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Instrument Installation Activities on Projects

EUROPEAN Engineering Specification
Instrument Installation4ECE-M20Revision 1 21 May 2015 Page 1 of 36

RESPONSIBLE GROUP: Process Controls *Formerly M20 Denotes Revision

Table of Contents DOUBLE CLICK ON GREEN NUMBER TO GO TO THAT SECTION

SectionTitlePage
Purpose2
Scope2
Related Documents2
Physical Measurements2
Regulating Devices4
Instrument Panels4
Installation of Instrumentation, Piping, and Wiring6
Testing, Including Precommissioning20
Commissioning and Acceptance29
Change Log30
Air Header Sizing Guide9
Piping and Tubing Supports11
Test Status Color Code21
Typical Cabling and Wire Marking Arrangements20
Blank Calibration and Test Sheets31
Instrument Site Query Form35

DOUBLE CLICK ON GREEN “TOC” TO RETURN TO TABLE OF CONTENTS

1.Purpose  

1.1 This general specification defines the practices that shall be used where applicable during instrument installation activities on projects.

2. SCOPE

2.1 This general specification applies to all types of projects undertaken by Air Products Europe (AP-E).

2.2 When there is a conflict between the requirements stated in this specification, the project-specific Instrumentation Scope of Work, contract documents, or National Codes, this shall be brought to the attention of the Engineer for resolution.

2.3 Project specific scope of work is beyond the scope of this document.

3. Related documents

3.1 Air Products Engineering Documents Worldwide: 4WEQ-6804 Painting and Corrosion Protection on New Construction for Design Temperatures to 649°C (1200°F) 4WPI-SW70001 Standard Clean (Class SC) Inspection and Acceptance Requirements 4WPI-SW70003 Oxygen Clean (Class AA) Inspection and Acceptance Requirements 3ES30600 Materials for Oxidizer Service Application Guideline European:  4ECE-M25 Cold Box/Can Temperature Element Installation

Note: The installation shall comply with all relevant national and international regulations, standards, and codes of practice.

3.2 International Organization for Standardization (ISO) ISO 8501-1, Part 1 Preparation of Steel Substrates before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness. Part 1: Rust Grades and Preparation of Grades of Uncoated Steel Substrates and of Steel Substrates after Overall Removal of Previous Coatings.

3.2 British Standards (BS) BS 6739:2008 Code of practice for instrumentation in process control systems: installation design and practice

4. Physical Measurements

4.1 Flow

4.1.1 Many flow measuring devices are in-line instruments, forming part of the process pipework. In general, the physical installation of in-line instruments will be done by Others rather than by the Contractor, and consequently is beyond the scope of this specification.

4.1.2 Flow elements, such as orifice plates and pitot tubes, shall be stored by the Contractor for installation by Others. The Contractor shall provide instrument supervision to ensure that all necessary precautions are taken to provide a satisfactory installation of in-line instruments (see Section 7).

4.1.3 To minimize the risk of measurement inaccuracies and instrument damage, the instrument manufacturers’ instruction manuals shall be carefully retained and the specified installation procedure strictly followed.  

4.1.4 Mounting of In-Line Flow Meters and Flow Measuring Primary Element

4.1.4.1 After line cleaning/blowing through is complete, flow meters and flow elements shall be installed in the process line by Others with assistance from the Contractor.

4.1.4.2 The Contractor shall verify that the installed flow meters and flow elements are correctly oriented.

4.2 Temperature

4.2.1 Thermowells

4.2.1.1 Thermowells are often provided by the temperature element or thermometer supplier, and are delivered as an assembly with the element. Under these circumstances, the Contractor shall remove the temperature element, head, and other parts from the thermowell. The Contractor shall then transfer the thermowell to Others for installation in the pipework. The Contractor shall reassemble the components on completion of the piping installation.

4.2.1.2 In some cases, a temperature element might be specified to be installed directly into the process line without using a thermowell. In these cases, the Contractor shall install the element into the boss provided by Others. The Contractor shall also attach a label warning of any danger that can result from removal of the instrument.

4.2.2 Expansion Thermometers  

4.2.2.1 The Contractor shall adjust the orientation of the dial to be easily accessible and safe to read.

4.2.3 Thermocouples and RTDs   

4.2.3.1 Thermocouples and RTDs shall be specified with connecting heads to ensure a positive connection between the element and the connecting wires.

4.2.3.2 The Contractor shall verify that: All connections are tight. Covers are securely fixed. All gaskets are correctly located and are in good condition.

4.2.3.3 It is essential that compensation cables are correctly installed with correct polarity. Color- coded insulation is often employed, and the cable manufacturer’s literature and termination schedule shall be consulted.

4.2.3.4 The construction of resistance thermometer elements makes them particularly susceptible to damage from shock and vibration. Care shall be taken to ensure that resistance element sheaths are not bent, as irreparable damage can occur to the internal element conductors.

4.2.3.5 For cold boxes manufactured off-site, the cold box manufacturer will generally install cryogenic thermocouple or RTD cable from the elements to the cold box face. The Contractor shall install a junction box at the cold box face and terminate the cables from both elements of the duplex assemblies at the junction box, sealing the cable penetrations. From the junction box, the Contractor shall cable only one of the thermocouple or RTD signals back to the control system.

4.2.3.6 For cold boxes manufactured on-site, the Contractor shall also be responsible for installing the thermocouples or RTDs into the thermowells or bosses (installed by Others), and for cabling to the cold box face in uninterrupted conduit as defined in the contract documents. The contractor shall ensure that the conduit installation is suitable for the expected thermal contraction of cold box internals during operation. Up to 150 mm internal movement can be expected at the top of a 50 m cold box.  

4.2.3.7 When thermocouples or RTDs are installed in hazardous areas, care shall be taken to verify that the system certification requirements of connected apparatus are fully met. The certificate should be inspected by the Contractor to ensure compliance with any specific installation requirements.

4.2.3.8 Care shall be taken in the case of intrinsically safe installations to ensure that earthing requirements are not invalidated.

5. Regulating Devices

5.1 Mechanical Protection  

5.1.1 The Contractor shall provide special care to ensure that control valves are not damaged when being transported and installed.

5.2 Pre-Installation Visual Inspection

5.2.1 Before a control valve is installed, the Contractor shall carefully check the control valve to verify that there is no physical damage.

5.3 Butterfly Valves  

5.3.1 If the valve is fitted with a power‑fail open type of actuator, the disc may protrude outside the valve body. In this event, the Contractor shall lock the valve in the closed position before being installed by Others to avoid possible damage.

5.4 Cold Box Control Valves

5.4.1 Control valves for cold boxes built off-site will normally be delivered to site with valve bodies already installed. However, the valve internals and top works might be supplied loose. Under these circumstances, the Contractor shall install the cold box control valve internals and top works and shall set the valve stroke all in accordance with the manufacturer’s instructions before testing.

5.4.2 Control valve bodies for cold boxes that are built on-site will normally be installed by Others. The Contractor shall remove the valve internals and top works, and then transfer the valve body to be installed by Others. Once the valve body has been installed, the Contractor shall install the valve internals and top works and shall set the valve stroke all in accordance with the manufacturer’s instructions before testing.

6. Instrument Panels

6.1 Handling and Reception

6.1.1 After taking responsibility for equipment and panels, the Contractor shall be financially responsible for any damage to control panels caused by poor or careless working, or inadequate protection. This shall include any damage caused by Others.

6.1.2 On arrival at site, crates that show obvious signs of being damaged shall not be opened until a representative of the company supplying the panel or their haulage contractor is present, and shall also be provided with protection from the weather.

6.1.3 Crates containing delicate electronic equipment such as computer equipment or analyzers shall not be opened until a suitable environment can be guaranteed. Every effort shall be made to ensure that heating and air conditioning are operating before installing the equipment.

6.1.4 When practicable, all major movements of the equipment shall be completed before the crates are opened.  

6.1.5 Crates should be slung in accordance with the manufacturer’s recommendations.

6.2  Instrument Panels and Consoles Mounted in Control Rooms, Computer Rooms, and Analyzer Rooms

6.2.1 Location

6.2.1.1 Liaison with the Engineer is essential to ensure that clear access is available, and that the room is weathertight, warm, and dry. If the control room is located inside the plant, the installation of mechanical equipment should be programmed to ensure that access for the panel or console is provided.

6.2.1.2 If control room walls have to be left unfinished to allow access for the panels, great care shall be taken to protect the panels and equipment whilst civil engineering work is being completed.

6.2.1.3 Concrete surfaces below false floors and above false ceilings should be sealed by Others before the room can be considered as being completed and ready to receive the panel or console.

6.2.1.4 If equipment is going to be located in a room that is held at a positive pressure to prevent the ingress of contaminants, prior checks should be made in the room to ensure that an acceptable positive pressure can be maintained indefinitely before the panel or console is installed.

6.2.1.5 Particular care shall be taken to ensure that no panel or console containing electronic equipment is exposed to direct or indirect sunlight as this can cause severe local heating problems.

6.2.2 Support and Assembly  

6.2.2.1 The size of the complete panel may be such that it will have been broken down into two or more sections for packing, handling, and transport. In such cases, care shall be taken during the installation to ensure correct alignment of the sections and correct connection of all cables and pipes between adjacent sections. All interconnected circuits shall be tested.

