1.

SCOPE.

This specification details the general requirements with respect to the installation and
commissioning of all the Control and Instrumentation equipment for this project.

The General Conditions, Instruction to Tenderers, Detailed specification and Contract

Documents are to be considered part of this specification.

2.0 GENERAL.
The instrumentation installation is required to confirm to this General Specification and the
Detailed Specification, and is to be in accordance with the latest revision of the standards:

Where there is conflict between the specific requirements of the Detailed Specification and this
General Specification, the Detailed Specification shall govern.

3.0

DEFINITIONS.

The instrument and process control equipment shall include all equipment required to
measure, indicate, record, compute and automatically control process variables such as fluid
flow, pressure, temperature, level, etc. It shall further include the equipment directly related to
control of electrical drives, remote operation of automatic valves, and other remotely
controlled items.
The Employer is .
The Engineer is the Employers appointed site representative.

4.0

CONTRACTOR RESPONSIBILITY.
All specified cable, piping, tubing, instruments and accessories required for the project
shall be supplied and installed by the Contractor in accordance with the projects
requirements.
The Contractor shall be responsible for transporting all equipment from the site project
store to the installation site.
All equipment supplied to or procured by the installation Contractor for installation shall
be safely stored and protected from the weather so as to prevent loss or damage. The
Contractor shall be responsible for replacement of equipment lost or damage whilst in his
care.
In all cases the Contractor shall ensure that he fully familiarizes himself with the
requirements for the correct installation and operation of each instrument type. Except
as is covered by the manufacturers guarantee, the Contractor, shall be responsible for
the correct operation of equipment once he has signed receipt of such equipment. He
shall obtain from the equipment supplier or Engineer full details of erection together with
any relevant handbooks or drawings. Should any installation be incorrectly effected, the
Engineer shall have the right to instruct the Contractor to re-install the item at no cost to
the Employer.
Cable, piping and tubing lengths indicated on the drawings and cable/piping schedule are
to be used as guides. The Contractor shall be responsible for determining the lengths

actually required before the lengths are cut.

The Contractor shall be responsible for providing his own communication equipment
(e.g. walkie-talkies, etc).
The Contractor shall be responsible for providing all scaffolding and ladders required to
effect the installation.
The Contractor shall be responsible for correct operation of all instrumentation and
control equipment installed and/or supplied by him. This responsibility shall only cover
the operation of individual items of equipment and shall not include the correct process
operation of a control loop or control system except where such control loop or control
system forms an intrinsic part of the operation of the item of equipment.
Any inability of the Contractor to comply with any requirements of this specification is to
be clearly highlighted.
The Contractor is to ensure that the completed installation will provide a reliable, easily
maintainable, easily operable, and safe plant as a result of a high quality of
workmanship.

5.0

EQUIPMENT STANDARDS.

All equipment is to be supplied by the Contractor, except where specifically stated as being free
issue supply. Offers from reputable manufacturers of industrial type instrumentation and
control equipment shall be submitted for the Contractor supplied instrumentation of plants,
where the equipment manufacturer or type is not specified. The manufacturer shall be
represented by well established agents in the Republic of South Africa who will be expected to
carry stocks of the spare parts required for the maintenance or replacement of the equipment.

5.1

Ranges and Accuracy.

Instrument ranges and spans shall be selected from the manufacturers standard ranges and
designs. All instruments and control equipment offered shall be of the most modern design,
and shall be in line with the latest developments.

5.2

Instrument Operating Media.

Only instrument and control systems operating with pneumatic or electric power shall be used.
The signal standards shall be:
Field Electronics : 4-20mA DC two wire
Control Panel Electronics : 4-20mA DC or 1-5V DC.
Pneumatics : 20-100 kPa.

The power standards shall be:

DC Power : 24V DC
Control Supply : 110V AC

MCC Control Supply : 240V AC

Instrument Supply : 110V AC
Solenoid Supply : 110V AC
Instrument Air : 600kPaG
Plant Air : 700kPaG

Field instruments requiring a separate power supply shall operate on a 110V AC supply. All
electrical power supplies will be separately fused at the supply distribution panel.

5.3

Units.

The International system of units (SI) shall be used:

Measured
Variable

Units

Sym
bol

Air Flow Rate

Normal cubic metre per

hour

Nm3/h

Liquid Flow
Rate

Cubic metre per hour

m3/h

Pressure

Kilopascal

kPa

Megapascal

Mpa

Temperature

Degree Celsius

0C

Level

Percent of capacity

Mass

Kilogram

Kg

Tonne
Dimension

Millimetre

T
mm

Measured at Standard Temperature and Pressure: unless otherwise stated, at a pressure

of 101,325 kPa absolute and 150C, dry.

6.0

SPECIAL INSTALLATION INSTRUCTIONS.

6.1

Supports and Brackets.

The drilling of the holes in structural steel work is not permitted without the prior
approval of the Engineer.
Where holes are drilled in galvanized steelwork for the installation of support brackets,
all such holes shall be treated with cold galvanizing paint within 12 hours of drilling.

