User:AniRaptor2001/Typical Project Spec

Source: Petrofac IPCI-2 Specification for Analyzer & Analyzer Management System, Doc. No. IPCI2-PF-8550-SP-0000-0013

1.0 INTRODUCTION
This specification together with the referenced documents defines the minimum requirement for design, engineering, manufacture, inspection and testing of Analyzers & Analyzer Management System for the INTEGRATED PETROCHEMICAL COMPLEX AND INFRASTRUCTURE PHASE 2 (IPCI-Phase 2 Project) facility.

1.1 Project Description and Location
The KLPE Integrated Petrochemical Complex Phase 2 Project is a new petrochemical plant with associated facilities to be constructed in the Atyrau Oblast (region) of Western Kazakhstan. The city of Atyrau (АтЬIрау), on the northern shore of the Caspian Sea at the Ural River estuary, is the nearest industrial centre. The IPC site lies approximately 2km to the north of Atyrau (АтЬIрау) – Dossor (Доссор) “highway”, and 4km north of the railway line and the station of Karabatan.

Karabatan is approximately 40km from Atyrau by road.

The GSU is located approximately 150km south-east of Karabatan, about 20km north of the Tengiz Chevroil Tengiz (TCO) Facilities. The site lies approximately 2km east of the “highway”, railway line and pipeline corridor between Tengiz and Karaton (Каратон).

DEFINITION
Within the document the following definitions apply:

COMPANY

shall mean the party that initiates the Project and ultimately pays for its design and construction. The COMPANY will generally specify the technical requirements.The COMPANY may also include an agent or consultant authorized to act for, and on behalf of the COMPANY.

CONTRACTOR

shall mean the party that carries out all or part of the design, engineering, procurement, contruction, commissioning or management of a project, or operation or maintenance of a facility. The COMPANY may undertake all or part of the duties of the Contractor. Where the context so admits, CONTRACTOR includes CONTRACTOR’s workmen, employees, agents and/or representatives, successors and permitted assignees. The term PURCHASER when referred in Codes and Standards shall also mean CONTRACTOR.

SUPPLIER

shall mean the party that manufactures or supplies equipment and services to perform the duties specified by the COMPANY or CONTRACTOR. Where the context so admits, SUPPLIER includes its representatives, successors, assignees and employees. The term MANUFACTURER/VENDOR when referred in Codes and Standards shall also mean SUPPLIER.

Within this document:

 The word ‘shall’ indicates a requirement

 The word ‘should’ indicates a recommendation

APPLICABLE CODES, STANDARDS, REGULATIONS AND SPECIFICATIONS
Equipment/ Services/ works/ Supply covered by this specification shall comply with the latest revision of project specifications, requisition and current revision (as on 11th Oct 2013) of the codes and standards listed below.

Project Specifications
Basic Engineering Design Data-Common

IPCI2-PGL-8110-DB-0000-0001

Philosophy for Instrument Design

IPCI2-PGL-8550-PH-0000-0001

Specification for Field Instruments

IPCI2-PGL-8550-SP-0000-0003

Instrument Cables Specification

IPCI2-PGL-8550-SP-0000-0011

Instrument Installation Specification IPCI2-PGL-8550-SP-0000-0015

Winterisation Philosophy IPCI2-PGL-8110-PH-0000-0012

Specification for Analyzer Shelters IPCI2-PGL-8550-SP-0000-0014

Instrument Numbering Specifications IPCI2-PGL-8550-SP-0000-0001

Electrical general specification (Design Basis) IPCI2-PF-8530-SP-0000-0001

Basis of Design- HVAC IPCI2-PF-8330-PH-0000-0001

Piping Material Specification IPCI2-PF-8230-SP-1000-0011

International Codes & Standards
http://excel2wiki.net/

The codes and standards referenced above are supplemented by this specification which states only requirements in addition to, or deviating from, those specified in the codes and standards.

This specification shall also be read in conjunction with all other specifications and data sheets attached to the requisition.

