GNRL in DBS 1 545B 04 00 Block 4 Design Basis Rev 00

Instrument and Control Design Basis (DOC No# GNRL-IN-DBS-1-545B-04-00)

Contract Number CFT/DG/45/10/508

Project:

EPIC OF BLCOK-4 RISER PLATFORM AND SUBMARINE PIPELINE

File No: GNRL-IN-DBS-1-545B-04-00

00 03/11/11 Issued For Approval EB NS SH

A1 06/09/11 Issued For Review EB NS SH

Rev. Date Issue Purpose Prepared By JPK Checked By JPK

Approved By JPK

Approved By ME Approved

Client Rep. Total Pages: Category Code Dragon Oil

Contract Code 0508 Description

Document Type DBS Offshore Installation

Client:

General

Area Code Discipline Code Classification

Code Country

Code Cluster Number

Serial Number

Sheet Number

GNRL IN DBS 1 545B 04 00

EPIC OF BLOCK-4 RISER PLATFORM AND SUBMARINE

PIPELINES INSTRUMENT DESIGN BASIS

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GNRL-IN-DBS-1-545B-04-00

Rev. 00

Date: 03-11-11

Table of Contents 1. INTRODUCTION.......................................................................................................................................... 7

1.1 PROJECT DESCRIPTION ........................................................................................................................... 7 1.2 DEFINITIONS ........................................................................................................................................... 7 1.3 ABBREVIATIONS ..................................................................................................................................... 8 1.4 SCOPE OF DOCUMENT............................................................................................................................. 8 1.5 UNIT........................................................................................................................................................ 8 1.6 HOLD REGISTER...................................................................................................................................... 8

2. REFERENCES............................................................................................................................................... 9 3. INSTRUMENTATION ............................................................................................................................... 11 4. DESCRIPTION OF THE PLATFORM BEING DESIGNED ................................................................ 23



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SAFETY HEALTH AND ENVIRONMENTAL ISSUES

No. DESCRIPTION OF ISSUE POTENTIAL MITIGATION MEASURE



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Document Review Comments Sheet Project :EPIC Of Submarine Pipelines and Associated Risers JPK / Client Job No: :140254.01/ CFT/DG/45/10/508 Date: 03-11-11 Document Title : Instrument Design Basis

Document Number: : GNRL-IN-DBS-1-545B-04-00 Issue / Revision: : 00

Section Comments (Reviewer)

Action Undertaken (Originator)

Closed Out

(Y / N)

- - I&C Design Basis Rev. 00 has been updated in accordance with CLIENTs comment and with the latest document format, hence reference sections and pages has been updated accordingly.

Y

1. Comments marked on the document annexure

1.2 Please check this project description based on present project scope of work and revise.

Complied Y

2 All instrument related standards shall be included Complied Y

3.2 Change IP65 to IP66 Complied Y

3.4 API-526 shall be followed for tagging and nomenclature of safety valve.

Complied Y

3.6 Change bar to Barg Complied Y

3.7 Instrument specification shall be provided for the following: 1. flowmeter 2. Pig signaller 3. Level gauge & switches

1. Please refer to section 4.6 of this document. 2. Only datasheet will be provided for pig signaller 3. Not included in CONTRACTORs scope

Y

3.7.1 Refer comments provided on datasheet of ESDVs Complied Y

3.7.2 Change IP65 to IP66 Complied Y

3.7.7 Change 5 inches to 6 inches Complied Y

3.9 1. Power supply requirement for multiphase flowmeter 1. Complied Y



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Closed Out

(Y / N) shall be briefed. 2. Please confirm availability of 110V from UPS. 3. Please confirm availability of UPS from existing platform

2. No interface with motor starter circuit envisaged in our scope. Referred paragraph shall be deleted. 3. No UPS requirement for instruments. Referred paragraph shall be deleted.

3.12 Add Conductor size shall be confirmed/indicated Complied Y

3.13 Change IP65 to IP66 Complied Y

3.14 Change EExe to EExd Complied Y

3.15 1. Change carbon steel to 316 SS 2. Add: 50 / 100 /150

Complied Y

3.16 Include MMSCFD/BOPD units for flow Complied Y

4.0 Add: Inst. air supply shall be taken from air cylinder bank which being provided by others. Connections for the new ESDVs shall be taken from the air supply header

Complied Y

4.0 1. Add: Inst. air supply shall be taken from air cylinder bank which being provided by others. Connections for the new ESDVs shall be taken from the air supply header 2. .partial shutdown of esd.. -shall be deleted since partial stroking is not to be considered. 3. Change IP65 to IP66

Complied Y

4.1 1. Change SDV to ESDV 2. Add: with the involvement of the existing control system vendor on the platform

Complied Y

4.2 Add: with the involvement of the existing control system vendor on the platform

Complied Y

4.3 Provide the requirement as per mark-up Complied Y

4.4 Add: with the involvement of the existing control system vendor on the platform

Complied Y

4.5 Update as per mark-up Complied Y

4.6 Multiphase flowmeter in 12 line is in Contractors scope

Complied Y

4.8.2 Update as per mark-up Complied Y

4.11 Please indicate the painting spec document number.

Complied Y



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Closed Out

(Y / N)

2. General Comments:

a. ME shall indicate their instrumentation scope very clearly. LAM B, LAM C and Zhd A, the ESD/ F&G System is PLC based and is separate from Well head Control Panel. The logic for pipeline ESDVs shall be developed in the platform ESD/F&G panel for monitoring and shutdown. All necessary modifications, interface with the platform ESD/F&G system including cabling/ wiring for these signals are in MEs scope of work. ME shall finalize with PLC vendors (e.g. CSE Global-Singaopre for LAM-B, Cimac for LAM-C) and carry out modification required in the existing PLC system which may be required before interface/ hook-up. These platforms shall be equipped with the electronic control systems based on PLC in addition to fusible plugs loop its required to add fire monitoring in the design areas by means of IR flame detectors with the corresponding modernization of the existing F&G systems. However for Block-4, Lam-28 and Zhd-25 only fusible loop system is envisaged. The number of sets of pilots for operating ESDVs shall be considered as per the P&ID for each platform.

Noted and agree with all the items except IR flame detectors. IR flame detector are not part of Contractor scope of work. Contractor scope is limited to supply of fusible plugs only (please refer to Note-b in section.4.2.140.8-HSE Engineering of detailed scope of work XXX-B004-GE-SOW-002.