6.2

Field Instruments.
Field-mounted instruments, excluding in-line and close- coupled devices shall be
mounted such that the housing is centered at a height between 1.5 and 1.8 meters
above grade, floor or platform.
Brackets shall be made of mild steel flat bar, angle or channel.
Outdoor instruments specified for surface mounting must be mounted with brackets.
Mounting positions are to be agreed with the Engineer.
When mounting each instrument, special attention shall be given to orientation of the
device with regard to access for maintenance, repair and calibration.
All instruments shall be located as close to the primary device or connection as possible,
consistent with instrument accessibility and mounting requirements as stated.
All instruments shall mounted in such a way as to permit ready space for withdrawal and
maintenance where required.
All instruments shall be installed in such a position that they do not protrude into any
walkways or access ways.
All indicating instruments shall be installed in a position easily visible and accessible from
the plant floor or platform. Where vibration on line or equipment is present, the
instrument shall be separately mounted.
Instruments shall not be mounted in locations where they are subjected to high
temperatures.
Instruments shall not be mounted in locations where they are exposed to leaks and
spills. Where such locations are unavoidable, a protective cover shall be provided over or
around the instrument. If specified, instruments shall be mounted in GRP field protection
boxes complete with hinged clam-shell style lockable cover with viewing window and
mounting plate/pipe and support stand.
All cables, instrument line to vessels, pipelines or equipment shall be properly supported
to relieve strain on connection and instruments, and routed to avoid damage by
expansion/contraction. Where the routing as shown on drawings cannot be adhered with,
alternate routes may be utilized provided approval has been obtained from the Engineer.
Capillary tubing for filled system temperature instruments, diaphragm level transmitters
and the like shall be supported and protected by running the tubing in galvanized steel
conduit for the entire exposed length capillary. Excess capillary tubing shall be neatly
coiled and secured out of the way. The minimum bend radius for capillary tubing shall be
75mm.

When installing any instrument assemblies in rubber-lined vessels and pipes, care shall
be taken not to damage the lining. No welding or cutting will be allowed on rubber-lined
vessels.
Wherever welding is performed, the Contractor is responsible for removing all welding
slag and burnt paint. The damaged area shall then be restored using a self-etching
primer and two coats of enamel paint.
The Contractor shall provide each field-mounted instrument with a stainless steel
nameplate in accordance with the plant tag numbering system. If not specified in the
drawings, nameplates shall not be less than 25mm high x 75mm long and fastened with
stainless steel screws. Letters shall be upper case, minimum 6mm high. Self tapping
screws shall nit be accepted. Nameplates shall be affixed adjacent to Instruments and
equipment on fixed structures. Under no circumstances shall nameplates be attached to
functional, removable equipment.

6.3

Cable Racks, Cables and conduits.

Cable Racks, Cables and Conduits are to be supplied, manufactured, installed and
terminated in accordance with Project Specification N50-610.

6.4

Pneumatic Tubing.
All pneumatic tubing on the plant is to consist of DEKORON type 1300 Dekabon (or
approved equivalent) tubing in sizes 6mm, 8mm or 12mm, except where specified
otherwise, or as follows:
Installation requiring flexible tubing shall use DEKERON type 1204 HP, Imperial
Eastman Polyflow (or approved equivalent) tubing in sizes 6mm, 8mm or 12mm.
As specified, grade 316 stainless steel annealed tubing to ASTM-A269 is to be used for
all installations not requiring flexibility.
Where specified, copper tubing is to be soft drawn annealed type.
Metal tubing shall only be cut with a proper tubing cutter the use of hacksaws is not
permitted. The inside diameter of the cut tubing shall be reamed to remove burrs.
Tubing must be blown clear of all fillings and debris before end connections are made.
Piping and tubing joints and connections shall be raised from any flat surfaces for
connection and disconnection.
Screwed piping and fittings shall conform to the project piping specifications which will
be supplied. Screwed joints shall have clean machine-cut threads and shall be made with
PTFE joining tape or a suitable compound to the approval of the Engineers.
Valves shall be accessible for operation from floors and operating platform unless
otherwise approved by the Engineer. Tubing shall not interfere with access to the valves
or equipment and shall not obstruct passageways. Headroom clearance of 2.1m
minimum shall be maintained below piping.
In cases where pipe penetration openings are not provided in gratings which were
installed by others, openings shall be field cut and the grating banded with suitable kickplates for protection by the Contractor. The Contractor shall prime coat the cuts and
welds with a primer compatible with the finish coat which is to be applied by others in

accordance with the project painting specification.

No piping or tubing shall be buried directly in the ground.
Piping and tubing shall be carried on overhead racks attached to the building frame or
other supports.
Every pipe installed on racking in a building or on supporting structures shall be
supported in such a manner that there is no undue mechanical strain on any
termination. Racking shall be painted before piping is attached. Painting shall be to the
project painting specification.
Care is to be taken to ensure that sharp corners on steel work, etc., cannot cut or abrade
tubing.
Where plastic tubing runs straight for more than 100mm it is to be supported and
protected using an angle iron tubing support or by enclosing it in galvanized steel
conduit which has been suitably cleaned and suitably bushed.
All tubing and piping shall be labeled in accordance with tubing schedules. Tubing and
pipes longer than 2m shall be labeled at both ends.
Care should be taken to protect piping and tubing from damage caused by falling
welding splatter.

6.5

Instrument Air Supply Tubing and Piping.