6.2.3 Cable Entries

6.2.3.1 When holes are made in brickwork, concrete, sheeting, or other materials to allow access for cables or piping, the Contractor shall be responsible for any damage and shall seal such holes with a fire retardant, waterproof sealant. The type of sealant used shall be submitted for approval by the Engineer before installation.

6.2.3.2 The Contractor shall ensure air tightness at all external building penetrations, or when internal segregation between areas is required.

6.3 Protection

6.3.1 Electrostatic Discharges

6.3.1.1 The clothing worn by personnel working on computer based equipment shall not be susceptible to static build up. For example, nylon overalls are not suitable.

6.3.1.2 When working on any part of the equipment, all personnel shall be connected to earth via wrist straps to prevent damage caused by the build-up of electrostatic charges.

6.3.2 Electric Arc Welding

6.3.2.1 Some types of equipment may be susceptible to damage by excessive induced voltages that can be generated by electric arc welding sets (for example, as a result of poor earth return paths).

6.3.2.2 To eliminate the possibility of damage from this source, the equipment shall be isolated from plant cables while any electric welding operations are in progress.

6.3.2.3 The Contractor shall be responsible for verifying isolation of vulnerable systems from welding damage.

7. Installation of Instrumentation, Piping, and Wiring

7.1 General

7.1.1 The Contractor shall manage the installation using skilled instrument personnel employing the best working practices and techniques. All personnel shall be qualified for the jobs they have to perform. In particular: All welding shall be done by welders who are coded to the appropriate weld procedures. Welder coding and weld procedure documentation shall be made available for inspection. Compression fittings shall only be installed by instrument personnel that have received training in the use of specific types of fittings on projects. Certificates of satisfactory completion of training shall be made available for inspection. All installations shall be secure and have a neat appearance with adequate access for maintenance and painting. All areas where work is occurring shall be kept clean and tidy, and protected against damage.

7.2 Installation and Documentation for As-Built Drawings

7.2.1 Two accurate sets of “As-built” drawing mark-ups shall be maintained throughout the construction period. One shall be a master set and the other set shall be for the plant’s use. Mark-ups shall be in: Red for additions. Blue for deletions.

7.2.1.1 On completion of testing, two complete, accurate, and neatly marked-up sets of “As-built” drawing mark-ups are required. One set will be retained for use on site, while the other set will be used by the Engineer to generate the “As-built” drawing issue.

7.2.1.2 The following is a listing of drawings that are generally “As-built.” Refer to project-specific contract documents for a complete listing of drawings that are required to be as-built. Underground wiring and tubing installation drawings. Control schematics Control panel wiring and tubing drawings (Include panel internal drawings) Analyzer panel wiring and tubing drawings (Include panel internal drawings)

7.3 Instrument Protection and Storage  

7.3.1 The Contractor shall keep instruments and panels in a properly constructed and heated store, and protect them from dust and dampness until installation. If the control room or analyzer room heating systems are not in operation when panels are installed, the Contractor shall install temporary heaters to ensure that the panels and instruments are kept warm and dry.

7.3.2 Throughout the construction period, instruments that are not provided with housings shall be protected by covering them with heavy-duty plastic bags or, when necessary, by applying more robust protection.

7.4 Instrument Mounting and Accessibility

7.4.1 Instruments shall be installed in their intended locations (for example, on brackets, sub‑panel, mounting post, or process connection), ensuring that they are leveled, vertically plumbed, and firmly secured.

7.4.2 Indicators shall be mounted in a position conveniently accessible and safe for reading.

7.4.3 For all installations, the manufacturer’s specific requirements shall be rigorously followed.

7.4.4 Instruments shall be located in accordance with the layout drawings and instrument hook-ups, and as close as possible to the process connection. This shall be consistent with accessibility for adjustment and servicing.

7.4.5 Instruments shall be secured to the nearest suitable firm steelwork or masonry so as to be, as far as possible, unaffected by vibration. Process lines, handrails, and the cold box face shall not be used for supporting instruments.

7.4.6 If permitted by the instrument hook-up drawing, pressure gauges may be supported by the process piping only if it is close-coupled to the process connection. When vibration is expected or when the connection is long, gauges shall be supported independently.

7.4.7 Instruments and instrument stands shall be located so they don’t obstruct walkways or equipment. They shall also be located to offer the maximum protection from damage that might be caused by passing or falling objects. They shall also be clear of drainage points for condensate, water, and process fluids from adjacent plant equipment.

7.4.7.1 The installation of instruments and instrument stands shall not obstruct platforms, ladders, stairs or be installed in any manner that would obstruct the operation and maintenance of equipment and the opening or removal of access doors and panels. 

7.4.8 Instrument stands shall not be mounted on platform flooring/grating nor at any location that will prevent the lifting of such flooring/grating.

7.4.9 All indicating instruments, and instruments requiring adjustments, shall be accessible for servicing from floor level, walkways, permanent ladders, or platforms. Instrument elevations will normally be indicated on the layout drawings.

7.4.10 Post‑mounted instruments shall be located at a height between 1.2 m and 1.4 m above floor level on permanent platforms, unless site conditions dictate otherwise (for example, when vibration could be a problem, a shorter post may be desirable).

7.4.11 All instrument stands shall be hot dip galvanized. If modifications have to be made on site, the affected surfaces of the support shall be retouched in accordance with 4WEQ-6804 as defined in the contract documents.

7.4.12 All indicating instruments shall be readable from floor level or permanent platforms.

7.4.13 When locating post‑mounted flow meters for liquid or steam service, care shall be taken to ensure that the elevation of the orifice installation is suitable so that sufficient slope in the impulse piping is obtainable.

7.4.14 Clearance shall be permitted above a control valve to allow for servicing of its actuator, and also below for servicing the valve internals, when applicable. Suitable clearances shall also be permitted to provide access to manual handwheels and valve positioners, and to allow overhead crane access to valves.

7.4.15 Brackets and supports shall be protected against corrosion (for example, by adequate priming and painting). When supporting steelwork or cable trays are cut or drilled, the exposed surfaces shall also be primed and painted.

7.4.16 Mounting materials containing asbestos in any form are strictly prohibited.

7.4.17 Mounting materials shall be selected to prevent electrolytic corrosion.

7.4.18 Care shall be taken to ensure that the forces developed by the expansion of piping or vessels will not damage instruments or impulse piping.

7.4.19 All pressure gauges shall be mounted with a clearance of at least 25 mm between the safety vent and nearest obstructing surface.

7.4.20 On completion of installation, all field-mounted instruments, air header isolation valves, tubing and wiring terminations, shall be identified by permanent labeling. 

7.4.21 The contract documents generally indicate typical instrument mounting details. These typical details are for guidance only. It is the Contractor’s responsibility to design and manufacture all instrument mounting stands or supports in accordance with these typical details and the requirements of this specification.

7.4.22 When instruments are located adjacent to painted surfaces, adequate clearances shall be maintained to permit access for painting. For instruments less than 100 mm wide, a minimum clearance of 150 mm shall be maintained. For instruments greater than 100 mm wide, a minimum clearance of 250 mm shall be maintained.

7.4.23 The minimum clearances listed above shall also apply between instruments and all cold box faces.

7.5 Instrument Piping and Tubing

7.5.1 The contract documents will define the scope of material supply. In general, all installation materials shall be supplied by the Contractor unless specified otherwise.

7.5.2 Routing and Location

7.5.2.1 Instrument piping and tubing shall be routed bearing in mind the following considerations such that, when possible, they: Are kept as short as possible consistent with good practice and accessibility. Do not obstruct traffic through the process plant. Do not interfere with the accessibility or removal of process equipment (for example, pumps, motors, and exchanger bundles). Shall avoid hot environments and potential fire‑risk areas. Will not be subject to mechanical abuse (for example, used as a step). Shall avoid areas where spillage is likely to occur (for example, from overflowing tanks). Are clear of drainage points of condensate, water, and process fluids from adjacent plant equipment. Shall avoid areas where escaping vapors or corrosive gases might present a hazard. Shall avoid process piping and provide sufficient clearance from piping which may require lagging. Are not supported from and do not obstruct the removal of floor gratings. Will allow for any relative movement between tapping point and instrument caused by expansion. Shall isolate the instrument from any mechanical vibration at the tapping point.

7.5.2.2 Vertical clearances for instruments and instrument piping over walkways and platforms should not be less than 2500 mm. Minimum clearances required at vehicle roads and driveways shall be 5 m, or level with the lowest process piping crossing the same point, whichever is lower.

7.5.2.3 Cable or pipe supports shall not run across cold box faces unless they follow joists, stanchions, or other structural members. This is necessary because during maintenance periods, access to the cold box is obtained by removal of cold box welded panels.

7.5.2.4 All pipes, trays, and supports shall have a minimum clearance from painted surfaces and from cold box faces as defined in paragraph 7.4.22.

7.5.3 Installation

7.5.3.1 Pipes or tubes that are installed, but not connected, shall have their ends closed to prevent the entrance of foreign material either by adhesive tape for short durations or caps/plugs for long periods.

7.5.3.2 When instrument pipes/tubes are running parallel to each other, joints shall be systematically staggered and neatly offset.

7.5.3.3 Horizontal runs of pipes and tubes shall be placed vertically one above the other as far as possible, and shall be run with the minimum number of changes in direction, consistent with good practice and neat appearance. 

