ENGINEER’S STAMP: CONTRACTOR’S STAMP:

00 Issued for Tender Documents December 2022

REV DESCRIPTION PREPARED CHECKED DATE

SALINE WATER CONVERSION CORPORATION

KINGDOM OF SAUDI ARABIA
Projects Engineering Department

SWCC WATER TRANSMISSION SYSTEMS

CONSTRUCTION WORKS

LOCATION: TITLE:

YANBU SPECIFICATION S03

INSTALLATION AND START-UP OF FIELD
INSTRUMENTATION
SCALE: DOCUMENT No.: REV:

Q C 1 0 - H - 1 2 3 00

SUBCONTRACTOR: Page 1 of 13
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Specification S03
Subject: Page 2 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

LIST OF CONTENTS
1 SCOPE................................................................................................................................ 4
2 CODES AND STANDARDS ................................................................................................ 4
3 OPERATION CONDITIONS ................................................................................................ 4
4 DESIGN REQUIREMENT.................................................................................................... 4
5 INSTALLATION ................................................................................................................... 5
5.1 General Requirements......................................................................................................... 5
5.2 Process Connections ........................................................................................................... 5
5.3 Local Instrument Boxes ....................................................................................................... 5
5.4 Instrument Location ............................................................................................................. 5
5.5 Specific Installation Requirements ....................................................................................... 6
5.5.1 Flow Measurement .............................................................................................................. 6
5.5.2 Pressure Measurement ....................................................................................................... 6
5.5.3 Level Measurement for Water Storage Tanks or Vessels .................................................... 7
5.5.4 Level Switches for Water Storage Tanks or Vessels ............................................................ 7
5.6 Installation of Instrument Cables .......................................................................................... 8
5.6.1 Material Inspection .............................................................................................................. 8
5.6.2 Pre-Installation Test ............................................................................................................. 8
5.6.3 Installation ........................................................................................................................... 8
5.6.4 Testing ................................................................................................................................ 9
6 START-UP OF INSTRUMENTATION .................................................................................. 9
6.1 General ............................................................................................................................... 9
6.2 Pre-Installation Testing ...................................................................................................... 10
6.3 Pre-Commissioning ........................................................................................................... 11
6.3.1 Testing of Instrument Cable ............................................................................................... 11
6.3.2 Mechanical Completion and Pressure Testing ................................................................... 11
6.3.3 Loop Testing...................................................................................................................... 11
7 DRAWINGS AND DOCUMENTS ....................................................................................... 12
7.1 Documents before Installation ........................................................................................... 12
7.2 Documents before Commissioning .................................................................................... 12
7.3 As-Built Documentation ..................................................................................................... 13
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Specification S03
Subject: Page 3 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

ABBREVIATIONS

PTFE Poly Tetra Fluor Ethylene

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Specification S03
Subject: Page 4 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

1 SCOPE

This specification covers the minimum requirements for materials and methods to install
instruments and associated equipment. The field instruments itself are not contained in
this specification.

2 CODES AND STANDARDS

The following standards, rules and regulations, all in the latest valid edition, must be
observed specifically:

- IEC 60529
- DIN EN 61518
Further standards, rules and regulations used by the instrument manufacturer for design,
manufacturing and testing may be allowed. However, all such other standards are
subject of approval and have to be furnished in English language or English translation.

3 OPERATION CONDITIONS

The used materials for all equipment, instrument connecting lines, fittings, valves,
mounting supports and instrument boxes shall be selected to withstand the product water
and the environmental conditions (see General Specification G02 “Description of Project
and Works”) for the life-time of the instruments without any negative effect.

The instrumentation assemblies shall be suitable for use in outdoor services and any
other particular ambient condition depending on location and type of instrument.

4 DESIGN REQUIREMENT

For the design, supply and installation of all instrumentation hook-up material, the
maximum possible uniformity and inter-changeability shall be considered throughout the
complete project in order to minimize different spare parts.
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Specification S03
Subject: Page 5 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

5 INSTALLATION

5.1 General Requirements

As far as possible and technical feasible the instrumentation assemblies shall be

provided as pre-fabricated, work-shop tested and calibrated package units. Additional
site calibration and testing works shall be performed prior to installation and connection
as far as necessary.

5.2 Process Connections

Process connections shall be performed in accordance with the project typical hook up
drawings. Process connections for pressure measurement shall be installed horizontally
to the main piping.