The instrument Air Supply lines shall be installed in such a way that water cannot
accumulate at any point in the line. The line shall have sufficient slope and shall be so
installed that that all the water condensed in it is discharged by a reliable water blow-off
device provided by the Contractor for this purpose. Instrument Air Supply headers are to
be manufactured from galvanized steel piping.
Compressed air for general plant use shall not be taken from the Instrument Air Supply.
Air supply lines shall be pressure tested and purged before being connected to
instruments.
Connection piping to instruments shall be as short as possible.
All instrument piping shall run in a neat and orderly manner with lines grouped wherever
possible. Instrument piping shall start at the block valve on the instrument air header.
From the air header 12mm OD grade 316 stainless steel tubing shall run to manifolds
supplying filter/regulator sets where required.
Manifolds shall be Sustech Manufacturing model range PH/84**TXH, manufactured from
316 stainless steel, and shall be fitted with the required amount of NPT stainless
steel nipples and isolating valves. A minimum of 20% spare stainless steel valves are to
be provided. Manifolds shall be pressure and leak tested at not less than 1000 kPa. The
manifolds are to be provided with a drain valve for connection to a water blow-off point.
All instrument piping entering or leaving a control cubicle, box or panel shall do so via a
bulkhead coupling.

6.6

Process Tubing and Piping (Impulse Lines).

All direct connections to process media shall be implemented using 12mm OD grade 316
stainless steel annealed tubing and fittings.
Connections between process vessels or piping and instruments shall be relieved of
strain by properly supporting such instruments (and seal port where used) and by
installing offsets for expansion.
Where the medium being measured is liquid, the instrument shall be mounted below the
tapping point. Where the medium being measured is a gas, the instrument shall be
above the tapping point. All instruments shall have their impulse lines sloped at a
minimum rate of 100mm per meter.
A 15 NB stainless steel isolating ball valve shall be provided at every process tapping
point by the piping Contractor, together with any stainless steel reducers/adopters
required to connect between the valve and the tapping point.

6.7

Pneumatic Fittings.
All instrument air tubing fittings shall be compression type.
All pneumatic tubing fittings shall be stainless steel, except where copper tubing is
specified, when all fittings shall be brass. No nylon fittings shall be permitted. All fittings
are to have NTP thread, except where an instrument is supplied with a different standard
thread, in which case an adaptor shall be used.
All tubing fittings are to be double ferrule of approved manufacture. (Gyrolok, Hy-lok,
Swagelok and Parker Hannifin are all approved).

6.8

Enclosures and Junction Boxes.

Reference should be made to the relevant layout drawing for position of junction boxes.
All enclosures are to satisfy minimum protection degree IP65.
All enclosure are to be sized to permit easy access to all electrical and tubing fittings for
maintenance purposes without removing the equipment from the enclosure.
Enclosure doors shall preferably open upwards, to provide drip protection. In such cases,
a support rod is required for the door.
Drip covers are to be provided for enclosures where specified.
Where stainless steel enclosures are specified, grade 304L stainless steel of 1mm
minimum thickness shall be used. GRP/Polyester enclosures may be used for certain
applications, e.g. indoors.
All boxes are to be clearly labeled internally and externally with equipment/enclosure

number and enclosure title. Nameplates shall consist of engraved traffolyte or stainless
steel, and shall not be less than 25mm high by 75mm long, and shall be screwed on to
the enclosures. Letters shall be upper case, minimum 10mm high. Nameplates, tags and
markers must be affixed as work progresses.

6.9

Earthing.
The high Quality (instrument earth) for each plant will be derived from an earthing mat
at one point only. The earthing mat and a tap-off point will be provided for others. The
Instrument earth is connected through to the Marshalling panels. No connections to any
other earthing system are to be made.
When connecting analogue cables, the Contractor is to ensure that all screens are
connected from the Marshalling panel high quality earth bars or screen terminals in the
junction boxes.

7.0

DETAILED INSTRUMENTATION INSTALLATION

7.1

Flow Instruments.
Flow Switches and Indicators
Flow switches shall be installed strictly in accordance with the manufacturers
recommendations and in agreement with the site Engineer, due consideration being
given to mounting for the correct direction of flow in the pipe-line, and to ensure
optimum operation and facilitate maintenance.
Flow Orifice Plates
Orifice plates shall be manufactured from a suitable grade of stainless steel and
calculated and installed in accordance with ISO Publication No.R541/1967.
Differential pressure tapping points are to be situated in accordance with the medium
being measured as follows:
For gaseous flow, the tapping points are situated horizontally on the side of the pipeline,
with the transmitter mounted so as to ensure that all liquid will drain back into the
pipeline.
For liquid flow, the tapping points are situated horizontally on the side of the pipeline,
with the transmitter mounted so as to ensure that all entrained gases will float back into
the pipeline.
Averaging Pitot Flowmeters.
Where Averaging Pitot type flowmeters are used for measuring gas flow, the flowmeter
shall be installed vertically, with the tapping points and transmitter mounted above the
process pipeline.
Where Averaging Pitot type flowmeters are used for measuring liquid flow, the flowmeter
shall be installed rapidly at an angle of 45 degrees from the bottom of the pipeline, with
the transmitter mounted below the process pipeline.
Magnetic Flowmeters.

Magnetic flowmeters are to be installed to the manufacturers specification. Care is to be

exercised to prevent damage to the liner and electrodes. 200mm spool pieces are to be
provided on either side of the flow tube for this purpose. The flow tube and spool pieces
are to be assembled as a unit on the ground before being installed in position in the
pipeline. Flange bolts on the flow tube are to be torqued to manufacturers specification.