7.5.3.4 The Contractor shall verify that only PTFE tape certified as “Oxygen Clean (Class AA),” “Class AA,” “AA,” or “A03” is permitted on site. PTFE tape shall not be used on oil service or on instrument air signal lines that are not protected by a filter. Examples of approved O2 compatible PTFE tape are: Crosslite tape—Henry Crossely Ltd. Damco tape. Polypenco Fluoroseal Tape—Polymer Corp. Sanden tape—Sanden Ind. Prod. Permacel #412—Permacel Thread Seal—General Tool and Supply Corp. or Markal Thred-Tape—Crane Packing Co. Scotch #48 tape—3M  

Note: Approval shall be obtained from the Engineer before the Contractor purchases other PTFE tape models.

7.5.3.5 When modifications are made to existing pipework or tubing systems involving threaded joints, it is essential that traces of previously applied sealant are removed from threads before the connections are remade.

7.5.3.6 The number of joints in pipework shall be kept to a minimum, consistent with good practice. Couplings shall not be used except when pipe is more than 5 m of straight length between fittings.

7.5.3.7 The Contractor is encouraged to purchase tubing in the longest possible lengths to minimize the need for joints.

7.5.4 Air Supply Piping and Transmission/Signal Tubing  

7.5.4.1 Typically, air supply piping (15 mm and above) between the main air header and the instrument air filters will be carbon steel with welded fittings. Other materials may be specified during the design phase, and would be defined in the contract documents. Carbon steel piping shall be painted in accordance with 4WEQ-6804 as defined in the contract documents.

7.5.4.2 Branch headers shall be installed to allow for self-draining and to provide adequate drainage facilities. On small headers, this will normally be achieved via the instrument air filter/regulators. On larger headers, manual blowdown valves shall be provided at low points.

7.5.4.3 When the size of instrument air supply piping has not been specified, it shall be chosen by the Contractor using Table 1 for general guidance. The sizes shown in Table 1 are based on a minimum pressure of 4 bar g at each takeoff point.  

Table 1 Air Header Sizing Guide
Number of UsersMinimum Size Metric (mm)Minimum Size Imperial (inches)
161/4
2 to 5151/2
6 to 20251
21 to 50401 to 1 1/2
51 to 100502
101 to 200803
Note: Typically, a user is an instrument using around 0.015 Nm3/min,

7.5.4.4 See control valve hook-up drawings, control valve specifications and GA drawings for individual user sizes on control valves.  

7.5.4.5 The Contractor shall provide tubing sizes larger than those listed in Table 1 when required to achieve specified response times. For example, large or fast acting valves may require larger diameter tubing to avoid time delays or instability caused by pressure drops in the tubing. In connecting a supply to a control valve, or in modifying valve internal pipework, the Contractor shall not use tubing that is smaller than the tubing used by the valve supplier for the valve’s internal pipework.

7.5.4.6 The Contractor shall include a minimum of one spare valved air take off on each subheader.

7.5.4.7 All pneumatic signal tubing shall be cleaned by blowing through with filtered air before connection to instruments. Nitrogen or bottled air may be used in place of plant instrument air if it is necessary to maintain the construction schedule, only if the Contractor operates a safe system of work to eliminate any asphyxiation hazard.

7.5.4.8 Sufficient slack shall be provided for all air tubing to avoid strain on the instrument connections and to facilitate dismantling of the instruments. All control valves and direct vessel‑mounted transmitters shall have an extra loop in their air tubing to allow maximum flexibility.

Note: Thermal expansion of up to 150 mm is common for control valves mounted near the top of the cold box.

7.5.5 Process Impulse Piping

7.5.5.1 Instrument impulse lines shall be made of a material that have a temperature and pressure rating equivalent to or better than that specified for the process piping, to which the instrument line shall be connected.

7.5.5.2 All impulse piping shall be sloped at least a 12:1 ratio. The slope of the impulse pipework shall be in accordance with the process hook-ups. The following general guidance is offered: Slope down from the tapping point for non-cryogenic liquids and steam/steam condensate to fill the line with liquid. Slope up from the tapping point for self-draining wet vapours back into the process line. Slope down from the tapping point for filled impulse lines for wet vapours. Dry gases impulse lines may be sloped in either direction. Special provisions may be made for venting and draining the impulse lines on the hook-ups.

7.5.5.3 Special attention shall be considered for the correct location of vents and drains. For example: Vent plugs or valves on high points in liquid‑filled lines Drain plugs or valves on low points in gas or vapor-filled lines Filling valves or plugs, on high and low points where lines are to be filled with sealing fluids Flushing and neutralizing connections for line and instruments in toxic and/or noxious applications Rodding‑out connections on lines that are prone to plugging or coking Hazardous fluids directed away from personnel

7.5.5.4 When impulse lines are situated in areas where the ambient temperature might approach the freezing or pour point of the measured fluid or vapor contained within the process gas, the lines shall be installed to facilitate the installation of thermal insulation and/or heat tracing. (The actual installation of insulation and/or heat tracing would be completed by Others, unless pretaped insulated tube assemblies are specified.)  

7.5.5.5 The Contractor shall paint stainless steel instrument and analyzer impulse lines, using aluminium-rich paint to avoid stress corrosion cracking, if the impulse lines meet both the following criteria: They will be insulated. They will be used for a continuous duty above 70°C.

Note: This applies to most heat-traced stainless steel lines (excluding pretaped insulated tube assemblies).

7.5.5.6 Paint shall be applied in accordance with the paint supplier’s data sheet.

7.5.6 Tubing and Compression Fittings

7.5.6.1 Tubing shall not be used to carry the weight of instruments or other heavy items (for example, seal pots). These items shall be supported by steel piping, nipples and fittings, or suitable brackets.

7.5.6.2 When installing tubing and fittings, care shall be taken to ensure that: The tubing is cut square to the centerline with a suitable pipe cutter, and deburred. The tube end is truly circular and without defect. The compression fitting ferrules are of the correct materials and are correctly swaged onto the tubing. Tube fittings shall be installed in strict accordance with the manufacturer’s instructions. The compression nut is tightened as prescribed by the manufacturer, using the manufacturer’s approved tightness gauge. Suitable tools are used for tube bending.

7.5.6.3 The Contractor’s working procedures shall include the disassembly, visual inspection, and reassembly of some (minimum 5%) installed compression fittings. The purpose of the inspection is to demonstrate the integrity on installation of compression fittings, minimizing the risk of failures caused by ferrules failing to deform the tubing.

7.5.6.4 Air Products reserves the right to witness such inspections.

7.5.7 Piping and Tubing Supports

7.5.7.1 Whenever possible, piping or tubing supports shall be kept free from vibrating structures or equipment.

7.5.7.2 Process piping, handrails, or the cold box face shall not be used to support instrument piping and tubing (unless specifically detailed on the installation drawings).

7.5.7.3 Piping and tubing runs shall be adequately supported and fixed at distances not exceeding those in Table 2 to prevent sag, vibration, or damage.

Table 2 Piping and Tubing Supports
Metric Size (mm)Imperial (inches)Maximum distance between

supports or clips (m)

Tubing
10 and less3/8 O.D. and less0.5
121/2 O.D.1.0
Multicore1.0
Piping
10 to 203/8 to 1/2 N.B.1.5
251 N.B.2.0
40 to 501 1/2 N.B. to 2 N.B.3.0

7.5.7.4 Whenever possible, cable trays shall be used for continuously supporting tubes, even though they might not be specifically indicated on the drawings.

7.5.7.5 The use of galvanized mild steel angle section is acceptable for supporting single tube runs.

7.5.7.6 When approved for a project, a maximum of three tubes may be supported by clipping the tubes to the air header at 0.5 m intervals.

7.5.7.7 Capillaries of filled systems shall be run independently from all other lines, and shall be continuously supported using low carbon (mild) steel angle.

7.5.7.8 Capillaries shall be continuously supported and protected, and any excess length shall be coiled on a former. Generally, capillaries shall not be bent to a radius less than 75 mm. Slack shall be allowed in the capillary at the insertion point to permit removal of the sensor from the pocket.

7.5.7.9 Ladder racks may be used for supporting long runs of multicore tubing.

7.5.7.10 Cable tray or ladder rack material shall be made of heavy gauge hot dipped galvanized steel construction with return flange for outdoors and indoors. Supports shall also be made of galvanized steel.

7.5.7.11 Trays shall be run with the breadth of the tray in a vertical plane. When a short section needs to be run with the breadth horizontal, the breadth shall revert to the vertical plane at the earliest possible location. If the tray runs in the horizontal plane, it shall be provided with additional supports to prevent sagging.

7.5.7.12 Trunking or conduit may be used to replace cable tray under certain circumstances (for example, when additional protection is considered necessary).

7.5.7.13 All tray and rack supporting brackets shall be galvanized mild steel angle. Supporting brackets shall preferably be bolted to the main plant structures. Welding of brackets to structures shall not be acceptable without the written approval of the Engineer.

7.5.7.14 When brackets are welded, the welds shall be of adequate strength for the steel to be supported, and shall be a full fillet weld. Tack or stitch welds are not acceptable.

7.5.7.15 Under no circumstances shall support brackets be welded to insulated cold box panels, pipes, or any process equipment.

7.5.7.16 Welded supports on cold boxes shall only be used for major runs of cable tray when indicated on structural drawings or with the prior agreement of the Engineer.

7.5.7.17 When welded supports on cold boxes are required, they shall only be welded to cold box joists, stanchions, or other structural member. Under no circumstances shall bracket fixings fitted to cold boxes penetrate the cold box wall, as this will cause a leakage of purge gas from inside the cold box.

