10080-1-SS-CI-016r0v1 - 0 - STD Spec For Instrumentaiton Installation

J3 Program 10080-1-SS-CI-016
Standard Specifications for Instrumentation Installation Date: 18/07/2012, Rev. 0
RECORD OF REVISIONS
Date Revision Details Revision Number
18/07/2012 Issued for Implementation 0

Contents
1. Purpose........................................................................................................................... 1
2. Scope .............................................................................................................................. 1
3. Cost competitive engineering and design ........................................................................ 1
4. Conflicts and Deviations .................................................................................................. 1
5. Definitions ...................................................................................................................... 1
6. References ...................................................................................................................... 2
7. General Requirements ................................................................................................... 2
8. Field Instrument Installation ........................................................................................... 5
9. Instrument Piping and Tubing Arrangements .................................................................. 5
10. Installation of Instrumentation Cables .......................................................................... 12
Appendix 1: Project Related Specification & Standard Drawings ............................................ 17
Appendix 2: Typical Arrangements for Instrument Mounting ................................................. 18
Appendix 3: Typical Electrical Heat Tracing Arrangement ....................................................... 19
Appendix 4: X-mas Tree Type Instrument Air Manifold Details ............................................... 20
Appendix 5: Junction Box Installation Details ......................................................................... 21
1. Purpose
The purpose of this document is to specify requirement for proper, smooth and
reliable installation of instruments and instrumentation requirements.
2. Scope
This specification covers the location of instruments, their position with respect to
process equipment or piping and standard connection methods to the process.
This also covers general guidelines for routing and installation of pipes, impulse
tubes, cables, trays and trenches.
These procedures shall be adhered to the construction site conditions in addition
to the requirements prescribed in the documents, drawings and specifications
prepared during the office engineering stage of the project. Also Manufacturer’s
drawings and installation instructions are required to be adhered in addition to
this.
The regulation for safety of personal and equipment as stipulated by Owner and
local authorities shall be strictly followed.
3. Cost competitive engineering and design
The engineering team shall maintain the cost focus throughout all phases of the
project. This should be done without compromising any specification and design
requirements.
4. Conflicts and Deviations
4.1. Supplier shall be responsible to inform any conflicts between this specification
and other applicable Company specifications, industry standards and codes to
Company representative or Buyer. The supplier shall proceed further in the
concerned matter only after the conflicts are resolved in writing by the Company
representative or Buyer.
4.2. In general, order of priority of the documents shall be as follows,
• Local regulatory and statutory requirement
• Project specification
• This specification and relevant equipment/system specification
• Codes and Standards
4.3. Supplier shall be required to obtain prior approval from Owner representative or
Buyer for any deviation from this specification.
5. Definitions
OWNER Company which initiates the project.
10080-1-SS-CI-016 Page 1 of 23
MANAGING CONTRACTOR Company which supports/carries out all or part

of the design, engineering, procurement,
construction and commissioning for the project.
DEC Company which carries out all or part of the
design, engineering & support for procurement.
Manufacturer/Supplier Company which manufactures or supplies
equipment and services to perform the function
as specified by DEC/ managing contractor /
Owner.
6. References
This Specification requires compliance with all applicable national laws, local laws,
regulations and standards relevant to the specific project.
Related project specifications and Standard Drawings are listed in Appendix-1 of
this document. This specification shall be read in conjunction with the documents
listed in Appendix-1.
Generally instruments shall be installed in accordance with API-RP-550 – Manual
on Installation of Refinery Instruments & Control System.
7. General Requirements
7.1. Location
Apart from the requirements for specific types of instruments as given in the
relevant sections, all plant instruments shall be so installed that they:
a) Shall be located in accordance with approved layout & hook-up drawings and
shall not obstruct walkways / access.
b) Are positioned at a maximum distance of 1 m or as close as possible, or are
mounted directly on the instrument process connection(s).
c) Provide a good representative measurement of the process condition under
surveillance.
d) Can easily be read. Indicating instruments shall be installed and oriented in
such a way that the centre of the indicator is approximately 1.3 m above
grade, platform or walkway level.
e) Are not subjected to vibration (e.g. on suction or discharge lines of pumps or
compressors, etc.) or to mechanical stresses, and are not exposed to
temperatures which will influence the measurement. Press gauge/switch
shall be mounted remotely on channel/ stanchion to avoid machine vibration.
f) Provide proper support and protection against mechanical damages to all
capillary type instruments.
10080-1-SS-CI-016 Page 2 of 23
g) Shall not affect instrument installation from forces developed by expansion of