7.2

Level Instruments.
Level Switches
Conductance and Capacitance Type.
Probe transmitter assemblies are to be solidly mounted to steel work alongside the
vessel in which the level is being sensed, in such a manner that the installation will not
be damaged when hosing down or when cleaning the vessel.
When level elements are to be tank mounted, they should be mounted in such a way as
to permit ready access to the probes for cleaning. Care should be taken to ensure that
sufficient headroom is available for withdrawal of the probes.
When conditions of vibration, turbulence and liquid swirl are anticipated in a tank, a
stout clamp shall be affixed to the tank to prevent movement of the probes. As an
alternative, a still well should be installed where possible.
Level Transmitters.
Ultrasonic Type
The ultrasonic transducer is to be mounted in accordance with the manufacturers
recommendations as appropriate to the situation. Where necessary, the Contractor is to
seek guidance from the equipment supplier.
Precautions are to be taken to render the sensor immune to the tank or silo vibrations
and a suitable anti-vibration and ultrasonic rejection damping mounting is to be
provided.
The sensor shall be located in a position that will minimise the effects of whirl,
turbulence and echo.
Connections between the sensor head and the screened signal cable shall be carried out
in a sealed junction box mounted on an adjacent walkway or access platform, away from
splash. All ultrasonic screened cables shall run in well-earthed galvanised conduit, three
cables being permitted in any one conduit.

7.3

Pressure Instruments.

a)
The pressure instruments shall be installed in accordance with the
manufacturers recommendations and in agreement with the Site Engineer.
b)
All pressure tap points shall be provided with a stainless steel isolating valve at
the taping point between the process piping/vessel and the impulse piping to the instrument.
12mm OD grade 316 stainless steel tubing as specified in section 6.6, Process Tubing, page 10,
shall be used for all impulse piping connection to the process medium.

Pressure Switches.
Switch assembly shall be securely mounted in an accessible position for re-calibration or
checking.
Pressure Gauges.
All gauges are to be 100mm minimum diameter dial face, stainless steel case with
blowout disk, threaded bottom or back connection. Gauges will be sited in a position
giving a clear unobstructed view of the dial, as close to head height as possible. An
isolating valve shall be provided at the tap point by the piping Contractor, to which the
gauge will normally be directly mounted. If the gauge is required to be remote mounted
then a second isolation valve at the gauge shall be provided by the Contractor.
Pressure Transmitters.
Electronic Differential (DP), Gauge and Absolute Pressure Transmitters shall be 2 pipe
stand mounted, and shall be housed in a suitable waterproof protective housing as
specified in section 6.8 Enclosures and Junction Boxes, page 11.
7.4

Temperature Instruments.
All remote sensing of temperature shall be implemented using thermocouple or
resistance temperature detectors.
A fully waterproof junction box is to be installed in close proximity to the detector, for the
junction of detector leads and extension cable. Where possible this junction box shall
mount directly to the temperature-sensing probe.
Head mounting temperature transmitters may be used, provided that they meet with the
specified accuracy.
In all cases where RTDs are used, the maximum distance over which the two wire
system may be used is 1 metre. All two-wire transmitters are to be mounted within the
distance.

7.5

Ionising Radiation Instruments.

a) The Contractor shall comply, where applicable, with the requirements of the Atomic
Energy Act (No. 15 of 1973), as amended, and the regulations applicable to the above act as
described in Government Gazette of 26th February 1993 R2-14596.
b) Shielding, warning signs, barriers and other protection or safely measures are to be
supplied and erected around the relevant items of equipment.
c)

No nuclear source shall be transported or installed WITHOUT the approval of the Engineer.
Nuclear Density Gauges
The source and detector on nuclear density gauges shall be mounted on the pipes so
that the measurement axis from the source to detector is at right angles to the direction
of laminar flow in the pipe, except where a special pipe is provided.
Density gauges should ideally be situated 10 pipe diameters from pump deliveries and
any branch or bend in the pipe system.
Manufacturers recommendations are to be adhered to by the Contractor.

The source and detector installation shall be enclosed in a purpose made guard in such a
way that the shutter mechanism is readily accessible for locking of the shutter. The
guard shall be capable of being removed for authorised maintenance of the density
gauge.
The guard shall be painted in accordance with the relevant paint specification and to the
relevant colour codes.
Radiation warning signs shall be prominently displayed on each guard.
Nuclear Scales.
Nuclear scales should ideally be situated at the head-end of the conveyer.
The scale shall be enclosed in a purpose made guard designed in such a way that the
shutter mechanism is redily accessible for locking of the shutter. The guard shall be
capable of being removed for authorised maintenance of the scale.
Radiation warning signs shall be prominently displayed on each guard.

7.6

Field Control Stations.

Field Control Stations are to be adequately supported on the angle iron frames in a
suitable position for access by operators. Where possible, they should not be installed in
any vessel or tunnel below flooding level. All cables to boxes or cabinets shall enter at
the bottom only.
Field Control Stations are to be housed in enclosures as specified in section 6.8
Enclosure and Junction Boxes.

7.7

Solenoid Valves.
Where solenoid valves are exposed to outdoor conditions, process media or spray, they
shall be housed in polyester boxes as specified in section 6.8 Enclosures and Junction
Boxes.
Cables to solenoid valves are to enter through the base of the box, and are to terminate
in terminals as detailed in Project specification 5485-000-N50-610.00.
Where solenoid valves has to exhaust to atmosphere, such exhaust shall be piped to the
outside of the box.
Instrument air piping to solenoids shall only enter through the bottom of the box.
Unused solenoid ports are to be blocked.

