Instrument Work Procedure

Escravos Produced Water Project Rofcom Energy Services Limited Chevron Nigeria Limited
(EPWD)
Client
C!E"R#N N$%ER$&
L$'$(ED

Contractor
R#)C#' ENER%*
SER"$CES L$'$(ED

Project (itle ESCRAVOS PRODUCED WATER DISPOSAL PROJECT
Contract No+
Document
(itle
INSTRUMENTATION WORK
PROCEDURE
Doc+ Ref

Date

Revision ,
N&'E C#'P&N* S$%N-D&(E
PREP&RED .*
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R#)C#'

C!EC0ED .*
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&PPR#"ED .*
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RE"$EWED .*

C#N(R&C( !#LDER
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Page 1 of 17
$nstrumentation Wor1 Procedure
(EPWD)
&PPR#"ED .*

$NS(R/'EN(&($#N W#R0 PR#CED/RE
(&.LE #) C#N(EN(S
,+2 P/RP#SE 3 3 3 3 3 3 3 4
5+2 SC#PE 3 3 3 3 3 3 3 4
4+2 RE)ERENCES 3 3 3 3 3 3 6
6+2 DE)$N&($#N 3 3 3 3 3 3 7
8+2 RESP#NS$.$L$($ES 3 3 3 3 3 3 9
7+2 PR#CED/RE 3 3 3 3 3 3 3 :
9+2 $NS(R/'EN( $NS(&LL&($#N 3 3 3 3 ;
:+2 (ES($N% 3 3 3 3 3 3 3 ,8
;+2 D#C/'EN(&($#N3 3 3 3 3 3 ,7
,2+2 PERS#NNEL 3 3 3 3 3 3 ,7
,,+2 S&)E(* 3 3 3 3 3 3 3 ,7
,5+2 N#N3C#N)#R'&NCE 3 3 3 3 3 ,7
1.0PURPOSE
(he <ur<ose of this <rocedure is to <rovide the <recise develo<ment
of minimum re=uirement Rofcom Energy Services Limited shall
a<<ly for the instrumentation >or1 activities at the Escravos
Produced Water Project+ (his has to ?e read and inter<reted in
conjunction >ith the <roject s<eci@cations-standards and esta?lishes
a techni=ue together >ith other related contractual documents
2.0SCOPE
(his $nstrumentation >or1 <rocedure covers all onshore
instrumentation construction activitiesA $nstallationA ins<ection and
testing to ?e done on 'ain dec1A Cellar dec1 and Bac1et of the
Page 2 of 17
(EPWD)
Escravos Produced Water Dis<osal facility+ (he overvie>s of >or1 are
as follo>s
/n?oCing and sorting of $nstruments+
Ca?le drums testing+
Ca?le (ray )a?rication and $nstallation+
Bunction .oC $nstallation+
Ca?le Pulling+
$nstrument $nstallation+
Ca?le %landing and (ermination
Ca?le (agging and Core $denti@cation+
(esting
$nstrument &ir (u?ing !oo13u<+
$nstrument Cali?ration+
'echanical Com<letion Chec1s+
&ll ins<ections during construction <hase shall ?e com<leted and
signed ?y CNLDs EE$ $ns<ector+
3.0REFERENCES
&ll constructionA installationA and testing shall ?e carried out in
accordance >ith good engineering <ractice and shall satisfy all
statutory re=uirements of the National and-or local authorities in
>hich the installations >ill ?e located+
(he follo>ing Standards and re=uirements shall form an integral
<art of the $nstrumentation Construction Wor1A ins<ection and tests
in the Project Wor1s
PWD3D2:83$CS3$$D3NE(32223;2264322 $nstrument !oo13u<s
DiFerential Pressure
$ndicator
Page 3 of 17
(EPWD)
Pressure
DiFerential (ransmitter
PWD3D2:83$CS3$$D3NE(32223;224:322 $nstrument $nstallation
Detail
Level Control "alve
Pressure
$ndicator
PWD3D2:83$CS3$$D3NE(32223;2265322 $nstrument !oo13u<s Level
$ndicating (ransmitter
PWD3D2:83$CS3$$D3NE(32223;2262322 $nstrument $nstallation
Detail
Pressure Control "alve and
Positioner
PWD3D2:83$CS3$$D3NE(32223;2,,:322 $nstrument 'ounting
Details
PWD3D2:83$CS3$$D3NE(32223;2,,9322 $nstrument 'ounting
Details
PWD3D2:83$CS3$$D3NE(32223;224;322 $nstrument !oo13u<s
Level %auge
PWD3D2:83$CS3$$D3NE(32223;226,322 $nstrument !oo13u<s
#n3#F "alve
$C'3D/3,,2,3. $nstrument
$nstallation
$C'3S/3,,+283& Pressure $nstruments
$C'3D/3,,+2,3& $nstrument
$nstallation
Page 4 of 17
(EPWD)
$C'3D/3,,+243& Level $nstruments
&P$ RP 886 Process $nstruments and