pipes.
h) Can be easily mounted and removed. Heavy equipment such as control valves
of 4” and larger, positive displacement meters and turbine meters should be
installed at grade level and shall be accessible by movable hoisting
equipment. Where this is not possible, permanent hoisting facilities shall be
provided.
i) Are surrounded by sufficient free space to allow rodding-out of process
connections and the removal of:
- Bolts, nuts and gaskets for control valves, positive displacement meters,
turbine meters, orifice flanges, etc.
- Orifice plates from the orifice flanges and Jack bolts
- Internals from the control valve
- Displacers from the displacer chambers
- Temperature elements from the thermowells
- Covers and enclosures from the instruments.
j) Are safely accessible, see (5.2).
7.2. Accessibility of instruments
After the plant construction has been completed and temporary scaffolding has
been removed, all instruments shall be safely and permanently accessible. This
means that, wherever possible, all plant instruments, their measuring elements
(such as orifice plates and thermocouples) and their process connections as well
as sample take-off points for on-line analyzers and for taking laboratory samples,
shall be located not more than 0.5 m horizontally away from, and not more than
1.7 m vertically above grade, platform or walkway.
When permanent accessibility as defined above is not practicable, the process
connections for pressure instruments and differential-pressure flow or level
instruments may be located not more than 4 m vertically above grade or 2 m
vertically above walkways or platforms, provided that such locations are
accessible by means of a mobile platform.
NOTE: In such cases the instruments shall be installed in a permanently
accessible location by extending the instrument impulse line(s).
In narrow platform/walkway instrument shall be mounted outside the platform
by providing 4”/6” channel extension and also can be easily accessed from the
platform/walkway.
10080-1-SS-CI-016 Page 3 of 23
The limited accessibility defined above is also acceptable for those analyzer
sample take-off and return points having a valve only, but retractable probes or
flue gas probes shall be permanently accessible.
For dial thermometers the limited accessibility is acceptable only when the
instrument (mounted directly on the process connection) can be read from an
accessible location Such as grade or platform at a maximum distance of 0.5 m
horizontally and/or 2 m vertically.
All other cases where limited accessibility is considered, such as for
thermocouples and resistance thermometers or displacer level instruments,
requires written agreement with the Owner.
Notes : (1) Cases of limited accessibility agreed upon in the design engineering
stage shall be listed in the relevant document.
(2) Special attention should be given to the accessibility of skin
thermocouples in large furnaces and stacks.
Where limited accessibility cannot be accepted, platforms shall be extended or
additional platforms shall be provided to attain the permanent accessibility as
defined above.
The Managing contractor shall, as far as is practicable, ensure that the
accessibility of instruments will not be affected by the later addition of the
equipment of other disciplines, e.g. steam-trap arrangements, electrical junction
boxes, etc.
7.3. Painting
All brackets and supports shall be protected against corrosion by adequate
priming and/or painting. Where dissimilar material are connected (e.g. stainless
steel and galvanized cable support), insulation shall be provided to prevent
galvanic corrosion.
Earthing continuity shall be maintained. Surfaces which will be inaccessible
afterwards shall be painted before installation with at least two coats of primer.
Plant-mounted instruments and stainless steel impulse lines shall not be painted.
Painting shall not jeopardize the proper operation of moving parts such as
linkages on control valve positioners etc., or foul threaded connections.
For painting specification and color code standards, project specification shall be
referred.
7.4. Nameplates
A permanent label engraved with the instrument details shall be fixed at the
location of each instrument. This label shall not be fixed to the instrument and
can be either stainless steel or Traffolyte.
10080-1-SS-CI-016 Page 4 of 23
Where necessary, the fixing facilities shall be made locally. Tapping points for
analyzer on/off valves, sequential control valves, ROV's, MOV's shall also be fitted
with instrument name plates.
The Contractor shall ensure that the nameplates or metal tags installed on all
instruments by the Suppliers are intact at the completion of the installation work,
and are in accordance with instrument data sheets. Where an instrument or
control valve is lagged, nameplates shall be attached by use of U bolts and
brackets, and not fitted to the lagging.
If not otherwise specified, the contractor shall make proposals, for approval by
the owner at an early stage in the project, on how to fix the instrument name
plates.
When impulse lines are very long and the tapping points are not visible from the
instrument location, a nameplate shall be fitted at these 'tapping points' with the
same tag number as the corresponding instrument, to facilitate identification
during installation, operation and maintenance and to avoid mistakes. Examples
of such tapping points are:, for draught gauges on large furnaces, analyser
impulse lines and differential pressure across columns, etc.
7.5. Explosion precautions
All electric/electronic instruments which may operate in hazardous atmospheres
shall be installed in accordance with specified requirements for preventing
ignition of flammable vapours.
7.6. Weatherproofing
All field-mounted instruments (except local gauges) installed in open areas shall
be provided with protective shades. Local panels having electronic mounted on
same shall have vortex coolers and FRP shade.
8. Field Instrument Installation
For various instrument installations refer Specification 10080-1-SS-CI-001
(Instruments for Measurement & Control).
9. Instrument Piping and Tubing Arrangements
9.1. General
Instrument piping and tubing to be installed can be classified in the following
categories:
• Instrument Air Supply Headers (see section 7.2)
• Transmission and Signal Tubing (see section 7.3)
• Instrument Impulse Lines (see section 7.4)
10080-1-SS-CI-016 Page 5 of 23
Instrument piping and tubing shall follow routes that;