7.8

Current to Pneumatic Transducers.

The I/P converters shall be mounted in close proximity to their associated actuator.
Preference is for control valves to have integral electro-pneumatic positioners.
The air supply to the I/P converter shall be via an isolating valve and suitable
filter/regulator. The regulator shall set to the rated supply pressure as specified by the

I/P converter manufacturer.

7.9

In-Line Instruments.
In-line instruments will be installed by the Piping Contractor. It shall be the responsibility
of the Instrument Contractor to arrange with the relevant Contractors
(Piping/Mechanical) for installation of the in-line instrumentation equipment.
The Instrument Contractor shall ensure that the following points are checked:
The correct instrument is being installed in the correct location and orientation and all
necessary prior flushing and pressure testing has been completed.
The correct flange type and sizes are being installed on the pipe, and all blanks, plugs
and stops have been removed from the instrument.
The pipe is adequately supported on both sides such that no stress is applied to the
instrument.

7.10

Weighing Instruments.
Load cells.
Suitably sized dummy load cells are to be installed in all load cell positions until all
mechanical work, including welding and cutting has been completed. Thereafter, the
loadcells may be installed, with due care being taken that the object to be weighed is not
dropped onto the load cells during installation.
All loadcells are to be provided with substantial flexible copper earthing straps securely
fastened between the surface on which the load cell is mounted and the object to be
weighed. Minimum cross-sectional area of the earthing straps shall be 35mm2.

Electromechanical Scales.
Electromechanical conveyor belt weighing scales are to be installed on horizontal
sections of conveyor, situated more than 50 metres from the closest rise or fall in the
conveyor. The weighing scales shall preferably be mounted near the tail end of the
conveyor, but more than 10 metres from the loading point, to allow the medium to
settle.
Drip and spill covering is to be provided for the scale to prevent the build up of slime,
dust and stones on the balance frame of the scale.

8.0

INSPECTION, CALIBRATION, TESTING AND COMMISSIONING.

General

The instrumentation installation shall to be the approval of the Engineer.

No equipment shall be commissioned until it has been authorized by the Engineer who,
thereupon, will become responsible for the safety of the relevant equipment and all

personnel having access to it.

When all the testing and flushing out of an instrument loop has been completed, the
Contractor shall notify the Engineer in writing and request inspection.

8.2

Instrument Calibration.
The contractor is required to calibrate all instruments as Specified in the scope of Work
in Detailed Specification.
All instrument calibration reports supplied with instruments shall be submitted to the
Engineer before installation.
The Contractor shall exercise due care to see that calibration of instruments is not
disturbed prior to and during installation.
Where the Contractor is required to calibrate instruments the following will apply:
The calibration and instrument adjustment shall be in accordance with the
manufacturers instructions.
Complete details of the Contractors calibration facilities, including specimens of his
calibration reports shall be provided. The Engineers approval shall be obtained for the
calibration equipment and procedure before calibration proceeds.
The contractor shall calibrate the instruments over the full loading range and submit
calibration reports. The instruments shall be calibrated individually.
The contractor shall submit test certificates of calibration standard instruments used for
the calibration.
All instrument calibration reports shall be approved by the Engineer before the
instrument is installed.
In cases where specified test equipment or test procedures are required, the Contractor
shall submit the proposals for testing to the Engineer.
The Contractor is required to supply all the equipment required to test and calibrate the
instruments unless stated otherwise.

8.3

Testing of Wiring and Cabling.

All control cable shall be tested for continuity and insulation resistance. High voltage
insulation testers shall not be used. The minimum acceptable value of insulation
resistance shall be 1MW line to line or line to ground. Specialised measurement cables,
e.g. for density gauges, are to be tested in accordance with the instrument suppliers
specification.
The Contractor shall check the electrical supply to ensure that the correct supply (AC or
DC) and correct voltage is being fed to the instrumentation equipment before it is
commissioned.
All electrical control valves, solenoids, etc. shall be tested energized to confirm the
correct action.
The shielding of cables or wires is to be tested to ensure continuity of shield and

earthing. The shields are to be disconnected at the Central Control Panel end to ensure
that they are not earthed anywhere in the field.

The procedures for checking a cable shall be as follows:

Check signal wires for correct destination on a core by core basis using a suitable
instrument.
Insulation checks shall be made as follows.
Short all cores together, and measure insulation to earth, to screen, and to armouring.
This should be greater than 1MOhm in all cases.
Screen and wire armour to earth. This should be less than 1 ohm in both cases.

8.4

Testing of Instrumentation Equipment.

All installations shall be checked against the Contractors approved quality data package
supplied as part of the contract documentation. This includes the following checks:

All instruments, control valves, and associated equipment shall be ascertain that they
confirm to the instrument data sheet information and that the equipment has been
supplied as ordered. The installation, including the piping, wiring, housing and other
details shall be inspected to ensure that it confirms to the drawings, diagrams and other
information supplied.
Any defects that are attributable to the Contractor shall be rectified at the Contractors
expense.
All equipment shall be inspected to ensure that it is properly identified. The Contractor is
responsible for ensuring that the correct instrument is installed in its location.
All connecting lines to instruments and instrumentation equipment shall be checked for
cleanliness.
All instrument piping shall be checked for alignment to ensure that no stresses are put
on the instruments.

