductors should be individually marked on each termination side with the corresponding terminal number. All cables shall be marked with embossed S. S. Strips attached with PVC covered S.S. bands.

6.2.6

Terminal and Core Identification

Instruments Signal cable cores to be identified by the terminal number to which they connect. Junction Box Signal cable cores to be identified by the terminal number of the Junction box terminal. Cable Connections in Cabinet Individual cores shall be identified, adjacent to each terminal to which it is connected. Core numbers shall be the terminal number to which they are connected.

6.2.7

Earthing
Screen Earthing Cable screens shall be earthed at one point only and connected to the instrument earth. This point shall be at the marshalling cabinet. Cable screens shall be electrically continuous throughout the cable run. Screen shall be isolated from earth at the field instrument and junction box ends. Armour Earthing Armoured cables shall have their steel wire armour (SWA) earthed (i.e. connected to safety earth) at both ends of the cable run. Cable glands shall also be connected to plant earth (safety earth). Equipment Earthing Marshalling cabinet and field junction box frames shall be earthed to the nearest safety earth bar using a 4.0mm2 stranded green/yellow insulated copper conductor.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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6.2.8

Cable Glanding
Cable glands shall be applied at all places where electrical signal cables enter the housings of instruments and junction boxes. All cable glands shall be of stainless steel and of the type which provide an armour clamp, as per BS 6121 or equivalent. The gland thread form shall match the equipment threaded cable entries directly without the use of adaptors wherever possible. Cable entries shall be ISO thread form wherever possible. All glands shall be protected by the use of PVC shrouds and silicon grease (Type M54). All cable installation shall be designed to prevent any ingress of moisture. Bottom gland entries to instrument and junction boxes shall be used wherever possible. Where this is not possible, e.g. side entries to junction boxes then cables shall be looped downwards, ('U' shaped loop to be used). P.C.P sealing washers shall be used on all field gland entries except those with a tapered thread. Sufficient slack cable shall be left at junction boxes, instruments and individual core terminals to allow for remaking connections.

6.2.9

Wire Terminations
Crimped ferrules shall be used for stranded conductors. Sufficient slack cable shall be left neatly at the terminals to allow for the remarking of terminations, additions and testing. All spare cores within multicore cables shall be terminated in terminals at field junction boxes, local panels and termination cabinets within the cable entry room.

6.2.10

Junction Box Mounting

Junction boxes, wherever possible, will be grouped into a common area, mounted onto a frame referred to as a "JB Frame".

6.3
6.3.1

Fiber Optic Cables

Pre-installation testing
Pre-installation testing shall be performed on a reel of fiber optic cable after it is received from the supplier and before it is installed on the job site. The pre-installation testing shall verify : Cable has not been damaged during shipment. Cable contains no factory defects.
Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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Attenuation of the fiber matches the factory test results, shipped with each reel of cable.

If a defect is found during the pre-installation testing, replacement shall be initiated immediately. Pre-installation testing can be performed with a fiber optic flashlight, a light source and power meter or an optical time domain reflectometer (OTDR). A fiber optic cable on a spool or reel shall be ordered wound so that both ends of the cable are accessible for testing. To use a light source and power meter, connectors, reusable mechanical splices, or bare fiber adapters shall be installed on each end of every fiber strand. The measurement results using bare fiber adapters are less accurate than when employing standard connectors, but are adequate for this purpose. Pre-installation testing utilising an OTDR requires access to only one end of the cable. Typically, a pigtail is temporarily spliced to each fiber strand. A pigtail is a length of fiber which has a connector on one end and no connector on the other end. The pigtail is connected to the OTDR and measurements taken. An OTDR can measure the following: End-to-end attenuation. This should be compared to the test report on the reel and any differences reported. Distance to a point of high attenuation. This could be a defect in the fiber strand or it could be the end of the cable. An example of the need for this form of testing would be to identify the location where a forklift damaged a cable during shipment. The OTDR will show the distance from the beginning of the reel to the damaged area in either feet or meters. The footage markers on the cable sheath can be used to assist in locating the damaged section.