(a) Are kept as short as possible consistent with good practice and accessibility.
(b) Do not obstruct traffic through the plant.
(c) Do not interfere with the accessibility or removal of equipment.
(d) Are clear of hot environments and potential fire-risk areas.
(e) Will not be subject to mechanical damage.
(f) Avoid areas where spillage may occur.
(g) Are clear of drainage points of condensate, water and process fluids from
adjacent plant equipment.
(h) Avoid areas where escaping vapours or corrosive gases could present a
hazard.
(i) Avoid process piping and are provided with sufficient clearance from piping
which may require lagging.
Piping or tubing, particularly containing flammable, toxic or corrosive materials,
shall be located where (in the event of fire) the risk of molten zinc falling on to
stainless steel from associated galvanised structures (or zinc chromate paint, etc.)
is eliminated. Such an event may cause zinc embrittlement of stainless steel. If
such locations are unavoidable, a cover shall be fitted to the top of the support
tray for protection.
Piping or tubing installed, but not connected, shall have the ends closed in an
approved fashion to prevent the entry of foreign material. For a period of up to
one week adhesive tape may be used, for longer period caps or plugs shall be
provided.
All tube bending, cutting, coupling and end terminations shall be carried out in
accordance with the recommendations of the manufacturer and according to
good installation practice.
Joints on instrument impulse pipes / tubes, laid parallel to each other should be
systematically staggered and neatly offset. There shall be at least two pipes /
tubes diameter distance between adjacent joints.
Where tubing is installed in a horizontal run, Contractor shall ensure that the fall
of tubing is in the correct direction and at the recommended degree of incline.
Tubing installed on galvanized tray shall be supported along its whole length with
proprietary moulded P.C.P. or similar material blocks of the correct size and fixed
to the tray with compatible nuts, bolts and washers. Spacing between blocks shall
be 1 metre maximum.
10080-1-SS-CI-016 Page 6 of 23
Threads for screwed fittings shall be as specified in the Project Specification. The
Contractor shall ensure that the correct mating thread and approved thread
lubricants and sealants are used in place of Teflon tape, these can be from any of
the following supplier or equivalent,
1. "GOOP", a Swagelok Co. USA,
2. "NEVER-SEEZ", Bostik Chemical Group, USA,
3. "C5-A ANTI-SEIZE", Fel-pro Inc, USA,
4. "LIQUID-O-RING" (Lubon) 404, Oil Research Center, USA.
Any discrepancies between the materials or fittings specified and those provided
shall be brought to the notice of the Owner without delay.
The number of joints in piping shall be kept to a minimum consistent with good
practice. Coiled continuous tubing is preferred for lengths greater than 6 m for
this purpose.
Where modifications are made to existing piping or tubing systems involving
threaded joints, it is essential that traces of previously applied sealant are
removed from threads before the connections are re-made.
9.2. Instrument Air Supply
9.2.1. Instrument Header
Instrument Air supply headers shall be galvanized as specified in the Piping
Materials Specification.
Sub-headers to users (including secondary and tertiary loops) branching off the
main header shall be connected to the top side of the pipe. Each take-off shall be
provided with a root valve. Each spare take-off valve shall have the free end
plugged by means of a nipple and screwed cap.
Sub-headers shall be installed so that they are self draining with adequate
disposal facilities. On small headers this will normally be achieved via instrument
air filter/regulators but on larger headers blow-down valves are to be provided at
low points.
Where the size of the instrument air supply piping is not specified its diameter
should be chosen from the table below.
1
Up to 5 Users /2” NB Pipe
3
Up to 12 Users /4” NB Pipe
Up to 25 Users 1” NB Pipe
10080-1-SS-CI-016 Page 7 of 23
9.2.2. X-mas Tree air distribution manifold