8.5

Plant Flushing and Cleaning.

If already installed the following equipment shall be removed during the flushing
operations: venturi flow elements, averaging pitot tubes, rotameters, orifice plates, inline flow meters, in-line flow switches and control valves.

8.6

Cleaning and Testing of Pneumatic Piping.

All instrument piping shall be blown down by removing the air supply for a period not
shorter than 2 minutes. The air supply to any filter/regulator shall first be blown down

before the line between filter/regulator and instrument is blown down.

Clean, dry, oil free compressed air shall be used for cleaning connecting lines as well as
all pneumatic tubing.
Filters shall be inspected for cleanliness before they are reconnected.
After all tests have been completed, air pressure regulators shall be set at the pressure
specified on the installation drawing or the pressure specified by the instrument
manufacturer.

**************

5.0

5.1

WORK EXCLUDED

The supply of free issue items identified in the Description of Work, Section 6.

5.2
The plant electrical installations, i.e. lighting and small power (not field instrument
power) plus motor power and control cable and racking except as specifically stated herein.
5.3

Civil and building work.

5.4
The supply and installation of above ground earthing and bonding, and the fixing
and terminating of tails from the in-ground earthing system to equipment and earth bars.
5.5
The supply and installation of the safety and high quality earthing conductors to
PLC/Interface panels and the control console, and safety earth connections to junction boxes
and instruments and the connection of the same to the main electrical earth system.

6.0

6.1

DESCRIPTION OF THE WORK

General

6.1.1
The supply and installation of cable racks and supports, and angle iron, flat bar or
conduit for upto 3 cables.
6.1.2
The supply and installation of all stands, brackets and mounting plates in accordance
with the specifications and drawings.
6.1.3
The supply, installation and termination of control cabling between the PLC interface
panel and the MCC marshalling cubicle.

6.2
6.2.1
panels.

Instrumentation
The receiving, offloading, handling and final installation of free issue PLC/interface

6.2.2
The receiving, offloading, handling and final installation of free issue control
Consoles, personnel computers, etc. located in the Central Control Room.
6.2.3
The supply and installation of approved local protection boxes at various locations in
the plant for each field instrument and control device.
6.2.4

The supply and installation of all necessary field junction boxes.

6.2.5

The supervision of installation by the piping/mechanical contractor of control valves,

and in-line instrumentation.

6.2.6
The installation of all field instruments and control devices, with the exclusion of
package equipment, including transmitters and switching devices inclusive of the supply and
installation of field equipment labels to the specifications.
6.2.7
The supply and installation of all necessary tubing, fittings, glands, terminal boxes
and materials for the field instruments and control valves as required by the relevant hookups.
6.2.8
The supply and installation of instrument air manifolds, and the connection of an
instrument air header installed by others.
6.2.9
Installation of free issue 2 KVA UPS; on inside the Plant MCC/Equipment room and
one inside the control room.
6.2.10 The supply and installation of instrument cabling, racking and glanding between
PLC/Interface Panels and field junction boxes, and between the latter and field instruments;
also between MCC starters and PLC/Interface Panels.
6.2.11 The supply and installation of the instrument power cable from the main instrument
DB to control consoles and PLC/interface panels, plus field instruments and Local Control
Panels via field instrument DBs, including the supply and installation of a double channel
power skirt complete with and wiring and sockets in the control room for the printers.
6.2.12 Instrument calibration, inspection and testing of all equipment, cables and pneumatic
systems, the recording thereof on loop calibration forms and inspections and test certificates to
the Engineers satisfaction and approval for cold commissioning.
6.2.13 The provision of artisans and/or technicians for assistance during hot commissioning
and initial production.
6.2.14 The instrument and battery limits are the power connection for the UPS in the
substations to the final control element or measuring device at the first isolation valve in the
field.

7.0

INSTALLATION CONSTRUCTION PROGRAMME

7.1

Order of execution of the Contract Works.

The overall proposed construction programme will be given to the Contractor. The Contractor
should provide a detailed programme indicating how the activities and duties are to be
executed in terms of the Contract, at the time of the tender.

The contractor is expected to execute his duties in accordance with the timing of the overall
projected programme, and to regulate his resources accordingly.

i)
A programme in bar chart format, indicating all expected interface dates with
the Contractors.
ii)
The Tenderer shall consider his resources available and schedule his activities
within the constraints thereby imposed.
iii)
Where applicable, the programme shall show dates where by the Tenderer shall
supply information to the Engineer.
iv)

The programme information shall be presented as follows: -

a)

The programme shall be drawn on standard metric drawing sheets;

b)

All major assumptions, such as time units used, etc, shall be indicated;

c)

Imposed dates and contractual dates shall be shown as calender dates;

7.2
The Tenderer shall include a brief schedule showing the proposed period in weeks
required by the Tenderer for each of the following steps starting from notice of award: -

i)
Submission of drawings and data of approval. A maximum of two (2) weeks is
allowed.
ii)
Submission of certified reproducible drawings on the approved media after approval. A
maximum of two (2) weeks is allowed for the Engineer to approve, and a maximum of a
further two (2) weeks for the Tenderer to submit the reproducible.
iii)

Securing of raw materials.

iv)

Securing of items bought out or imported.

v)

Completion of manufacture or assembly.

vi)

In-shop testing (platform, staging and factory acceptance testing).

vii)

Packing and dispatching.

viii)
Total overall time from date of award to date of delivery at site or port, whichever is
applicable.