Process connections have to be installed in a way that the function of the

instrument/transmitter is not influenced and an undisturbed access to the instrument is
possible.

Entrance to the instrument protection box has to be fitted with screwed glands.

Each instrument shall have its own main process connection except the combination of
transmitters, switches and gauges. In addition every pressure instrument shall have its
own isolating manifold valve, including the appropriate test connections.

In case hook-up piping provides an unwanted connection between catholically protected

piping and ground potential, insulating joints has to be installed as close as possible to
the main piping. The insulating inner part of the insulated joint has to have a minimum
length of 30 mm.

Each instrument or the combination of pressure transmitter, switch and gauge shall have
separate valves for venting and flushing.

5.3 Local Instrument Boxes

In case instrument boxes are to be used, these shall be mounted directly on walls or on
separate free-standing and stable hot dip galvanized steel supports.

5.4 Instrument Location

Instruments shall be mounted in such a position as to guarantee the specified accuracy

of measurement, easy access for maintenance, good visibility of indicating devices and
standardization of installation.
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Specification S03
Subject: Page 6 of 13
Installation and Start-Up of Field Instrumentation
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All instruments and associated equipment shall be mounted at an elevation of maximum

1.5 m from the ground, floor level or operating platform that no scaffolding is necessary
for reading, routine inspection and maintenance.

5.5 Specific Installation Requirements

In addition to the requirements contained in the typical hook up drawings all

specifications, recommendations and mounting instructions of the instrument
manufacturer must be considered and also the requirements listed below.

5.5.1 Flow Measurement

Electromagnetic flow meters with flanged process connections shall be used in general.
The straight pipe length shall be at least 5 D at the inlet side and 2 D at the outlet side,
the flow meters shall be installed at low points to prevent from partial filling.

For auxiliary and utility systems other types of flow meters may be used, for specific
installation requirements reference is made to the manufacturer instructions, but at least
following:

a) The electrode axis shall be horizontal in order to prevent contamination of the

electrodes and to prevent contact loss due to gas bubbles around the electrodes.
b) Grounding of electromagnetic flow meters (including earthing rings) requires
special attention. The recommendations of the flow meter manufacturer shall be
followed.
c) Avoid installation of electromagnetic flow meters close to large conducting surfaces
such as metal supports. These large metal objects may interfere with the magnetic
field of the flow meter and hence influence its accuracy and behaviour.
d) For abrasive liquids, the inlet part of the liner is easily damaged. For protection of
the liner inlet, earthing rings with edge protection shall be considered.
e) In order not to damage the liner, spiral wound gaskets shall not be used for
magnetic flow meters. PTFE envelope packing shall be used for tightening the
process bolts; the torque specifications of the flow meter manufacturer shall be
followed.
f) Short spool pieces may be installed upstream and downstream of the meter to
protect the liner during removal from the pipe (the meter and the spool pieces can
then be removed together).
5.5.2 Pressure Measurement

Generally, process connections shall be 1 ½"-taps and include a block valve as part of
the piping erection. For utility systems 1” or ¾"-taps shall be used also with a block valve.
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Specification S03
Subject: Page 7 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

Each pressure measuring instrument as well as local indicators, pressure transmitters,

pressure switches or indicators with contacts shall have their own isolating valve (3-way-
manifold-valve) and shall be equipped with appropriate test connections for calibration.

For differential pressure instruments block valve combination or a 5-way-manifold block

shall be positioned directly at the pressure instrument connections. It shall also be
equipped with a test connection and it shall be possible to shut off the test connection
without isolating the service pressure for the instrument.

Each instrument or the combination of indicator and transmitter shall have a separate
vent/flushing valve.

The pressure gauges at the suction and discharge connections of the main pump units
shall be arranged on the access platform near to each pump and mounted on a separate
fixing support. In order to avoid vibrations of the instrument equipment, a special
compensation loop shall be provided in the process pipe before the instrument
connection.

The dimensions of the pressure piping shall be ½" or 12 mm. If pulsating pressure is to
be assumed, generally pulsating dampers shall be installed.

5.5.3 Level Measurement for Water Storage Tanks or Vessels

Level measurements in

- vertical surge vessels shall be carried out using the level transmitter based on the
differential pressure measuring principle. To allow the level calculation two nozzles
are required for the installation of the differential pressure transmitters. Special
care is required for consideration of temperature effects.

- horizontal surge vessels shall be carried out using level transmitters based on
guided radar or differential pressure measuring principle.
- water tanks shall be carried out using level transmitter based on radar or
differential pressure measuring principle.