The use of ‘X-mas tree’ type air distribution manifolds shall be maximized.
Standard types to be used are 6/12/18 way, details of the installation shall be as
per Instrument Installation drawings and in accordance with the requirements
outlined in the General Instrument Specification.
At individual instrument take offs isolation valves shall be provided. Each valve
shall be identified by the instrument tag number. One more isolation valve shall
be installed near valve.
Each header or sub header shall have 10% spare capped valve take-offs, with a
minimum of two.
Instrument tubing between the valve take-off and final user shall generally be
3/8” OD PVC coated copper tube unless either the project drawings or final user
connection size dictate otherwise.
No hose connection shall be made on the instrument air supply header or sub-
headers, nor shall any header or sub-header be connected to the production
process or other system.
All instrument air supplies shall be filtered and regulated. Where the
filter/regulators are not part of the Supplier supplied instrument or equipment,
they shall be supplied and fitted by the Contractor, in accordance with project
standards.
Air sets shall be mounted in such a way as to be readily accessible for inspection
and cleaning. Typical mounting details are shown in Appendix-4.
9.3. Transmission and Signal Tubing
Tubing fittings shall be compatible with or of the same material as the tubing to
which they are connected. Only the correct fittings selected for the project
installation shall be used. Contractor shall ensure that technicians installing tubing
fittings are trained in the correct procedure.
Where required, an approved brand of sealing compound shall be used and shall
be applied sparingly so that there is no intrusion of the sealant into the air lines.
All pneumatic signal tubing shall be cleaned by blowing through with filtered air
before connection to instruments.
Air tubing installation shall avoid strain on the instrument connections and
facilitate dismantling. Control valves and direct vessel or machinery mounted
transmitters shall have an extra loop in their air tubing for maximum flexibility.
The loop shall be in the vertical plane and above the horizontal line of the tube to
ensure condensate will not build up in the tubing.
10080-1-SS-CI-016 Page 8 of 23
9.4. Instrument Impulse Lines

All impulse piping shall be self draining and run with an incline to ensure adequate
fall back to the process connection. The slope of the impulse piping shall be down
from the tapping point for liquid, steam and condensing fluids, and up from the
tapping point for gas service unless special provisions are made for venting and
draining.
Impulse lines shall be kept as short as possible, consistent with good practice and
accessibility. Vents and drain lines shall be connected according to the piping
installation design. Vent/drain piping shall be routed away from operator access
and shall not terminate on a walkway or close to potentially hot surfaces.
Instrument impulse tubing material shall comply with the requirements of the
Project Materials Specification but shall be 316 SS as a minimum.
The exact material will be as specified on the project drawings. If no material is
specified the Owner shall be consulted for a ruling.
The preferred size for SS impulse tubing shall be 1/2”OD x 0.049” wall thickness.
Tube fittings used shall be 316 SS as a minimum and of the double ferrule type.
Where there is a danger of mechanical damage to pipes (abrasion caused by sharp
edges and rough surfaces) protective measures shall be taken, e.g. utilizing
corrosion resistant protective bushings. Penetrations shall be made watertight by
means of a sealing compound, or by the use of bush couplings.
Where welding on instrument process lines is required or specified, it shall be
performed only by welders qualified to ASME 1X and inspected by an approved
NDE specialist to the same standard as the associated process piping including X-
Ray requirements.
9.5. Piping and Tubing Support
Instrument piping or tubing supports shall be isolated from vibrating structures or
equipment.
Process piping or handrails must not be used to support instrument lines unless
the drawings indicate that this is the preferred method or where prior approval is
obtained from the Owner.
Piping and tubing runs shall be adequately supported and fixed at distances not
exceeding those in the following table.
10080-1-SS-CI-016 Page 9 of 23
SIZE MAXIMUM DISTANCE BETWEEN SUPPORTS

3
TUBING /8” and less 0.9m (Continuous support - see below)
1
/2” 1.0m (Between supports)
3
/4” 1.5m (When clipped to continuous support)
3
PIPING /8” - 1/2” 1.5m
1” 2.0m
11/2” - 2” 3.0m
Pipe / Tube Clamps shall be used for supports. Depending on the line
temperature, below recommended clamps can be used. For further details J10-
045 shall be refered.
Temperature Range Recommended MOC
-30 to 90DegC Polypropylene (PP)
-55 to 260DegC Aluminium (Al)
Cable tray shall be used for continuously supporting four or more copper tubing
runs, each shall be secured to the tray at 0.9 metre intervals.
Three or fewer copper tubes may be secured by mounting blocks or clips at 0.5
metre intervals to mild steel strip (not less than 16 SWG/1.6mm), or laid in small
section angle bar. Such routes shall be approved by the Owner.
Capillaries of filled systems shall be run independently of all other lines and shall
be continuously supported using mild steel angle with clips at 0.5 metre intervals.
Where pipes are led through apertures made in the body of tray, the edges of
these apertures shall be lined with lead or plastic.
Where steel support is considered sufficient, the parts shall be properly primed
and painted in accordance with the project Painting Specification.
The run of the pipe and tube supports shall be determined with proper reference
to the general layout of the installation served.
Where piping or tubing runs penetrate walls or floors separating different area
classifications, the penetrations shall be made using proprietary transit frames
and blocks, to ensure and maintain the security of the different areas.
10080-1-SS-CI-016 Page 10 of 23
In accordance with the specifications and good engineering practice, no