Control
&P$ RP 88, Process 'anagement
$nstrumentation
$S& 8+, $nstrumentation Sym?ols
&nd $denti@cation
4.0DEFINATION
&$ &nalogue $n<ut
&# &nalogue #ut<ut
&P$ &merica Petroleum $nstitute
CNL Chevron Nigeria Limited
C#'P&N* Chevron Nigeria Limited
D$ Digital $n<ut
D# Digital #ut<ut
EE$ Electrical and $nstrumentation
$S& $nternational Society of &utomation
$(P $ns<ection and (est Plan
PE$D Pi<ing E $nstrumentation Dra>ing
Page 5 of 17
(EPWD)
PWD Produced Water Dis<osal
G&-GC Guality &ssurance and Guality Control
GC Guality Control
5.0RESPONSIBILITIES
Inst!"#nt T#$" L#$%
Shall ensure <ro<er im<lementation of this <rocedure+ !e shall
coordinate the activities of the $nstrument Engineer >ho leads
the $nstrument team+
Inst!"#nt En&'n##
(he $nstrument Engineer Shall ?e res<onsi?le for the follo>ingH
"erifying all activities relevant to installation and testing of
@eld mounted $nstruments+
"erifying the availa?ility of the materials re=uired for
installation+
Pre<aration and su?mission of as3?uilt dra>ings and
resolving all technical <ro?lems that may arise during
installation activities+ !e is also res<onsi?le for
Page 6 of 17
(EPWD)
coordinating >ith the G& - GC Engineer for resolving
technical =ueries+
Inst!"#nt S!(#)'s*
Shall lead the instrumentation activities at construction stageH
carry out all ins<ection re=uiredH issue the relevant re<ort or
chec1list and coordinate >ith the G& - GC $ns<ector and the
$nstrument Engineer+
+!$,'t- C*nt*, Ins(#.t*
Shall monitor the <ro<er im<lementation of the <roject
<rocedures and s<eci@cations+ Shall also ?e res<onsi?le for
conducting of tests on ca?les and instruments during delivery
and ?efore installationH res<onsi?le for all @nal ins<ection
activitiesH rectify all <unch list items and sign oF all @nished
>or1s+
Inst!"#nt T#./n'.'$n
$nstrument (echnician shall ?e res<onsi?le for
$nstalling all @eld instruments+
Coordinating >ith the $nstrument Su<ervisor and G&-GC
Engineer and $nstrument Engineer in instrument installation
and in resolving technical =ueries+
0.0PROCEDURES
0.1 R#.#')'n& $n% Ins(#.t'*n *1 Inst!"#nt
E2!'("#nt3M$t#'$,s
/<on recei<t of instrument materialsA the GC $ns<ector and
Store 0ee<er shall ins<ect visually the materials and
e=ui<ment for <ossi?le defectsA <hysical damages or missing
<art+ (he conformance of the $nstrument to s<eci@cationsA
haIardous area classi@cation and mechanical certi@cation
shall ?e veri@edA chec1ing against Engineering Data sheets if
a<<lica?le+ (he <rovision in the follo>ing documents shall
form the ?asis for all the ins<ection in this <roject+
Page 7 of 17
(EPWD)
Guality &ssurance-Guality Control
$ns<ection and (est Plan
'anufacturers data and technical manuals
Engineering data sheets >here a<<lica?le+
)orm for ?asic instrument e=ui<ment
0.2 M$t#'$, St*$&#
Pro<er stac1ing and identi@cation are necessary to de@ne and
minimiIe the <ossi?ility of damage or lo>ering of =uality due
to corrosionA contaminationA deterioration or <hysical damage
during the time an item is stored and until it is removed from
storage and <laced in its @nal location+ (here shall ?e a routine
ins<ection of the stac1ing area+ Prior to stac1ing of materialsA
the diFerent stac1ing <oints shall ?e esta?lished and adhered
to+
0.3 P#4Inst$,,$t'*n T#st $n% Ins(#.t'*n
&ll instruments shall ?e veri@ed against data sheetsA
'anufacturerDs $nstructionsA and >hen necessary undergo
testing in the instrument <rior to installation+
0.3.1T#st *n C$5,#s
(he order of test shall ?e $nsulation Resistance (est for
