TECHNICAL SPECIFICATION

PART V – INSTRUMENTATION WORKS

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KUWAIT OIL COMPANY (K.S.C.)

(Register of Commerce No.21835)

TECHNICAL SPECIFICATION
-for-
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH
SMOKELESS TYPE FLARES AT NK GCs-15, 23 & 25

PART V: INSTRUMENTATION WORKS

1. GENERAL

1.1 The Instrumentation Works shall comprise of, but not limited to, Site survey, design,
detailed engineering, procurement, inspection, supply all temporary and permanent
materials, calibration, installation, testing, pre-commissioning, commissioning and
performance test for the complete new instrumentation and modifications / expansions
to the existing DCS, ESD and FGS systems for the new air assisted smokeless flares,
knock out drums, condensate transfer pumps, modifications to the existing equipment
and associated Works at GC-15, 23 & 25 as detailed herein and other specifications &
Drawings provided in this Contract.

1.2 All Company’s Drawings and Technical Specification included in this Contract shall be
considered as guidance for minimum requirements. In case of any conflict or ambiguity
between Company standards / specifications, existing philosophy and documents /
Drawings provided / listed in this Contract, the most stringent shall apply. However, the
Company’s decision shall be final as to which is the most stringent.

1.3 The described scope of Works is not intended to be exhaustive, nor to limit the Works
in any way, rather it is intended to be an overview of the extent of the Works and the
Contractor shall be deemed to have visited the Sites, carefully perused all of the Contract
documents and included all things described therein, or as may be reasonably inferred
there from, so as to provide the Company with a fully proven and operable facility upon
the completion of the Works.

1.4 For the avoidance of doubt, the Contractor is advised that items or matters not
specifically provided for, or partially described or otherwise missing from the
specifications but which are nevertheless necessary for the execution and completion of
the Works, shall be deemed to have been included by the Contractor in his Contract
Price.

1.5 The Contractor shall be responsible for his own material quantity take-off. Wherever
material quantities are listed or noted in the Contract, the same shall be considered for
reference only. The Contractor shall provide all materials and equipment necessary to
complete the Works as detailed in the Contract.

1.6 The instrumentation systems shall be based on latest proven technology. Nevertheless,
it should show broad experience in practice with these types of solution and assure that
the chosen components sound in quality and reliability.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

1.7 The Works shall be staffed at all times by engineers, installers, supervisors and
technicians who, in the role of lead crafts persons, shall be able to provide leadership
and technical resources for the remaining crafts persons on the Works.

1.8 All equipment provided by the Contractor shall be new and shall meet Technical
Specification.

1.9 The Contractor shall furnish all materials, software, firmware and accessories whether
specifically mentioned herein or not, to ensure complete and operating system.

1.10 Where specific standards have been withdrawn, superseded or made obsolete, the latest
replacement standard shall be used. The Contractor shall comply with the latest issue of
Company’s standards available at the time of execution of the Works.

1.11 Compliance with these specifications and standards shall not relieve the Contractor of
their responsibility to supply equipment and software suited to meet the specified design
and service conditions and applicable regulations.

1.12 The Contractor shall use his best endeavors to verify and satisfy itself to the extent
reasonably possible the accuracy and sufficiency of all information and data, including
Site data, furnished to the Contractor by the Company.

1.13 The Contractor shall evaluate the Vendor’s proposals for the supply of material and
equipment for incorporation into the Works, having regard to its technical capabilities,
cost of operation, flexibility and ease of operation, cost and ease of maintenance and the
cost of and need for spare parts.

1.14 This technical specification consists of the following appendices;

Appendix 5A : Data sheet for Pressure Safety Valve

Appendix 5B : Data sheet for Ultrasonic Flowmeter

1.15 The requirements described herein shall be the minimum requirements without
prejudice to the Contractor’s obligations to complete the Works in satisfactory operable
conditions to meet the desired objective of the project:

2. ABBREVIATIONS

AMS : Asset Management System

CCTV : Closed Circuit Television
DCS : Distributed Control System
DSIP : Direct Spark Ignition Panel
DVR : Digital Video Recorder
ESD : Emergency Shutdown System
F&G : Fire & Gas
FGS : Fire & Gas System
FFG : Flame Front Generator
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

FIT : Flow Indicating Transmitter

GWR : Guided Wave Radar
HP : High Pressure
IRP : Interface Relay Panel
I/O : Input / Output
ITP : Inspection and Test Procedure
KOD : Knock Out Drum
LAHH : Level Alarm High High
LALL : Level Alarm Low Low
LCP : Local Control Panel
LP : Low Pressure
MOV : Motor Operated Valve
NVR : Network Video Recorder
OEM : Original Equipment Manufacturer
P&ID : Piping & Instrumentation Diagram
PIT : Pressure Indicating Transmitter
PLC : Programmable Logic Controller
PSLL : Pressure Switch Low Low
PTZ : Pan Tilt Zoom
PSV : Pressure Safety Valve
QRA : Quantitative Risk Assessment
SIL : Safety Integrity Level
SOE : Sequence of Events
SIF : Safety Instrumented Function
TIT : Temperature Indicating Transmitter
UCP : Unit Control Panel
UPS : Uninterrupted Power Supply
UV/IR : Ultraviolet / Infrared

3. SCOPE OF WORK

3.1 The scope of Works to be performed as outlined in the following clauses shall be read
in conjunction with instrumentation project Drawings, reference Drawings, standard
Drawings and documents along with other clauses of this Technical Specification and
specifications pertaining to other disciplines in this Contract. The scope of work shall
consist of, but not limited to, survey of the existing system & instrumentation, detailed
design & engineering, procurement, supply, inspection, installation, testing pre-
commissioning and commissioning of Flare Systems and associated equipment.

3.2 Supply and install, as a minimum, all new instruments and valves as shown in the
P&IDs, Part-I General, specifications outlined herein and in line with the Company’s
standards and specifications for the new process areas and equipment. All
instrumentation shown on the P&IDs cover only the minimum requirements of the
Company. The design of the new instrumentation shall conform to Company’s standard
KOC-I-001 and 015-JH-1903 and installation shall be as per Company’s standard KOC-
I-002.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

3.3 Expand / modify existing DCS, ESD and FGS systems with necessary hardware,
software and licenses to connect the new control, monitoring, indication and
interlocking I/O signals for the new instrumentation.

3.4 Supply and install flare package including instruments, valves, FFG / DSIP / LCP
panels, UCP etc.

3.5 Modify the existing LP flare KOD in GC-15 to install new level transmitters and
magnetic level gauges in place of existing level switches and level gauges.

3.6 Replace existing PSVs (Conventional type, Pilot operated type etc.) with Balance
Bellows type PSVs and twinning of single PSVs at GC's-15, 23 & 25.

3.7 Supply and install new F&G detectors & devices in KOD / flare areas and connect them
to the existing facility FGS.

3.8 Supply and install new CCTV system in GC-15, 23 & 25 to monitor the flare.

3.9 Supply and install new push buttons, key switches, lamps, cables, terminals, accessories
and the like in the existing ESD and F&G matrix fascia panels in line with the existing
philosophy to cater to the new requirements in the project. New ESD and F&G matrix
fascia panels shall be provided in case modification is not possible in existing panels.