6.3.2

Fiber Optic Cable Installation

All work shall be carried out in accordance with the highest standards of craftsmanship in the communication industry. The project site shall be surveyed to establish the exact cable routing and cutting lengths prior to the commencement of any work or commitment of any materials. When ordering fiber optic cable, extreme caution to be exercised to ensure that no additional splicing will be required. Splicing is allowed for the programmed connection of reels only. All work areas shall be made clean and orderly at the completion of work and at times required by Purchaser during process of work.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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6.3.3

Cable Placement
Fiber optic cables shall be installed in continuous lengths without intermediate splices throughout the project, except at the location(s) specified on the construction plans. The cable installation personnel shall be familiar with the cable manufacturer's recommended procedures including but not limited to the following : Proper attachment to the cable strength elements for pulling during installation. Cable tensile limitations and the tension monitoring procedure. Cable bending radius limitations.

Equipment Requirements : Standard plowing equipment may be used. However, modifications may be required to conform to the cable manufacturer's specifications. The equipment shall be large enough to perform the task. A Dynamometer shall be used for measuring cable tension. The cable feed system shall comprise of a reel carrier, rollers or guide tubes, and a cable chute which must allow the cable to be placed while following the manufacturer's product specifications for tension and minimum bend radius. The cable chute shall have a removable gate to allow the cable to be inserted or removed at intermediate points. The reel carrier shall accommodate one or more reels of adequate size and shall ensure easy and safe loading and unloading. When required the cable shall be buried at least one (1) meter deep or in accordance with local zoning regulations. At locations to be designated, selected lengths of fiber optic cable shall be coiled and secured with tie raps to racking hardware. The minimum bending radius of the fiber optic cable shall not be compromised when preparing this stored cable slack. Slack is required in case of emergency splicing needs. When power equipment is used to install the fiber optic cables, low speeds shall be used, not to exceed 30 meters per minute. The tensile and bending limitation for fiber optic cables shall not be exceeded under any circumstances.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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6.3.4

Cable Splicing
The following are minimum requirements for splicing and connecting of the specified fiber optic cables. a) All required brackets and other racking hardware required shall be provided for the fiber optic cable racking operations as specified. All splicing equipment shall be in good working order, properly calibrated, and meet all industry standards and safety regulations. Cable preparation, closure installation and splicing shall be accomplished in accordance with respective manufacturer's procedure. Upon completion of the splicing operation, all waste material shall be deposited in containers, removed from the job site, and disposed of in an environmentally acceptable manner. Determination for appropriate disposal of waste material shall be at the discretion of the Purchaser. Contractor shall use the fusion method for all fiber optic splicing. The average splice loss of each fiber shall be 0.15 dB or less. The average splice loss is defined as the summation of the attenuation as measured in both directions through the fusion splice, divided in half. No individual splice loss measured in a single direction shall exceed 0.25 dB. Splices shall be contained in a splice joint box designed for use on fiber optic cables.

b)

c)

d) e)

f) g)

6.3.5

Cable Termination
Optical fibers shall be terminated by means of a fusion splice connection to a factory connectorized pigtail. Pigtail terminations shall be accomplished in accordance with the design drawings. Cable armour shall be grounded/bonded in accordance with EIA/TIA 607.

6.3.6

Optical Link Testing and Acceptance

An advanced notification of fourteen (14) working days of any test shall be provided. All tests shall be witnessed. Upon completion of the fiber optic cable installation (and splicing) the following tests shall be performed and documented: Verify and record the total attenuation of all passive components in the link and ensure it is within the design parameters. Verify and record the passive components were installed properly. Establish accountability when circuits are configured with multiple links connected together, including links installed by others. Provide a benchmark for comparing future measurements.
Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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A recording OTDR shall be utilised to test for end-to-end continuity and attenuation of each optical fiber link. The OTDR shall be equipped with an 850 nm and 1330 nm light source for multi mode optical fibers. The OTDR shall have an X-Y plotter to provide a hard copy record of each test measurement. The OTDR shall be calibrated with sufficient internal masking to allow the entire cable section to be tested. This shall be accomplished by using an OTDR with sufficient normalisation to display the required cable section. An insertion loss test shall be performed using an 850 nm and a 1300 nm stabilised light source, with an 850 nm and 1300 nm optical power meter. This transmission testing shall be conducted end to end on each optical fiber. Attenuation tests shall be performed through the fiber interface equipment, connectors, and pigtails, and shall demonstrate that the fiber links are in compliance with the optical link performance as indicated herein and on the drawings. Optical fibers connectors and jumpers shall be measured at the fiber optic termination panel, in accordance with the tests defined in FOTP-34. The test results of each measurement shall be recorded on the "Fiber Optic Link Attenuation Record." The record shall show test date, OTDR model no. and serial number, OTDR distance, wavelength, splice location (point), sheath distance and name of technician who perform the test. All test documentation shall be assembled into loose leaf binder(s). One (1) original set and two (2) copies of said test documentation shall be submitted: a. End-to-End Attenuation Data sheet. This form shall record OTDR traces of each optical fiber. Optical Link Attenuation Data sheet. This form shall document the results of the bidirectional insertion loss test. Connector Loss Data Sheet. This form shall record each connector dB loss, fiber number, unit I.D. and fiber colour. Splice Loss Data Sheet. This form shall record each splice loss.

b.

c.

d.