The connection shall be either by DN 100/ 4" or DN 80/ 3"-flange equipped with a
suitable shut-off valve.

All transmitters and instruments at surge vessels and tanks shall be easy accessible for
calibration and testing from operating platforms.

5.5.4 Level Switches for Water Storage Tanks or Vessels

Fixed installed flange type level switches, operating on electronic principle, shall be
provided in the top and bottom part of the tanks, accessible from the maintenance
platform respectively stair/ladder.
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Specification S03
Subject: Page 8 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

For surge vessels, adjustable side cage level switches are to be provided for the low and
high level monitoring at locations accessible from maintenance platforms.

5.6 Installation of Instrument Cables

All cables shall be installed in one unbroken length between two termination points, cable
splicing joint are not acceptable.

Multi-pair cable runs between control or equipment room(s) and field junction boxes and
shall be routed underground and/or in pipe racks. Single pair cable to individual
instruments shall normally run above ground supported on galvanised ladder rack and/or
cable tray. Cable rack and tray shall be supported from permanent structures only.
Pipework, handrails, etc. shall not be used.

Cable runs shall be routed to avoid plant high fire risk areas, loading and lifting zones
and process hot spots.

5.6.1 Material Inspection

Prior to transport to work site, cable drums shall be inspected for mechanical damage.
Where damage to cable drum is observed, the cable drum shall be opened and cable
shall be inspected. If a cable is damaged, this shall be recorded on the cable report.

5.6.2 Pre-Installation Test

Cables shall be tested on the cable drums prior to transport to the work site.

Instrument cables shall be tested as follows:

a) The continuity of each core shall be checked.

b) The insulation resistance between cores and between individual cores and screen
or armouring, as applicable, shall be checked.
c) The results shall be recorded and shall be greater than 100 Meg. Ohm.
d) After completion of the tests, the ends of cable shall be sealed to prevent the
ingress of moisture.
5.6.3 Installation

1. Where cables drum schedules are available it it shall be ensured that the individual
cable lengths are taken from a designated drum.
2. Throughout the cable pulling process it shall be ensured that undue stress is not
applied to the cable. Where a cable winch is used, the manufacturer’s permissible
pulling tension values shall be adhered to.
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Specification S03
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Installation and Start-Up of Field Instrumentation
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3. Where instrument cables cross power carrying cables, they shall be arranged to do
so at right angles (90 deg.)
4. Cables shall be identified at either end and at 30 meters intervals throughout their
length.
5.6.4 Testing

1. On the completion laying cables, and where installed in trenches prior to backfilling,
individual cable lengths shall be tested and recorded.
2. After completion of joining, glanding, and end termination, the cables shall be re-
meggered and recorded.
3. All test certificates have to be signed and submitted to the Employer immediately
after completion of test works.
4. In case of unsuccessful test results Employer has to be informed immediately and
cable must be replaced.

6 START-UP OF INSTRUMENTATION

Additional to the general requirements mention in the specification S01 “Design and
Construction of I&C System” following aspects have to be taken into consideration.

6.1 General
A process for certification and documentation which provides an auditable trail for all
systems and equipment from purchase to hand-over shall be provided. It shall be
applicable to all instrumentation and to the work carried out on the construction site.

In general all tests shall simulate, as closely as possible, design process conditions, by
the use of manometers, potentiometers, resistance bridges, dead weight testers, test
pressure gauges, etc., utilising hydraulic, electric or pneumatic supplies.

No tests shall be carried out on electronic instruments until an adequate warm-up has
elapsed. Wherever possible the instruments shall be energised for at least 24 hours prior
to testing.

All test equipment used shall have as standard of accuracy one quality class more than
the manufacturer's stated accuracy of the instrumentation to be tested. The test
equipment shall have a valid calibration certificate.

All instrumentation has to be tested with respect to:

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Specification S03
Subject: Page 10 of 13
Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

- connections (to piping / vessel), mounting position, flow direction, removal of

transport fastening
- mounting position and mounting material
- power supply (electric power, air)
- grounding, screening
- accessibility, maintainability
- labelling
- measurement span scales
- environmental protection
- adjustment
Inline equipment which had to be removed from the piping for testing and calibration
purposes shall be tested again after been mounted.

The scope of the testing must at least be such that all possible faults are detected and an
operation according to the specification can be assured.