3.10 Supply, lay and terminate new cables required to transfer the signals from the field to
the control Room and from the substation to the control building as required. The cables
shall be in accordance to Company’s standard KOC-I-011 and installed in accordance
to KOC-I-002 and KOC-E-008.

3.11 Supply, lay and terminate new fiber optic and power cables for CCTV cameras from
main control building.

3.12 Supply, lay and terminate cables between DCS/ESD/FGS/UCP.

3.13 Supply and install intrinsic safe (Ex ‘ia’) and increased safety (Ex ‘e’) Junction Boxes
as required for signal transfer.

3.14 Supply and install 1.5/ 2.5 mm2 klippon terminal or equivalent in the junction box, local
panels and instrument cabinets for connecting the new I/O signals.

3.15 Supply and install all materials, tubings and fittings required for installation / hook-up
of the field instruments, valves, F&G detectors and other devices.

3.16 Supply and install all necessary explosion proof cable glands, terminals, cable markers,
ferrules, IS barriers, terminal labels and other bulk materials as required to complete the
work.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

3.17 Supply and install all required instrument air tubing / piping & fittings, cable trays, non-
corrosive metallic cable ties, protective pipes / ducts, instrument sunshades, suitable
supports and mounting accessories.

3.18 Interconnection Works between all new instruments, valves, F&G detectors and the like
as shown in the project P&IDs and field Junction Boxes.

3.19 Interconnection Works between MOV actuator and dedicated field Junction Boxes.

3.20 Interconnection Works between all field Junction Boxes and DCS/ESD/FGS/UCP.

3.21 Interconnection Works between flare control panels (FFG/DSIP/LCP) and UCP / DCS.

3.22 Interconnection Works between DCS, ESD and FGS.

3.23 Interconnection Works between UCP and DCS.

3.24 Interconnection Works between DCS / ESD / UCP and IRP.

3.25 Interconnection Works between existing and new DCS/ESD/FGS cabinets, as required.

3.26 Interconnection Works between ESD/FGS cabinets and ESD/F&G matrix fascia panels,
as applicable.

3.27 Interconnection Works between UPS DB / Power distribution cabinet and

DCS/ESD/FGS/UCP cabinets.

3.28 Supply of pre-commissioning and commissioning spares as per Company’s standard

KOC-G-009.

3.29 Configuration and graphic/alarm/report/modification/generation Works as required to

integrate the new instruments & valves in DCS in line with existing philosophy,
technical specifications and Company’s standards. All the DCS associated Works shall
only be carried out by OEM representatives.

3.30 Configuration and generation/modification/alarm/logic Works as required to integrate

new instruments and valves in ESD system in line with existing philosophy, technical
specifications and Company’s standards. All the ESD system associated Works shall
only be carried out by OEM representatives.

3.31 Configuration and generation/alarm/logic Works as required in flare PLC system to

integrate the new instruments and valves in line with existing philosophy, technical
specifications & its appendices and Company’s standards. All the PLC system
associated works shall only be carried out by OEM representatives.

3.32 Configuration and modification Works as required in FGS to integrate the new F&G
detectors & devices in the KOD / flare areas in line with existing philosophy, technical
specifications and Company’s standards. All the FGS system associated works shall
only be carried out by OEM representatives.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

3.33 Configuration and modification Works as required in existing POIS and GMIS in line
with existing philosophy and Company’s standards. All the POIS and GMIS associated
works shall only be carried out by OEM representatives.

3.34 The demolition scope for the existing KODs, burn pits, non-smokeless flares and
pipelines shall include the removal of old instruments & devices, valves, local panels,
junction boxes, tubing, cabling from the instruments & DCS/ESD/FGS/Flare panels etc.
The existing DCS, ESD, POIS and FGS systems shall be configured suitably to delete
the old I/O tags, alarms, graphics, trends, history, reports, logics etc. and the existing
documents shall be updated accordingly. The demolished I/Os shall be identified as
spares in field junction boxes and in the respective DCS/ESD/FGS marshalling and
system cabinets.

4. DESIGN & OPERATION PHILOSOPHY AND DETAILED SCOPE OF WORK

4.1 The Contractor shall be responsible for developing the detailed design based on survey
work to be carried out after award of contract together with the preliminary Drawings
listed and Technical Specifications included in the Contract. Any additional documents
of the existing facilities that may be required for the design and installation Works will
be provided to the Contractor upon request, to the extent these are available in the
Company records.

4.2 All instrumentation shall be designed as per various Company’s standards and
specifications and selected to provide high level of integrity / reliability and it shall have
low maintenance requirements.

4.3 The wetted parts of all instrumentation, flanges and its hook-up materials including
tubes, valve manifolds, valves, fittings, accessories etc. shall be SS316L, as a minimum,
for all services except for condensate services and shall conform to NACE MR 0175 /
ISO 15156 latest edition. The wetted parts of all instrumentation, flanges and its hook-
up materials including tubes, valve manifolds, valves, fittings, accessories etc. for
condensate services shall be Hastelloy C276 or better and shall conform to NACE MR
0175 / ISO 15156 latest edition. Erection of instruments, valves and accessories shall be
as per standard KOC-I-002 and standard hook-up drawings. The hook-up of new
instrumentation and valves shall take into account the site and process requirements and
it shall be the Contractor’s responsibility to provide all materials, fittings, valves and the
like for the satisfactory hook-up of the same.

4.4 The level transmitters in KODs shall be guided wave radar type. The GWR probe shall
be selected based on the installation, dielectric properties of the material which impacts
signal reflectivity, overall distance to be measured and the coating or sticking properties
of the fluid. The material of chamber shall be Inconel-625 or better.

4.5 The level gauges in KODs and flare gas liquid carry over pots shall be magnetic type
and shall be provided with SS scale to determine the tank level. Wherever the height to
be covered is more, multiple level gauges shall be provided. Level gauges on the
chemical drain pits shall be top mounted magnetic type. The design of the gauges shall
ensure proper readability during day and night times. The materials of cage and float
shall be Inconel-625 and Titanium respectively, as a minimum.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

4.6 All the level instruments shall be side mounted for both upper and lower process tapping.

4.7 Diaphragm seal type DP level transmitters shall be provided in flare gas liquid carry
over pots.

4.8 Differential pressure type transmitters with orifice plates as primary flow elements shall
be provided in the discharge lines of condensate transfer pumps. The orifice plates shall
comply with ISO 5167-1&2 standards and other relevant international standards.
Upstream and downstream straight pipe run requirements as per vendor
recommendations shall be considered.

4.9 Dedicated transmitters shall be provided for shutdown Works with separate process
connection and shall not share connections with the instruments used for control and
indication Works as well as other safety instruments. In addition to the instrument
manifolds in line with KOC-I-002 requirements, process take-off (isolation) valves shall
be provided in line with the project isolation philosophy.

4.10 All field electronic transmitters shall be of analog SMART type with HART protocol.
The transmitters shall have integral digital indicators for local indication. The accuracy
of the transmitters shall be 0.05% or better for level transmitters and 0.01% or better for
other transmitters.

4.11 The pressure instruments shall be supplied with 2-valve manifold while the DP
instruments shall be supplied with 5-valve manifold. The material of the manifolds shall
be SS316L.