unnecessary junctions shall be made in tubing,.
All supports shall have 25% spare space.
All cable trays shall have 25% spare space.
9.6. Heat Tracing
The requirement for heat tracing will be specified on the P&ID’s and should be
installed in accordance with the following:
• In-line instruments that require tracing shall be traced using an extension of
the line tracing.
• For remote mounted instruments where operating temperature preludes the
use of seal type instruments, impulse lines shall be used with tracing.
• The tube shall be seamless copper tube, solid drawn soft annealed to BS 68 or
75 or equal. 3/8” OD x 0.035” wall thickness. For temperature below 200°C,
compression type single ferrule brass fittings shall be used. For temperature
above 200°C, stainless steel fittings shall be used.
• Steam Traced impulse lines shall be properly insulated using approved
insulating tape / rope.
Steam heat tracing branch shall have isolation valve near each heat traced tag.
A typical electrical heat tracing arrangement is shown in Appendix 3.
9.7. Instrument Mounting Support
Subject to environmental conditions, instruments may require protective shades.
The shade shall be fixed in a way allowing quick installation and removal.
In the remote mounting concept, instruments are installed on dedicated
mounting supports.
The use of instrument mounting supports mounted on the process line requires
the approval of the Owner. They shall not be applied on:
• process line sizes smaller than 4".
• insulated process piping.
• vibrating service.
If instrument mounting supports are clamped around process piping of a different
material, insulating barriers (e.g. tape or gasket material) shall be applied to
prevent galvanic corrosion.
Instrument mounting supports shall not be fixed to grating, as this does not
provide sufficient stiffness and does not allow the grating to be removed for
10080-1-SS-CI-016 Page 11 of 23
painting. If instrument mounting supports have to be fixed to fireproofed plant

structures, these supports should be welded to the steel structure before the
fireproofing is applied.
A typical 2" pipe stand shall be used for instrument mounting, as per Appendix 2.
10. Installation of Instrumentation Cables
10.1. Junctions and Terminations
All cables shall be terminated and connected according to the Project connection
diagrams for instruments, junction boxes (Refer Appendix 5), termination cabinets
and skid mounted junction boxes. No intermediate terminations shall be made in
any cable.
Cable manufacturer installation requirements shall be followed especially where
cables are being pulled along trays, through ducts and around bends. The
minimum bending radius shall be observed at all times to ensure cables are not
damaged.
Earthing of cable armouring shall be continuous throughout the installation, but
isolation between different earthing systems shall be maintained.
IS and non-IS cables shall be segregated throughout the installation. If IS and non-
IS cables have to share the same cable tray/rack then an earthed metal partition
should be provided between the IS and non-IS cables.
Sufficient slack cable shall be left neatly looped at terminals to permit re-making
of terminations, additions and testing. All spare cores shall be provided with
individual terminal blocks, jumpered together and connected to Reference or IS
earth, as applicable.
Where termination is made to a measuring element which has to be withdrawn
(e.g. thermocouple), sufficient length of flexible cable shall be allowed for the
element to be withdrawn without requiring electrical disconnection.
Co-axial and other special cables shall be terminated in accordance with
manufacturer instructions.
Unistrut Cable clamp system shall be used to anchor multicores to termination
cabinets located in Control buildings. Refer J10-074 for details.
Cable cores and terminations shall be ferruled and identified in accordance with
the project drawings. Heat Shrink Ferrules shall be used for ferruling cables.
For Foundation Fieldbus cables, shield should be covered by heat shrink sleeve to
avoid any possibility of inadvertent grounding.
Following points shall be checked for FF cable terminations:
• Cables are installed with proper bend radius (>110 deg.)
10080-1-SS-CI-016 Page 12 of 23
• All cables are short & direct connection to the terminations (No Loops around
JB)
• Single pair cables have minimum exposure of signal lines and the jacket and
shield are properly covered with heat shrink.
• Multi-pair (5) FF cable individual pair shield foil should be intact up to the
termination point and properly supported with Heat Shrink at the end so it will
not unwrap.
• On Multi-pair cable outer shield and drain wire should be properly cut back &
isolated at the outer Jacket cut off point and covered by the Heat Shrink.
• If a two pair cable is being used for a MUX application, terminate the Overall
Shield Drain wire to the Green/Yellow terminal on the spur output terminals.
• Multi-pair (2) FF cable individual pair shield foil should be intact up to the
termination point and properly supported with Heat Shrink at the end so it will
not unwrap.
• Ground the isolated ground bus to the Junction Box ground point. All the
ground connections should be properly lugged and tighten.
• Motherboard Shield ground should be connected to instrument earth bar in
panel.
• Connect all Thermocouple and RTD input shields to the isolated ground bus.
• Shield should be properly cut back & isolated by the Heat Shrink.
• Proper cable dressing with nylon cable ties.
• Check for the individual segment connection polarity while terminating
10.2. Cable Installation
Instrument cables shall be run in separate trenches or tray/rack and not along
with electrical power cables. Separation of instrument and power cable shall be
as follows:
Power Cables Minimum Spacing
33 kV and 6.6 kV 1000mm