Y

b. b. Block-4, LAM-28 are pneumatically controlled. All modifications, tubing and connections to control panel required for hook-up shall be in MEs scope. Refer P&ID- L028-PR-PID-1-T001-01-00, all necessary interfaces with this ESD panel including tubing for pressure pilots and ESDVs shall be carried out by ME. Fusible loop with plugs shall be considered for pig launcher/ receiver areas at Lam-28.

Noted Y

c. c. At Zhd-25 new pneumatic ESDV panels and fusible loop system shall be provided by contractor as per the P&IDs along with 3 sets of air cylinders (with 4 compressed air cylinders on each set assembled as cassette total of 12 cylinders in 3 cassettes). One set of cylinders shall supply air to ESDV control panel, one set shall be on hot stand-by and third set shall be for re-filling purposes (refer Z025-PR-PID-1-T001-02-00 Rev A2).

Noted Y

d. d. All pig receivers should have 2 isolation valves. All isolation valves 8" and above should have bypass line fitted with globe valves and ball isolation valves. fe All ESDvs should have manual over rides and not hydraulic. Hydraulic overrides have a tendency to leak and repairing them is a problem (If hydraulic override valves have to be repaired, they are to be in a shut-in condition).

Noted Y



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1. INTRODUCTION 1.1 Project Description

Dragon Oil (Turkmenistan) Ltd, (DOTL) here-in after, called as COMPANY is engaged in exploration & production in Lam and Zhdanov Fields located about 35 km off Turkmenistan in the Caspian Offshore. The COMPANY is having Production Sharing Agreement with the Turkmenistan Government for 25 years. The LAM and Zhdanov fields produce oil and condensate together with associated gas from a series of stacked reservoir sandstones. With alignments of COMPANY growth and future plan and based on the production forecast, Block 4 manifold platform and subsea pipelines are required to be installed to receive production from surrounding platforms. For this purpose, DOTL had invited proposals from prospective bidders for EPIC of Block-4 Riser Platform and Submarine Pipelines. Further, this EPIC Contract divided into two packages for Riser Platform and Submarine pipelines. Momentum Engineering (Dubai) has been awarded the EPIC Contract for Subsea Pipelines and Associated Risers. Momentum Engineering has appointed JP Kenny Ltd (Abu Dhabi) as Sub-CONTRACTOR to perform Detailed Engineering associated with subsea pipelines, associated risers and topside hook-up to existing or new facilities designed by others. This project consists of the following pipelines:

Sr. No. Item detail

1 10 oil/condensate/gas Subsea pipeline from Zhdanov A to Block 4

2 12 oil/condensate/gas Subsea pipeline from Block 4 to Tee point on 30 Trunkline

3 6 oil/condensate/gas Subsea pipeline from Zhdanov 25 to Tee point on 30 Trunkline

4 14 oil/condensate/gas Subsea pipeline from Lam C to Lam 28

5 14 oil/condensate/gas Subsea pipeline from Lam C to Lam B

1.2 Definitions COMPANY DRAGON OIL TURKMENISTAN LTD

CONTRACTOR MOMENTUM ENGINEERING

SUB-CONTRACTOR The party, which provides services to perform the duties specified by CONTRACTOR/COMPANY (J P KENNY for Detailed Engineering).

SUPPLIER/VENDOR The party, which manufactures and/or supplies equipment, technical documents/drawings and services to perform the duties specified by CONTRACTOR/COMPANY.



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SHALL Indicates a mandatory requirement.

SHOULD Indicates a strong recommendation to comply with the requirements of this document

PROJECT EPIC of BLOCK-4 RISER PLATFORM AND SUBMARINE PIPELINES

WORK All activities associated with EPIC PROJECT

1.3 Abbreviations AC Alternating Current BS British Standard CB Circuit Breaker DC Direct Current Deg Degree IEC International Electro-technical Commission IP Ingress Protection ESD Emergency Shutdown FGS Fire & Gas System Hz Hertz JB Junction Box SPDT Single Pole Double Throw P&ID Process and Instrument Diagram

1.4 Scope of Document This document summarizes the minimum design basis, data, parameters, codes and standards and the design criteria to be used for the Detailed Engineering of submarine pipeline and associated risers for the following pipelines:

10 ZHDANOV A to BLOCK 4 12 BLOCK 4 TO Tee point 30 Trunk pipeline 6 ZHDANOV 25 to Tee point on 30 Trunk pipeline 14 LAM C to LAM 28 14 LAM C to LAM B

1.5 Unit An International System of Units shall be adopted throughout the project unless otherwise specified.

1.6 Hold Register The HOLD items are summarised in the below Table.

Section

Description Action



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2. REFERENCES

The Instrument System design and installation shall comply with the latest edition at the time of Contract award of the following codes and standards as listed below

BS 5490 Classification of degrees of protection provided by enclosures.

ANSI B 16.5 Steel pipe flanges, flanged valves and fittings

ANSI B 2.1 Pipe threads

BS 1904 Industrial platinum resistance thermometer elements

BS 2765 Dimensions of temperature detecting elements and corresponding pockets

BS 5501 Electrical apparatus for potentially explosive atmosphere parts 1 and 7 BS EN 60079 - 14 - 2008

Electrical apparatus for explosive gas atmospheres. Electrical installations in hazardous areas (other than mines)

BS 1259 Intrinsically safe electrical apparatus and circuits for use in explosive atmospheres

ISO 9000 9004 Quality Management and Quality Assurance System

ISO-31 Quantities and Units General Principles

BS 5308 Specification for Polyethylene Insulated Instrument and Control Cables

BS 1442 Specification for Galvanised Mild Steel Wire for Armoured Cables

BS 6234 Specification for Polyethylene Insulation and Sheath of Electrical Cables

ASTM A123/BS 729 Hot Dipped Galvanised Coating for Iron & Steel

IEC 60228 Conductors of Insulated Cables

IEC 60331, Part 2 Test for Electric Cables under Fire Conditions Circuit Integrity

IEC 60332, Part 3 Test for Electric Cables under Fire Conditions Test on Bunched Wires or Cables

IEC 60754-1 Test on Gases Evolved During Combustion of Materials from Cables, Part 1 - Determination of Amount of Halogen Acid Gases