4.12 Multi-path (minimum two paths) Transit-time ultrasonic flow meters shall be provided
in HP & LP flare headers downstream of flare KODs and shall have high range to
accurately measure flow in severe process conditions for the whole operating scenarios
from gas purge low flow condition to design flow during emergency relief. The flow
meter shall be flanged spool type with retractable sensors. Pressure and temperature
compensation for the flow rate shall be configured in DCS. Upstream and downstream
straight pipe run requirements as per Vendor’s recommendations shall be considered
prior to finalizing the location of flow meter. The location of flow meter shown in the
project Drawing is for guidance only.

4.13 The existing DCS shall be suitably modified to configure the new flow meter signal for
the blower speed control of existing smokeless flares.

4.14 The On-Off valves shall be installed at the outlet of flare gas liquid carryover pot. On-
Off valves shall have Class-V leakage class and shall operate based on an automatic
reset facility. The material of On-Off valves including its wetted parts shall comply with
Company’s standard KOC-MP-010. The On-Off valves shall conform to relevant
clauses of Company’s standards KOC-I-010, KOC-MP-033 Pt. 1 etc. and all other
relevant Company as well as international standards.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

4.15 The Control valves shall be installed in the purge gas line. The control valves shall have
Class-V leakage class and shall conform to Company’s standard KOC-I-010 and all
relevant Company as well as international standards. Control valves shall be provided
with SMART positioners.

4.16 Control valves shall be sized to cover the entire operating range / process parameters as
required. The Contractor shall consider into the design any process condition that may
have an effect on the control valve, such as corrosive fluids, entrained solids, high
pressure, high temperature, low temperature, etc. The Contractor shall submit sizing
calculation along with datasheets for Company review and approval. The Contractor
shall supply special trims or select particular type of control valve as and when required
to mitigate wide operating flow range, noise / flashing / cavitation predicted by sizing
calculations.

4.17 The existing PSVs (Conventional type, Pilot operated type etc.) installed in the process
streams at GC's-15, 23 & 25 shall be replaced with Balance Bellows type PSVs having
individual isolation valves, if not existing. Existing single PSVs installed in the process
streams at GC's-15, 23 & 25 shall be twinned with mechanical key interlock
arrangement having individual isolation valves, if not existing. The Contractor shall also
carry out proper Site survey in these GCs to gather all the necessary data related to these
PSVs. The material of PSVs including its wetted parts shall comply with KOC-MP-010
standard. The PSVs shall conform to Company’s standards KOC-MP-027 Parts 1 & 2,
015-JH-1903 etc. and all other relevant Company as well as international standards. All
new relief valves shall be tested at Company’s Workshop as per approved ITP.

Shutdown may be required for the modification of existing pipelines / equipment

associated with the installation and twinning of new PSVs. Contractor shall properly
plan and utilize the available GC shutdown schedule.

4.18 Discrepancy alarms, to give immediate indication of unacceptable drift or malfunction,

shall be configured for the following:

a) When two or three transmitters in a process measurement deviate more than a preset
percentage value from each other to give immediate indication of unacceptable drift
or malfunction in any one of the transmitter. Contractor shall indicate identical
measurement range of the above transmitter pairs in data sheets, instrument index
and instrument I/O list.

b) When the instrumented valve status differs from the control order.

4.19 Flare Instrumentation

4.19.1 The flare instrumentation and control shall be in compliance with relevant Company
standards & international standards and shall be of proven design.

4.19.2 Flare UCP

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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

4.19.2.1 Flare system monitoring and control shall be implemented through dedicated Unit
Control Panel (UCP) having dedicated PLCs for each flare.

There are two HP flares each in GC-15 & 23. Flare Vendor shall evaluate the feasibility
of locating dedicated PLCs (complete with all hardware & accessories) for both these
HP flares in a common UCP (in GC-15 & 23) without deviating from relevant Company
standards, as part of his detailed design and propose to Company with sufficient
technical justification for approval. Separate UCPs shall be provided for both the HP
flares in GC-15 & 23 in case the flare Vendor’s proposal is not deemed suitable.

4.19.2.2 Redundant processor modules, power supply modules & communication modules and
simplex I/O modules shall be provided. UCP including the PLC system shall be
complete with all the necessary hardware, software, licenses and accessories including
bulk power supply, terminals, cables, relays etc.

4.19.2.3 Monitoring, control and sequencing functions for flare system and air blowers shall be
implemented in flare PLC. All the process parameters, alarms and diagnostic signals
from flare PLCs shall be made available at DCS via redundant modbus link. Trip signals
to / from PLC and existing ESD system shall be hardwired.

4.19.2.4 UCP including the PLC system shall comply with Company’s standards KOC-I-001,
KOC-I-007, KOC-ME-021 and KOC-G-007. It shall also comply with relevant clauses
of Company’s standard KOC-I-004.

4.19.2.5 Processor module shall be fitted with sufficient non-volatile memory to store all
collected data for a period of 72 hours following a communication failure. The processor
shall be capable of handling the required number of inputs and outputs plus 50% extra.
A minimum of 50% spare memory capacity shall be included.

4.19.2.6 The number of analog or discrete inputs and outputs shall be as per the approved P&IDs
with a minimum of 20% spare I/O capacity.

4.19.2.7 Flare PLC shall have Schedule of Events (SOE) recording and the same shall be stored
for a minimum period of 31 days. Events data shall be easily downloadable to the laptop.

4.19.2.8 Online modification of logics, overrides etc. shall be possible in PLC.

4.19.2.9 The Contractor shall provide one (1) industrial type laptop computer as programming
terminal for each GC. Programming software under Windows shall be preloaded and all
necessary cables or accessories included. In addition, one (1) set of original operating
system and programming software CD’s shall be included. Dedicated RS-485, RS-232
and USB communication port shall also be made available for connecting PLC system
to a programming terminal and interfacing to other systems.

4.19.3 Duplex type retractable type thermocouples shall be used for pilot flame monitoring.
One element of each thermocouple shall be used while the other element shall be
terminated in grade junction box and available as a spare. Two (2) thermocouples shall
be provided for each pilot and each thermocouple shall be connected to dedicated
temperature transmitter.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

4.19.4 Two (2) Infrared Pyrometer type flame monitors shall be installed additionally for flame
monitoring of the pilots since thermocouples are highly prone to failures.

4.19.5 FFG panel / DSIP / LCP shall be designed for fully functional and safe operation &
maintenance of flare. The necessary push buttons, selector switches and indications shall
be provided in these panels. The indication lamps on these panels shall be high intensity
LED type to make it visible from a distance. P&IDs are for guidance and indicate only
the minimum requirements. FFG/DSIP/LCP shall be interfaced with UCP. These panels
shall be located outside the flare radiation zone as per vendor recommendation.

4.20 The cables for instruments and devices in the flare area shall be suitable to handle high
temperature and radiation levels. Special cables shall be supplied and installed as per
manufacturer recommendation, if deemed necessary. These cables shall also be
protected with suitable sleeves or conduits.

4.21 The instruments and devices in the flare area shall be suitable to handle high temperature
and radiation levels. These shall preferably be installed outside the flare radiation zone,
wherever possible.