415V 600mm
240V and 110V 300mm
10080-1-SS-CI-016 Page 13 of 23
The above figures apply to parallel runs of cable. For crossover a minimum of
500mm separation distance shall be provided. The crossover shall be made at
right angle.
Instrument cable will be routed overhead on ladder-type tray for main cable
routes from the control rooms to junction boxes.
This tray shall be in accordance with the following specifications:
The cable trays/cable racks and their accessories shall be fabricated from 10 SWG
(3.12 mm thick) mild steel hot rolled sheets conforming to IS-1079, in 2.0m
lengths. Site fabricated bends, junctions etc are not acceptable for cable ladder
racks.
The accessories and cable racks/trays shall be supplied with necessary coupler
plates and fasteners. The fasteners shall be electroplated. Each coupler plate
shall be provided with 8 sets of fasteners.
The accessories for cable racks/trays shall be hot dip galvanized as per IS-2639 or
IS-2629 with minimum of 80 microns thickness of zinc coating.
The width of cable rack and trays shall be as follows:
Ladder Rack Perforated Tray
300 mm 50 mm
600 mm 100 mm
900 mm 150 mm
300 mm
Perforated galvanized steel trays shall be specified from junction boxes to
individual instruments in accordance with the following specifications:
• Field cabling shall enter the control room via multi cable transit frames. The
cables shall be routed inside the control room beneath the false floor and will
be installed on racks maintaining segregation between signal types, entering
the respective control panels or racks from below.
• Trays and ladder racks shall be positively bonded to plant earth. All trays and
ladders shall be sized in accordance with project drawings. Should no size be
indicated the Contractor shall install tray/ladder large enough to take the
known cables plus a 25% spare space allowance.
• All trays and ladders shall be adequately supported when fully loaded with
cables, with 25% spare space allowance for additional cables.
10080-1-SS-CI-016 Page 14 of 23
10.3. Cables Inside The Auxiliary Room