IEC 61034-1 Measurement of Smoke Density of Cables Burning Under Defined Conditions

IEC 60811 Common Test Methods for Insulating and Sheathing Materials of Electric Cables



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IEC 60529 Classification of Degrees of Protection Provided by Enclosures

IEC 60079-0 Electrical Apparatus for Explosive Gas Atmosphere, Part 0 General Requirements

IEC 60079-1 Electrical Apparatus for Explosive Atmospheres, Part 1 - Equipment Protection by Flame Proof Enclosures D

IEC 60079-7 Electrical Apparatus for Explosive Atmospheres, Part 7 - Equipment Protection by Increased Safety E

IEC 60079-14 Electrical Apparatus for Explosive Atmospheres, Part 14 Electrical Installations in Hazardous Area

API RP 520 (2000) Sizing, selection and installation of pressure relieving devices in refineries Part 1: Sizing and selection

API RP 521 (1997) Guide for pressure relieving and depressurising stems

API STD 526 (1995) Flanged steel pressure relief valves

API STD 527 (1991) Seat tightness of pressure relief valves

CENELEC EN 10204 (1991) Metallic Products types of inspection documents

ASME B 16.5 (1996) Pipe flanges and flanged fittings

ASME Section VIII, Division 1 (1998) Pressure vessels codes

API 6FA (1999) Specification for Fire test for valves

ISO 5211 (2001) Industrial Valves- Part turn actuators

ASMEB31.3 Process Piping

ASTM A269 2000 Specification for seamless welded austenitic stainless steel tubing for general services

API RP14J Recommended Practice for Design and Hazards Analysis for Offshore Production Facilities

BS 6755(PART1) Specification for Production Pressure Testing Requirement



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3. INSTRUMENTATION 3.1 Design Philosophy

The instrument systems shall be designed to ensure the following:

The process is operating safely and should systems fail it shall be to the safest possible condition.

Energy losses needed to establish control would be minimised. Provision for changes and expansion during design is to be included. Equipment and systems have a high degree of reliability. Equipment and installation is

designed for ease of operation, maintenance and replacement.

Standardisation of equipment to reduce spares holding and operators training. The guidelines for selecting analogue versus digital monitoring shall be as follows: For control of level, pressure, flow and temperature, generally use transmitters. For level shutdowns generally use switches. For pressure, flow and temperature shutdowns, generally use transmitters.

3.2 General All materials utilised in the construction of instruments shall be of the latest design, new and in current production. Material scheduled for modifications shall not be used unless approved by the company.

Prototype or unproven equipment not having a well-established operating record will not be considered.

Only standard designs that are in regular and current production manufactured for offshore oil and gas platforms and onshore oil storage and process facilities shall be provided.

Supplier is to state the expected level of reliability of the equipment in service and Mean Time Between Failure (MTBF) data for similar units in service.

Component stress levels being one of the key factors governing failure rate, the supplier is to ensure that all equipment will be conservatively stressed rather than just meeting the specified design requirements.

To minimise the consequences of failure, the supplier shall ensure that the design provides for ease of diagnosis and repair. Replaceable items with long deliveries shall be identified.

Easy maintenance or unit replacement is necessary, and consideration in the design should be given to twin or multiple alarm and shutdown sensors to avoid failure or spurious system operation.

All instrument and electrical equipment and materials shall be suitable for the environmental conditions of the site such as:

Exposure to salt laden marine atmosphere Hazardous area classification Exposure to damaging fumes or vapours



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All instrumentation located in any hazardous areas and/or outside of the positively pressurised building shall, as a minimum, be classified suitable for Zone 2, Gas Group IIA, and Temperature Class T3.

Classification shall comply with the requirements of IP Model Code of Safe Practice Part 15.

All instrumentation outside positively pressurized air-conditioned buildings shall be protected to IP66 as per IEC-60529 as a minimum. All field devices exposed to direct sunlight should be provided with standard instrument sunshades.

In selecting materials and equipment, particular attention shall be given to painting and corrosion protection because of the harsh environment. All nuts, bolts, studs, washers, clamps etc. used throughout the instrument and electrical installation shall be type 316 SS unless specifically stated otherwise.

3.3 Environmental Data All items are to be suitable for operation on unmanned offshore platform. These are suitable for continuous duty, in the severe environmental conditions prevailing at site, without temperature rise of any part of the electrical equipment exceeding the maximum temperature rise values stipulated in the relevant standards.

The following environmental data for this project derived from the 8982-NDE-HDI-Metocean Data for LAM & Zhdanov Fields provided by Dragon Oil will be used for this project:

Maximum ambient temperature = 43 C Minimum ambient temperature = - 20 C (with wind chill); Minimum ambient temperature = - 6 C (without wind chill); Maximum sea water temperature (summer) = 28 C Minimum sea water temperature at surface = 3.4 C Sea bed temperature = 5 C Maximum wind speed at 10 m. = 29,7 m/sec; Seismic Loads 0.3G (Strength level earthquake, 400 years).

3.4 Tagging of Equipment

Supplier shall supply each equipment item with a 316 SS name plate screwed or riveted to the units body with 316 SS hardware. If the item is such that screws or rivets are not acceptable, a 316 SS tag may be wired to the item using a minimum of 18 gauge 316 SS wire. Adhesives shall not be used as the sole means of attachment. Tagging and nomenclature for safety valves shall be as per API-526.

Tagging information shall include all the following, as a minimum:

Equipment identification number Manufacturer Model number Pressure/ temperature rating of pressure containing parts Materials of construction of pressure containing parts Hazardous area classification Power consumption Switch contact rating



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Setpoint 3.5 Instrument Connection Size

In general, all process line connected instruments shall have the following connections:

Connections shall be as per the piping specification Pressure and differential pressure instruments shall have inch NPT connections. Thermowells shall have inch NPT screwed or 2 inch flanged connections, as per the piping

specifications. Supplier shall adhere to the above to the maximum extent possible.

3.6 Units of Measurements For all locations other than custody transfer skids, the units of measurement shall be metric, unless stated otherwise.