Submittal and approval of the test documentation is required prior to acceptance of the Work.

6.3.7

Site Installation & Testing

The Supplier shall carry out all required cable fiber splicing, performance testing and further services to achieve a properly documented and operational cable network.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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7.

INSTRUMENT CABINETS AND PANELS

CONTRACTOR shall supply and install all required cabinets and panels. The quantity of cabinets and panels shall be determined by the CONTRACTOR. 20% spare space for future expansion shall be available in these cabinets and panels. The cabinets shall be accessible from two sides and shall be approximately 2100 mm high, 1200 mm wide and 600 mm, deep the two opening doors at both sides shall be turnable over 180. It shall be possible to lift the doors up and off their hinges to allow easy removal of the doors. Cabinets and panels shall be completely wired to the terminals, requiring only connections to the external wiring circuits at site. The cabinets shall be shop tested. The cabinets shall be adequately ventilated through natural circulation in order that the heat generated by the equipment mounted there shall remain within the rated temperature limit, should mechanical ventilation be used, it should be an addition to the free cooling and not to bring the working temperature to the acceptable limits, the IP rating shall be to IP 54. Extra electrical sockets for test and repair purposes shall be provided in the control panel and cabinets. These sockets shall be according to British Standards suitable for flat and round pins, instrument cabinets and panels shall also equipped with space heaters. The door shall have separate handle and locks. Each lock shall be provided with 2 keys. Internal fluorescent type illumination shall be provided for every cabinet. Door switches shall be provided to switch off the illumination. Internal wiring shall be adequately sized for the required voltages and currents. Cable ducts shall be provided with at least 30% spare capacity after complete wiring. Separate ducting shall be provided for the wires carrying different voltages. Safety earth connection shall be provided for every cabinet. 2 tinned copper earth-bars for signal earth connection shall be provided one of them shall be isolated from cabinet frame, another earth bar shall be used for safety earth. They shall be wired to separate earth-pits by Contractor. Panels shall be provided with two copper earth bars of minimum dimensions 6*25*100 mm. The cabinets shall be fabricated of cold rolled sheet-steel and shall be rigid and stable the minimum thickness of the ground plate shall be 5 mm, for doors and other plates a minimum thickness of 2 mm. The cabinets shall be of high standards quality in terms of visual appearance, colour, finish, smoothness of surface, etc. Materials for nameplates shall be selected in accordance with the weather data and area conditions and shall be of the non-metallic type, with black inscriptions on white background.
Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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All cabling, tubing and terminal boxes shall be marked clearly in a consistent manner with durable markers. Terminals in the cabinets shall be numbered consecutively in accordance with the relevant cable connection diagrams. All the cores of the field cables shall be terminated on the terminal strip. All the spare I/O channels shall also be terminated on the terminal strip. 25% spare capacity shall be provided in the panel after complete wiring for future additions. Use shall be made of exclusively new and modern materials suitable for the intended purpose. Only first class modern trade practices shall be used and all work shall be carried out to the satisfaction of the ADWEA/ENGINEER. Wiring to equipment mounted on hinged doors shall be carried out through flexible conduits or spiral wrap. Wiring terminal block shall be arranged and positioned to afford easy access for carrying out external cabling, testing, inspection and maintenance. All internal wiring to be ferruled at both ends. Provision shall be made for bottom entry cables and suitable removable gland plate shall be provided. Wires shall be laid in flame retardant PVC trunking.

7.1

System/Remote I/O Cabinets

The system cabinets shall be freestanding type. Cable entry shall be from the bottom. Extra openings shall be blanked. The cabinets of remote I/Os shall have IP 65 enclosure. The size shall be decided by the CONTRACTOR subject to ADWEA/ENGINEER approval. Separate remote I/O Cabinets shall be supplied and installed for individual pump, reservoir level, MCC, LDC etc.