Any conflicts between the referenced documents shall be identified to the CONTRACTOR in writing for resolution.

Compliance by SUPPLIER with provisions of codes/standards does not relieve SUPPLIER from the responsibility to furnish equipment and accessories of proper design suitable for the specified service conditions and/or local codes governing health and safety.

3.3 Order of Precedence of Documents
SUPPLIER shall bring to the attention of CONTRACTOR, any conflicts between the referenced documents. In general, when resolving such conflicts, the following order of precedence shall apply:

 Kazakhstan Regulations

 Kazakhstan Codes and Norms where more stringent than International Codes and Norms

 Contracts

 Licensor Specifications, Standards and Requirements

 Facility Specification, reference number 1CD1439A, July 2013 (Project Specifications)

 Recognized International Codes and Norms, and Process Industry Practices, referred in Engineering Execution Plan (Annexure-2)

 Common CONTRACTOR’s Standards prepared for this project

While deciding on the order of priority, due consideration shall be given to safety and ease of operation and maintenance in this order of precedence.

3.4 Deviation & Concession Control
The SUPPLIER shall list down, if any, all the deviations to the specifications, codes and standards. Unless any deviations are identified by SUPPLIER and accepted by the CONTRACTOR during bid stage, the SUPPIER shall be deemed to have confirmed to comply with all the listed specifications, codes and standards.

Any deviations or exceptions shall be raised in a “Concession Request Form”. CONTRACTOR will give his resolution/approval in writing and this decision shall be binding on SUPPLIER without any time/cost impact to CONTRACTOR.

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENT
Health, Safety and Environmental consideration is of foremost importance. Hence, in case of a local regulation whose specification and requirements are more stringent than this specification that stringent requirement will apply. The SUPPLIER shall be responsible for ensuring that the equipment/system supplied meets all applicable regulations on health, safety and environment. It shall be designed to operate safely and satisfactorily at all expected combinations of process, utilities and site conditions which include those at start-up, operation, shutdown and emergency cases while retaining the overall system security, reliability and availability.

SITE CONDITIONS & UTILITY DATA
The site conditions and utility data are outlined in Basis Engineering Design Data – IPCI2-PGL-8110-DB-0000-0001and data sheets attached with the requisition.

SUPPPLIER shall advise expected electrical load demand and other utility requirements for their equipment, so that the required utility is made available.

Utility Data
230V AC, 2 Wire 1 ph 50 Hz power supply from UPS will be available for system. For utility purpose, Non-UPS 230V AC will be made available. For HVAC (for free standing cabinets in field), 400V AC, 3Ø, 50Hz, supply shall be made available. SUPPLIER shall derive all other required voltage levels from this supply within their cabinets. The power rating shall be suitable for voltage variations of ±10% and frequency variations of ±3%.

All field devices shall be loop powered at 24V DC fed from dual power supply units.

Requirement of 230V AC, UPS power supply for package field devices shall be catered from electrical UPS distribution board and same shall not be fed from package UCP.

Instrument air will be supplied at the following pressures:

 Maximum: 10.0 barg (Design)

 Maximum: 7.5 barg ( Operating )

 Normal: 6.5 barg

 Minimum: 4.0 barg

Filter regulator assemblies shall be provided for all instruments requiring an air supply.

6.0 SCOPE OF SUPPLY AND WORK
Scope of supply and work/services shall be as per the requisition.

SUPPLIER has single point responsibility for supply of hardware and software, design, engineering, configuration, testing, start up and commissioning support of on-line process analyzer systems including interface with PCS, if any, to meet the technical requirements covered in this specification.

SUPPLIER scope shall include as minimum, but not limited to, the following:

 Supply of on-line Process Analyzer Systems including Sample Handling System (SHS), free standing rack or stanchion (if necessary), Analyzer Transmitters as defined in requisition specification and datasheets

 Supply of all carrier gases, calibration gases in cylinders along with regulators and other kits (Cylinder connections shall be compliant to local codes & norms). SUPPLIER shall indicate recommended calibration frequency per month or per year for each type of analyzer. Based on which, SUPPLIER to provide recommended consumption of calibration gases per year. These should include consumption of carrier gases as well.