Inst!"#nt $n% .*nt*, .$5,#s
&nalogue in<ut and out<ut ca?les (&$ - &#)
Digital in<ut and out<ut Ca?les (D$- D#)
DC C*n%!.t* #s'st$n.# t#st
(est e=ui<ment to ?e used are as follo>s
'egger (ester 3 422" 3 822"
)lu1e 'ulti3tester
C*nt'n!'t- T#st
(est e=ui<ment to ?e used are as follo>s
)lu1e 'ulti3tester
0.4 Inst!"#nt E2!'("#nt St*$&# $n% P#s#)$t'*n
'aterial storage shall com<ly >ith the 'aterial Control
Procedure+ (he $nstruments shall ?e stored >here a<<ro<riate
Page 8 of 17
(EPWD)
in accordance >ith "endor - manufacturerDs recommendation+
Ca?le drums shall ?e stac1ed horiIontally in a safe <lace+
0.5 C$,'5$t'*n *1 T#st E2!'("#nt
&ll test e=ui<ment shall ?e cali?rated in accordance >ith
Cali?ration Procedure+ (est e=ui<ment shall have valid and
tracea?le cali?ration certi@cate+ Rofcom Energy Services
Limited shall su?mit a detailed list of all test e=ui<ment
com<lete >ith co<ies of certi@cates it intends to use for test to
Com<anyDs for a<<roval <rior to commencement of testing
along >ith the su?mission of test <rocedures+
6.0INSTRUMENT INSTALLATION
6.1 7#n#$,
(his section mainly covers the installation of ne> instruments
on the PWD facility+ 'ajor mechanical-<i<ing >or1s shall ?e
su?stantially com<lete ?efore commencement of instrument
installation+ (he .asic $ns<ection (est Sheet shall ?e
com<leted for all $nstruments+
(he correct tools shall ?e used for all installation >or1+ &ll
$nstruments shall ?e installed leaving around enough
headroom to allo> maintenance and - or removal+ Where
access from normal o<erational <latforms is not feasi?leA
additional access facilities shall ?e <rovided+
&ll instruments shall ?e <ositioned referring to relevant
installation hoo13u< and as close to its <rocess connection as
<ossi?leH after installation and during the >hole construction
<eriodA all instruments not <rovided >ith housing shall ?e
<rotected from the >eather in the event that <ainting
activities are in <rogress in adjacent areas+
$ndicating instruments shall ?e installed and oriented
according to engineering detailed dra>ings su<<lied in such a
>ay that the center of the indicator is a<<roCimately ,+4m
Page 9 of 17
(EPWD)
a?ove grade to allo> vie>ing from <latformA or >al1>ay level
as recommended ?y Com<any+
&ll instruments shall ?e so installed such thatA they are not
su?jected to vi?ration or to mechanical stresses and are not
eC<osed to high tem<eratures >hich >ill inJuence the
measurements and far from <otential @res+
& clearance of at least 422mm shall ?e given ?et>een any hot
surface and those instruments >hose functioning can ?e
aFected ?y hot environments and also a clearance of at least
422 mm shall also ?e given ?et>een any instrument and cold
surface (less than minus 52KC)A >hich may lead to
condensation+ No $nstrument Su<<orts shall ?e >elded to a
vessel or e=ui<ment containing Process )luid+
During and after installationA a @eld visual ins<ection shall ?e
carried out to ensure that each instrument
!as the correct tag num?erA rangeA etc+
$s in <ro<er <osition+
Correctly E rigidly installed according to dra>ings+
$s <ro<erly connected to signal - su<<ly ca?les+
$s <ro<erly earthed >herever necessary+
$s suita?ly <rotected against adverse environmental
conditions+
Ca?le gland is <ro<erly @tted+
#utstanding items and deviation shall ?e recorded on general
<unch list+
&ll mounted instruments shall ?e <rovided >ith Name Plates+
SuLcient s<are length of ca?le for connection shall ?e coiled
near the instrument side+ &ll Local Panels and Bunction .oC