4.22 CCTV coverage for new flares

4.22.1 New standalone CCTV system shall be provided in GC-15, 23 & 25 to monitor the status
of new flares. The CCTV system shall be state-of-the-art and based on latest proven
technology.

4.22.2 The Contractor shall supply all the items required for a fully functional and operational
CCTV system which shall include, but not limited to:

a) CCTV cameras with support poles

b) Telemetry system including fiber optic convertors, transmitter/receiver etc.
c) Fiber optic signal cables, Power cables, Coaxial cables, data cables etc.
d) 16 channel Digital Video Recorder (DVR), 3TB internal Hard Disk Drive for video
storage, H.264 video compression
e) Joystick controller for PTZ & DVR operation with RS485, RS232 port, LCD
display and on-screen menu
f) Video Matrix Switcher, if required
g) Latest 42” professional LED monitor with minimum 1920*1080 (16:9) resolution,
multi-input and ceiling mount bracket
h) Switches, routers, encoders, transformers, power modules etc., as needed.
i) Cable Glands, junction boxes, mounting accessories, miscellaneous fittings etc.
j) CCTV cabinet
k) All required software and firmware

4.22.3 The CCTV cameras shall have the following minimum requirements:

a) PTZ type, Pan 360o continuous rotation

b) CMOS / CCD sensor
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

c) day/night colour camera with auto white balance, auto iris, varifocal lenses and IR
illuminators
d) 40X optical zoom
e) Rugged construction for harsh outdoor environments
f) IP65 rating
g) Sun shade
h) high resolution (minimum 670 TVL)
i) H.264/MJPEG, configurable encoder
j) Wash & Wiper and Heater
k) ONVIF compliance

4.22.4 Dedicated CCTV cameras shall be provided for each type of flare (HP or LP).

There are two HP flares each in GC-15 & 23. Same CCTV camera may be utilized to
monitor both these HP flares if there is sufficient coverage since the operator can
position the camera to the HP flare, which is in operation. Dedicated CCTV cameras
shall be provided to monitor each HP flare in these GCs, if the above is not deemed
feasible.

4.22.5 The camera shall be suitable for outdoor installation. The video data shall be stored for
a period of minimum 31 Days. The cameras shall be strategically located inside the GC
fence in a nonhazardous area. The focal length of the cameras shall be selected based
on the location of new flares.

4.22.6 The cameras shall be mounted on poles having safety cages and platform. Camera poles
made out of steel shall be free standing and suitable for mounting on a concrete
foundation. The pole shall be complete with all the necessary components, fixings etc.;
for mounting the complete camera assembly and for the installation of the pole itself.
The existing cameras are located on 15 to 20m poles. The exact height of each tower
shall be determined by the Contractor to meet the specification requirements and provide
optimum coverage for the cameras. Particular attention shall be paid to avoid glare from
overhead floodlighting.

4.22.7 Single mode (SM) fiber optic cables and power cables shall be laid from main control
building to the CCTV cameras. The specification and installation of fiber optic cables
shall be as per Company’s standards KOC-T-006 and KOC-T-008 respectively.

4.22.8 New CCTV system shall be complete with all the necessary hardware, software and
accessories. CCTV cabinet shall be provided to accommodate all the new hardware and
accessories including matrix switches, DVR, MCBs etc. Contractor shall utilize the
existing CCTV cabinet in GC-15 if there is sufficient space available to accommodate
the new hardware and accessories.

4.22.9 It shall be possible to operate the CCTV cameras from the control room itself in line
with the existing philosophy and all the required hardware including joy sticks shall be
provided accordingly.
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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

4.23 F&G Detectors and Devices

4.23.1 F&G detectors and devices shall be provided at the newly installed facilities in GC-15,
23 & 25 to alert personnel of the presence of fire, combustible gas and toxic gas.

4.23.2 The various types of F&G detectors and devices, which shall be installed in the new
facilities, shall be finalized as per QRA study and in line with Company’s standards.

4.23.3 The Contractor shall install F&G detectors & devices in KOD areas to alert personnel
of the presence of fire, combustible gas & toxic gas and shall be connected to existing
F&G system. F&G detectors & devices shall be provided in Flare areas, if deemed
necessary, as per QRA study.

4.23.4 2oo3 voting logic shall be implemented for the flame detectors in KOD area to activate
ESD Level-1 shutdown. New fire zone for ‘KOD / flare area’ shall be created in F&G
matrix fascia panel and F&G Workstations as applicable.

4.23.5 F&G Modifications in existing Auxiliary Control building at GC-15

4.23.5.1 The Contractor shall install F&G detectors and devices in the new battery room of
existing Auxiliary control building at GC-15 to alert personnel of the presence of fire &
hydrogen gas and shall be connected to existing F&G system. The detectors and other
devices in battery room shall be explosion proof certified for Zone-1 Exd IIC T3.

4.23.5.2 Confirmed detection of hydrogen in battery room (2oo2 voting) shall operate the
standby exhaust fans in the battery room and inhibit the boost charging of UPS through
F&G system.

4.23.5.3 The existing M/s ABB make local repeater panel in GC-15 auxiliary control building
shall be modified in line with existing philosophy.

4.23.6 The quantities of F&G detectors and devices such as UV/IR flame detectors, heat
detectors, toxic gas detectors, flammable gas detectors, manual call points, sounders and
strobes, indicated on the project drawings are for reference, guidance and minimum
requirements only. Contractor shall carry out F&G mapping study and shall provide
additional detectors and devices, if deemed necessary, based on the same.

4.23.7 Fire & Gas detectors & devices shall be FM / LPC approved or UL listed and shall
comply with KOC-L-006, KOC-L-036, NFPA-72 & other relevant KOC and
international standards.
4.23.8 The gas detectors shall be fitted with integral LCD indicators for local display.
4.23.9 It shall be possible to access the local display and calibrate the hydrogen detectors from
the floor level of battery room and all the required accessories & tubing shall be installed
accordingly.
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4.23.10 Comprehensive calibration kits shall be supplied to facilitate regular checking and re-
calibration of each type of gas detectors. The kits shall include zero and span
gases/samples, as well.
4.23.11 The Contractor shall ensure that all the F&G sensors are at the beginning of sensor life
span at the time of commissioning.
4.24 Line break monitoring devices shall be fitted with instrument head where this does not
infringe on the certification. Where this is not possible, they may be installed at the
nearest available junction box point to field sensor.
4.25 All new air supply tubing/fittings/valves shall be of 316SS material. All instrument air
piping shall be SS316L.
4.26 All cables, accessories and junction boxes for the new instruments and detectors shall
be new. Interconnecting control cables between the Instrument and Electrical systems
shall also be new. The instrument cables shall be sized based on distance and power
requirements. The cable sizes mentioned in Company’s standards are for guidance and
minimum requirements only. The sizing of cables is Contractor’s responsibility.
4.27 Multicore control cables as well multipair signal cables shall be provided with at least
25% spare cores or pairs. The spare cores of these cables shall be terminated in junction
boxes and instrument cabinets.
4.28 New signal as well as control cables shall be laid as required between the substation IRP
panels and DCS/ESD/UCP in the auxiliary control building to provide the start/stop
logic for the various new pumps and flare air blowers being installed in the facility.
4.29 All field underground / partially underground cabling shall be in compliance with
Company’s standard KOC-I-011. In addition, all cables for ESD and F&G applications
shall be fire resistant and other cables shall be flame retardant type as per KOC-I-011.
4.30 The Contractor shall conduct SIL study and verification to identify / review the SIL
level for the Safety Instrumented Functions by engaging services of a Third Party
Functional Safety Consultant in accordance with Company’s standard KOC-I-017:
KOC Recommended Practice for Implementation of Safety Instrumented Functions
(SIF) IEC-61508 & IEC 61511. Contractor shall provide all relevant documents and
participate with appropriate specialists as required in KOC-I-017.
4.31 The Contractor shall be responsible for fulfilling the utility requirements.