Pressure : psig/ Barg or inches of water if pressure is positive Temperature : Degrees centigrade

3.7 Instrument Specifications

Supplier shall refer only the relevant portion of this document as required for various instrument specifications depending on the scope of supply. The items to be supplied against this specification shall include but not limited to the following:

3.7.1 Shutdown Valves

All shutdown and blow down valves shall be supplied as a fully assembled unit complete with actuator and accessories like combined position indicator. For details, refer to datasheet no. GNRL-IN-DAT-1-545B-04-00.

Ancillaries such as solenoid operated valves, manual reset latch, filter regulators, speed controllers and the like shall be installed inside a junction box readily accessible from a single location 1400 mm above ground.

Shutdown valves shall be reset either manually at the field (ESDV control panel) or via reset at the existing remote ESD System.

Pneumatic actuators shall be of failsafe, single, spring return, piston type. All shutdown valves shall be certified fire-safe to API 6FA or API STD 607.

Shutdown valve closing speed shall be better than 1 second per inch of line size diameter.

On applications where the valve is closed most of the time, shutdown valves shall have class VI leakage per ANSI 16.104/FCI-70-2 (2006), and in very critical applications where leakage is not allowed, valves shall have MSS SP 61 leakage classification. All accessories including filter regulators, etc. shall be of 316L stainless steel constructions or aluminium with epoxy powder coating.

Manual override, hydraulic operated with hand pump, tank and relevant accessories shall be provided for all shutdown valves.



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3.7.2 Solenoid Valves

The following guidelines shall be adhered for solenoid valve selection.

Solenoid valves shall have operating voltage of 24 VDC. They shall be certified explosion proof depending on the area in which they are installed.

The body material shall be stainless steel unless otherwise specified. The coil shall be provided with Class H (high temperature) coil suitable for temperatures up to 180 deg. C.

The housing for solenoid valves shall be Type 7 and weatherproof in compliance with IEC 60529, IP 66. The solenoid valve lead wires shall be terminated to an adjacent box with screw terminals for field wiring termination. The cable entry to junction box shall be suitable for M-20 ISO glands.

Solenoid valve shall be pneumatic, energize to open, 3-way with exhaust..

3.7.3 Pressure Relief Valves

Safety relief valves shall be of full nozzle / full lift type.

Bodies and flanges shall be of the same alloy material. All valves shall have full nozzles with one piece disc construction.

The safety relief valves shall be conventional / bellows type as indicated on the data sheets.

The end connections, rating and facing of the safety relief valves shall be flanged as indicated on the data sheets (based on the calculations). SUPPLIER shall confirm selection and provide detailed calculations.

The safety relief valves shall be sized according to the procedures and formulae of API RP-520.

The safety relief valve seat leakage shall be in accordance with API STD-527.

When the safety relief valve is handling two-phase flow, the calculations shall be as per the latest API RP-520 using DIERs method.

The materials indicated for nozzles, disc, body and spring on the data sheets are indicative only. SUPPLIER shall review and either confirms selection or offer suitable alternative material based on the experience in similar service conditions. The nozzles shall be forged type only; cast nozzles are not acceptable.

The material for spring shall be selected according to the temperature of the fluid. Spring material shall be corrosion resistant coated carbon steel between -25 to 230 Deg C. Beyond these temperatures either corrosion resistant coated alloy steel or stainless steel based on the process conditions shall be used.

Manual lifting levers shall be provided for valves in air or hot water service if the operating temperature is above 60 Deg C.

Where fire case is mentioned in the data sheet; the valve, spring material shall be selected considering the maximum anticipated conditions.

The type and the material of the bonnet, cap shall be as indicated on data sheets.

An adjustable ring (blowdown ring) shall be provided for the safety relief valves. The blowdown rate shall be adjustable between 2.5% to 7.9% of the set pressure.



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All the necessary accessories such as nuts, bolts, gaskets shall be suitable for the valve material and operating conditions.

3.7.4 Pilot Operated Safety Relief Valves

Use of pilot operated safety relief valves shall ve restricted to services with clean fluid.

Pilot operated safety relief valves maybe used where flow capacity , set pressure can not be met by standard safety relief valve. This will be indicated on the datasheets.

Pilot shall be snap acting non-flowing type to reduce the flow of line media through the pilot.

All the other specifications indicated in previous sections shall also be applicable for pilot operated safety relief valves.

3.7.5 Balanced Bellow Safety Relief Valves

As first preference, conventional safety relief valves shall be used. However as indicated on the data sheets balanced bellows type safety relief valves can be used where the backpressure is more than 10% of the set pressure.

Besides balancing, the bellows may be used to isolate the spring and guiding surfaces in valves from corrosive, dirty fluids.

3.7.6 Thermal Relief Valves

The thermal relief valves shall be standard 1D1 type. The inlet and outlet connections shall be flanged in line with inlet and outlet piping classes/ specifications. The body, seat, spring material, rating shall be suitable for the design pressure and temperature.

All the safety relief valves shall be painted in accordance with Specification for Painting and Coating.

Inspection and Testing

All safety relief valves may be subject to inspection by Third party agency representative or as mentioned on the material requisition/ purchase order.

Acceptance of shop tests shall not constitute a waiver of requirements to meet service requirements under specified conditions and final guarantee for material design, workmanship and performance.

The safety relief valve shall not be dispatched by the Supplier until it is released by COMPANY/COMPANYS representative.

The safety relief valve shall be inspected for physical and dimensional details as per the specification/data sheets/drawings.

The safety relief valves shall be tested for at set pressure as laid-out in the specifications/ standards/ codes. The seat leakage tests shall be in accordance with API STD 527.

The materials test certificates, internal shop test reports, and welding reports (if any) etc shall be verified during inspection. For all pressure retaining parts material inspection and certification shall be in accordance with EN 10204: 3.1B



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All welding, brazing, heat treatment and non-destructive examination used in construction of safety relief valve bodies, bonnets shall be in accordance with application requirements of ASME section VIII, Division 1.

Packaging and Preparation for Shipment

All openings of safety relief valves must be positively sealed by proper backing plates or other methods to ensure against ingress of dirt and transportation hazard. The use of adhesive tape alone is prohibited.

Machined or threaded surfaces exposed to the atmosphere in shipment or storage shall be coated with rust preventive.

All safety relief valves made of austenitic stainless steel must be stored under cover and out of contact with the ground and shall not be exposed to salt water spray.

Following the testing, all components especially body cavities are to be thoroughly dried prior to preparation for packing and shipping.