)rames shall ?e shimmed as <er a<<lica?le dra>ings+ $f any
e=ui<ment is mounted at Joor levelA relevant su<<orts shall ?e
grouted+ $nstrument im<ulse line E <neumatic signal lines
shall ?e installed as <er Com<any <rocedure for $nstallation
and (esting of Pneumatic Signals and $m<ulse (u?ing+ Ca<illary
(u?ing shall ?e ade=uately <rotected against mechanical
Page 10 of 17
(EPWD)
damage and su<<orted ?y instrument trays and run
inde<endently oF all other lines+
6.2 C$5,# T$- S!((*t
(he ca?le tray su<<orts shall ?e very rigid and the ca?le tray
shall sit on them having a good anchorage+ (he ca?le tray
su<<ort material shall agree >ith the <roject s<eci@cation+ (he
ca?le tray su<<orts shall ?e fa?ricated and installed according
to <roject ca?le tray su<<ort detail dra>ings+ Ca?le tray
su<<orts shall in no circumstance come oF from a <rocess
<i<e+ (he intervals of these su<<orts shall ?e in accordance to
<roject s<eci@cations+ &ll dissimilar metals shall ?e insulated
from each other+
&ll cuts or >elded <oints-<arts of the ca?le tray su<<orts shall
?e cleanedA shar< edges removed and <ainted accordingly to
<revent corrosion+ &ny deviation shall ?e formerly made
1no>n to client for acce<tance+
6.3 C$5,# T$- 3 L$%%#s
(he Ca?le (rays shall ?e installed as given on the dra>ingsA for
<o>erA control and instrumentation ca?lesA arranged on
su<<orts+ &ll ca?le trays-ladders and associated accessories
used shall ?e as s<eci@ed for the PWD <roject s<eci@cation+ &ll
dissimilar metals shall ?e insulated from each other+
Ca?le trays shall ?e corrosion freeA have no shar< edges and
laid on solid and >ell leveled ca?le tray su<<orts+
Where they are lin1ed >ith another ca?le traysA they shall ?e
?olted >ith the right connectors-hingesA the ca?le tray shall ?e
grounded according to <roject s<eci@cations+
Ca?le trays-ladder shall ?e rigidly su<<orted and trays shall ?e
?onded and connected to the common earthing grid as <er
<roject s<eci@cations+
6.4 C$5,# Inst$,,$t'*n
Ca?les shall ?e dra>n from ca?le drums on stands+ Drum shall
Page 11 of 17
(EPWD)
?e strong and in good condition and shall ?e installed as <er
<roject dra>ings+ &ll cut ends shall ?e >atertight sealed+
Rofcom Energy Services Limited shall ensure that suLcient
ca?le rollers and side rollers are used >hen <ulling the ca?le
into <osition >here necessary+ (his >ill considera?ly reduce
the eFort re=uired and hel< to ensure that the ca?le outer
sheath is not damaged+ (he ca?le shall not ?e <ulled over or
around hard rough surfaces or shar< edgesA >hich might
damage the outer sheath+
/nder no circumstances shall any ca?le ?e su?jected to a
?ending radius less than the minimum recommended ?y the
manufacturer for the <articular ty<eA siIe and form of
construction of the ca?le concerned+
(he segregation of instrument ca?les from other ca?les shall
?e carried out in accordance >ith the re=uirements of
Standard S<eci@cations+
6.5 Inst!"#nt A..#ss'5','t-
&ll instruments e=ui<ment shall ?e accessi?le for servicing ?y
tem<orary or <ermanent accesses (tem<orary if instruments
are located lo>er than 6 meters a?ove ground level) &?ove 6
meters a <ermanent access shall ?e <rovided+
6.5.1A..#ss 1*" P,$t1*"
$n the event of the access from a <latformA the
instrument location shall satisfy the follo>ing
re=uirements
(he instruments shall ?e located close to the
<latform
When the e=ui<ment is located a?ove a <latformA the
to< of the o<erating mechanism shall neither ?e
more than 5+,' nor less than ,82mm a?ove the
<latform+