4.32 The hazardous area classification shall be as in the existing plant. All process
instruments and valves shall be certified according to the existing area classification. All
process instruments, valves, junction boxes, local control panels etc.; in KOD area shall
be certified for intrinsic safe and shall follow all IS wiring and installation methods for
complete installation. All process instruments, valves, junction boxes, local control
panels etc.; in flare area shall be certified for explosion proof. The gas group and
temperature class of instrument / valve certification shall be ‘IIC’ and ‘T6’ respectively,
as minimum. Intrinsic safe instruments shall be terminated in EEx ‘ia’ IIC T6 certified
junction boxes and explosion proof instruments shall be terminated in EEx ‘e’ IIC T6 /
Ex ‘d’ IIC T6 certified junction boxes.
4.33 The instruments, junction boxes, local control panels and accessories shall be weather
proof to IP65 as a minimum.
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AT NK GCs-15, 23 & 25

4.34 Dimensions of flanges, fittings, valves, etc., shall meet the relevant ANSI / ASTM
standards.
4.35 During the installation Works, any damage caused to the existing equipment and
services shall be repaired and replaced by the Contractor at his own expense.
4.36 Loop checking shall be carried out for all instrument loops from the Control room up to
field in the presence of Company’s representatives. Two (2) Weeks prior notice shall be
given before starting loop checking activities. All loops shall be verified and signed by
the Company’s representative after satisfactory completion.
4.37 For Instrument Cable Routing, refer to project cable routing layout Drawing. Survey
and slit trenching shall be conducted to determine the exact cable route and cable length.
If any services are present in the proposed cable route, the same shall be rerouted or
protected with sleeves by the Contractor after obtaining Company’s approval. New
cable route shall follow existing route as much as possible.
4.38 All instruments, junction boxes and cables shall be properly identified with proper
stainless steel plates with details inscribed on it. The details shall be submitted to the
Company for approval. They should have details like tag no., manufacturer’s name,
model no., type, serial number, electrical classification, certification mark, range, rating,
set point etc. Junction Box shall be provided with channel mounted terminal blocks
tubular clamp type and vibration proof.
The JB shall be suitably sized to accommodate the required quantity of terminals
keeping enough clearance on all sides for easy field termination i.e. minimum 100 mm
space above and below the terminal strips and 75 mm on the sides. All spare entries
shall be plugged with explosion proof plugs. In addition to the nameplate referred above,
each field instrument shall be provided with Equipment Identification number (EIN) and
Site Number (SN) plates. The Contractor shall survey for the required EIN and SN
numbers, prior to construction stage.
4.39 Separate Junction Boxes shall be provided for different services, signal types & voltage
levels and shall be installed in accordance with standard KOC-I-002.

4.40 The material of construction for the instrument electronic enclosure, junction box and
local control panel shall be SS316L as a minimum. The material of construction for
junction boxes and local panels (FFG/DSIP/LCP) supplied as part of flare package shall
be as per relevant Company standards and other specifications / documents included in
the tender. Aluminium and its alloys shall not be used.
4.41 MOV actuator signals shall be terminated in dedicated junction boxes and shall not be
terminated in MOV isolator panels.
4.42 The Contractor shall provide identifying ferrules (same as the tag no. provided in the
P& IDs) for all the single and multi-cable wires (associated with the replaced or newly
added instruments), including inside the existing and new junction boxes.
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AT NK GCs-15, 23 & 25

4.43 All field instruments shall be provided with sunshades in accordance with Drawing No.
55-02-056 if the instruments are exposed to direct sun light. It shall be possible to zero
check, calibrate or remove the instrument without removing the sunshade. A sample of
the shade shall be submitted for Company approval.
4.44 All instruments installed at heights shall be provided with suitable Company approved
access platforms to enable operation and maintenance of the same.
4.45 All the removed instrumentation, valves and accessories shall be transported and stored
safely at a designated location as per the instruction of the Superintendent’s
representative.
4.46 The local control stations / panels for pumps and air blowers shall meet the minimum
requirements specified in the P&IDs, other project documents and relevant Company
standards.
4.47 The tag numbers shall not be duplicated and Contractor shall propose Instrument tag
numbers in line with existing philosophy and Company’s standards for approval.
4.48 Modification works in existing LP KOD (15C-103) at GC-15
4.48.1 One (1) existing Level high-high switch installed in KOD shall be replaced with new
guided wave radar level transmitter. KOD shall be modified to cut extra nozzles to install
two (2) additional guided wave radar level transmitters. The existing ladder or other
services installed on this KOD shall be suitably relocated for this purpose. These three
(3) level transmitters for LAHH service shall be connected to ESD system for 2oo3
voting to generate Level-2 shutdown.
4.48.2 One (1) existing Level low-low switch shall be replaced with new guided wave radar
level transmitter and shall be connected to ESD system to trip condensate transfer pumps
upon actuation of LALL.
4.48.3 One (1) existing Level gauge shall be replaced with new magnetic level gauge.
4.48.4 One (1) existing Level transmitter connected to DCS shall be suitably configured for
high and low level alarms for start / stop logic of condensate transfer pumps.

4.48.5 The new level transmitters shall be terminated in new junction boxes and shall be
connected to the ESD system through new instrument cables.

4.49 Modification Works in Dual tank (23-T-91) vapour line at GC-23

4.49.1 The existing field instruments (FIT, PITs, TIT, PSLL etc.) on the old vapour line shall
be removed and relocated to the new vapour line, as shown in the P&IDs. The existing
secondary cables associated with these instruments shall be disconnected from the field
instrument & junction boxes and looped & buried underground in consultation with the
Company’s representatives. The new secondary cables from the relocated instruments
shall be terminated in these existing junction boxes. The existing small junction box,
where PSLL instrument is connected, shall be replaced with new junction boxes, if the
existing JB cannot be utilized due to some constraints, the contractor shall supply new
JB along with cables, terminals, cable glands etc..
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AT NK GCs-15, 23 & 25

4.50 DCS, ESD and F&G Modification / Expansion Works in GC-15, 23 & 25

4.50.1 EXISTING CONTROL BUILDING INSTRUMENTATION

DCS ESD F&G POIS GMIS

Honeywell ABB
GC-15 Honeywell FSC Honeywell ABB
Experion TPS AC800M
Honeywell HIMA H51q ICS Triplex
GC-23 Honeywell ABB
Experion TPS HRS TMR
ABB ABB
GC-25 ABB AC800M Honeywell ABB
AC800M AC800M

4.50.2 The existing DCS, ESD and FGS hardware & software shall be expanded, modified and
configured to perform the required monitoring, control, shutdown functions for the new
installations. All the hardware required for expansion, modification and integration of
the existing DCS, ESD and FGS system shall be supplied and installed.