3.7.7 Temperature Instruments

Thermowells

Thermowells shall be provided for all temperature measuring devices and be typically supplied with their associated instrument.

Thermowell shall normally be AISI type 316 SS. Minimum wall thickness shall be 5mm.

Thermowells must be suitable for stresses caused by stream velocity conditions and frequency vibration calculations, in accordance with the accepted calculation methods.

Test wells shall have a screwed plug and 150mm 316 SS chain.

Thermowell dimensions shall be specified on the data sheets. Lagging extensions or 75mm or 150mm, as applicable, shall be used on insulated pipe.

Thermowell lengths shall be limited due to vibration caused by fluid velocity. Subject to these limits, threaded thermowells should generally have a U dimension of 112mm for pipe 6 inches and larger and 62mm for 3 and 4 inch pipe.

Flanged thermowells shall generally have similar U dimensions, depending on flange stand off. These dimensions should generally result in bore depths (S dimension) of 100, 150, 225 or 300mm depending on pipe size, insulation, thickness etc.

Transmitters shall have adjustable zero and span, dual compartment housing (or equivalent) to separate electronics from wiring connections in an integral (or attached) junction box.

Temperature Indicators

Locally mounted, hermetically sealed, bi-metallic type dial thermometers shall be used unless otherwise specified in the data sheets. Stems shall be 316 SS.

Indicators shall have a dial size of not less than 6 inches and shall be direct reading in Degrees Centigrade (C).



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Indicators shall be selected such that the normal operating temperature will read approximately 50% to 70% of full scale.

3.7.8 Pressure Instruments

Where indicated, pressure instruments shall have direct reading indicating scales in engineering units. Transmitter indicators shall have digital readouts, if available.

Instruments measuring absolute pressure shall be compensated for barometric pressure changes.

Where the instrument is mounted remotely from the sensing point, a block valve shall be provided at both the process line and at the instruments location. The block valve at the instrument shall also have bleed/test valve incorporated into the piping.

Pressure Gauges

Gauges shall be generally 6 inch (150mm) diameter and shall have liquid filled (normally glycerine, however silicone filled if temperatures are less than -18C) cases and micrometer pointers with white dials and black numerals and markings. Pressure or receiver gauges that are mounted in a local panel shall be 4 inch (100mm) diameter.

Range shall be that normal operating pressure is approximately 50% to 70% of full scale.

Accuracy shall generally be to BS 1780.

Over-range protection to a minimum of 130% of full-scale reading shall be provided. Gauges subject to pressure peaks beyond this should be provided with Gauge savers.

Gauges with ranges of 40 barg and above shall be of the safety pattern with an integral baffle plate between the Bourdon tube with the dial as described in BS 1780 part 2. These gauges shall be fitted with a blow out back.

Gauges with ranges below 40 barg shall have solid backs with blow out disc.

Pulsation dampers shall be provided on pulsating duties such as reciprocating pump outlet. Pulsation dampers shall not be used when the fluid is dirty or waxy.

Gauge materials to be 316 SS with toughened safety glass front.

Bourdon tubes shall be 316 SS except in those services where stainless steel is not compatible with the fluid being measured. For seawater service a Monel Bourdon tube shall be used.

Pressure Switches

Requirements for the following shal be the same as pressure gauges:

Range Over range protection Process connections Pulsation dampers Materials

Switching point shall be easily adjustable over full range and be provided with a scale to show set point pressure.

Adjustable system shall not be susceptible to vibration or accidental alteration.



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Care shall be taken to ensure that the switch dead band shall be less than the difference in pressure between the normal operating pressure and the set point.

Datasheets shall specify the set points for either rising or falling pressure. The set points shall generally be within the middle 80% of the adjustable range.

Electronic Transmitters

All transmitters shall have non-interactive zero span adjustments. Field wore terminal strips shall be contained within the housing.

Transmitters shall have a weather resistant housing and shall meet the requirements of Zone 1 EExia, IIC, T6.

Transmitters shall have the following attributes:

0.1% accuracy (% of calibrated span) or better for custody transfer or allocation metering services, 0.25% accuracy for other services (excluding sensor error).

0.2 stability (%of calibrated span for 6 months). 0.1% repeatability. Minimum 3 to 1 rangeability. Ambient temperature range of -300C to +700C. The electrical requirements for instrumentation shall be in accordance with the relevant sections of the electrical design philosophy and Electrical installation specifications.

Transmitters with electrical input and output sections shall be electrically isolated from each other.

3.8 Field Instrumentation Requirements

Dedicated field instruments shall be utilized for ESD and FGS application directly connected to plant safety system via field junction box. It shall be independent and will NOT be shared with any of the other loop.

3.9 Electrical Requirements

All electrical equipment located in hazardous areas shall be certified intrinsically safe or flame proof for the area classification.

All switches, RTDs and other terminations shall be brought out to terminal blocks suitable for external connection of 2.5mm wire. A separate terminal shall be provided for each conductor to be connected, i.e. no communing of conductors on one terminal.

All terminals, switches and other electrical equipment shall be mounted in weatherproof housings suitable for the environmental conditions and shall be to a minimum IP 65.

Housings shall have 20mm isometric female, electrical thread entry or reduced with approved type reducers to 20mm thread entries.

Housings shall be certified suitable for the area specified.



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All equipment shall be constructed in such a way that the operation in the normal working mode, i.e. with instrument covers on, is unaffected by radio transmissions, electrical power supplies, motors, rotating equipment and switchgear etc.

All micro switches shall be hermetically sealed.

Voltages lower than these shall be provided and derived from the above complete with miniature circuit breakers for maintenance and isolation purposes.

All instruments such as transmitters, solenoid valves, relays, switches, coils and etc. shall be 24V DC, standardised plant wide.

Electrical Power supply to multiphase flowmeter skid shall be standardised at 240 VAC, 50 HZ, single phase, direct earth neutral, and 2 wires via redundant feeders from Solar Panel provided at the skid B/L at single point. Further distribution, step-down, and derivation shall by VENDOR.

3.10 Tubing

The following tubing sizes shall be used: inch OD x 0.035 inch wall thickness for individual services inch x 0.049 inch wall thickness for control panels. All fittings used with 316 SS tubing shall be swagelok type 316 SS. For incoloy 825, swagelok type Inconel 600 fittings shall be used.