The cable entry shall be through proper sleeves so that the entry is fire resistant
and waterproof. Such installation should be tested with fire water jets.
MCT (Multi-cable transit) should be applied for control room entry cables. The
same MCT shall also be used for cable passages through inner walls and through
floors and ceilings.
A dedicated cable channel should be provided for intrinsically safe and
telecommunications cables.
10.4. Cable Trenches
Cable trenches in concrete floors of pump rooms and other plant structures are
normally made by civil engineering in accordance with detailed drawings. Other
cable trenches, such as those between plant structures or in road sides to tank
farms, shall be excavated as indicated in general lay-out drawings, etc.
Unless otherwise specified for particular applications, the following details shall
be adhered to:
• The trenches shall have such a depth that the signal cables are not damaged
by traffic passing over them. Where possible, the bottom of the trench shall
be kept above ground water level to avoid water seepage and deterioration of
the cables.
• Where large quantities of signal lines cross or branch off, the depth of the
trenches shall be increased locally.
• Trench bottoms shall have a maximum slope of 10 degrees: the transition to
horizontal surfaces shall have a smooth curvature.
• The curvature of corners in trenches shall be compatible with the bending
radius of (armoured) cables.
• Trenches shall be kept away from buried pipes containing hot fluids and from
pipes liable to temperature rise caused for example by steaming-out.
• Where trenches for signal cables cross with those for electric power cables,
the separation between the highest cable in the lowest trench and the lowest
cable in the highest trench shall be at least 0.3 m.
• Where trenches for signal cables pass under roads or under trenches for
electric cables or other services, the signal cables shall be laid in pipe sleeves
of 150-200 mm in diameter to facilitate cable laying in the future.
• Where cable trenches cross areas where heavy traffic can be expected, the
trenches shall be covered with pre-cast covers.
10080-1-SS-CI-016 Page 15 of 23
10.5. Earthing
Earthing should be in accordance with the design drawings. For Details Refer
Design Basis 10080-1-ENGG-DBD-CI-004 (Interface with Electrical & Control
system) Separation between systems shall be maintained and the following
general conditions applied:
10.5.1. Plant Earth
This shall be utilized for earthing all process equipment metalwork, Package skids
and cabling/tubing support tray and ladder rack. The final connection shall be
taken back to the Electrical Central Earthing Point.
10.5.2. Instrument Earth
This shall be utilised for earthing all IS and non-IS instrument cable armouring,
panel mounted equipment and instrument enclosures located in control buildings
or in the field. The final connection shall be taken back to the Electrical Central
Earthing Point.
10.5.3. Intrinsically Safe Instrument Earth
This shall be utilised only for Intrinsically Safe (IS) installations and shall be
connected only to IS equipment as shown and indicated in the loop drawings and
connection diagrams. Cable screens and drain wires shall be open at the field end
and connected via insulated terminals and earthing bars mounted in the IS field
mounted junction boxes back to the IS earthing bar in the Control buildings CCR,
LCR or PIB. The final connection shall be made to the Instrument Earthing System.
Earthing and bonding shall be generally in accordance with Project drawing for
Typical Earthing and Termination arrangement for Instrument Cabling’.
The resistance of any single conductor between the control centre earth bar and
its other terminal point in the control centre earthing system shall not exceed 0.5
ohm.
The resistance measured between the panel reference bar and true earth
incorporating the conductors and earth electrode shall be not greater than 5 ohm
or that which is lowest determined by:-
a) The earth loop impedance requirements of the certification for intrinsically
safe circuits (1 ohm maximum).
b) Electrical safety requirements.
c) Computer or other special system requirements.
10080-1-SS-CI-016 Page 16 of 23
Appendix 1: Project Related Specification & Standard Drawings
Later Piping Material Specification

Later Painting Specification
Later Typical Earthing & Termination arrangement for Instrument
Cabling
J10 Typical Installation Drawings
J55 Hook-up Drawings
Later Instrumentation Location Plans / Layouts
Later Wiring Drawings
Later Cable Schedule / MTO.
10080-1-SS-CI-007 Instrument Cable Specification
10080-1-SS-CI-001 General Instrumentation Specification
10080-1-SS-CI-010 Analyser Package Systems
10080-1-SS-CI-004 Control Valve Specification
10080-1-SS-CI-005 Safety Relief Valve Specification
10080-1-SS-CI-006 Isolation/Shutdown Valve Specification
10080-1-SS-CI-015 Automatic Tank Gauging System
10080-1-SS-CI-002 Instrument Specification for Package Units
10080-1-SS-CI-016 Page 17 of 23
Appendix 2: Typical Arrangements for Instrument Mounting
Item No. Descreption

1 2 IN PIPE, CS, SCH HEAVY
2 STRUCTURAL STEEL PLATE 10mm THK Grade E 250 BR IS 2062
3 STRUCTURAL STEEL FLAT 50x8 THK Grade E250A IS2062
4 TYPE 2 ANCHOR BOLT M12 X 300 LONG OR M12 Expansion Anchor
for Paved Area
10080-1-SS-CI-016 Page 18 of 23
Appendix 3: Typical Electrical Heat Tracing Arrangement
Typical Electrical Trace

Heating Assembly
10080-1-SS-CI-016 Page 19 of 23
Appendix 4: X-mas Tree Type Instrument Air Manifold Details
Item
Descreption
No.
1 Flange 1", CL-300 RF, SS316, TO ANSI B16.5
2 NIPPLE 1", SCH140, SS316, LENGTH TO SUIT DIMENSION-A
3 REDUCER 2" X 1". SS316
4 PIPE 2", SCH40, SS316, LENGTH TO SUIT DIMENSION-B
5 NIPPLE 1/2", SCH40, SS316, 100mm LONG
6 NEEDLE VALVE 1/2" NPT(F), CL-3000, SS316, PTFE PACKING
7 PLUG 1/2" NPT(M), SS316
8 FULL BORE BALL VALVE 1/2" NPT(F), CL-3000, SS316, PTFE PACKING
9 TAG PLATE, SS316
10 REDUCER 2" X 1/2", SS316
11 2" PIPE MOUNTING BRACKET WITH U CLAMP, NUTS & BOLTS, SS316
NOTE: 1) All Dimensions are in mm.