4.50.3 Expansion of all instrument systems shall be with the latest technology. The hardware
and software of DCS, ESD and FGS systems shall be the latest at the time of execution
of this project, wherever applicable.

4.50.4 DCS, ESD and FGS vendors shall provide long-term support for hardware, software and
services for the new systems for a period of minimum 10 years. Contractor shall not
supply any obsolete systems, controllers, hardware and software.

4.50.5 The Contractor shall be fully responsible to design, supply and install a fully functional
system and shall carry out all other Works, which could reasonably be deemed as
necessary to provide the Company with complete, proven and operable facility.

4.50.6 All systems including DCS, ESD and FGS and other sub systems shall be integrated as
per the existing design philosophy and Company’s standards.

4.50.7 If the latest model hardware / software cannot be directly accommodated by the existing
hardware / software due to compatibility issues of any nature, then the new hardware
shall be supplied with its own cabinets/racks/slots and new application software also
shall be supplied to support the new model of software.

4.50.8 The latest best practices shall be implemented for the existing and newly expanded /
upgraded parts of the control and safety systems to achieve configuration integrity and
higher security.

4.50.9 As the existing plant network shall be expanded, a detailed assessment of monitoring,
control and shutdown networks shall be carried out and necessary improvements /
modifications / expansions shall be implemented to cater to the new requirements of
data handling, communication, monitoring / control and improved integrity.
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AT NK GCs-15, 23 & 25

4.50.10 The new DCS, ESD and FGS hardware shall be fully compatible and integrated with
the existing respective systems without disturbing its normal and safe operation in line
with the existing design philosophy and Company’s standards.

4.50.11 The existing ESD and F&G fascia panels in all NK facilities shall be suitably modified
/ expanded in line with the existing philosophy to cater the project requirements. New
fascia panels shall be provided in case the expansion / modification is not possible due
to some reasons.

4.50.12 The existing F&G HMI workstations shall be expanded with the complete facility field
detection system graphics as per locations / zones.

4.50.13 The logics, graphics, events and other configurations in the existing DCS, ESD and FGS
systems shall be suitably modified to meet operation requirements and in line with
existing philosophy. Any existing control and/or logic that shall be affected by
modification/installation in this Contract shall also be tested to the extent of satisfactory
operation.

4.50.14 The Contractor shall be responsible to ensure that software modification works on the
existing DCS, ESD and F&G systems do not effect negatively on its performance.

4.50.15 The new system and marshalling cabinets shall match the existing cabinets with respect
to colour and other relevant aspects.

4.50.16 The instrument cabinets shall be minimum IP-20 rated. The cabinets shall have standard
dimension i.e. 800(W) x2000(H) x800(D) mm. The cabinets shall be installed on plinth
as per existing philosophy.

4.50.17 The instrument cabinets shall have 25% spare space for future expansion. The complete
installed spare capacity shall be 25% after all the subsystems have been fully integrated.
This spare capacity shall be across the board in respect of racks, I/O cards, power
supplies, terminations, barriers etc. and shall be fully wired down.

4.50.18 All inputs and outputs for DCS, ESD and FGS systems shall be monitored type with
line fault detection and suitable EOL resistors shall be provided.

4.50.19 The time synchronization for new DCS/ESD/FGS equipment shall be in a manner,
which is consistent with the existing GC practice.

4.50.20 The Contractor shall provide all equipment, parts, components, hardware, software and
licenses related to DCS, ESD and FGS systems that are actually required, but not
explicitly specified in this specification, for a complete and integrated functional system
within GC.

4.50.21 All latest software licenses, authorization keys and access to manufacturer support shall
be provided. All the software supplied shall be of latest version at the time of system
handover to end user. All updates / patches released until the time of final hand over
shall be included.
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AT NK GCs-15, 23 & 25

4.50.22 The loading of DCS, ESD and F&G controllers shall not be greater than 50% of its
design capacity.

4.50.23 The Contractor shall carry out power supply and heat dissipation calculation for the
cabinets which will undergo modification due to addition of new power consuming
components and shall ensure the adequacy of the existing power supplies.

4.50.24 The Contractor shall upgrade the existing level of software to the required level to
support the latest hardware including upgrading / replacement of any existing hardware.

4.50.25 The Contractor shall be fully responsible for implementation of new system equipment
in a manner, which does not degrade the current performance of any of the existing
system equipment into which it is being integrated. The Contractor shall be responsible
for the complete integration of control, safety and F&G systems at different
locations/areas and other third party package systems.

4.50.26 Redundant 110 VAC UPS feeders shall be provided in control system cabinets such as
DCS, ESD, FGS and UCP from existing or new power distribution boards / cabinets, as
required. Contractor shall modify the existing power distribution cabinets and lay &
terminate the power cables from these cabinets to control system cabinets, if deemed
necessary. UPS backup time for DCS/FGS/Flare PLC and ESD systems shall be one (1)
hour and four (4) hours respectively.

4.50.27 The earthing of instrument cabinets shall be in line with existing philosophy and
Company’s standard KOC-I-007.

4.50.28 Instrument wiring core colors, DCS graphics design and other system formats shall be
in line with the existing practices of the facility unless mentioned otherwise.

4.50.29 The Contractor shall utilize the spare space available in auxiliary control buildings at
GC-15, GC-23 and GC-25 to install the new instrument cabinets pertaining to these
facilities.

The Contractor shall modify the auxiliary control building in GC-23 to install the
necessary support structure for new instrument cabinets and cable trays in line with the
existing philosophy. Contractor shall utilize the new auxiliary control building to be
built under EF/1989 project in case of any space constraints inside the existing auxiliary
control building in GC-23.

4.50.30 The duct bank / sleeves installed for cable entry to the existing control buildings /
substations shall be utilized for new cable entries. Contractor shall provide new duct
banks / sleeves as required if the existing setup cannot be utilized due to some reasons.

4.50.31 All related Works including training of Company personnel to achieve expansion,
modification and upgrade Works shall be executed by respective OEM’s specialist
engineers.
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AT NK GCs-15, 23 & 25

4.50.32 Expansion / Modification of existing DCS in GC-15, 23 & 25

4.50.32.1 The existing DCS systems in GC-15, 23 & 25 shall be expanded and modified with all
the necessary hardware, software, licenses and accessories including cabinets, racks,
redundant processors, redundant power supplies, redundant I/O modules, redundant
communication modules, cards, FTAs, cables, barriers, relays, terminals etc. in line with
Company’s standards and existing philosophy. Separate System and Marshalling
cabinets shall be provided.

4.50.32.2 DCS controllers shall have redundant serial interface modules to communicate with new
flare PLCs (installed inside UCPs) and existing ESD and FGS controllers. Contractor
shall supply and install the necessary hardware, cables and accessories required for this
interface.

4.50.32.3 New cabinets shall be powered with redundant 110 VAC UPS feeders and 250 VAC
feeders as required.

4.50.32.4 The expansion / modification Works in DCS shall be in compliance with Company’s
standards KOC-I-001, KOC-I-007 and 015-JH-1904 and other relevant Company &
international standards.