7.3
The Contractor shall submit the following programme information to the Engineer
within two (2) weeks of award of Contract, for approval: i)
The Contractor shall supply manhour curves, (S-curves), selected by work type,
indicating manhour required per week for onsite installation and/or erection.
ii)
A programme in bar chart format broken down by activity showing the
estimated manhours on each activity, that corresponds to those shown in the price Schedule.
iii)
Each activity shall be broken down to show design, procurement of materials,
delivery, erection and construction.
iv)

The programme shall show all expected interface dates with other Contractors.

v)
The Contractor shall consider his resources available and schedule his activities
within the constraints thereby imposed.
vi)
Where applicable, the programme shall show dates where by the Contractor
requires information from the Engineer and/or when the Contractor shall supply information to
the Engineer.
vii)

The programme information shall be presented as follows: -

a)

The programme shall be drawn on standard metric drawing sheets;

b)

All major assumptions, such as time units used, etc, shall be indicated;

c)
The longest time unit to be used shall be the calender week, and certain
activities shall be require one-day units. The imposed dates and contractual dates shall be
shown as calender dates;
d)
The symbols and terminology used in the programme shall be explained in a
legend on each sheet.

The above conditions for Contractors are binding, and shall be adhered to. No progress
payment shall be paid to the Contractor until the above-mentioned information is supplied.

8.0

SITE FACILITIES

Site facilities shall be the responsibility of the Contractor.

9.0

9.1

ASPECTS REQUIRING SPECIAL ATTENTION

Existing Services

The Contractor shall take all necessary precautions to safeguard his site establishment and
installations from theft or damage. The Contractor shall avoid damage to, or interference with
existing plant equipment, buildings, fences, wells, roads, trees and all services, whether hidden
or exposed.

The cost of repair or replacement resulting from any such damage shall be at the Contractors
expense.

9.2

Design Criteria and Requirements for Temporary Works.

The Contractor is fully responsible for the design and construction of all temporary works under
the supervision of the Site Manager.

9.3

Free Issue Instrumentation Equipment.

Immediately on taking delivery the Contractor shall move the equipment to indoor storage
where it shall be suitably protected from damage, dust and damp. As soon as possible after
installation, the rooms where the Scada and the PLC interface panels are housed should have
their air conditioning unit operating.

9.4

Tests and Calibration Equipment.

All test and calibration equipment to be provided by the Contractor shall have a current (within
12 months) calibration certificate issued by a recognized body such as the SABS. Tenderer
shall provide a list of such equipment.

9.5

Cable Procurement.

Cables shall be purchased from the following manufacturers:

v

10.0

10.1

Instrumentation Aberdare, ATC or Lonspeare.

INSPECTION AND TESTING

Calibration

The calibration of field instruments is part of this scope of work. Specifications are included for
reference of the calibration activities will be carried out. Internal calibration of the PLC system
is not included in the scope of work and will be carried out by others simultaneously as
Contractor performs a field loop test.

10.2

Pre-installation Testing.

The Contractor shall be responsible for the integrity of his finished product and thus shall carry
out further testing as considered necessary to satisfy himself.

The object of pre-installation testing is to ensure that each instrument has been supplied in
accordance with its specifications, is functionally correct and is in working order.

The Contractor shall be responsible for pre-installation testing of the instruments in accordance
with the specification.

All shipping stops shall be removed from the instruments before starting the procedures listed
below.

The EPCM Instrument Engineer shall be informed immediately of any defects which cannot be
rectified or of any instrument which cannot be rectified or of any instrument which cannot be
calibrated within a reasonable period of time. This notification shall be confirmed in writing.

Where the pre-installation test is not specified, or where circumstances prohibit the carrying
out of the prescribed test, the Contractor shall agree, in writing to a test method with the
EPCM Instrument Engineer.

The approval of the EPCM Instrument Engineer shall be obtained in writing before any nonstandard modifications or adjustments are made.

In general all tests will simulate as closely as possible design process conditions, by the use of
Manometers, Potentiometers, Resistance Bridges, Dead Weight Testers, Test Pressure Gauges,
etc. utilizing hydraulic and pneumatic supplies and check that all instruments are in accordance
with the calibrated ranges as detailed in the data sheets.

All instruments, except as noted herein are to calibrated in the upscale and downscale
directions and if necessary adjusted until their accuracys conform to those limits stated by the
manufacturer. Upon completion, calibration forms signed by the Contractor shall be handed to
the EPCM Instrument Engineer.

All evidences and records of abortive tests shall be handed to the EPCM Instrument Engineer at
this time. Typical check calibration forms are attached.

The contractor shall be responsible for the protection and safe keeping of the instruments on
acceptance of delivery to site or acceptance of delivery from the EPDM Instrument Engineer.

The EPCM Instrument Engineers representative may inspect the site premises of the
Contractor without notice to satisfy himself that the facilities are suitable and in accordance
with requirements.

All tests and calibration equipment, including specialized tools or equipment shall be provided

by the contractor. A list of such shall be submitted with the offer.

10.3

Loop Testing.

The Contractor shall be responsible for complete loop testing of all works defined as part of the
scope of supply of this enquiry.