7.2

Field Mounted Panels

Field mounted panels shall conform the following requirements: Panel shall be non-corroding. Weatherproof construction shall be used, IP65 minimum. Exposed devices on the panel shall be weatherproof to IP65. A sunshade/rain shall be provided with front and rear overhang.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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7.3

Remote Area Enclosures

All electronic equipment, cabinets and panels installed in remote areas shall be additionally provided with a second GRP enclosure to IP 55 rating. This enclosure shall be weatherproof and there shall be enough space between the equipments to allow proper ventilation and access.

8. 8.1

IDENTIFICATIONS Labelling and Name Plates

A nameplate with the panel description shall be permanently attached to a prominent position on the front door of the panels. An identical nameplate shall be permanently attached inside the panels. The nameplate shall be indelible, non-removable and with black lettering on white background. All warning or danger labels shall be indelible, non-removable with white lettering on red background. The panel doors shall be fitted with a warning label stating "Isolate before working on equipment". Where voltages exceed 110 V ac, warning labels showing the voltage level shall be attached to the terminals, using nylon screws. The label shall span all the terminals carrying the higher voltage. All wiring shall be ferruled at each end, using slip-on-colour coded markers. All wiring shall be uniquely identified with a number. The markings shall be as shown on the assembly wiring and circuit diagrams. All instruments mounted in field/panel shall be provided with traffolyte nameplates engraved with unique identification tag number and description, which shall be subjected to approval by ADWEA/ENGINEER. Fixing screws of all nameplates, tags or inscriptions shall be non-corrosive type. Each relay, contactors, switch and every other item of equipment within the panel shall be identified by labels permanently attached adjacent to the equipment concerned, indicating circuit reference, description and rating. Where equipment is terminated in a plug-and-socket type connection both the plug and the socket shall have permanently attached identifying labels.

8.2

Tag Numbers
All instruments shall have engraved stainless steel nameplates showing their tag number and service in the English language. On the panels these name plates shall be mounted visible near or on the instruments. For station mounted instrumentation equipment the nameplates shall be mounted on a bracket near the equipment. The numbering system standard shall be according to the KKS, AKS or ADWEA identification standard.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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document: W-I-SS-008

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For each panel mounted instrument an additional stainless steel nameplate shall be provided for mounting at the back; it shall be engraved with tag numbers only. These plates shall be attached to the panel or instrument support near the instrument. Method of fixing nameplates shall be submitted for ADWEA's/ENGINEER's approval. All instruments shall be delivered to job site immediately prior to their installation to minimize the possibility of damage. No instruments, motor operated valves etc. shall be left lying around on the construction site. Materials and equipment not required for immediate installation shall be stored in a separate store protecting them from shock, weather, dust and damage from chemical and construction material. Do not stack instruments in a store unless crated. Upon receipt check each item for complete compliance with purchase specifications, damage, shortage and shortage of components. Repair, replace or notify vendor of non-conformance as required. All cover sand plugs on instrument connections shall be left in place until the moment the connection is used. Rubbish and scrap material shall not be allowed to remain at site. This shall be collected daily and removed from the site. Upon completion of the work all tools shall promptly be removed.

9.

INSPECTION AND FUNCTIONAL TESTING

This section broadly specifies requirements and gives recommendations for inspection and testing of instruments, before and after installation, during the construction and start-up phases. It deals with activities and requirements to confirm that instrumentation conforms to ADWEA/ENGINEER requirements and is installed and functioning according to the approved engineering/construction drawings and data.

9.1

Quality Plan
CONTRACTOR shall prepare a comprehensive Quality Plan to be approved by ADWEA/ENGINEER in accordance with ISO 9000 or equivalent. The Quality Plan shall describe the quality documents (i.e. procedures, specifications and work instructions) to be used in the dedicated organisation to assure quality in each activity. All documents and drawings that are used shall be listed and properly controlled. Changes during the course of activities shall be handled according to the agreed change procedure. The organisation and reporting hierarchy of all involved in testing and inspecting shall be included in the Quality Plan. Formal Inspection and Functional testing procedures ADWEA/ENGINEER approval by the CONTRACTOR. shall be submitted for

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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9.2

Field Instrumentation
Static testing and calibration should be done in a specifically designed site workshop prior to installation in the plant. CONTRACTOR shall ensure that : The calibration procedure demonstrates a proper and accurate method of performing static testing and alignment operations of the instrument, as well as full range (and overrange) capabilities according to the manufacturers specifications. All testing and calibration is to be witnessed by the ADWEA's/ENGINEERs representative and documented on approved test-sheets. Appropriately, "defects" should also be recorded. A full record is submitted to the ADWEA's representative following calibration completion.