4.50.32.5 DCS tags shall be configured in existing POIS and GMIS servers, as applicable.
Additional licenses for POIS and GMIS tags shall be provided.

4.50.32.6 All process control, monitoring, graphic generation, display, trend generation and all
activities required for the proper running of the new facility shall be carried out in the
DCS in line with the existing philosophy. All existing DCS functionalities, without
exceptions, shall be updated.

4.50.33 Modification of existing ESD systems in GC-15, 23 & 25

4.50.33.1 The existing ESD systems in GC-15, 23 & 25 shall be modified with all the necessary
hardware, licenses and accessories including racks, I/O modules, cards, FTAs, cables,
barriers, relays, terminals etc. in line with existing philosophy and Company’s
standards. New marshalling cabinets shall be provided in case the existing marshalling
cabinets cannot be utilized due to space constraints.

4.50.33.2 Redundant serial interface modules shall be provided in existing ESD system to
interface with new DCS controllers.

4.50.33.3 The modification Works in ESD system shall be in compliance with Company’s
standards KOC-I-001, KOC-I-004, KOC-I-007 & KOC-I-017 and other relevant
Company and international standards.

4.50.33.4 The logics, interlocks, events and other configurations in the existing ESD systems shall
be suitably modified to meet operation requirements and in line with existing
philosophy. SOE recording for the new parameters shall be added to the existing SOE
stations.

4.50.34 Modification of existing FGS in GC-15, 23 & 25

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AT NK GCs-15, 23 & 25

4.50.34.1 The existing FGS in GC-15, 23 & 25 shall be modified with all the necessary hardware,
licenses and accessories including racks, I/O modules, cards, power supply, FTAs,
cables, cabinets, barriers, relays, terminals etc. in line with existing philosophy and
Company’s standards in order to connect the new F&F detectors & devices. New
marshalling and IO expansion cabinets shall be provided, if deemed necessary.

4.50.34.2 Redundant serial interface modules shall be provided in existing F&G system to
interface with new DCS controllers.

4.50.34.3 The modification Works in FGS shall be in compliance with Company’s standards
KOC-I-001, KOC-I-005, KOC-I-007 & KOC-I-017 and other relevant Company and
international standards.

4.50.34.4 The logics, interlocks, events and other configurations in the facility FGS shall be
suitably modified in line with existing philosophy to meet operation requirements.

4.50.35 The existing AMS systems in GC-15, 23 & 25 shall be modified to integrate the new
HART field devices.

5. WORKS TO BE PERFORMED

The Contractor’s Work shall consist of, but not be limited to, the following:

5.1 Project management including project controls and reporting system.

5.2 Site survey, Site preparation and all other Works.

5.3 The Contractor shall carry out a detailed Site survey along with approved design sub-
contractor and shall submit a report to Company. The Site survey report shall include,
but not limited to, report on existing cable routes / trenches from field to control room,
instrument air tapping points etc. Contractor shall also carry out a separate site survey
along with system (DCS/ESD/F&G/Flare PLC/POIS/MIS) vendors and approved
design sub-contractor in order to collect all the information of the existing systems
including the details of spare space & spare I/Os in the existing cabinets, I/O
segregation, spare space for new cabinets in the control room, power distribution etc.
The Contractor shall submit the reports within three (3) months after the Date for
Commencement.

5.4 The Contractor shall submit reservation request within 6 months after award of Contract
for the utilization of the following, but not limited to:
a) Spare channels in existing I/O modules
b) Space inside the existing instrument cabinets
c) Space for the installation of new instrument cabinets
d) Power reservation for the instrument cabinets
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AT NK GCs-15, 23 & 25

Contractor shall be responsible for any consequences due to delayed submission of

reservation request after this period and shall bear all the expenses to fulfill the
requirements of the Contract.

5.5 Preparation of all data sheets (in ISA format), specifications, Drawings and other
documents.

5.6 Procurement services including purchasing, expediting, inspection, traffic and logistics,
spare parts procurement where required by the Contract and material and equipment
management.

5.7 Subcontract formulation and administration.

5.8 Construction services including the supply of labor, construction equipment,

consumables, temporary facilities and materials and various supporting services.

5.9 Quality assurance services as per Technical Specification entitled “Quality Assurance/
Quality Control (QA/QC)”.

5.10 Miscellaneous services including office facilities and accommodation support for
Company personnel.

5.11 Facility operations service including pre-commissioning, commissioning and

performance testing.

5.12 Removal of existing instruments, equipment, facilities and services, including those
decommissioned and disused, where specified and required to allow completion of the
Facility.

5.13 Mechanical protection and rerouting / relocation of existing services including cables
under skid/shelter areas as per Company’s standards.

6. INSPECTION, TESTING AND CALIBRATION

6.1 Inspection

6.1.1 All materials and equipment supplied (including flow meter, control valves, DCS, ESD,
UCP and FGS equipment) shall be subject to the Company’s inspection and approval.
This shall include Factory Acceptance Test (FAT) and Site Acceptance Test (SAT). This
inspection shall not relieve the Contractor of any obligation to fulfill all the conditions
of the specification. The responsibility for inspection during installation rests with the
Contractor.

6.1.2 The FAT shall be performed at the manufacturer's facility where the equipment is
engineered and assembled. FAT shall be carried out in the presence of Company
representatives.
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AT NK GCs-15, 23 & 25

6.1.3 The Contractor shall submit Inspection & Test Plan (ITP), FAT procedure, SAT
procedure etc. for Company’s approval.

6.2 Calibration and Functional Testing

6.2.1 The Contractor shall provide the required calibration and testing equipment as specified
by the instrument supplier, and all other necessary facilities and services to calibrate and
test all instruments at site including field instruments. The Contractor shall follow
manufacturer’s recommended calibration procedures. Error between actual and
theoretical calibration figures shall not exceed those specified by the manufacturer. The
test and calibrating equipment to be used shall have valid test certificates from third
party sources traceable to relevant ISO and other international standards and shall be
submitted to the Company for review and approval.

6.2.2 The Contractor shall make available at his own cost DCS, ESD, Flare PLC and FGS
system manufacturer’s representatives to configure, interface and hook-up the whole
system, generate all relevant Graphics and other journals and put the entire system on
line.

6.2.3 The Contractor shall document all final calibrations with the Company for their sign-
off. This document, as a minimum, shall include five-point calibration, in case of analog
loops. The test equipment used, the date test equipment was calibrated, the date of
calibration and person performing calibration shall also be included. The calibration
record formats shall be prepared by the Contractor and approved by the Company.

6.2.4 The Contractor shall give the Company sufficient advance notice so that its
Representative may be present to witness testing. The Company reserves the right to
request additional testing as deemed necessary to assure functionality.

6.2.5 Prior to requesting the Company’s Representative for the witnessing of testing, the
Contractor shall have performed the following tests:

6.2.5.1 All electrical circuits checked for continuity, insulation, termination, tagging,
operability and compliance within this specification. All instruments shall be checked
against data sheets and if any discrepancies are found by the Contractor, the same shall
be brought to the notice of the Company.

6.2.5.2 All instrument installations are in accordance with manufacturer’s recommendations.

6.2.5.3 Alarm circuit tested for correct operation.

6.2.5.4 All symbols and nameplates checked for correct spelling, tagging, size, and the like.

6.2.6 The instruments shall be subjected to the above-mentioned tests as and when necessary
to demonstrate proper operation.
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6.2.7 Complete reports of all inspection and testing shall be submitted to the Company’s
representative for approval.