Instrument valves and pipe fittings shall be of the same material as the tubing above. It should be noted that Hastelloy C276 and Inconel 625 are acceptable substitutes for incoloy 825.

All tubing shall be neatly laid out and adequately supported by stauff clamps.

Preservation

After tubing has been flushed to remove any debris, tubing caps or plugs shall be installed on any open tubing.

At no time shall manufacturers protective seals with cover openings or parts of any instrument gauge, valve, indicator, controller etc. be removed from same until the component is ready to be connected in to the system. At no time shall these components be placed in a position so as to allow foreign matter (such as blasting sand, metal shavings, paint spray, rust, scale etc.) to contaminate their interior. At no time shall completed units be shipped without all unused openings being properly covered.

Inspection and Testing

Tubing may be spot checked for reaming and cleaning by the purchasers representative, and if found to be unsatisfactory, the supplier shall be responsible for re-cleaning any and all tubing designated by the suppliers representative.

Any damage to panel devices caused by foreign particles shall be repaired or replaced at the suppliers expense.

All pneumatic tubing and related equipment shall be pneumatically pressure tested for 30 minutes to 150 psig.



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Rev. 00

Date: 03-11-11

All process instrument piping and sensing lines and equipment shall be hydrostatically pressure tested for 30 minutes to rated pressure, with gauges disconnected. Results shall be recorded using a calibrated pressure gauge.

3.11 Air Supply

Instrument air to individual transmitters, control valves, positioners, etc. shall be provided with filter regulators with suitable 0-30 or 0-60 pound ranges and gauges unless other means of supply are specified. Filter regulators shall be provided with pressure gauges of suitable range for indication.

If lubricators are used, they shall be mounted downstream of the air supply regulator. The lubricator shall be filled with automatic transmission fluid or other low viscosity (10-wt) oil.

Each instrument air supply shall have shut-off valve installed in such a manner as to allow the instrument to be removed without removing the valve.

3.12 Instrument Cabling

Multi-pair, 250V rated cables shall be used from the control room (onshore) to field junction boxes. Separate cables shall include signals for 4-20 mA, DC on off and thermocouple. Separate junction boxes shall be used for instrumentation systems to isolate them from 220V AC and higher power systems.

Individually shielded pairs shall be provided for all turbine meter pick-ups (where applicable), vibration transducers and other pulsing type transmitters. Overall cable shielding is required for all other analogue or thermocouple instrument signals.

Shielding of signal wiring shall be as follows:

Earthing of the shield on intrinsically safe circuits shall be made at one end only, typically in the control room. Typically the field end would be left isolated.

Earthing of the shield on non-IS circuits shall be made at both ends, typically in the control room and at the field instrument.

Shielding shall be electrically continuous from the signal source to the receiver. Shielded cables entering/leaving junction boxes shall have their respective shields connected via terminals supplied in the box.

The shield shall not be earthed along the route of in the junction box. The shield shall not be used as the circuit conductor. The conductor size shall be confirmed/indicated during detailed engineering by the CONTRACTOR, taking due account of any voltage drop limitations for selected equipment.

Cable lengths shall be selected against the cable schedule and spare requirements. Joining of cables or use of junction boxes to extend cable-installed length is not permitted.

All instrumentation and control cables for monitoring & control and power cables are required to be flame retardant in accordance with IEC 60332-3 and instrumentation cables used for critical applications like ESD and Fire & Gas services shall be fire resistant in accordance with IEC 60331-2, i.e. it shall withstand temperatures up to 750 deg C for a period of three hours.



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Rev. 00

Date: 03-11-11

The materials used for cable construction shall have high performance electrical characteristics and enhanced mechanical properties. The method of cable construction and the use of materials shall allow cables to be manufactured with small overall diameter and low weight without sacrificing performance.

The cables shall be resistant to water, oil, solar radiation, ultra-violet light, seawater spray and traces of sour gas in the atmosphere.

The CONTRACTOR shall prepare detailed cable data sheets for each type of cables during detailed engineering for COMPANY approval.

3.13 Cable Glands

The cable gland body, earth tags and washers shall be manufactured from nickel-plated brass. The cable gland thread form shall be ISO metric.

The cable gland types and sizes shall be as indicated within the bill of materials / material requisitions.

The cable gland shall be suitable for use in a hazardous area classification as per hazardous area layout drawings and shall be dual certified for both EEx(d) and EEx(e) in accordance with IEC standard 60079-1/7 respectively.

The cable gland shall meet the minimum requirement of IP66 for suitable weather protection, in accordance with IEC-60529.

The cable gland shall be of double compression type suitable for use with steel wire armoured/braided type cable or unarmoured cables. Complete compatibility between each size and gland is required. Cable gland data sheets and cable gland selection details shall be provided.

Each cable gland shall be provided with a complete kit comprising of earth tag, thread sealing washer (manufacturers standard), serrated washer, locknut and PVC shroud.

3.14 Junction Boxes

The junction boxes (JB) shall be segregated between analog and digital signals.

The JB shall be manufactured from 1.5mm thick SS grade 316. The JB shall be provided with a front-hinged screwed type cover.

All accessories such as nuts, bolts etc. shall be manufactured from SS grade 316.

The JB shall be supplied with a detachable gland plate suitable for bottom single/multipair cable entry.

The gland plate shall be supplied drilled for the total no. of cable entries.

All JBs shall be suitable for back mounting onto a support frame and shall be provided with four (4) support lugs for surface mounting.

SS grade 316 breather / drain plug shall be provided at the bottom of each gland plate to prevent condensate build-up. All the spare cable entries shall be plugged with EEx e plugs.

A suitable wallet shall be provided /fixed to the inside of the JB front cover for holding the drawings / documents.



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Rev. 00

Date: 03-11-11

Each JB shall be completely fitted out with terminal rails, terminal assemblies, end plates, nuts / bolts, gland plates, drain plugs etc.

A screen terminal shall be provided for each multipair cable overall screen and each individual screen of multipair cables as applicable. The JB shall include an internal earthing continuity terminal with an external earth connection.

Terminals shall be suitable for cable conductors, between 0.5sq mm to 4.0 sq mm cross-sections.

The terminal strips shall be vertically mounted within the JBs and dekafix markers for terminal reference shall be placed on both sides of the terminal strip.