9.3

Instrument Calibration
The purpose of instrument calibration is to obtain a permanent record of the equipment precision and to verify that it measures, indicates, and records within the tolerances guaranteed by the manufacturer. Instrumentation shall be calibrated using conventional output signals measured, adjusted to correlate with the relevant input signals. As far as possible instrument re-installation testing and calibration shall be carried out in a dedicated workshop located near to the plant area. This workshop will be equipped with all necessary testing materials, tools and consumable media (clean instrument air, nitrogen, temperature bath oil etc.). Portable calibration equipment will also be available for testing instrumentation not destined to be removed from its site location. All the test and measuring instruments shall be certified with ADWEA/ENGINEER recognised testing laboratory. Proposed list of Test and Measuring instruments shall be listed in the bid documents by the CONTRACTOR.

9.4

Calibration Guidelines
Electronic instrumentation shall be energised for a suitable "warm-up" period prior to calibration tests. All field mounted analogue signalling instruments will be calibrated by simulating an appropriate process signal. Outputs will be recorded at (5) selected intervals corresponding to 0% - 25% - 50% - 75% - 100% of input range. This calibration will be recorded for rising as well as falling input signals. Digital on/off devices such as pressure switches need only be checked at the required setpoint (with either rising or falling input as specified in the detailed specification). The resetting value will be verified and any hysteresis within acceptable manufacturing limits accepted. All calibrations shall be witnessed by the ADWEA's/ENGINEERs representative at his discretion.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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All the findings shall be properly recorded and signed off with relevant remarks about the status and any "hold" point. Before installation, all the "hold" points shall be fully addressed and approved by ADWEA/ENGINEER.

9.5

Field Inspection
The following are the minimum requirements for field inspection.

9.5.1

Underground Cable Installation

Trench Inspection: This inspection is required to ensure, prior to pulling cables, that the trench preparation is complete and in accordance with the specification and route drawings. Cable Laying: This inspection is required to ensure that cables have been laid and identified in accordance with the specification and route. This inspection is required for each layer of cables within a trench. Cable ends shall be protected from moisture ingress. Glanding & Termination: This inspection is required to ensure that the cables have been glanded and terminated in accordance with the specification and termination drawings. Care shall be taken to ensure that the field cabling is not energised by the instrument systems. The field termination/isolation (knife terminals) shall be opened and clearly labelled. Cable Testing: Megger test of underground cables should be carried out after laying, trench backfilling, glanding & termination have been completed for the cable and prior to paving.

9.5.2

Above Ground Cable Installation

Cable Supporting Infrastructure: This inspection is required to ensure that the cable supporting infrastructure is complete (prior to pulling cables) and in accordance with the specification and route. Cable Laying: This inspection is required to ensure that the cables are correctly installed to their final destination. Cable ends shall be protected from moisture ingress. Glanding & Termination: This inspection is required to ensure that the cables have been glanded and terminated in accordance with the specification and terminal drawings.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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Testing: Megger test of above-ground cables should be carried out after laying, glanding and termination activities have been completed.

9.5.3

Instrument Air Sub Header

This inspection is required to ensure that the instrument air sub headers supporting and infrastructure is complete and in accordance with the specification.

9.5.4

Instrument Impulse and Air Lines

Impulse/Air Lines: This inspection is required to ensure that instrument impulse and Air lines have been installed in accordance with the specification and drawings. Visual Inspection: Tubing shall be checked to ensure that wall thickness and tubing material are proper for the service conditions. Disconnect the compression fitting to verify that the tubing is cleanly cut without burring, and that it rests firmly on the base of the fitting with ferrules present and properly positioned. Pressure Testing of Air Lines: Instrument air tubing and supply piping shall not be hydrostatically tested. Only clean, dry, oil-free air shall be used for the cleaning and testing of air tubing. Testing shall be performed in accordance with ISA RP 7.1 "Recommended Practice for Pneumatic Control Circuit Pressure Test". The CONTRACTOR shall verify that the 1/4-inch instrument air tubing leakage rate is less than 1.0 psi/100 feet/5 seconds. Pressure Testing of Impulse Lines: All process impulse piping shall require a full inspection and hydro (or pressure) test to at least 1.5 times the normal operating pressure. Suitable leak detecting agents (or assemblies) shall be used to test the integrity of the tubing.