2) Material of construction shall be SS316.
3) Number of Users and Dimensions shall be decided at engineering stage.
10080-1-SS-CI-016 Page 20 of 23
Appendix 5: Junction Box Installation Details
10080-1-SS-CI-016 Page 21 of 23
Sr. No. Description

1 ISMC 100 X 50 X 9.56 Mild Steel (NOTE21)
2 Structural Steel Plate100MM Thk Grade B (Note 16)
3 M16 Expansion Anchor
4 ISA 50 X 50X 6 Mild Steel
5 PAN Head Screw M6 X 25 with washer
6 M6 Nut
7 Cable Tray – 300mm wide Galvanised Mild Steel
8 Hexagon Head Bolt M16 x 75N IS6639 Property Class 4.6
9 Structural Steel Flat 50 x 6
10 Plain Steel Machined Washer to IS2016 of size 17mm suitable for 1mm Bolt
11 Type 2 Anchor Bolt M16 X 300 Long (L) with Nut & Washer OR M12 Expansion
Anchor for Paved Area
NOTE:
1) All Dimensions are in millimetres.
2) Junction Boxes to be fixed to frame using M6 fixings
3) Steel work to be blasted & painted in accordance with project painting
specification .
4) Cables to be supported on cable tray as required.
5) Maximum height based on a rack for 2 rows of 2 JB’s.
6) Base plate to be welded to channel upright.
7) Installation Sub-contractor to supply non stockcoded items.
8) Frame 1 to be used for (4) 12 spur fieldbus boxes.
9) Frame 2 to be used for (4) conventional boxes or (4) 4 spur fieldbus boxes.
10) Frame 3 to be used for (2) 12 spur fieldbus boxes or (2) conventional boxes or
a combination of (1) fieldbus box and (1) conventional box.
11) Dimensions A and B are to suit largest junction boxes of each type. May be
adjusted to suit actual dimensions.
12) For back to back mounting of junction boxes on the frame, double the MTO
for item 4, 5, 6, 7 & 8. Back to back arrangements to be used only whenever
there is free access way on either side of the frame.
13) Frame (4) to be used for mounting single JB of size 340.5 x 340.5 on a grating.
14) Items 3, 8 and 11 are to be used for paved area, grating area and grade
respectively.
15) For instrumentation precast block refer relevant civil drawing.
16) For installation on grating double the quantity for item 2.
10080-1-SS-CI-016 Page 22 of 23
17) JB mounting for Frame (5) is same as Frame (4).

18) Distance is to suit the site condition.
19) Frame (5) shall be used for mounting of Vibration JB on outside of the
platform.
20) Height of the JB is to suit the site condition subject to Handrail clearance.
21) For Frame (5) quantity item 1 is approximate. Actual quantity to suit the site
condition by site contractor.
10080-1-SS-CI-016 Page 23 of 23

10080-1-SS-CI-016r0v1 - 0 - STD Spec For Instrumentaiton Installation

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

10080-1-SS-CI-016r0v1 - 0 - STD Spec For Instrumentaiton Installation

Uploaded by

Copyright:

Available Formats

J3 Program 10080-1-SS-CI-016

Standard Specifications for Instrumentation Installation Date: 18/07/2012, Rev. 0

Date Revision Details Revision Number

18/07/2012 Issued for Implementation 0

MANAGING CONTRACTOR Company which supports/carries out all or part

g) Shall not affect instrument installation from forces developed by expansion of

Instrument piping and tubing shall follow routes that;

9.2.2. X-mas Tree air distribution manifold

9.4. Instrument Impulse Lines

SIZE MAXIMUM DISTANCE BETWEEN SUPPORTS

In accordance with the specifications and good engineering practice, no

painting. If instrument mounting supports have to be fixed to fireproofed plant

Power Cables Minimum Spacing

33 kV and 6.6 kV 1000mm

Ladder Rack Perforated Tray

10.3. Cables Inside The Auxiliary Room

b) Electrical safety requirements.

c) Computer or other special system requirements.

Appendix 1: Project Related Specification & Standard Drawings

Later Piping Material Specification

Appendix 2: Typical Arrangements for Instrument Mounting

Item No. Descreption

Appendix 3: Typical Electrical Heat Tracing Arrangement

Typical Electrical Trace

Appendix 4: X-mas Tree Type Instrument Air Manifold Details

NOTE: 1) All Dimensions are in mm.

Appendix 5: Junction Box Installation Details

Sr. No. Description

17) JB mounting for Frame (5) is same as Frame (4).

You might also like