 Analyzer Shelter, if applicable for respective Analyzers, according to Specification IPCI2-PGL-8550-SP-0000-0014

 Analyzer Management System as defined in Section 7.12 of this document and Inquiry specification.

 Calibration equipments as required

 All software with licenses

 FAT, IFAT (if required) and SAT

 Site installation supervision

 Start-up support & commissioning

 Documentation including as-built after commissioning.

 Training for COMPANY Personnel

 Supply of special tools and tackles, if any.

In case of a new design of equipment/system which is technologically superior to the standard product but not adequately proven due to low period of operational experience, the SUPPLIER should quote an optional price. The CONTRACTOR will decide on the selection of the option.

Tie-in / Interface With Other Equipments / Systems
Interfaces with plant main piping will be at nominated flanged tie-in points and Instrument/Electrical systems will be at at junction boxes. Hardwired / serial interface with plant PCS shall be provided as required. The tie-in flange material, size and ratings shall be as per project PMS (IPCI2-PF-8230-SP-1000-0011). Junction boxes shall be provided based on type of signals.

List of Make & Type For Subcomponents / Subsystems
Refer to the requisition / approved SUPPLIER list attached with the requisition.

In case, subcomponents & subsystems are not specifically listed, the make and type shall be of reputed brand proven in the Hydrocarbon industry. However, SUPPLIER shall obtain explicit approval from CONTRACTOR for use of the same.

Spare Parts
 Construction, Pre-commissioning, Commissioning and Start-up spares shall be as recommended by SUPPLIER and part of SUPPLIERs scope of supply.

 SUPPLIER shall also recommend list of Capital spares and 2 years Operational spares with price. Consumables spares for 6 months operation shall also be Included.

 The above spare lists shall be approved by the CONTRACTOR.

 All software licenses covered by this requirement shall be included. Installation and commissioning spare parts shall be included as part of the equipment scope of supply.

 The SUPPLIER shall complete and submit the Spare Parts and Interchange ability Record (SPIR) provided by the CONTRACTOR with the offer.

Site Supervision
SUPPLIER shall quote per diem rate (or lump sum as specified) for site supervision of installation and commissioning of equipment/system supplied, excluding Airfare, Local Transport and Accommodation if indicated in the requisition.

Training
SUPPLIER shall quote per diem rate (or lumpsum as specified) for training services on the equipment/system to COMPANY/CONTRACTOR’s personnel in RUSSIAN and ENGLISH languages as indicated in the requisition. SUPPLIER shall indicate location of training (ie, Site or works) in offer.

The SUPPLIER shall provide training courses for the COMPANY’s personnel to assist them in the commissioning and maintenance aspects of the process analyzer systems.

The SUPPLIER shall propose the course content in both Russian and English and shall provide necessary equipment and course materials required for the training.

A certificate authorizing trainee to work independently and managing of all level software configuration with right to make corrections and introduce changes to the user’s system shall be issued by SUPPLIER upon completion of training program.

Special Tools & Tackles
SUPPLIER shall include all special tools and tackles that are required for safe installation, operation, periodic inspection, testing and maintenance of the equipment.

The prices of these tools shall be listed separately in the bid.

Spreader Beams for loading/ unloading, handling and erection shall be included in the quote.

The equipment Installation, Operation and Maintenance Manuals shall include instructions on how to use the special tools for equipment maintenance.

DESIGN REQUIREMENTS
The analyzer shall be microprocessor based, providing a high degree of self diagnostics. The analyzers shall be hardwired / serial linked to PCS as indicated in datasheets. SUPPLIER shall indicate accuracy, repeatability, zero drift, span drift, sensitivity, linearity, response time and cross-interferences, as applicable for the analyzer unit. All electronic components shall have protective / conformal coating suitable to G2 class (HOLD) of environment as per ISA S71.04.

