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Appendix A
Page 1 of 17
INDEX
1.0
INTRODUCTION
2.0
OBJECTIVE
3.0
4.0
5.0
6.0
GENERAL REQUIREMENTS
7.0
8.0
SITE SURVEY
9.0
10.0
11.0
12.0
SAFETY
13.0
COMMISSIONING
14.0
15.0
16.0
CONTRACT DURATION
17.0
GUARANTEE
18.0
TRAINING
19.0
WORKING HOURS
Appendix A
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ATTACHMENTS:
Attachment I
Attachment III
Attachment IV
ABBREVIATIONS
BS
: British Standard
CCR
Co60
Cs137
CRCS
DCS
GM Counter
HSE
mCi
MoE
NOC
: No Objection Certificate
OEM
PTW
: Permit To Work
RPO
SAT
SER
SPDT
Appendix A
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1.0
INTRODUCTION
QP owns and operates a Refinery at Mesaieed, which is around 35 km. south of Doha
in the State of Qatar.
Radioactive Level Measurement and Alarm Systems are installed in Continuous
Catalytic Reformer (CCR) Unit 63 at QP Refinery in the year 2000 and presently some
radioactive sources are weak due to radioactive decay. Also, the system has been
obsolete and it is not possible to get spare parts or support from the Original
Equipment Manufacturer (OEM).
2.0
OBJECTIVE
The objective of this CONTRACT is to utilize the services of a competent, safetyconscious and experienced OEM as CONTRACTOR to undertake the critical
replacement of radioactive level measurement and alarm systems in accordance with
this scope of work, specifications, standards and requirements specified herein on or
before SCHEDULED COMPLETION DATE to QPs Satisfaction.
3.0
4.0
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mono rack and transmitters are installed at remote location called Satellite Equipment
Room (SER 5).
4.1
4.2
5.0
Appendix A
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Once the new level measurement and alarm system is installed and commissioned,
CONTRACTOR shall export all old radioactive sources either to OEM or to any
authorised company for appropriate disposal as per Qatari and International Rules and
Regulations.
6.0
GENERAL REQUIREMENTS
6.1
The intent of this Appendix is not to specify completely the details of design,
engineering, procurement, supply, installation, testing, commissioning and
documentation of radioactive level measurement system at QP Refinery.
6.2
CONTRACTOR shall retrieve and review existing drawings and documentation and
shall carry out detailed WORKSITE survey to verify drawings are as-built before
proceeding with detailed design. In case of any discrepancy, CONTRACTOR shall
mark up actual as-installed details on drawings or documentation. QP is not
responsible for any difference between drawings or documentation and actual
WORKSITE installation. CONTRACTOR shall update existing drawings or
documentation related to the WORK.
6.3
All design data, drawings, specifications, and other information provided either directly
or indirectly by QP are for CONTRACTORs information and guidance only.
6.4
6.5
6.6
CONTRACTOR shall ensure that the new system is designed, procured, installed,
tested, pre-commissioned and commissioned in accordance with QP and other QP
recognized national/international codes and standards.
6.7
Except as expressly provided herein, CONTRACTOR shall procure and supply all
materials including cables, testing devices, equipments, tools, consumable materials
and every other item of expense necessary for the execution of this CONTRACT.
CONTRACTOR shall install all items including cable laying, cable support, and
associated wiring/termination at the like as required. CONTRACTOR shall arrange
required specialists and labors as required.
6.8
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6.9
CONTRACTOR shall advise QP of any design alternatives that may offer better
techno-economic solutions, if any.
7.0
:
:
:
:
:
:
:
+50 Deg C
+4 Deg C
50% (min) / 95% (max)
3 to 4 days with visibility < 1000 m
0.001 to 0.1 mm
0.15 to 0.3 mm
Highly Saliferous
7.1
Type of measurement
The existing radioactive level measurement and alarm systems shall be replaced with
latest state-of-art measurement system. The new system shall be capable of
measuring levels of solid catalyst in cylindrical metal vessels of different diameters and
wall thicknesses with radioactive source and scintillation type detection system.