6.2.8 All instruments shall be checked for compliance with the instrument specifications and
purchase orders.

7. PRE-COMMISSIONING AND COMMISSIONING

7.1 The impulse lines shall be isolated near the tap points and shall be plugged/ capped at
the instrument ends before the hydrostatic test. The impulse lines between first isolation
valves and instruments shall be tested hydraulically at 1.5 times maximum operating
pressure after flushing. The impulse lines shall be blown with air after the hydrostatic
tests.

7.2 Instrument impulse lines shall be flushed along with the main lines. All line instruments/
valves shall be removed before flushing. Instrument air lines shall be purged / flushed
with air before connecting to any instrument.

7.3 Instrument air piping and signal tubing shall be tested for air leak with soap solution
after applying maximum operating air pressures. The leak test shall be carried out after
flushing of air piping and signal tubing.

7.4 All cables shall be checked for continuity / insulation.

7.5 Open and close loop checking by simulation.

7.6 Checking of logic schemes in DCS, ESD and FGS by simulation.

7.7 The contractor shall carry out commissioning after completion of the activities above
under the supervision of the Company’s Representative.

8. SPARE PARTS AND MAINTENANCE REQUIREMENTS

8.1 The manufacturers of all instruments, valves, equipment and DCS/ESD/Flare PLC/FGS
shall guarantee the availability of spare parts and continued support of the offered
products for a minimum period of 10 years.

8.2 The Contractor shall submit recommended priced spare parts list for all equipment in
Company approved format for two (2) year operation.

8.3 The Contractor shall supply any special tools and instruments for equipment
maintenance.

8.4 For further details on spare parts and maintenance requirements, refer to Company
Standard No. KOC-G-009: KOC Standard for Spare Parts and Maintenance Data.

8.5 System Registration and Warranty:

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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

8.5.1 Registration and licenses of operating systems, interfaces, program development tools,
application software etc. shall be in the name of Company. It shall be ensured that the
Company Operations Group is fully aware of any updates or upgrades of the
equipment/software and warranty claims could be dealt with directly and not through a
third party.

8.5.2 Guarantee and warrantee period for complete equipment including that of DCS, ESD,
Flare PLC & FGS systems and field instruments / valves shall be as per the Defect
Liability period stipulated in the General Conditions of Contract.

8.5.3 Software with all the required licenses shall be supplied including backup of all
application software configuration, programming etc.

9. MANUFACTURER AND COMPLIANCE TO LOCAL STANDARDS

9.1 The Contractor shall ensure that all the systems, field instruments and other equipment
offered shall be supplied by the manufacturers who shall also be on the Company's
approved manufacturer's list. For items not covered by this list, the Contractor shall
submit his proposed Vendors (for each item) complete with QA/QC Manual, users list,
detailed Catalogues, etc. (for each vendor proposed) for Company's review and
approval. All relevant test certificates shall be submitted for Company review and
approval.

9.2 The Contractor shall be responsible for all submittals of complete design information to
Company and for obtaining all necessary approval certificates prior to the
commencement of installation and commissioning Works.

10. PACKING, MARKING AND DOCUMENTATION

Packing, Marking and Documentation shall be as per Company’s standard KOC-G-004:

KOC Standard for Packing, Marking and Documentation.

11. DOCUMENTATION

11.1 The Contractor shall furnish instrumentation-related documents and drawings as

required in KOC-I-001, for design, engineering, procurement, testing, and construction
in the English language for Company’s review and approval as follows, but not limited
to the following:

11.1.1 Document Index

11.1.2 All Piping and Instrumentation Diagrams

11.1.3 Site survey report

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TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

11.1.4 Enquiry Requisitions complete with Specifications and Data sheets in ISA format,
vendor data requirements, inspection requirements, etc.

11.1.5 Purchase Requisitions complete with make and model number, vendor’s detailed
technical information/ model decoding procedures, etc.

11.1.6 Vendor’s documentation as indicated in the enquiry requisitions.

11.1.7 Specifications / drawings for DCS/ESD/FGS/Flare PLC systems such as Functional

Design Specification, Detailed Design Specification, Bill of material, Power & Heat
dissipation calculation, Power distribution diagrams, cabinet internal & external GA
drawings, Cabinet wiring drawings, I/O allocation, I/O list, I/O schedule, Schematic
diagrams, Control building equipment layout, Control system architecture diagram,
block diagrams, Interconnection diagram, Graphics, Trend, Reports etc.

11.1.8 Instrument Index (for information only)

11.1.9 Instrument Data Sheets

11.1.10 Instrument I/O List (for information only)

11.1.11 Cause and Effect matrix

11.1.12 Cable schedule

11.1.13 Cable routing layout

11.1.14 Cable Block Diagrams

11.1.15 Loop Diagrams

11.1.16 Logic Diagram

11.1.17 Interconnection Diagrams

11.1.18 Junction Box layout & wiring Drawings

11.1.19 Junction Boxes Schedule/ List

11.1.20 Junction Box Wiring diagram

11.1.21 Instrument Location Layouts Drawings

11.1.22 F&G detector layout drawings

11.1.23 F&G design philosophy

 Page 26 of 27

TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

11.1.24 F&G Mapping study report

11.1.25 Control and Safeguarding philosophy

11.1.26 Control Loop Narratives

11.1.27 Relief Valve Sizing Calculations

11.1.28 Orifice plates and flowmeter Sizing Calculations

11.1.29 Thermowell dimensional drawings and wake frequency calculations

11.1.30 Alarm & Trip schedule

11.1.31 Process / Pneumatic Hook-ups

11.1.32 Instrument Support Drawings

11.1.33 SIL study and Sil verification reports

11.1.34 Inspection, Calibration, Testing Reports

11.1.35 Pre-Commissioning and commissioning Procedures for the whole plant

11.1.36 Operation & Maintenance and Configurations Manuals

11.1.37 Other relevant Drawings/Documents

11.1.38 Quality Control Procedures

11.1.39 As-Built Documentation and Drawings both hard as well as soft copies

11.1.40 The Contractor shall ensure that Control System Architecture to be provided for
DCS/ESD/F&G systems shall be the updated system architecture which shows all the
existing systems, in addition to the proposed new systems.

11.1.41 All Company Drawings and documents included in the Contract are for guidance only.
The Contractor shall develop all necessary documents to complete the Works to
Company satisfaction.

11.1.42 The Contractor shall revise the existing documentation like Cause & Effect matrix,
P&IDs, Control philosophy, O&M manuals etc. that are affected by the project in order
for the facility to maintain only one set of updated documentation instead of producing
new sub-set documentation.

11.1.43 The Contractor shall handover the native files of all the documents / drawings to
Company at the end of the project.
 Page 27 of 27

TECHNICAL SPECIFICATION PART V - INSTRUMENTATION WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE FLARES
AT NK GCs-15, 23 & 25

12. TRAINING

12.1 The Contractor shall provide classroom and on-the-job training in the operation and
maintenance of all the systems / equipment for personnel designated by the Company
as detailed in Technical Specification Part I – General.