The JBs shall be suitable for use in a hazardous area classification as per hazardous area layout drawings, with an ingress protection rating of IP66 in accordance to IEC 60529 and EExd certified for increased safety as per IEC 60079-7 for the complete enclosure / assembly.

3.15 Cable Ladder/Trays

Minimum requirement for cable trays, cable ladders and fittings shall be as follows:

Shall be of robust construction and corrosion resistant Manufactured from 1.5mm thick 316 SS before hot dip galvanizing Hot dip galvanized with a coating of 47 microns minimum Nuts/bolts/washers/spacers shall be hot dip galvanized Smooth edges to prevent damage to the cable installation VENDOR shall include the following information in his offer: steel, average coating weight

in g/m2, zinc coating thickness in micron & recommended technique for rectifying damaged galvanized-coating due to welding, cutting or rough treatment during installation.

Cable Ladder & Associated Fittings:

Cable ladder and fittings shall be manufactured from side rails containing upper / lower flanges with intermediate rung spacers. The rungs shall be of standard manufacturers size, spacing and profile to accommodate the required cable loading. All cable ladder fittings shall be supplied with manufacturers standard plate couplers, bolts, washers and nuts, fittings, hold down/bolt clamps, earth straps etc.

The cable ladder and fittings shall be heavy duty type.

The preferred cable ladder sizes which shall be utilised are 300/450/750 mm (usable width) x 75mm (minimum usable height).

The cable ladders shall be supplied in 6 metre standard lengths. Cable Tray & Associated Fittings:

The cable tray and fittings shall be heavy duty type.

The standard cable tray sizes which shall be utilised are 50/100/150/300/450/ 750mm (usable width x 75mm (minimum usable height).

The cable trays shall be supplied in 3 metre standard lengths.



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Rev. 00

Date: 03-11-11

3.16 Scales

The instrumentation units will be based on following table:

4. DESCRIPTION OF THE PLATFORM BEING DESIGNED EPIC CONTRACTORS Instrumentation work scope includes, but not limited to the items listed hereafter:

Instruments, ESD Valves, PSVs etc. Junction boxes Instrument cables Cable ladders/trays c/w covers Cable glands Instrument Tubes, Valves & Fittings Supports for all installations All consumables (Traffolyte Instrument Tags, Cable Ties, Cable Markers, Core Markers,

Lugs, Tube Clamps etc)

Pig Signalers required at both Launcher and Receiver (Mechanical Flag) system. Safety Interlock system/Castell Key system to be fitted to both Launcher and Receiver

Valves to stop inadvertent opening of door will still under pressure.

Variable Units Scale

Temperature Deg C (& deg F) Direct Reading

Pressure Bar(g) (& Psig) Direct Reading

Flow (Differential) m3/hr or kg/hr 0-10 Sq. Root

Flow (Linearized) m3/hr or kg/hr 0-100 Linear

Flow MMSCFD/BOPD 0-100 Linear

Level 0 100% 0-100 Linear

Signal to Valves - 0-100%



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Rev. 00

Date: 03-11-11

Platform protection system allows for process shutdown in case of fire within the platform area. The fire occurring where major topside process equipments are located is to be detected via fusible plug loops. Instrument air is used to pressurize the loops. In case of a fire the fusible plugs melt releasing the air and actuating the ESD-1.

Monitoring & control instruments shall consist of pressure gauges, Hi/ Lo Pilots, ESD Valves and ESD system consisting of Fusible loop, ESD push buttons, fire protected, fail safe design and ESDV panel for ESDV operations etc. ESDV location must be as close as possible to the riser, preferably below lowest deck and as far down the pipeline riser as it is practicable whilst still being above the highest anticipated wave crest and available for maintenance with working platform, ladder provided as may be required.

One ESDV (FC-Fail Closed) control panel shall be provided for the Emergency shutdown. Control Panel shall have nine units (4-active and 5-spares for future). Each unit shall control 1 ESD valve (FC) (in Contractors scope) based on 2oo3 Voting of the pressure. Following ESD valves shall be connected to ESDV Control Panel:

ESD Valve at Manifold Block-4 ESDV Valve at Pig Receiver B004-PR-01 at Block-4 All pneumatic operated Emergency Push Button Stations shall be connected to Fire Protection Module of ESDV Control Panel as well as all the fusible plugs.

Instrument air cylinder bank shall be used to supply for instrument air supply to control ESD valves and instruments. These cylinders shall be refilled as and when required so we should have 3 sets of cylinders. One set of cylinder shall be supplying air to ESDV controls and two extra sets (one set shall be on stand-by and other set shall be for re-filling purpose). No air compressor is envisaged under this project. Instrument air shall be taken from air cylinder bank, which is being provided by others. Connections for the new ESDVs shall be taken from the air supply header.

Panel shall be made of 316L stainless steel. The thickness shall be 3 m.m for the side and 4 m.m for the doors. Panel shall be free standing with a C-channel plinth. The protection shall be IP66.

4.1 ESDV Requirement at LAM-B Pig Receiver L00B-PR-01 At LAM B the ESD/ F&G System is PLC based and is separate from Well head Control Panel. The shutdown valve at the pig receiver shall be controlled by a digital output from the ESD/ F&G System to the solenoid valve on SDV based on ESD-1 / ESD-2 logic. The pressure switches associated with ESDV shall be taken to ESD/F&G panel for monitoring and shutdown purposes. The necessary modifications, interface with the existing control system, coordination & support with the existing control system VENDOR of the platform, supply and cabling/ wiring activities shall be carried out.

4.2 ESDV Requirement at LAM-C Pig Launcher L00C-PL-01 & L00C-PL-02 The shutdown valve at the pig launchers LC-PL-01 and LC-PL-02 shall be controlled by a dedicated digital output from the ESD/ F&G System (provided by others) to the solenoid valve on each SDV based on ESD-1 / ESD-2 logic. The pressure switches associated with each SDV shall be taken to ESD/F&G panel for monitoring and shutdown purposes. The necessary modifications, interface with the existing control system, coordination & support with the existing control system VENDOR, supply and cabling/ wiring activities shall be carried out.