Analyzer models shall be selected in accordance with their required process analysis.

Calibration gases bottles shall be installed outside the analyzer houses, under a canopy. Tubing and fittings for the analyzers and sampling systems shall be made of Duplex 22-07 (HOLD), seamless types as minimum. For corrosive services high grade materials such as Monel, Hastelloy shall be used. 12 mm and 6 mm are the preferred sizes for tubing. It shall be Swagelok or equivalent quality. PTFE (Teflon) tubing, where used, shall be installed and connected with the aid of special thread- type fittings.

Where the type of measurement dictates that a sample has to be drawn from the process, the analyzer shall be supplied complete with fast-loop sampling system as required. The sampling system shall be located close to the point of measurement to minimise sample line lengths.

The sample shall preferably be returned to the process downstream of the sample take-off point utilising an in-line device such as a control valve, orifice plate, etc., to provide a suitable pressure differential. If this is not practical, alternatively the sample shall be piped to the plant flare/closed drain system/ safe vent point with flame arrestor, if required.

Where low-level signals from the in-line probes dictate that the electronics unit must be mounted local to the probe, the unit shall be capable of functioning under the ambient conditions indicated in section 5.0 and certified for the hazardous area, Zone 1 Gr IIA / IIB T3 and meet IP 65.

Local indicator for analyzers shall be digital display visible without opening enclosure. Analogue outputs shall be isolated current output 4-20 mA and SUPPLIER shall indicate the number of analogue outputs available wherever applicable.

Material of construction shall be as per the analyzer data sheets. Wetted parts shall be in compliance with NACE MR 0175/ISO 15156, as applicable.

All analyzer cabinets,where provided, shall have certified purging assembly.

In General, all analyzer system including accessories shall be of Ex i type design and shall be suitable and certified for Hazardous area classification Zone 1 Gr IIA / IIB T3. Ex d & Ex p type design (respectively) can be considered, incase Ex i type is not available. If purge panels are offered then the entire unit shall be certified by third party.

7.1 Sampling System
The analyzer sample systems shall be designed to extract, transport and condition the sample at the analyzer inlet as required by the process analysis. The design shall ensure that none of the sample properties are altered between samples process take-off point and analyzer inlet. Suitable Kazakh weather protection at plant site shall be designed as required, and implemented for all sample systems elements.

The sampling systems shall be designed to provide ease of operation and maintenance. Each analyzer shall have own sample delivery and conditioning system.

The optimum installation configuration must be determined on a case by case basis to suit the required application.

Typically the complete sample system will consists of the following components:

- Sample tap with local sample probe (sample take-off)

- Sample conditioning

- Sample return (to flare vent or fast loop)

- Calibration gas linkage

It shall be designed taking into account operation & maintanance suiatability. Sampling panel shall be free standing & fully complying with the hazardous area classification.

Probe assemblies shall be supplied with double isolation ball valves as required. Probe assemblies shall terminate in a 2” flange for connection to site piping. Flanges shall be stamped with the instrument tag number, size, rating and direction of flow. Complete assembly components shall be in compliance with project piping specification and it shall be retractable type.

Process parameters such as pressure, temperature, flow rate to be downgraded or upgraded to the acceptable functional limits of analyzers.

Each sample system enclosure shall facilitate a sample collection point with quick connectors, provision for sampling for lab testing purposes. Provision shall be made to ensure that adequate flow to the analyzer is maintained while purging or taking a sample.

Instrument air supply and nitrogen supply lines shall be provided with a filter reducer complete with a pressure gauge and back flow protection.

Necessary coarse filters, fine filters, condensate removal, safety valves, fittings, flame arrestors etc. shall be used while designing the sample conditioning panels.

Fast loop calculations shall be provided by supplier as a backup to the recommended sampling lengths.

In case of wet sampling e.g. flue gas analyzers, the sampling tubes shall be electrically heat traced. CONTRACTOR shall indicate the length of such tube and SUPPLIER shall include it in their scope of supply.