Loop test shall be in accordance with the Specification.

The procedure to be adopted in carrying out these tests is detailed in the above-mentioned
specification, but in general the complete instrument loop shall be tested as one system, and
where necessary, adjustments shall be made to calibrations. Associated alarms and trips shall
be checked during loop testing.

10.3.1

Preliminary Loop Test

The object of Loop Testing is to prove that the installed instrumentation functions correctly
and is in fit condition for hand over to commissioning stage.

Loop Testing is a two-man operation, one man in the field and one man in the control room.
The Contractor shall ensure these men are provided with adequate means of remote
communication, i.e. field telephones or radio contact, as approved by the Site Engineer.

During Loop Testing the Site Engineer shall be in attendance to check out his inter-related
sections of the work during trip and alarm checks. The Contractor shall request his attendance,
giving adequate notice.

Loop Testing shall never be carried out on electronic equipment that has not been allotted an
adequate warm-up period. Where possible the instrument shall be energized at least 24 hours
before testing or in accordance with the manufacturers specification.
In most instances the Site Engineer will witness the final loop test and countersign the test
certificates. The Contractor shall be responsible for informing the Site Engineer in advance, by
means of a programme or schedule, when final tests are being performed.

10.3.2 Final Loop Testing

Inspect the loop, setting air/electrical supplies where appropriate. Check in particular that the
air supply pressures for control valves are set in accordance with the specification.

For electronic loops check polarity, measure the loop impedance and make the necessary
compensating adjustments.

Further instrument zero settings are re-calibration adjustments shall be made as required.

Transfer all controllers to manual operation and by applying the appropriate signals ensure that
the control valve or valves stroke correctly. Valve positioned gauges shall also be checked

during this stage.

Check alarm and trip actions by varying the actuating signals and adjust as necessary.

Locally mounted controllers or transmitting only loops shall be tested in a similar manner to
that specified above omitting transfer and / or / auto / manual checks as necessary.

Special installation, where applicable, shall be checked according to manufacturers instructions

and/or by agreement with the Site Engineer.

Trips and alarms not previously covered in the preliminary loop tests shall be checked out in
conjunction with the Site Engineer.

All systems shall be checked for fail safe operation which will include the checking of burn
out features on thermocouple installations.

The Contractor shall, upon completion hand over a test certificate, which records all results, for
every installation to EPCM Instrument Engineer. Should any of the tests not be witnessed, and
hence not countersigned, the Contractor shall produce written confirmation from the Site
Engineer that this is acceptable. Failure to comply shall render the specific test invalid.

The Battery Limit for the Contractor of the loop checking will be the incoming field terminal of
the PLC termination panels within the marshalling cabinet.

10.4

Commissioning.

For the purpose of clarification of the scope of this enquiry we define the activities related to
commissioning as follows:

Cold commissioning without product.

Cold commissioning with product but non commercial service.

Optimization commercial service.

The scope of this enquiry shall be inclusive of cold commissioning but does not include for hot
commissioning and optimization. An additional daywork rates schedule must be submitted for
this work.

A detailed cold commissioning bar chart or programme shall be presented for the approval for
the Site Engineer. A further report shall be made out at the time the work is performed in
order to enable the progress of the commissioning work to be followed in detail.

These reports shall be kept fully up-to-date by the Contractor. As the commissioning of each
loop is completed a copy of the form is handed to the Site Engineer for his records. The site
Engineer will require unrestricted access to these forms at all stages of completion.

A final visual check of all parts of each loop or circuit shall be made after all other recalibration or commissioning work is finished before declaring loop or circuit ready for service.

11.0

SITE MANAGEMENT

11.1

Reporting.

Progress reporting on the delivery of material and construction activities shall be in accordance
with the requirements of the Site Manager.

11.2

Document control.

The Contractor shall be responsible for ensuring that the latest revisions of construction
documents are used, and that superseded documents are returned to the Site Manager.

12.0

12.1

CONTRACTOR DOCUMENTS

Vendor Document Requirement List

The VDRL lists of all the documents which must be provided by the Contractor at the times
indicated.

12.2
Tenders shall submit their Loop Checkout and cold commissioning procedures and
standard I & T Certificate and Loop Check sheet forms in their tenders to enable their
competence in this respect to be assessed.

12.3

As Built Drawings

Acceptance of the works depends on, inter alia, the completion and handling over to the LTAPG
Instrument Engineer for the Project Managers records, the following documents:

Inspection and Test Certificates.

Instrument calibration and Loop Check Sheets.

As-built drawings.

The cost of these shall be included in the installation rates of all equipment and materials.

12.3.1 As built drawings in the form of red line mark-ups shall be submitted to the EPCM
Instrument Engineer on completion of the installation. These drawings shall be stamped As
Built, with the Contractors company name, and signed and dated by the Contractors
authorized representative.

12.3.2 One set shall be transmitted to the EPCM Instrument Engineer, a copy or duplicate set
retained for the Contractor for at least 3 months after the submission date.

12.3.3

As built drawings shall include but not be limited to:

(a)

Cable routing.

(b)

Instrument location drawings.

(c)

Schematic and wiring diagrams.

(d)

Cable schedules.

(e)

Loop diagrams.

(f)

Instrument data sheets.

(g)

Termination diagrams or schedules.

(h)

Layouts and general arrangements.

13.0

QUALITY ASSURANCE

See the Special conditions of the Contract.