7.5.7.18 Tray and rack shall not be supported from insulated process lines.

7.5.7.19 In all cases, adequate clearance shall be maintained between trays, racks, and the supporting structure to permit access for painting. The minimum clearance shall be in accordance with paragraph 7.4.22.

7.5.7.20 In all cases, damaged paint or exposed steel on trays, racks, supports, structures and boxes caused by cutting, drilling, or welding shall be repainted to a standard equivalent to the original paint or protective coating in accordance with 4WEQ-6804 as defined in the contract documents.

7.5.7.21 Before painting, the exposed surface shall be cleaned by wire brushing or other method to remove all loose paint, scale, rust, and other foreign materials.

7.5.7.22 Damaged or cut galvanized surfaces shall be repaired with the following procedure: The affected areas shall be power wire brushed or manually prepared to a minimum of ST3 standard, as defined in ISO 8501-1, ensuring that the damaged galvanized edge is feathered back to a sound edge. The prepared area shall then be painted with 75–100 micron of two-pack zinc rich inorganic primer.

Note: The use of “Galvafroid” or similar is not permitted.

7.5.7.23 All instrument piping or tubing shall be mechanically clamped at 300 mm to 450 mm from the connections to the instrument, to prevent whipping of tubing if a fitting is released under pressure.

7.5.7.24  When pipes rise through floors or exit from below ground, they shall be protected for a minimum of 150 mm with steel “Kicker plates” or equal.

7.5.8 Cleanliness

7.5.8.1 The cleaning of instrument tubing, fittings, and valves is divided into two categories: General service lines Clean lines

7.5.8.2 For General Service Lines, the Contractor shall clean these materials in accordance with the requirements of 4WPI-SW70001. The lines shall be blown out before instrument commissioning with clean, dry, oil-free air, or nitrogen. These lines are designated as “Standard Clean (Class SC),” “Class SC,” “SC,” or “A01” on the instrument drawings.

7.5.8.3 For Clean Lines, the following shall apply: The Contractor shall either purchase materials certified cleaned to 4WPI-SW70003 or clean these materials in accordance with 4WPI-SW70003. The lines are designated as “Oxygen Clean (Class AA),” “Class AA,” “AA,” or “A03” on the instrument drawings, and are used for oxygen duty, and other duties where a high standard cleanliness is required. In the event of unsatisfactory cleaning of any item, the Contractor shall reclean it to the satisfaction of the Engineer. The Contractor shall verify that once cleaned, the material is protected and installed in a manner to maintain its cleanliness. All valves that are required to be cleaned to 4WPI-SW70003 acceptance criteria will normally be supplied in this condition. The Contractor shall inspect all applicable valves for degree of cleanliness to determine compliance with the classification. When valves are to be decontaminated, the Contractor shall decontaminate the valves in accordance with this specification. Valve gland packing used on valves for oxygen duty shall be Teflon or PTFE. When the packing requires cleaning, the Contractor shall rinse it in clean solvent, and then leave it to dry out just before installation onto the gland.

7.5.8.4 For Storage, the following shall apply: All equipment to be installed shall be stored indoors in suitable containers to prevent contamination. All instruments, pipes, valves, fittings, and other equipment that are received at the site in protective packages marked “Oxygen Clean (Class AA), “Class AA,” “AA,” or “A03” shall remain in these protective wrappers until they are ready for use. If for any reason, the seal on the wrapper of the packaging is broken and/or the item becomes contaminated while in the Contractor’s custody, it shall be recleaned to the satisfaction of the Engineer at the Contractor’s cost.

7.5.8.5 During installation of process lines, adequate precautions shall be taken to ensure no contamination takes place.

7.5.8.6 For Oxygen and High Purity Service Line Degreasing, the following shall apply: The Contractor is responsible for cleaning to 4WPI-SW70003 using materials permitted by Local and National Legislation. The Contractor shall specify at the proposal stage the regime he will adopt to meet these requirements. The Contractor shall supply all solvents, cleaning fluids, and materials. Checks shall be made on cleaned equipment in accordance with 4WPI-SW70003. A special clean area protected from the weather and well ventilated, in which there is minimal dust and dirt, shall be provided and used by the Contractor for cleaning purposes. The Contractor shall ensure that windblown dust does not enter the ports of the valves or the bores of the pipes. A clean bench shall be available for placing items when they are cleaned, and for wrapping them or protecting the pipe ends or valve ports, with polythene sheeting or bags. It is essential that every tool used shall be degreased. The Contractor shall ensure that all cleaned lines are thoroughly dried and purged with hot, dry nitrogen. It is the Contractor’s responsibility to ensure that solvent does not come into contact with, or damage, any instrument. Disposal of used cleaning fluids shall be to an approved disposal point off-site.

7.5.8.7 Inhibited methylene chloride shall be used as the standard chlorinated solvent for cleaning in oxygen service.

7.6 Instrument Cabling

7.6.1 The Contractor shall ensure that the cable system complies with the contract documents and all local codes and standards.

7.6.2 The Contractor shall exercise the best wiring techniques to assure a neat appearance and proper job.

7.6.3 Instrument cables fall into two main categories as follows:

7.6.3.1 Category 1 is instrument power and control wiring (above 50 V). This group includes ac and dc power supplies and control signals.

Note: Any cable having a total loading of more than 10 A shall be regarded as an electrical power cable and is excluded from this classification.

7.6.3.2 Category 2 is signal wiring (up to 50 Vdc). This group includes digital signals, alarm signals, 24 Vdc solenoid valves and shutdown signals, analogue signals (for example, 4 to 20 mA, temperature signals and communications signals (such as, fieldbus, profibus, and ethernet).

7.6.4 Instrument Cable Installation

7.6.4.1 For Cable Routing, the following shall apply: The instrument layout drawings indicate the approximate routing of main cable trays and/or trunking. These routes may be modified by agreement with the Engineer. Site‑run cabling shall be routed bearing in mind the considerations and requirements of paragraph 7.5.2 (routing and location of instrument piping and tubing). In areas where the hazards described in paragraph 7.5.2 cannot be totally avoided, consideration shall be given to installing cables within metal conduits or trunking. Heat insulation such as mineral wool with outer aluminum cladding may be applied externally to the trunking to provide additional protection in high fire risk areas. When possible, above ground cable routes shall be selected to maximize the physical protection offered by structural steel work. When possible, the layout of cable trays shall be done so that only the instruments in the immediate vicinity will be affected if a local plant fire damages the signal lines. When signal lines pass through hazardous areas of different classification (for example, through walls of pump rooms or control rooms), the transition points shall be pressure tight.

7.6.4.2 For Cable Separation from Electrical Power Cables, the following shall apply: Instrument cables shall be routed above or below ground separately from electrical power cables (that is, ac cables usually above 50 VAC with a loading of 10 A or greater). Parallel runs of instrument cables and power cables should be avoided. However, when unavoidable, adequate physical separation shall be provided. A spacing of 300 mm is recommended from ac power cables up to 10 A rating. For higher ratings the minimum spacing shall be 600 mm. When a crossover between signal and power cables is unavoidable, the cables shall be arranged to cross at right angles with separation of at least 300 mm from ac power cables up to 10 A rating. For higher ratings, the minimum separation shall be 600 mm.

7.6.4.3 For Separation between Instrument Cables, the following shall apply: Instrument cables shall be separated into two groups according to the signal classification (categories 1 and 2, see paragraph 7.6.3). Minimum separation between category 1 and 2 cables shall be 300 mm. Cable separation shall be maintained both for above and below ground installations. The problem of electrical interference becomes more acute where long parallel runs are unavoidable. Whenever possible, the cables of emergency shutdown circuits shall take an independent route from the cables of other systems that they protect, to provide higher integrity. Intrinsically safe circuits shall be contained in separate cables and terminated separately; otherwise, segregation is the same as for other signal cables in the same group. Cables containing intrinsically safe circuits may be run in the same ducting or tray as other cables of the same category if either the intrinsically safe cables or the other cables are armored or metal sheathed. However, armoring or metal sheathing is not required when the risk of mechanical damage is slight (for example, ducting in a control room), but in such cases, both types of cables shall be insulated and sheathed. It is not necessary to segregate fibre optic cables from instrument or power cables. They should be installed in a location where they will not be subject to vibration.

7.6.4.4 During installation, multicore and multipair cables shall not be bent in a radius less than the supplier’s recommended minimum bending radius (normally not less than eight times the overall diameter).

7.6.4.5 The Contractor should be aware of the risk of damage to the PVC outer sheathing during installation at low temperatures. The Contractor shall take all necessary precautions to prevent cable damage.

7.6.4.6 When cables are run through pipes or conduits, the entries and exits shall be smooth and free from burrs. Care shall be taken when cables are pulled into such conduits to ensure that there is no damage to the cable.

7.6.4.7 For metallic conduit, all conduit runs shall be mechanically and electrically continuous. Running threads shall be secured by locknuts. After the conduit is installed, all exposed threads shall be painted with a sealing compound.

7.6.4.8 When conduits terminate at cabinets, terminal boxes, or trunking, they shall be securely locknutted, bushed and ferruled. Sharp edges shall be removed, and conduits not otherwise connected shall be terminated in smooth bushes.