Where access from normal o<erational <latforms is
not feasi?leA additional access facilities shall ?e
Page 12 of 17
(EPWD)
<rovided+
&ccess from ladder to ?e accessi?le from a
<ermanent ladder the e=ui<ment shall not ?e more
than ,' from the centre3line of the ladder+
6.0 C$5,# T$&&'n&8 C*# I%#nt'9.$t'*n : Inst!"#nt T$&
N!"5#s
Permanent ca?le mar1ers shall ?e attached to all ca?les just
?elo> the ca?le glands on either side of Bunction ?oC transit
frames and e=ui<ment gland <lates+
'ar1ers shall ?e of ,+8 mm thic1 C ,: mm >ide Stainless Steel
stri<+ (he circuit identi@cation and ca?le schedule num?ers
shall ?e stam<ed on each mar1er in 7mm high letters and
digits+ &lternatively mar1ers in stainless steel or <lastic may
?e used <rovided that they are attached <ermanently to the
ca?le and not su?ject to deterioration ?y environment+
&ll ca?le tagging and core identi@cations shall ?e legi?leA
reada?leA rigidly @Ced and shall ?e in accordance >ith the
Com<any s<eci@cationA standards and a<<roved <roject
dra>ings+
&ll ca?le cores shall carry <ermanent identi@cation of the
<hase color and >ire num?ers+ $denti@cation shall ?e in the
form of ca<tive MoM ring ferrules of the a<<ro<riate diameter
engraved or indeli?ly <rinted >ith the ca?le num?erA the core
num?er and the terminal num?er+ $denti@cation num?ers shall
read from the terminal out>ards+ $nstruments (ag Num?ers
shall ?e in accordance >ith Com<any S<eci@cation+
6.6 F,*; Inst!"#nts
Pi<e #rientation and )lo> Direction shall ?e in accordance
>ith the follo>ing ta?le
'easuring
Device
Preferred
#rientation
5
nd
Choice
#rientation
#ri@ce Plate !oriIontal &ny
Page 13 of 17
(EPWD)
#nly if <referred orientation cannot ?e used >ill 5nd choice
orientation ?e considered >ith a<<roval+
$n vertical lines the <referred )lo> Direction shall ?e
u<>ard for li=uid and do>n>ards for gases and steam+
)lo> $nstruments shall ?e located to ?e accessi?le from
grade or <ermanent <latform+ &ccess shall ?e >ithin 5
meters of grade or <ermanent <latform+
6.< L#)#, Inst!"#nts
(he Com<anyDs Engineering (eam shall determine orientation
during detail design+
Level $nstruments shall ?e located to ?e accessi?le from
gradeA <ermanent <latform or @Ced ladder+ &ccess should ?e
>ithin 5 meters of grade or <ermanent <latform+
6.= P#ss!# Inst!"#nts
(he <referred noIIle orientation for <ressure $nstruments is
horiIontal (side) for all services on vertical lines+
)or gas servicesA the ta<<ing shall ?e vertical (to<) or side
for li=uidA steam or condensa?le va<ors on horiIontal
lines+
(he <referred noIIle orientation for <ressure gauges shall
?e vertical (to<) for all services on horiIontal lines+
)or all services on vertical linesA the ta<<ing shall ?e
horiIontal (side) >ith a Janged ;2K el?o> to orientate the
connection u<>ards+
(he selected orientation and location of the ta<<ing shall
<ermit remote instruments to ?e self3draining or self3
venting+
Pressure $nstruments shall ?e located to ?e accessi?le from
gradeA <ermanent <latform as sho>n instrument location
dra>ing+ &ccess should ?e >ithin 5 meters of grade or
<ermanent <latform+
Location of the @rst isolation valve at the height shall not
eCceed 7 meters from grade <ermitting access ?y
tem<orary means+
Pressure gauges shall ?e installed in such a manner to
Page 14 of 17
(EPWD)
avoid o?struction of their ?lo> out <rotectorsA oriented
a>ay from the o<erator+ Clearance ?et>een the ?lo> out
Disc and a near?y o?struction shall ?e at least 58mm+
6.10 C*nt*, V$,)#s
Com<any shall determine the re=uired valve <ositioner