6.2 Pre-Installation Testing

Generally, all calibration and pre-settings shall be performed, as far as possible, either at
the manufacturer's workshop or laboratories, independently from the assembling
operations and shall be certified accordingly. Certificates have to accompany the
instrumentation.

All instrumentation shall be subjected to a pre-installation test and this test shall
commence as soon as practicable after delivery to site.

The tests shall be performed generally in the manner described herein with due attention
to the particular manufacturer's instructions.

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

All instruments, except as noted herein are to be calibrated in the upscale and
downscale directions and, if necessary, adjusted until their accuracy’s conform to those
limits stated by the manufacturer.

Upon completion of tests the instrument shall be drained, the components removed and
the shipping stops put in place.

Calibrated instruments are to be kept sealed after calibration.

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Specification S03
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6.3 Pre-Commissioning
6.3.1 Testing of Instrument Cable

Immediately after instrumentation cables are laid and before connection to the instrument
the wiring shall be checked for polarity, continuity and insulation resistance between
conductors and between conductors to earth. These tests must be carried out before
final loop tests.

Continuity and insulation resistance checks shall be carried out using the proper test
equipment to comply with the rules and regulations with which the installation has to
comply.

Underground cables shall be tested before backfilling is commenced.

6.3.2 Mechanical Completion and Pressure Testing

After installation on site the mechanical completion of the work shall be checked. This
includes also tests which ensure that the installations incl. impulse piping is tight to 1
times the maximum working pressure (maximum working pressure corrected by
temperature or test pressure of the associated process line or vessel, whichever is
higher). The pressure testing of process impulse pipe work on a given loop shall be
completed before final loop testing.

6.3.3 Loop Testing

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
commissioning.

In general the completed instrument loop shall be tested as one system, and where
necessary, adjustments shall be made to ensure that the loop is fully operational as a
system and is correctly calibrated. Associated alarms and trips shall be checked during
loop testing.

During loop testing also the inter-related electrical equipment shall be checked with
respect to controls, trips and alarms.

Loop testing shall not be carried out on electronic equipment until an adequate warm-up
period has been elapsed. Where possible, instruments shall be energised at least 24
hours prior to testing.

For electronic loops the polarities shall be checked, the loop impedance shall be
measured and the necessary compensating adjustments shall be performed.

Instrument zero settings and calibration adjustments shall be made as necessary.

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Specification S03
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Any controllers shall be set to manual operation and by applying the appropriate signals
it shall be ensured that the control valve or valves stroke work correctly. Valve positioner
gauges shall also be checked during this stage.

Actuating signal shall be applied to the controller equivalent to 25, 50, 75 and 100% of
the instrument range and the manual regulator output adjusted to 25, 50, 75 and 100%.
The controller set-point shall be adjusted to 25, 50, 75 and 100% and by switching the
auto/manual transfer switch, checked for "bumpless" transfer.

The alarm and trip actions shall be checked by varying the actuating signals and
adjusted as necessary.

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

After each loop is satisfactorily tested the controller shall be switched to manual.

Prior final loop tests are processed an adequate notice shall be given so that the
necessary witnesses may be made available and countersign related test certificates.

Upon completion, a test certificate for every installation, recording all results, shall be
handed over. Certificates for any test not witnessed shall be provided with a written
confirmation that witnessing has been waived.

Before commissioning all loop tests have to be finished.

7 DRAWINGS AND DOCUMENTS

7.1 Documents before Installation

A full detailed list of all special tool and accessories required for installation and start-up
of each type of field instrument shall be provided.

7.2 Documents before Commissioning

Following documents and drawings shall also be provided:

- detailed hook‐up drawings

- guide drawings of equipment assembly in field (pump house / shafts), incorporating
the instruments installation as per hook‐up
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Specification S03
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Installation and Start-Up of Field Instrumentation
Doc. - No.: Q C 1 0 - H - 1 2 3 Rev. 00

- Instrumentation List (chart) containing data of manufacturer, installation and

process, for each instrument (i.e. inst. tag, location, service, manufacturer, model
no., operating range, process range1, hook‐up drawing no., etc.)
The commissioning test reports shall contain at least following:

- instrument TAG number

- test value (pressure, temperature, resistance, flow, etc. within the measure range)
- output value within the control system (at least at 4 points within the span)
- date of test
- signature of the responsible test engineer.

7.3 As-Built Documentation

The as-built documentation shall include all above mention reports and documents in the
last revision.


1
Process range reflects measurement span for instrument calibration, and shall be recommended by hydraulic designer of