9.5.5

Cabinet Installation
A full inspection of instrument system cabinets shall be carried out to assess any transport damage from transportation prior to installation. Any defects found during this inspection shall be reported to the ADWEA and noted on the delivery notes of the equipment prior to the supplier being informed.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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9.5.6

Grounding System
The grounding systems shall be checked for proper separation and networking. This shall include the isolation and checking of "mechanical" earth ; "instrument" earth ; "electronic" and "intrinsic safe" earth.

9.6

Loop Testing
The aim of loop testing is to verify the functionality of equipment, it's compliance with process and engineering requirements, and to prepare the equipment for commissioning. Loop Testing can start only after completing all the inspection items in 9.5 "Field inspection minimum requirement". The internal functions of each instrument system shall be tested live (i.e. with power-on). This shall include complete testing of all communications between systems. The limits of a Loop Testing are from the field instrument thro' the Marshalling Cabinets to the Control system and vice a versa. The Loop Testing shall include all aspects of the instrument system or tag being tested. This shall include: All associated SCADA/DCS/ESD etc. functions, displays and reports. The Loop Testing shall verify all entities or items that are internal to all systems (such as the SCADA/DCS etc.). This shall include Numerics, Timers, Flags, Matrices and Parameters. The loop test shall be designed to verify that the field instrumentation and the designated control system (SCADA/DCS/ESDetc.) function according to the specifications. This is accomplished by simulating process signals at the sensor of each analogue transmitter and digital switching device, verifying that the corresponding output is correct and that it is received (in accordance with loop diagrams) at the workstation display or other system console of the control system. Control loop output signals shall be manually sent via the control workstation operator interface to field control devices such as control valves, shutdown solenoids, relays etc., and their reponses monitored. The analogue and digital input signals will be function tested using certified test equipment. These will be used in simulating process variable conditions and to verify the validity of transmitted data. Following approved procedures simulated process signals will be injected, as far as possible, at the process connection. Analogue output signals will be similarly checked and shall include parameters such as direction, bias, split-range values etc.. Digital signals will be checked at two points. The process will be simulated at the process connection and the change-of-state, as well as the re-setting level, recorded. Engineering documentation and vendor data must be consulted to verify that the calibration is within the manufacturers tolerances.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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On satisfactory completion of the loop check, all covers, doors and access plates shall be properly secured. All wiring shall be returned to its original configuration and any test jumpers removed. The CONTRACTOR shall define and submit for approval "Lock-Out" procedures which safeguard the operational integrity of equipment not directly associated with the specific loop, but interlocking with it. Personnel will follow "lock out" instructions once equipment is turned over from Construction and when it is capable of being commissioned. Technicians qualified for all related disciplines shall be provided by the CONTRACTOR. These shall be capable of operating the test equipment and performing the loop checks and re-calibrations (if necessary) of all components on the control system in preparation for the plant transfer phase. Formal records of all testing shall be compiled on appropriate test forms and witnessed by the ADWEA/ENGINEER representative. This should take the form of a "Functional Test Sheet" which shall be signed by the CONTRACTOR and ADWEA alike. Two-way communications shall be provided between all parties involved in the loop tests. Any component found to be faulty or outside design parameters shall be highlighted and brought to ADWEA/ENGINEER attention. Defects shall be logged on a pre agreed "Fault Report" or "Punch List" format and suitably rectified at the earliest by the CONTRACTOR. All loop checking results shall be properly documented and signed by authorised personnel of ADWEA. This shall be the milestone activity for completion of pre-commissioning activities.

10.

COMMISSIONING AND START-UP

All instruments including packaged units shall be installed and all systems and loops fully tested before the plant is commissioned. Standby of instrumentation specialists shall be available. Stores and workshops shall be open for emergency repairs and modifications. The CONTRACTOR shall assist the representative of package vendors and ADWEA during the Commissioning activities.

11.

SITE ACCEPTANCE TEST

Instrumentation work shall only be accepted after the plant is in full commercial operation and all instrumentation systems are working satisfactorily. The normal acceptance procedure shall include handing over of all records made during the construction period, such as test results, instruction manuals, as-built drawings, etc. CONTRACTOR shall carryout Site Acceptance Test (SAT) for the Control system based on ADWEA/ENGINEER approved procedures. Approval of the SAT reports by ADWEA/ ENGINEER completes the milestone activity for SAT.

Client Project: Title:

ADWEA STANDARD SPECIFICATIONS FOR WATER WORKS SPECIFICATION FOR INSTRUMENTATION & CONTROL SYSTEMS INSTALLATIONS

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project:

document: W-I-SS-008

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sheet: 32

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