Preffered sampling tube sizes are 12 mm or 6 mm. However SUPPLIER can use other size tubes (as required), by submitting fast loop calculations and get it approved from CONTRACTOR.

SUPPLIER shall check whether the certification of analyzers or cabinets requires barrier gland. If so, same shall be supplied by SUPPLIER.

7.2. Calibration Facilities
Sample systems shall be designed to allow the analyzer to be checked using standard calibration gases. Analyzers shall be equipped as far as possible with local means of calibration and zero setting.

SUPPLIER shall provide all the necessary requirements for the calibration of the proposed equipment and define the period between routine calibrations.

SUPPLIER shall advise if they recommend a permanently installed calibration system and supply it with the analyzer.

Gas cylinders, cylinder racks and manifolds shall be provided with two-stage pressure regulation with inlet and outlet pressure gauges. Low pressure valves shall be provided for carrier and calibration gas. High pressure gas cylinder regulators shall be equipped with a pressure relief valve. Systems shall include first fill gases.

SUPPLIER shall indicate the standards used to certify the calibration gases.

7.3. Analyzer Shelters
Analyzers covered herein will be mounted within environment controlled analyzer shelter as defined in requisition. These shelters are the subject of a separate specification IPCI2-PGL-8550-SP-0000-0014. It is the intent that analyzer shelters be supplied complete with analyzers and that SUPPLIER delivers against both specifications.

7.4. Gas Chromatograph
A gas chromatograph shall be used for quality and compositional measurements of gas.

The detection device shall be TCD (Thermal Conductivity Detector) or FID (Flame Ionization Detector). Type of detectors and their quantity shall be decided based on gas composition to be analyzed.

The chromatograph shall separate measured peaks from all interferences so a few seconds of base-line are provided on either side of each peak. SUPPLIER shall indicate cycle time, sample flow rate and sample return pressure etc.

Loss of power shall not cause loss of analyzer memory. SUPPLIER shall state the memory storage and back up battery life details. Also, the analyzer shall automatically be zeroed after each component measurement.

Low carrier gas pressure alarm,low air pressure, low fuel gas pressure and flame out for flame ionization detectors shall be generated and displayed in the analyzer.

The chromatograph shall measure and provide output data for the sample composition as indicated in process data sheets attached along with requisition.

Carrier gas / burner gas shall be used as required. The flow rate of the carrier gas shall be adjustable with the system on-line. The analyzer shall be equipped with electronic pressure control. SUPPLIER shall provide any safety accessories required for use with the carrier gas, including a system design which will limit or disconnect the detector power on loss of carrier gas.

The chromatograph oven shall be equipped with independent temperature controls to provide a stable operating temperature for the analytical columns and detection assemblies to facilitate reproducible gas component analysis. The oven shall also be protected from overheating caused by malfunction or utility failure. Chromatograph sampling shall be inhibited until the analyzer detector system reaches operating temperature.

Analyzer system shall be protected against EMF/RFI and SUPPLIER shall submit the certificate for EMF/RFI protection. The analyzer shall be shielded against common mode and normal mode noise in addition to RFI and EMI.

The analyzer shall be supplied complete with the necessary modules required to transmit the sample component composition and other data via serial interfaces to the ANMS. ANMS is again serially connected to PCS. The serial link shall be Modbus RTU Slave. It shall also have provision of Signal output in 4 – 20 mA HART @ 24V DC isolated.

The SUPPLIER shall provide all the necessary requirements for the calibration of the proposed equipment and define the period between routine calibrations. SUPPLIER shall advise if they offer a permanently installed calibration system and supply it with the analyzer.

7.5. Moisture Analyzer
Moisture analyzers shall be used for the measurement of water vapour content of dehydrated natural gas in accordance with the requirements specified on the analyzer data sheets.

The analyzer shall be of quartz crystal-type or ceramic or Laser type. Moisture analyzers shall have field mounted sample systems with sample transport lines as short as possible. The sample probe shall be mounted directly into the gas stream through a nozzle.