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Rev. 00

Date: 03-11-11

4.3 ESDV Requirement at LAM-28 Pig Receiver L028-PR-01 The shutdown valve at the pig receiver L028-PR-01 shall be operated and controlled by the existing pneumatic ESDV control panel. All shutdown valve and actuating buttons connections shall be terminated from therein. New fusible plugs shall be provided, as required and new fusible loop shall be connected at the existing ESDV control panel.

4.4 ESDV Requirement at ZHD-A Pig Launcher Z00A-PL-01

The shutdown valve at the pig launcher Z00A-PL-01 shall be controlled by a dedicated digital output from the ESD/ F&G System (ESD system is provided by others) to the solenoid valve on each SDV based on ESD-1 / ESD-2 logic. The pressure switches associated with each SDV shall be taken to ESD/F&G panel for monitoring and shutdown purposes. The necessary modifications, interface with the existing control system, coordination & support with the existing control system VENDOR of the platform, supply and cabling/ wiring activities shall be carried out.

4.5 ESDV Requirement at ZHD-25 One ESDV (FC-Fail Closed) control panel shall be provided for the High Integrity Pressure Protection System. Control Panel shall have four units (2-active and 2-spares for future). Each unit shall control 1 ESD valve (FC) based on 2oo3 Voting of the pressure. ESD valve for Pipeline from ZHD-25 to Tie-in Point at 30 T/L shall be connected to ESDV Control Panel.

All Pneumatic Operated Emergency Push Button Stations Shall Be Connected To Fire Protection Module of ESDV Control Panel As Well As All The Fusible Plugs.

Instrument Air Cylinder Bank shall be used to supply for instrument air supply to Control ESD Valves and instruments. These cylinders shall be refilled as and when required so we should have 3 Sets Of Cylinders. One set of cylinder shall be supplying air to ESDV Controls and two extra sets (one set shall be on stand-by and other set shall be for re-filling purpose). No air compressor is envisaged under this Project.

Control Panel shall have the possibility of SDV response testing, i.e. partial shutdown of ESD valve during test mode. Test mode shall check the shutdown logic.

Panel shall be made of 316L stainless steel. The thickness shall be 3mm for the side and 4mm for the doors. Panel shall be free standing with a C-Channel Plinth. The protection shall be IP66.

4.6 Multiphase Flowmeters at BLOCK-4 A multi phase flow meter skid (1 No.) shall be installed at manifold of the topside facilities of the riser platform located in the Block-4 area. For details refer to document no. GNRL-IN-DAT-1-545B-22-00, Specification and Datasheet for Multiphase Flow meter.

4.7 Fire & Gas Requirement Fire & Gas System requirement shall be limited to supply of fusible loops, to be supplied based on area & routing. Fusible loop with sufficient number of fusible plugs shall be provided in the pig launcher, pig receiver, riser areas for the fire detection and shall have provision for connecting to the ESDV panel. Gas detectors are not presently envisaged at these areas and are



Page 26 of 27


Rev. 00

Date: 03-11-11

not included in the CONTRACTORs scope, as this will be installed by the other CONTRACTORs (Platform CONTRACTOR), if additionally required.

4.8 Material Recommendation 4.8.1. Valves and Fittings

The service environment at this facility is not highly corrosive and carbon steel is to be used for fittings; materials for valve bodies are selected with regard to the environmental corrosiveness. These materials are to be procured as cast or forged product to suit pressure, temperature and code requirements. The relevant specifications are ASTM A 216 WCB and A 350 LF2.

4.8.2 Instrumentation Pressure Tubing Many instruments are sensitive to debris resulting from internal corrosion of the pipe surface which could cause blockage of fine nozzles/ orifices. To prevent any risk of blockage the instrument air is to be delivered through a corrosion resistant alloy (316 SS). The fittings are made from the same material as that of tubing.

4.8.3 Instrument Cable Trays Cable trays shall be 316 SS, perforated type and shall be designed to be maintenance free for complete design life as replacement in service is expensive.

4.8.4. Electrical Conduits For areas where risk of mechanical damage or the risk of being stepped on is insignificant, non-metallic material such as fiber-reinforced material is used. For areas where severe mechanical damage is expected and for horizontal pipes which can be stepped on the material is plastic lined steel pipe.

4.8.5 Instrumentation Junction Box The instrument junction boxes located in hazardous areas are to be EEx d..; the enclosure protection is IP66 in GRF or SS 316 construction.

4.8.6 Radio Frequency Interference All instruments located in hazardous areas and/or out of a room with an excessive pressure are provided for use in Zone 2, Gas Group IIB, and Temperature class T3 (according to IP Model Code of Safe Practice Part 15 requirements). All instruments located out of conditioned rooms with an excessive pressure are IP66 as per IEC- 60529. All field appliances exposed to direct sunlight have standard sunshields.

4.9 Radio Frequency Interference Unless otherwise specified by the COMPANY, with reference to IEC 61000-4-4, for portable radio transmitters/ receivers which have electromagnetic strength of 10 mV in the frequency range of 20 to 1000 MHz, the total effect of radio frequency interference shall be equal to or less than 0.1% of the output span with the instrument enclosure (cover) in place, and equal to or less than 0.5% of the output span with the instrument enclosure (cover) removed.



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Rev. 00

Date: 03-11-11

4.10 Instrument Grounding Earthing conductors used shall be stranded and insulated, 600/1000 V grade to BS 6346 and be colour coded green / yellow.

Earthing for analogue and digital loops is as follows:

Metallic instrumentation enclosures shall be bonded to the platform/plant steelwork by bolted connections or through process connections.

The braiding of the field cables are connected through the respective glands to the instrument housing on the field side and the dirty earth bar within the marshalling cabinet or junction box on the other side.

The screens of the field cables are isolated at the field instrument side and connected to the insulated instrumentation earth bar in the panel. This enables single earthing at the panel end of the loop.

4.11 Painting

The external surfaces of Control Valves, Safety Valves, Junction Boxes & relevant instrument will be painted in accordance to B004-PP-SPE-I-XXXX-05-00 Specification for painting and Coating.

4.12 Inspection and Testing

Individual, testing of instruments will be required as well as pressure testing, leak testing as stated in data sheets / material requisition.

4.13 Spare Parts and Special Tools Required spare parts and special tools shall be provided as per vendor recommendation. List of recommended spare parts for two year continuous operation shall be provided to COMPANY.

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GNRL in DBS 1 545B 04 00 Block 4 Design Basis Rev 00

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