7.6.4.9 Conduit or mineral insulated metal sheathed cables shall be neatly run, attached to structures and steelwork.

7.6.4.10 Care shall be taken when PVC conduit or ducting is used that it is not run adjacent to plant or equipment operating at elevated temperatures.

7.6.4.11 Conduit junction boxes shall be provided at distances not exceeding three random lengths of conduit (approximately 3 m per random length) with not more than two right angle bends occurring in one pull.

7.6.4.12 When mineral insulated (MICC) cables are used, it is essential that all seals be made using the correct components and the methods specified by the manufacturer, and that correct insulation resistance tests are conducted.

7.6.4.13 When mineral insulated cables are not immediately glanded, they shall be temporarily sealed after cutting.

7.6.4.14 The Contractor shall ensure that all cable runs are measured before cutting the cable to avoid wastage. If excessive cable wastage occurs, Air Products reserves the right to be reimbursed by the Contractor for any free issue cable wasted.

7.6.4.15 The Contractor will return all unused and scrap free issue cable to the Engineer on completion of the contract.

7.6.5 Junctions and Terminations

7.6.5.1 Cable joints shall be made only at appropriate terminals in instruments, junction boxes, or approved equipment. No intermediate joints shall be made on cable trays, ladder racking, or in conduit.

7.6.5.2 Field-mounted junction boxes shall be of robust, weatherproof construction. Cable glands shall be used to anchor the cable and provide a seal.

7.6.5.3 Junction boxes shall be selected to give the degree of protection appropriate to the hazardous area within which they are installed and shall be suitably certified when required.

7.6.5.4 Junction boxes shall be fitted with sectional type, screw clamp terminals (where the terminal screw does not directly contact the wire) mounted on rails. Sufficient terminals shall be provided to terminate all signal wires (including spare wires) and for connecting the cable screens where appropriate.

7.6.5.5 When specified in the design, cable glands shall be insulated from the junction box to permit the earthing of the cable sheath and/or armor at one point only. In cable terminations where armor/sheath and screen are not earthed, they shall be positively isolated from each other.

7.6.5.6 All terminations shall be made with approved tools. Crimped type terminations shall be used for stranded conductors. When instruments are fitted with flat‑headed screw‑type terminals, wire ends shall be fitted with crimped spades having a retaining lip.

7.6.5.7 Sufficient slack wire shall be left to permit remaking terminations, alterations, and testing.

7.6.5.8 When a termination is made to a measuring element that has to be withdrawn for testing, (for example, thermocouples or RTDs), sufficient length of flexible cable shall be allowed for the element to be withdrawn without electrical disconnection. 

7.6.5.9 Coaxial, fibre and other special cables shall be installed and terminated in accordance with the manufacturer’s instructions.

7.6.5.10 In control rooms, cable clamps can be used to anchor multicores to the panel frame.

7.6.5.11 The outer jacket of multiconductor cables entering control rooms or enclosures shall be stripped back as little as possible to maintain organization and prevent the screens shorting to structural or panel steel.

7.6.5.12 Screens and outer jackets of individual pairs shall be stripped back as little as possible for maximum noise protection and to maintain organization of conductors. Foil or other screen material shall be stripped back and removed to the same point as the outer jacket to prevent shorting to panel or structural steel.

7.6.5.13 All exposed screen drain wires or foil shall be covered with heat shrinkable tubing to the termination point to prevent shorting to panel or structural steel. All heat shrinking shall be done using a hot air source. A naked flame is not permitted. The use of rubber sleeving such as “Hellerman” is not permitted.

7.6.5.14 All cable screens shall be connected to earth at one end only. The earthing point will be defined in the contract documents. When circuits are terminated but screens are not to be terminated (that is, at the “floating” end), the screen and drain wire shall be cut back to match the cable outer jacket and the outside surface of the cable shall be covered with heat-shrinkable tubing to prevent shorting to panel or structural steel. Crimp-type connectors shall be used for all braided screens. The bare braid must not be the connection onto the terminal.

7.6.5.15 Wiring shall not be connected or terminated in conduit boxes. When additional terminals are required, these shall be of the screw clamp type, and shall be rigidly mounted in purpose-made weatherproof metal junction boxes with screwed, gasketed covers.

7.6.5.16 Cable entries into instruments, control valves, field junction boxes and panels shall be at the bottom. When this is not practical, then cables may enter junction boxes at the side but shall do so with a “drip loop.”

7.6.5.17 Cables entering control panels or large junction boxes shall be glanded. If the quantity of cables is too great for glanding, the cables may be secured to a tie bar. In all cases, cable entries into panels shall be sealed, to a standard equal to that of the panel to prevent the ingress of dust or moisture.

7.6.5.18 Control panel trunking will be sized for one run of each cable. The Contractor shall not install large loops of cable within trunking.

7.6.5.19 Plastic shrouds shall not be fitted to cable glands.

7.6.5.20 For installations in hazardous areas, the cables, glands, and installation methods shall be appropriate to the type of hazardous area protection, and shall comply with the hazardous area certification requirements of the associated instruments.

7.6.6 Cable Tray and Supports

7.6.6.1 Cable tray or ladder rack material shall be hot‑dipped galvanized steel.

7.6.6.2 Cable tray and supports shall be in accordance with the requirements of paragraph 7.5.7 (Piping and Tubing Supports).

7.6.6.3 Clips, saddles, and strapping securing cables to steelwork or trays shall be metal with a plastic coating. However, proprietary UV stabilized plastic cable ties may be substituted on horizontal cable runs if: The ties are of adequate size and quality. Every fourth tie is of metal with a plastic coating.

7.6.6.4 The spacing of cable clips shall be not more than 250 mm on vertically run or 500 mm on horizontally run cable trays.

7.6.6.5 When signal cables are installed in trunking, spare space shall be left in accordance with the design requirements. Preferably, not more than 50% to 70% of the cross‑sectional area of the trunking shall be occupied by the cables.

7.6.6.6 When condensation is likely to occur in trunking, for example, drain holes shall be provided at the lowest points.

7.6.7 Cable Duct Systems

7.6.7.1 When the cable installation design specifies that cables shall be installed in underground ducts, the ducts will be supplied and installed by Others, unless stated otherwise in the contract documents.

7.6.7.2 Before drawing cables into cable ducts, the Contractor shall rod the ducts clean of all obstructing foreign matter.

7.6.7.3 On completion of installation, the Contractor shall: Leave the draw wires in the cable ducts for future use. Seal any unused duct openings with hardwood plugs and compound.

7.6.8 Buried Cable Systems

7.6.8.1 When outdoor cables are buried directly in the ground, the Contractor shall dig the trenches, lay the cables to the procedure specified, backfill and level the ground, unless stated otherwise in the contract documents.

7.6.8.2 Before any excavation work for the cables commences, the cable routes shall be ranged and pegged out by the Contractor and approved by the Engineer.

7.6.8.3 When excavation work is taking place in the vicinity of an existing operating plant, a permit to work must be obtained by the Contractor from the Engineer.

7.6.8.4 The cables shall be laid in horizontal layers. The top surface of the largest cable in the top layer shall be a minimum of 750 mm below finished grade, and the burial depth shall not normally exceed 1500 mm.

7.6.8.5 Having excavated the trenches, the cables shall be laid in accordance with the following procedure: The bottom of the trenches shall be covered to a depth of 100 mm by a bed of soft sand. The cables shall be laid on the bed of sand, in linear formation without unnecessary crossovers. Each layer of cable shall be covered to a depth of 100 mm by a layer of soft sand, well tamped down. Protective cable tiles 50 mm thick shall be placed on top of the sand covering the top layer of cables. The tiles shall be of the fully interlocking pattern and shall be of the appropriate dimensions to give an overlap of 50 mm on either side of the span of cables covered. The protective cable tiles shall be covered to a depth of 150 mm by a fine backfill of earth. On top of the fine backfill, plastic cable warning tapes shall be laid along the entire length of the cable routes in the trenches. The tapes shall be colored bright yellow, with the phrase “DANGER – ELECTRIC CABLES” printed repetitively along the length of the tape (in the local language). Finally, the trenches shall be completely back-filled using sieved backfill and the ground prepared to grade level. When the original finished surfaces have been disturbed, these shall be reinstated to the original specification and to the satisfaction of the Engineer.

7.6.8.6 The Contractor shall install concrete surface marker posts along the routes of all buried cables, and the posts shall be fitted with permanent noncorrodible metal warning and identification plates inscribed as follows:”DANGER – ELECTRIC CABLES” (in the local language)

7.6.8.7 Surface marker posts shall be installed at all points where cable routes change direction, and at maximum intervals of 20 meters along straight sections of routes.

7.6.8.8 Direct buried cables must be spaced at least 600 mm from underground pipes, whether crossing or following parallel routes. When cables and pipes cross, in general, the cables shall be laid above the pipes if the cables can still be buried at a minimum depth of 750 mm below grade; if this minimum depth cannot be maintained, the cables shall be routed under the pipes.

7.6.8.9 Underground joints must not be made on buried instrumentation cables.

7.7 Identification and Labeling

7.7.1 The Contractor shall fix tags and labels to identify all instruments, circuits, valves, pipes, and junction boxes in the contract documents including all “Supplier provided” packages.

7.7.2 Plastic labels referred to in this section shall be made from laminated phenolic plastic, engraved with black lettering on a white background (Trafolyte or equivalent). The labels shall be secured using suitable stainless steel screwed fixings. Glue or wire shall not be used.