orientation in relation to the )lo> Direction (to ensure
accessi?ility of valve <ositioner) and also shall <rovide for
each control valve a dimensional dra>ing >hich >ill detail the
re=uired clearanceA >eightA etc+
Control valve shall ?e located to ?e accessi?le from gradeA or
<ermanent <latform+
<.0TESTIN7
)ield $nstruments shall ?e tested in accordance >ith Com<any
Procedure on $nstallationA testing of @eld mounted $nstruments+
$m<ulse line E <neumatic signal lines shall ?e tested in
accordance >ith Com<any Procedure on $nstallation and testing
of <neumatic signals and $m<ulse Line+
&ccessories shall ?e chec1ed against dra>ings and ensure that
they are installed in accordance >ith dra>ings+
&ll individual instruments shall ?e tested and re3cali?rated if
necessary ?efore installation+
&<<ro<riate test e=ui<ment shall ?e used for testing of
instruments+ Every instrument tested shall ?e <rovided >ith a
la?elA indicating the cali?ration details+
Control valves E shutdo>n valves e=ui<<ed >ith actuators shall
?e tested for full stro1e time+
&fter testingA $nstrument $nstallation $ns<ection Re<ort shall ?e
com<leted and signed oF+
&ll electronics instrumentsA >hich may o<erate in haIardous
atmos<hereA shall ?e installed in accordance >ith s<eci@ed
re=uirements for <reventing ignition of Jamma?le va<ors+
&ll Locations and (ags of each $nstrument shall ?e chec1ed in
Page 15 of 17
(EPWD)
accordance >ith the relevant PE $D+
$nstruments clearance and access re=uirements shall ?e in
com<liance >ith relevant dra>ings+
(hermometers and <ressure gauges shall ?e reada?le from
grade or <latforms and <ro<erly oriented+
&ll $nstruments located in <i<ingA such as )lo> elementsA Control
"alves etc+ shall ?e erected in the correct )lo> Direction+
&ll instruments <rocess leads for <ro<er routing and su<<orts
shall ?e chec1ed to ma1e sure that movement due to thermal
eC<ansion or vi?ration >ill not strain the instruments or interfere
>ith other e=ui<mentDs+
&ll <rocess leadsA drain lines and vent lines shall have the
s<eci@ed slo<eA free from any <oc1ets or tra<sA connected to the
<ro<er vent and drain headers+
)or diFerential <ressure ty<e Jo> instruments the lo>3<ressure
side of the instrument shall ?e connected to the do>nstream ta<
of the Jo> element+
=.0DOCUMENTATION
&ll records as <er the a<<lica?le $ns<ection E (est Plan ($(P) shall ?e
@lled u< during a<<ro<riate stages of ins<ection and signed ?y the
ins<ectors from Rofcom and Com<any after installation and testing
and shall ?e maintained in com<liance >ith Com<anyDs Guality
Records 'anagement
10.0 PERSONNEL
&ll construction activities shall ?e carried out ?y a team of
<ersonnel >ith ade=uate =uali@cation and eC<erience in
installation and testing of $nstruments under the control of the
EE$ Engineer according to Personnel =uali@cation and (raining+
&ll the activities of the team shall ?e coordinated E directed ?y
the $nstrument (eam Lead+
11.0 SAFET>
&ll the a?ove activities shall strictly ?e carried out in accordance
>ith safety rules and <rocedure contained in ProjectDs !SE Project
Plan+
Page 16 of 17
(EPWD)
12.0 NON4CONFORMANCE
&ny non3conformance found during the installation and testing of
@eld mounted instrument shall ?e dealt in accordance >ith
Com<anyDs non3conformances re<orting <rocedure+
Page 17 of 17

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Escravos Produced Water Project Rofcom Energy Services Limited Chevron Nigeria Limited

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