The analyzer shall include a microprocessor based control module with local display and automatic calibration features and shall be supplied with facility for serial communications.

Loss of power shall not cause loss of analyzer memory. SUPPLIER shall state the memory storage and back up battery life details.

As a minimum, the analyzer output signals shall be 4-20 mA HART @ 24V DC, isolated.

The material of construction and the functional requirements for the analyzer system shall be fully compliant with the analyzer data sheet.

The analyzer section shall be designed to simplify maintenance and application requirements for removal and replacement as a single unit.

Certified quality gases shall be used for calibration checks. Quartz crystal type moisture analyzers shall have internal moisture generator for continuous validation.

The analyzer system shall include facilities for alarming errors and faults.

7.6 Oxygen Analyzer
Online Oxygen analyzer shall be used for the measurement of oxygen in accordance with the requirements specified on the analyzer data sheets.

The analyzer shall be of continuous monitoring. The principle of measurement shall be paramagnetic or zirconium oxide or suitable type based on application.

The analyzer shall include a microprocessor based control module with local display and automatic calibration features and shall be supplied with facility for serial communications.

Loss of power shall not cause loss of analyzer memory. SUPPLIER shall state the memory storage and back up battery life details.

As a minimum, the analyzer output signal shall be 4-20 mA HART @ 24V DC isolated.

The material of construction and the functional requirements for the analyzer system shall be fully compliant with the analyzer data sheet.

Certified quality gases shall be used for calibration checks. Suitable system diagnostics for continuous validation of analyzer output is required. The analyzer system shall include facilities for alarming errors and faults.

7.12 Analyzer Management System
The complex process analysers shall be provided with an Analysers Management System (ANMS) for maintenance and data management of the analysers located in the analyser houses. The ANMS architecture is anticipated to comprise of data acquisition units (DAU’s) located in the SRR’s with direct hardwired connections to analysers’ dedicated measurement memories and via serial links (especially for gas chromatographs), data communication modules, central computational module, communication network, and maintenance Work-Stations located at the SSR’s, CCB and the Analyser Houses.

This Analyzer Management System (ANMS) is also used for data acquisition of all chromatograms analysed values, validation of these values, logging the performance of the analyzers, calibration and diagnostics data, statistical data handling, etc., as outlined in the Control Systems Philosophy IPCI2-PGL-8550-SP-0000-0021 (DCS System Specifications).

The objective of the ANMS is to monitor, evaluate, and improve the performance of all on-line analysers in the most efficient manner.

Automatic collection, analysis and reporting of data shall be maximised for the purpose of analyser reliability and efficiency. The system shall automatically collect real-time data from the analysers and shall interpret the analyser performance, such as availability and reproducibility. The ANMS shall also be designed to permit analyser personnel and operators to enter data manually at the appropriate workstation.

The Analyzer Management System network(s) shall, at the same time, carry all the validated analysis data required for PCS operator displays and PCS detail displays diagnostics.

Other complex analyzers shall be connected preferably to the GC network, or directly by individual Data Link to the PCS.

Refer IPCI2-PF-8550-SP-0000-0025; GSU, IPC and Ethane Pipeline - Combined PCS architecture (DCS/ESD/F&G/RTU), which shows schematic connection between analyzer system with the PCS.

A graphical user interface shall be used to display the analyser status and issue commands. The ANMS user interface shall use fill-in forms displayed on the ANMS workstation as well as PCS consoles. These forms shall be designed specifically for the required task, e.g. validation, calibration, reports, trends, performance limits (control and warning), etc. The forms shall be laid out as such, that entering of data is quick and easy.

The ANMS shall also interface to the Laboratory Information Management System (LIMS) to provide the necessary analyser information for comparison with the Laboratory analyser readings.

8.0 QUALITY ASSURANCE
SUPPLIER shall demonstrate to operate a quality system in accordance with ISO 9001-2008. The effectiveness of the quality system and SUPPLIER’s compliance with it will be subject to monitoring by CONTRACTOR; and in addition may be audited following an agreed period of notice.