7.7.3 Identification of Instruments

7.7.3.1 Plastic labels shall be supplied and fitted by the Contractor local to each instrument. When the instrument is mounted on an instrument stand, the label shall be screw-fastened to the stand.

7.7.3.2 These plastic labels are required in addition to stainless steel tags supplied with the instrument.

7.7.4 Instrument Lines, Cables and Terminals

7.7.4.1 All instrument tubing and cables shall be tagged at each junction box and bulkhead, indicating the instrument served. The designations shown on the contract documents shall be used for this purpose. Labels shall be positioned to facilitate accurate tracing of all pipework and cables, as detailed in the drawings.

7.7.4.2 When the contract documents do not show a designation, the tag used shall be the same as the field instrument served.

7.7.4.3 Cables and terminals shall be identified in accordance with the project requirements. In the absence of other information, terminals shall be numbered in accordance with the interconnection diagram, and wires shall be marked with the instrument tag numbers and wire suffix given on the interconnection diagram, as detailed in Figure 1. 

Figure 1 Typical Cabling and Wire Marking Arrangements

Typical Cabling and Wire Marking Arrangements

7.7.4.4 The major wire number can be fixed over the sheathed twisted pair, with the modifying suffix number affixed to the appropriate conductor.

7.7.4.5 Wire number identification markers shall either be the tubular color-coded type of correct size for wire or a pre-marked weatherproof heat shrink PVC sleeve. If a pre-marked sleeve is used, the Contractor shall satisfy the Engineer that the marking is indelible. Pre-marked sleeves shall not be used for cable markers.

7.7.5 Junction Boxes

7.7.5.1 The Contractor shall label all junction boxes with plastic labels showing the junction box number.

7.7.6 Isolating and Sample Valves

7.7.6.1 The Contractor shall label all instrument isolating valves and analyzer sample valves with plastic labels fitted showing the instrument served and its function where appropriate (that is, 1PW-FT‑1011HP).

7.7.6.2 This requirement also applies to valves in analyzer lines.

7.8 Ladders and Scaffolding

7.8.1 The Contractor shall provide ladders and scaffolding as required to fulfill his scope of work.

8. Testing, Including Pre Commissioning

8.1 Testing before Commissioning

8.1.1 Before commissioning (or start up) of a new installation, the Contractor shall test the completed instrumentation and control equipment installation to ensure that the equipment is in full working order.

8.1.2 Instrument testing work shall be done only by instrument personnel that are fully skilled to do the work. When unfamiliar specialized equipment is being installed, the Contractor shall provide the instrument personnel performing the installation with supplementary training on that equipment.

8.1.3 Instrument testing may be comprised of some, or all, the following stages: Inspection upon receipt Preinstallation testing Pressure testing of instrument piping Testing of instrument cables Precommissioning (including loop testing)

8.2 Responsibility for Testing and Approval

8.2.1 The Contractor shall provide a fully equipped workshop on site, including all necessary test equipment to perform in situ calibration and functional tests, and to troubleshoot any problems that might arise during precommissioning.

Note: Dead weight testers and hydraulic pressure calibration equipment shall not be used, as they will contaminate cleaned instruments on process equipment. The Contractor shall only use “Oxygen Clean (Class AA),” “Class AA,” “AA,” or “A03” cleaned test equipment on “Oxygen Clean (Class AA),” “Class AA,” “AA,” or “A03” cleaned instruments. It is not permitted to use one piece of test equipment on instrumentation for both general service and clean lines (as defined in paragraph 7.5.8). On plants that contain hazardous areas, the Contractor shall supply tools, communication, and test equipment certified for use in hazardous areas.

8.2.2 All test equipment used by the Contractor shall be approved by the Engineer, and its accuracy shall be higher than the accuracies claimed by the manufacturer for all instruments that are to be tested. All test equipment shall have a valid calibration certificate issued by a recognized authority (for example, NAMAS Approval) and shall be periodically rechecked. The interval between checks shall be agreed with the Engineer.

8.2.3 The test and calibration equipment shall be calibrated in the units of measurement selected for and appropriate to the project.

8.2.4 Approval shall be obtained from the Engineer before electric power or pneumatic supplies are applied to any panel or to any section of the plant. On any plant, whether or not it is operating, it is essential to comply with any permit to work procedures that are in force.

8.2.5 On completion of each test, the stage of the testing procedure reached shall be indicated by a temporary label affixed to each instrument or installation.

8.2.6 The Contractor shall use colored labels to make identification easier. Suggested colors are shown in Table 3. 

Table 3 Test Status Color Code
BlueVisually inspected
YellowPressure tested
GreenCables tested
RedPre‑commissioned (ready for commissioning)
WhiteTest failed (written message may be added giving reason for failure)

8.2.7 Such identification shall be shown on all components in the loop to enable personnel to see the current status of the installation.

8.2.8 When testing is finished, all connections and entries shall be sealed temporarily to prevent moisture and dirt getting into the equipment.

8.2.9 A record of all test results shall be made on standard sheets in AppendixA. In addition, when appropriate, approval signatures shall be obtained (see Section 8.9).

8.2.10 The Engineer will monitor activities during loop checking and will witness all loop tests.

8.3 Inspection upon Receipt

8.3.1 Immediately upon receipt on site, each item of equipment shall be visually inspected to ensure that the instrument is not damaged in any way (for example, damage to enclosures). If any defects or deficiencies are found, these shall be reported to the Engineer and remedial action shall be agreed before the equipment is put in storage.

8.4 Preinstallation Testing

8.4.1 Preinstallation testing of instrumentation on site is generally not required and should not be done unless otherwise specified.

8.4.2 However, temperature switches may be tested in the workshop before installation (see paragraph 8.8.5), as an acceptable alternative to field testing these devices.

8.5 Pressure Testing of Instrument Piping and Tubing

8.5.1 Pressure Testing – General

8.5.1.1 The object of this phase of the testing procedure is to verify that all instrument piping and tubing are pressure-tight under the specified working/testing conditions.

8.5.1.2 The pressure testing of any equipment fabricated on site (for example, cooling chambers, capacity pots, and catch pots) shall be witnessed by the Engineer unless this requirement has been waived, in which case the Engineer shall be provided with test certificates.

8.5.1.3 The instrument piping and tubing that will be tested can be classified in the following categories: Air supply piping (see paragraph 8.5.2) Transmission signal tubing (see paragraph 7.5.4) Process impulse piping (see paragraph 7.5.5)

8.5.1.4 The pressure testing of air supply piping, transmission tubing, and process impulse pipework on a given loop shall be completed before the final loop testing.

8.5.2 Air Supply Piping

8.5.2.1 The testing of the main instrument air header from the source up to and including the first isolation (that is, branch shut‑off valves usually on the pipe track) is not included in this procedure. The tests described in paragraphs 8.5.2.2 to 8.5.2.6 assume that the instrument air compressors and driers have been commissioned and an instrument air supply established at the specified working conditions (that is, clean, dry, and oil‑free). If the permanent air supply has not been established, an alternative source of clean, oil‑free, dry air, or nitrogen shall be used. This can be obtained either from storage cylinders or an oil‑free compressor with dryer.

8.5.2.2 Branch air lines to individual instruments shall be disconnected immediately upstream of and adjacent to the instrument air filter regulator, and blown through with clean air until clear of all foreign materials. The tubing downstream of the filter regulator shall be blown through before connection to the instrument.

8.5.2.3 The open end(s) shall be blanked off and a suitable test pressure gauge shall be connected into the system.

8.5.2.4 The isolation valve immediately upstream of the piping to be tested shall be opened, and when the line is pressurized, it shall be closed. This test shall have a duration of 10 minutes and the test gauge shall be observed to detect leakage. In addition, all joints shall be checked for leaks by the application of soap or similar solution, and leaking joints remade as required.

8.5.2.5 On completion of the test, the line shall be reconnected and the joint(s) that have not previously been proven shall be checked with soap solution.

8.5.2.6 The pipe shall then be color-coded as shown in paragraph 8.2.6.

8.5.3 Transmission Signal Tubing 

8.5.3.1 Each individual tube shall be disconnected at both ends and blown through with clean, oil‑free, dry air.

8.5.3.2 The tubes shall be blanked off and pressurized to 1.4 bar g (20.3 psig) from an existing air supply, via a pressure supply and gauge. If an air supply is not readily available, the tubes may be pressurized using a foot pump and with a manometer connected into the system. With the pressure source isolated, the reading shall remain constant for a period of 10 minutes. The tube shall then be reconnected and, when an air supply has been established, the joints that have not previously been proven shall be tested with soap solution. This may be achieved by setting the transmitter/controller outputs to maximum.

8.5.3.3 Underground tubing shall be tested before trench backfilling is commenced.

8.5.3.4 The tubing shall then be color coded as shown in paragraph 8.2.6.

8.5.4 Process Impulse Piping

8.5.4.1 When practicable, process impulse piping shall be disconnected at both ends for testing after fabrication.

8.5.4.2 During pressure testing, instruments shall be isolated from the process line and protected from damage caused by overpressurization.

8.5.4.3 Isolation may be omitted only when the supplier’s documentation demonstrates that the instrument will be unaffected (in terms of damage or calibration shift) by the maximum possible pressure in which the instrument could be exposed to.

8.5.4.4 The Contractor shall not flush instrument tubing with water.

8.5.4.5 The cleaning requirements for process impulse piping are defined in paragraph 7.5.8.

8.5.4.6 The Contractor shall leak test instrument tubing with dry, oil-free air, or nitrogen (not water). Test pressure shall be a minimum of 1.1 times the design pressure of the associated process pipework.