Each system shall consist of a radioactive source of appropriate size, approved source
container, detector assembly, power supply, control unit and the like.
Appendix A
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7.2
Appendix A
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7.3
Level Switches
All level switches are required to be operated when the level reaches switching point.
The detector and its electronics unit shall be capable of sending a signal to the
Catalyst Regeneration Control System (CRCS) to initiate defined action. In case of low
level switch, the normal level of catalyst is above radiation beam. In case of high level
switch, the normal level of catalyst is below radiation beam. During normal operation,
removal or addition of catalyst is continuous.
Detector electronics shall drive an output relay at designed switching point, which shall
change a SPDT or DPDT contact. CONTRACTOR shall furnish contact ratings of this
relay. The relay shall be de-energized when the solids are below the radiation beam
(Low level fail-safe). Fail-safe action implies that the design of the unit maximises the
probability that the unit will fail in the position specified. Details of existing level switch
wiring is shown in Attachment-IIA & Attachment-IIB of this Appendix A.
.
Set point drift caused by electrical and ambient variations shall not exceed 10 % of
designed field strength or count rate.
The response time specified in the document applies only to the direction of emptying
as indicated for each item. Response time in opposite direction is not critical to the
process and may be adjusted as necessary to optimize the primary response. The
response time specified shall include any time required for recovery of electronics from
the effects of high field strengths on the detector.
CONTRACTOR shall replace all radioactive detectors with latest type of scintillation
counter type detectors for all switching applications. This type of detector will
considerably reduce source size, source activity and increase accuracy of switching
point.
CONTRACTOR shall offer industrially proven type of scintillation detector.
CONTRACTOR shall confirm that required response time will be achieved at required
Appendix A
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catalyst path length. Details like vessel dimensions, process specifications, and the
like are provided in Attachment-IV of this Appendix A.
7.4
Level Transmitter
The level transmitter shall generate an output proportional to the level of solids over a
range of measurement. The output shall be 4-20 mA DC, which is compatible with
Honeywell DCS for process monitoring. The removal and filling rates of catalyst is
continuous. CONTRACTOR shall replace all detectors with new type of scintillation
type detectors.
Level transmitter systems shall have a point source and a linear detector.
CONTRACTOR shall provide latest scintillation type detector. CONTRACTOR shall
mention maximum height of measurement possible with a single detector with a point
source.
If one set of source and detector is not enough to cover required range of
measurement then CONTRACTOR shall supply provide two detectors. Wirings and
configuration shall be carried out accordingly to accommodate two detectors. Similarly,
if one source cannot cover entire length of measurement then two sources shall be
provided. Sources shall be tilted in order to cover active length of detectors.
CONTRACTOR shall supply and install remote display unit for all Level Transmitters at
appropriate location at the same plat form.
Details of existing level transmitter wiring is shown in Attachment-III of this Appendix A.
Details like vessel dimensions, process specifications, and the like are provided in
Attachment-IV of this Appendix A.
7.5
Power Supply
New detectors shall operate with 24 VDC power supply. QP will provide redundant 110
VAC, 50 Hz single-phase power supply at one location in SER5. CONTRACTOR shall
install a redundant 24 VDC power supply units in SER5 and shall distribute power
supply to all control units/radioactive detectors. CONTRACTOR shall keep a provision
to isolate any instrument independently.
7.6
7.7
Cable
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CONTRACTOR shall check suitability of existing signal cable between field detector
and electronics located at SER5. The existing cable may be used for signals from new
radioactive detectors. If existing cable is not suitable then CONTRACTOR shall
replace the same with suitable cable. If cable tray or support is required for any new or
existing cable then CONTRACTOR shall supply and install the same. CONTRACTOR
shall supply/install cables and any other materials to hook-up new control unit and
power supply units, which will be installed in SER5.