SUPPLIER shall submit a quality control program for CONTRACTOR review as specified in the requisition/SDRL.

SUPPLIER shall provide facilities for and cooperate with CONTRACTOR during manufacturing, assembly and testing.

INSPECTION & TESTING
SUPPLIER shall submit a detailed written Inspection and Test Plan (ITP); Factory Acceptance Test Procedure (FAT) in accordance with the SUPPLIER Document Requirements List (SDRL). ITP and FAT approved by CONTRACTOR shall be available prior to commencement of tests.

No witnessed testing will take place until all the latest relevant drawings, technical specifications, certificates and completed data sheets have been issued to and approved by the CONTRACTOR.

Where applicable, specialist equipment SUPPLIER’s shall be notified. SUPPLIER shall indicate the sequence and timing of all inspection, testing and pre-commissioning requirements.

The SUPPLIER shall complete all internal inspection and routine tests prior to inspection by the CONTRACTOR, to ensure that the witnessed testing is not prolonged by fault finding and rectification. Faults or unsatisfactory operations that result in abortive witness tests shall be rectified at the expense of the SUPPLIER. Any expense incurred by the CONTRACTOR resulting from abortive tests will be chargeable to SUPPLIER.

The SUPPLIER shall have necessary test equipment, tools and facility required to satisfactorily carry out all the factory tests. All test instruments shall be calibrated, and copy of calibration certificates should be provided on request.

The CONTRACTOR shall be allowed access to manufacturer's shop and offices at all reasonable times for purposes of inspection and obtaining information on the progress of work.

The equipment/system installation with its components shall be tested and certified, fully in accordance with the referenced codes and standards and the requisition.

The functional test will include a communications test where the system has a requirement to communicate data to a remote system, typically the plant main PCS. The functional test (IFAT) procedure will be provided by the SUPPLIER and reviewed by the CONTRACTOR.

FAT and IFAT shall be carried out with all sub systems connected and all I/O simulated.

All documents and test procedures shall be approved by the CONTRACTOR before starting of any testing.

Type Tests & Special Tests
Any Type tests and Special tests (witnessed / non-witnessed) to be carried out will be identified in the requisition / data sheet.

Routine Tests
Each pressure retaining instrument shall be hydrostatically pressure tested at minimum 1.3 times the design pressure. For NACE MR-01-75/ ISO 15156 requirements, the instruments shall be subjected to a NACE hardness test.

SUPPLIER shall test all the instruments for functionality, accuracy, rangeability, hysteresis, repeatability etc and shall submit the certificates of calibration.

Material test certificates, Positive Material identification, Impact testing, fugitive emission (helium leak test for H2S service), Charpy tests, Cryogenic tests, Radiography tests (for 600# and above), other NDE tests & PWHT shall be carried out on the devices as applicable.

Factory Acceptance Test (FAT)
All works will be subject to inspection at the SUPPLIER’s premises generally accompanying the FAT. All original SUPPLIER documentation shall be available for inspection at this time. This shall include but not necessarily limited to calibration and test data, material certification, SIL accreditation etc.

All instruments shall be mechanically complete to the skid junction boxes and to the process at battery limit and shall have been tested by the SUPPLIER prior to the FAT. Testing shall satisfy all regulatory requirements.

The test procedure shall include the SUPPLIER’s own in-house testing, that the CONTRACTOR can witness at their discretion, followed by FAT where the SUPPLIER demonstrates the functionality of the complete system to the CONTRACTOR. Testing should cover, but not necessarily be limited, to the following areas:

Mechanical Integrity

 Hydrostatic proof testing of hydraulic pressure parts including impulse tubing

 Locked in pressure test at normal working pressure

 Function of HVAC / heating System

Electrical Integrity

 Circuit Breaker Checks

 Earthing Tests

 Cable / wire insulation test

Instrument Tests

 Instrument calibration and functional tests

 Function of Analyser management System

 Function of Sampling System

 Transmitter tests

 Logic system functionality

 Analog I/O calibration and discrete I/O simulation test.