8.5.4.7 After testing, the lines shall be reconnected to the instrument manifold and all manifold valves shall be checked for tight shut‑off.

8.6 Testing of Instrument Cables 

8.6.1 Immediately after cables are laid and before being connected at either end, all conductors shall be checked for continuity, and insulation resistance between conductors and between conductors to earth. Voltage insulation tests shall not exceed the insulation rating of the cable being tested.

Note: Severe damage may be caused to barriers and electronic equipment if inadvertent insulation testing of cables is done after connection.

8.6.2 Underground cables shall be tested before trench backfilling is commenced.

8.6.3 After all tests have been completed, the cables shall be color coded as shown in paragraph 8.2.6.

8.7 Cold Box Temperature Element Tests

8.7.1 Tests for Cold Boxes Packed with Insulation On-Site

8.7.1.1 For full details, refer to M25.

8.7.2 LIN Dipping Tests before Cold Box Packing Operations

8.7.2.1 After the cold box temperature elements have been installed and cabled back to the associated junction boxes, the elements shall be LIN dipped as a final check of integrity and accuracy before cold box packing takes place. LIN dipping consists of withdrawing the element from its associated well without disconnecting the cabling at the head, dipping the element in a flask of liquid nitrogen, and checking the stabilized millivolt/resistance values.

Note: For LIN dipping to be possible, the Contractor must leave sufficient length of cable coiled inside the head to facilitate element withdrawal (see paragraph 7.6.5) as part of the installation.

8.7.3 Tests During Cold Box Packing Operations

8.7.3.1 When cold boxes are packed with insulation on-site, the Contractor shall monitor and record thermocouple continuity, insulation resistance cores to earth, and cores to screen during the packing period. Similarly, the Contractor shall monitor and record resistance element resistances, and insulation resistance cores to earth and cores to screen, during the packing period.

8.7.3.2 These checks shall be done at least once every 4 hours during the packing period.

8.7.3.3 The Contractor shall report any faults to the Engineer.

8.8 Precommissioning (Including Loop Testing)

8.8.1 Precommissioning – General 

8.8.1.1 The object of loop testing is to ensure that all instrumentation components in a loop are in full operational order when connected together, and are in a state ready for plant commissioning.

8.8.1.2 The adopted procedure in performing these tests is described in paragraphs 8.8.1.3 to 8.8.1.7, but in general, the completed instrument loop shall be tested as one system and, when necessary, adjustments shall be made to calibrations. Associated alarms and trips shall be checked during loop testing.

8.8.1.3 As a prerequisite to testing the equipment, inspection and testing of the associated pipework, wiring, and mounting shall be performed to ensure that the installation is complete and generally acceptable, and has been completed in a professional manner and in accordance with this specification. Checks for mechanical/electrical completeness shall be done using the first part of the instrument loop check sheet described in paragraph 8.9.

8.8.1.4 Loop testing of remote control loops is a two‑man operation, with one man in the field and one man in the control room. The Contractor shall provide adequate means of communication (that is, field telephones or radio transceivers) as approved by the Engineer.

Note: Attention is drawn to the possibility of r.f. interference from such equipment, which may affect the accuracy of certain electronic equipment and systems. In case of doubt, the advice of the manufacturer of the equipment and systems shall be obtained.

8.8.1.5 Loop testing shall not be performed on electronic equipment until an adequate warm-up period has elapsed. When possible, the equipment shall be energized for at least 24 hours before testing.

8.8.1.6 In most instances, the Engineer will witness the final loop tests and countersign the test certificates.

8.8.1.7 Upon completion, one copy of the test certificate for every installation, with all results recorded, shall be made available to the Engineer.

8.8.2 Loop Testing Procedure and In-Situ Calibration Check

8.8.2.1 The loop shall be inspected and air/electrical supplies shall be set when appropriate. In particular, a check shall be performed to ensure that the control valve air supply pressures are set in accordance with the manufacturer’s specification.

8.8.2.2 For electronic loops, a check shall be made to confirm that the polarities are correct.

8.8.2.3 Each loop shall be tested from the field signal input through to the receiving instrument. In the case of controllers, the output shall also be checked through to the final control element operation. During a loop test, all ancillary items in the loop shall be tested (for example, signal converters and alarm switches).

8.8.2.4 Before loop testing, all components shall be checked for correct zeroing and adjustments made if required.

8.8.2.5 To perform a loop test, it may be necessary to isolate the transmitter (or input device) from the process and to connect a process signal simulator. If any such items are isolated for the loop test, these shall be tested and checked separately with the results recorded.

8.8.2.6 The process input signal shall be increased and the corresponding output signal and/or scale readings recorded at 0%, 50%, and 100% of the instrument range. The readings shall always be taken when the signal is rising.

8.8.2.7 The process input signal shall be decreased and the corresponding output signal and/or scale readings shall be recorded again at 100%, 50%, and 0% of the instrument range. The readings shall always be taken when the signal is falling.

8.8.2.8 The percentage error calculated from the above tests shall not exceed the manufacturer’s stated limits for both accuracy and hysteresis.

8.8.2.9 When necessary, adjustments shall be made according to the manufacturer’s instructions and the tests shall be repeated. Accuracy of readings shall be better than, or equal to, the accuracy limits stated in the manufacturer’s specification.

8.8.2.10 After the tests have been completed, the instrument shall be color-coded as shown in paragraph 8.2.6.

8.8.2.11 If errors in overall loop calibration are detected, repeat tests shall be performed on individual items of the loops.

8.8.2.12 For controller applications, the controller shall be switched to manual mode and, by applying the appropriate signals, it shall be verified that the control valve strokes correctly. Valve positioner gauges shall also be checked during this stage.

8.8.2.13 Alarm and trip actions shall be checked by varying the actuating signals and adjusting as necessary.

8.8.2.14 Locally mounted controllers or transmitting‑only loops shall be tested in a similar manner to that described above, omitting transmitter and/or auto/manual checks as required.

8.8.2.15 Each control loop shall be checked for correct action before being switched to manual, ready for commissioning. 

8.8.3 Temperature Loops (Thermocouple and Resistance Thermometer) 

8.8.3.1 Thermocouples and resistance thermometers shall be removed from their wells and checked to confirm that they are not damaged. The resistance of each resistance thermometer shall be measured at ambient temperature, and both resistance and temperature shall be noted. For temperature loop simulation, signals from resistance thermometers shall be simulated by decade boxes or equivalent, and signals from thermocouples by the use of precision millivolt signal generating sources.

8.8.3.2 Thermocouples and resistance thermometers that are inaccessible (for example, because of their location inside a cold box that was built off-site) shall be tested remotely from the adjacent junction box.

8.8.3.3 After testing, all thermocouples/resistance thermometers shall be replaced in their thermowells and reconnected. It is important to verify that the element is “bottomed” in the thermowell and that the polarity of the thermocouple connections is correct.

8.8.4 Temperature Gauges

8.8.4.1 The function of local temperature gauges shall be verified immediately before installation by checking that they read the correct ambient temperature, and respond to a change in temperature.

8.8.5 Temperature Switches

8.8.5.1 Temperature switches shall be tested at their operating point using a temperature bath.

8.8.5.2 A continuity test circuit shall be connected across the contacts to ensure proper operation.

8.8.5.3 Care shall be taken to ensure that the switch operation is in the correct mode (that is, with a rising or falling signal according to the instrument specification).

8.8.5.4 When the switching differential is stated in the specification, it shall also be checked.

8.8.5.5 The Contractor shall include repeatability tests when checking temperature switches.

Note: Temperature calibration baths are generally suitable for use only in a workshop. If required for use in the field, they shall only be used under cover and in a nonhazardous environment (unless a hot work permit has been provided by the Engineer).

8.8.6 Differential Pressure Level Transmitters

8.8.6.1 Installation details, as defined in the hook-up diagrams, depend on the volatility of the liquid being measured. While the span of the differential pressure instrument should be set in the factory and should not need adjustment on site, the Contractor shall adjust the zero elevation during commissioning as required, to account for the relative elevations of the instrument and vessel, and the hydrostatic heads associated with any wet legs.

8.8.6.2 For cryogenic differential pressure level measurement, both the range and zero elevation are set in the factory to account for the hook-up arrangement. The zero and span should not be adjusted during commissioning, unless because of a design change or error, and with the agreement of the Engineer.

8.8.7 Level Displacers

8.8.7.1 The valves isolating the chamber containing the displacer should be closed.

8.8.7.2 A graduated glass or plastic column should be connected in parallel with the displacer chamber via the bottom drain connector or gauge tapping.

8.8.7.3 The top of the displacer chamber should be freely vented to atmosphere.

8.8.7.4 The level can be varied by injecting a process compatible fluid into the chamber. This may be achieved by using a container and hand pump connected via a bottom drain connection.

8.8.7.5 If the density of the calibration fluid is different to that of the anticipated process fluid, then the manufacturer’s instructions shall be followed for compensating the specific gravity at the operating temperature.

8.8.8 Level Switches

8.8.8.1 Level switches shall be tested mechanically before installation. Care shall be taken to confirm that the switch operation is correct.