 Communication and interface checks to PCS/ANMS.

If any leaks or failures are detected during the tests, they shall be repaired or corrected and the test repeated to the satisfaction of CONTRACTOR.

All test equipment shall have a current certificate of an approved test authority and shall be used in accordance with the CONTRACTOR’s QA system.

The SUPPLIER shall maintain up-to-date documentation at all times reflecting the inspection/testing status of the equipment. However, the submitted documentation shall not be regarded as the total requirement, and the CONTRACTOR may wish to inspect retained documentation such as internal test results, equipment logs and fault /correction records.

The SUPPLIER shall provide all necessary support for the successful completion of the communication tests.

Integrated FAT (I-FAT)
An Integrated Factory Acceptance Test shall be carried out to ensure all the Interfaces of package units are configured correctly and in accordance with the design criteria.IFAT shall be carried out after completion of individual FAT at the analyzer SUPPLIER premises.The actual sub-systems may be required to transported to the PCS IFAT location or only sufficient communication and testing equipment to fully verify all the interface databases between the subsystems and the DCS.

Site Acceptance Test (SAT)
SUPPLIER shall provide a SAT procedure which shall be approved by CONTRACTOR prior to commencement of test.

SAT shall consist of a series of tests to confirm/demonstrate that the system has not been damaged in transport, correctly powers up, and is fully operational for the commencement of pre-commissioning. Test will include, as a minimum, all interfaces to other systems, redundancy, configuration and data linking etc.

SUPPLIER shall provide the necessary technical support for successful completion of SAT.

10.0 NAMEPLATES AND LABELS
All Instruments, valves, Cabinets/Panels, junction boxes etc. shall be fitted with a stainless steel name plate permanently fastened by SS rivets or screws without adversely affecting the degree of protection / certification of the same.

All items of equipment shall be identified with a tag number. Instruments, valves, cables, junction boxes, marshalling cabinets and system cabinets will be tagged with a number according to Instrument Numbering Specifications IPCI2-PGL-8550-SP-0000-0001. Tag Nos. will be provided by CONTRACTOR during Detail Engineering.

All Instrument Name plates and labels shall be provided in dual language (English and Russian). Lettering shall be black on white background for normal service instruments and black on red background for safety critical instruments involved in ESD / F&G logic and stamped minimum as follows:

 Tag Number, Manufacturer’s name, model number, serial number, range, supply, output signal, Hazardous area certification (Type of protection), Material of construction,

Pressure rating (Applicable for Inline instruments) & CV, Trim material, size and characteristics (Applicable for Valves), Set pressure & cold differential pressure (Applicable for Safety Valves) etc.

Additional labels for service description shall be provided for all field instruments in both English and Russian. Valves and in-line flow meters shall have an arrow on the body indicating the direction of flow.

11.0 SURFACE PREPARATION AND PAINTING
Refer requisition / purchase order for surface preparation and painting requirements.

Painting system shall take into account the local climatic conditions.

12.0 PREPARATION FOR SHIPMENT/PACKAGING
Preparation for shipment/packing shall be as per requisition. Packing and Preservation of Leak Detection system shall be in accordance with the Project Specification: “Packing, Shipping, Preservation and Marking Instruction.”

13.0 DOCUMENTATION
SUPPLIER shall provide all documents with the number of copies and soft-files, as listed in the SDRL attached with the requisition. All documents, catalogs, manuals shall be in English language as marked in SDRL. As needed, local maintenance documents shall be provided in Russian Language also.

Documents shall include, but not be limited to, the following:

 Complete documentation for the purchased hardware, software and configuration.

 All Engineering deliverables as per the approved document register during the detailed Engineering

 SUPPLIER shall submit the As-built documentation after final completion of the project.

14.0 PERFORMANCE GUARANTEE
Refer to the requisition / purchase order and its attachments for guarantee requirements.