8.8.9 Pressure Gauges

8.8.9.1 Pressure gauge zero shall be checked and adjusted immediately before installation, if required.

8.8.9.2 Pressure gauge span shall be checked using a pneumatic calibrator. This check shall normally be performed after installation via the vent port of the gauge’s two valve manifold. If a two valve manifold is not installed (for example, for a close coupled gauge), the calibration check shall be performed immediately before installation.

8.8.10 Pressure Switches

8.8.10.1 Pressure switches shall be tested in-situ at their operating pressure using a pneumatic calibrator.

8.8.10.2 Care shall be taken to ensure that the switch operation is in the proper mode (that is, with a rising or falling signal according to the instrument specification).

8.8.10.3 When the switching differential is stated in the specification, this shall also be checked.

8.8.10.4 The Contractor shall include repeatability tests when checking pressure switches.

8.8.11 Flow Meters

8.8.11.1 In-line flow meters and flow elements usually cannot be tested in the field, and manufacturers’ test certificates are normally accepted.

8.8.11.2 Before installation, the flow device shall be checked to verify that the data and material specification stamped on the data plate or tab handle agrees with the specification.

8.8.11.3 The Contractor shall accurately check and record (on test certificates) all orifice plate and Venturi bores. Orifice plates shall be examined for flatness and to confirm that they are undamaged. The Contractor shall check the installed flow meters and flow elements for correct flow orientation.

8.8.11.4 The Contractor shall remove all transit equipment from in-line instruments before installation by Others.

8.8.12 Control Valves

8.8.12.1 These tests shall normally be conducted in-situ after the valve has been installed in the line. Tests shall not be performed until the valve is in its final operating state. When hydrostatic testing has occurred with the valve in-situ, the valve packing shall be checked and replaced if damaged.

8.8.12.2 The valve and data plate shall be checked to verify that they agree with the control valve specification.

8.8.12.3 The actuator shall then be checked for travel, with rising and falling signals at 0%, 50%, and 100% of the valve stroke, against the appropriate valve position output current or pneumatic signal. The following shall also be checked against the valve datasheet: The valve moves accurately and smoothly over its full range. The speed and direction of movement is correct for the application. The valve moves to the correct position in the event of a supply failure.

8.8.12.4 If necessary, adjustment shall be made in accordance with the manufacturer’s instructions, and retested.

8.8.12.5 When mechanical limit switches or torque switches are fitted, these shall be checked using a continuity test set, for correctness of setting and for operation. When proximity limit switches are fitted, these shall be checked by monitoring the return signal voltage. On motorized valves, care shall be taken to check the setting of the limit switches before switching on the actuator.

8.8.12.6 Solenoid valve action shall be verified, including any electrical and mechanical reset, override, and time delay features.

8.8.12.7 The Contractor shall check that all control valve transducers and air sets are installed vertically with their drains pointing downwards, and reposition/repipe any that are not. When control valves have integral pressure gauges, the Contractor shall check that they are in a readable orientation and reposition any that are not.

8.8.12.8 The Contractor shall check that control valves are installed in the correct flow direction.

8.8.13 Safety Valves

8.8.13.1 The testing of safety valves is outside the scope of work for the Contractor on-site.

8.8.14 Computer-Based Control Systems

8.8.14.1 Precommissioning of the internal logic of the computer-based control systems, such as distributed control systems and programmable controllers, will normally be performed by the Engineer.

8.8.14.2 The associated field instruments, wiring, and interfaces to the computer-based control system will be commissioned by the Contractor.

8.8.14.3 The Contractor shall work in close cooperation with the Engineer to test the operation of field equipment and interconnections in conjunction with the computer-based control system.

8.8.14.4 The Contractor shall only apply power to computer-based control systems as follows: Once the electrical supply has been fully commissioned by Others. Under the supervision of the Engineer.

8.8.15 Shutdown Systems

8.8.15.1 A specific procedure shall be agreed in advance with all parties before validation of the emergency shutdown system. This procedure shall cover, but not be limited to, the testing by the Contractor of each individual function, the sequence of functions, and the logic of the interaction. Such testing will be witnessed by the Engineer.

8.8.15.2 A certified record of all tests shall be kept. Any failures of the shutdown logic shall be reported to the Engineer.

8.8.15.3 For computer or programmable logic controllers (PLC) based shutdown systems, precommissioning of the panel will be performed by the Engineer. The Contractor will work in close cooperation with the Engineer to test the operation of field equipment and interconnections in conjunction with the computer or PLC-based shutdown system.

8.8.16 Alarm Systems

8.8.16.1 Alarm systems shall be energized. Checks shall be made to ensure that: All display windows are functional. Alarm sequences and groups operate as specified.  Window colors and engravings are correct and are located in the correct positions. All lamps illuminate. In particular, displays using two or more lamps in parallel per window shall be checked to verify that all lamps illuminate.

8.8.16.2 Computer-based alarm systems will be tested by the Engineer. The Contractor shall work in close cooperation with the Engineer to test the operation of field equipment and interconnections in conjunction with the alarm system.

8.8.17 Process Analyzers and Associated Equipment

8.8.17.1 Except where stated otherwise in the contract documents, process analyzers will be checked by the Engineer. The Contractor shall work in close cooperation with the Engineer to test the operation of field equipment and interconnections in conjunction with the process analyzers.

8.8.18 Preparation for Commissioning

8.8.18.1 Upon completion of loop testing, the installation shall be made ready for process commissioning: All final pre-commissioning activities such as setting zero elevations and suppressions, filling liquid seals, and adjusting purge rates shall be completed. The Contractor shall check that all accessories such as charts, ink, fuses, and safety glasses are fitted. The installation shall be checked for mechanical/electrical completeness. The site or area shall be cleaned up (that is, all surplus materials and tools shall be removed, and all painting work completed), unless otherwise agreed by the Engineer.

8.9 Check Sheets

8.9.1 The results of all calibration checks and loop tests shall be recorded on suitable check sheets, signed by the Contractor, and countersigned by the Engineer.

8.9.2 Blank calibration and check sheets are shown in AppendixA. The Contractor shall use these sheets unless other project-specific sheets are specified in the contract documents or have been agreed by the Engineer.

9. Commissioning And Acceptance

9.1 General

9.1.1 Commissioning is defined as the bringing on‑stream of a process plant and the tuning of all instruments and controls to suit the process operational recommendations.

9.1.2 Commissioning will be performed by the Engineer with the assistance, as needed, of the Contractor.

9.2 Ready for Commissioning

9.2.1 A plant, or section of a plant, is considered to be ready for commissioning when precommissioning is complete. 

9.3 Commissioning

9.3.1 When specified on the contract documents, the Contractor shall ensure that instrument personnel shall be available on standby, or on call, until the official handover and acceptance of plant has taken place.

9.3.2 Stores and workshops shall be available during the commissioning period. Consumable spares shall be kept available at all times.

9.3.3 During commissioning, all errors, omissions, and alterations to the installation, whether because of design changes or for any other reason, shall be carefully noted and remedial action agreed with the Engineer and recorded on the “As-built” drawing mark-ups.

Appendix A Blank Calibration and Test Sheets

A1. Appendix A contains blank instrument inspection, and calibration/test sheets.

A2. The Contractor shall use these sheets to meet the testing and precommissioning requirements of this specification unless alternative sheets are specified in the contract documents or agreed with the Engineer.

Appendix A (continued) 

INSTRUMENT INSPECTION REPORT  INSPECTION UPON  RECEIPT

 

Project Number:Report Number:
AP Data Sheet Number:

 

Tag NoSerial NoMake/ModelChecked for DamageComplies with Data Sheet

 

REMARKS

 

BYAIR PRODUCTS APPROVAL
DATEDATE

Appendix A (continued)

INSTRUMENT CALIBRATION TEST REPORT PRECOMMISSIONING TEST
Report Number:
AP Data Sheet Number:
Instrument Installed Correctly (YES/NO)
Instrument Piped Correctly (YES/NO)
Tubing Blown Out and Cleaned (YES/NO)
Tubing Leak Tested at
Air Supply Set at
Instrument Wired Correctly (YES/NO)
Cable Continuity and Insulation checked (YES/NO)
Instrument Earthing Checked (YES/NO)
Instrument Power Supply Checked (YES/NO)
Test Equipment Serial Numbers

CALIBRATION DATA

%INPUTOUTPUT/READING%INPUTOUTPUT/READING
0100
5050
1000
INSTRUMENT SETTING:

 

REMARKS

 

BYAIR PRODUCTS APPROVAL
DATEDATE

Appendix A (continued)

INSTRUMENT CALIBRATION TEST REPORT LOOP CHECK TEST

 

Tag Numbers of Instruments in LoopPrecommissioning Test Certificate Numbers

 

Loop Installed Correctly (YES/NO)
Loop Functions Correctly (YES/NO)
All Cable Screens Connected Correctly (YES/NO)
All Screen Earths Correct (YES/NO)
All Calibrations Correct (YES/NO)
All Trips and Alarms Set (YES/NO)
Complete Loop Ready for Start-up (YES/NO)

 

REMARKS

 

BYAIR PRODUCTS APPROVAL
DATEDATE

Appendix B Instrument Site Query Form

B1. Appendix B contains a blank instrument site query form.

B2. The Contractor shall use this sheet for all technical queries.

Appendix B (continued)

INSTRUMENT SITE QUERY FORM

 

Project Number:Query Number:
Project Name:
Query Raised By:Date Sent:
Query Sent To:Copy To:
Details of Query:
Response:
By:                                 Date:

 

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