If the new detector require external power supply (4 wire system) then QP will permit
the CONTRACTOR to use existing Junction Box (24VDC) between SER5 and CCR
platform. It is the responsibility of CONTRACTOR to provide necessary branch cables
(2C X 2.5 Sq.mm) from junction box located at CCR platform to each radioactive
detector. Contractor shall supply/install cables, cable glands, cable tray/support and
any other materials to power new radioactive detectors from SER5.
All instrumentation cables shall be flame retardant type conforming to BS 50288
Part 7 with outer sheath colour light blue for intrinsically safe circuits and dark grey for
other non-intrinsically safe circuits. Core colours shall be White (Positive) and Black
(Negative).
All power cables shall be flame retardant type conforming to BS 5467 with outer
sheath colour black. Core colours shall be Red (Positive) and Black (Negative).
7.8
Mounting Brackets
CONTRACTOR shall make use of existing mounting brackets on vessels to install
radioactive source and detectors. If not suitable, CONTRACTOR shall pre-fabricate
new mounting brackets or supports, which can be bolted/hooked to the existing
brackets welded on the vessel. Any kind of new welding on vessel is not permitted.
If the weight of the new system is heavier than existing system then CONTRACTOR
shall inform QP in order to verify vessel support and additional support/reinforcing
requirements.
7.9
Cooling Jacket
Cooling jacket shall be provided for all detectors as they are exposed to high
process/ambient temperature.
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8.0
SITE SURVEY
CONTRACTOR shall visit WORKSITE at QP Refinery before bid submission for
preliminary site survey, as built documentation and any technical clarifications to
visually check installation/mounting arrangements of radioactive sources/detectors,
electronics units, junction box location, cable routing, instrument air header location
and cabling/tubing routing. CONTRACTOR shall verify name plate of existing source
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9.0
reacceptance by OEM to take back old radioactive sources after end of useful life or is
no longer required by QP Refinery.
Appendix A
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12.0 SAFETY
CONTRACTOR shall follow all local and international safety rules and regulations for
personnel and radiation safety. CONTRACTOR shall ensure that all CONTRACTOR
PERSONNEL shall have undergone necessary safety training as required by QP
procedures as well as statutory requirements and shall provide records to substantiate
the same.
12.1 No work shall be carried out without necessary Permits to Work (PTW).
CONTRACTOR shall adopt and follow the PTW system in all QP restricted and
unrestricted areas.
12.3 CONTRACTOR shall keep first aid accessories and shall immediately report
any accident or near miss incident to QP.
12.4 CONTRACTOR shall conduct a detailed investigation and identify all hazards
that arise of any incident and submit the intended corrective actions to QP.
Based on frequency of incidents, CONTRACTOR performance will be subject to
review and where necessary, WORK shall be stopped until corrective measures
are in place.
13.0 COMMISSIONING
CONTRACTOR shall ensure that all equipments and cables are properly installed and
terminated before commissioning the system.
CONTRACTOR shall carry out preliminary checks and required loop testing prior to
commissioning of the system.
It may not be possible to empty or fill catalyst to required level. Hence, new radioactive
level measurement and alarm systems shall be commissioned on-line. CONTRACTOR
shall simulate catalyst before putting the new system in service. The system will be
kept under observation for at least four weeks after successful commissioning.
CONTRACTOR shall inspect all hardware upon receipt for any transit damage.
CONTRACTOR shall inspect hardware installation, cabling, termination, grounding,
and the like before power-on.
CONTRACTOR shall configure detectors/associated electronics as per requirement
and carry out all calibration/commissioning, which will be witnessed and signed off by
QP REPRESENTATIVE. CONTRACTOR shall rectify any faults discovered during
inspection and testing before proceeding further. All previously tested circuits that may
be affected by repairs shall be tested again.
The SAT shall include complete performance and functional testing of the installed
equipments. Some of the SAT activities may co-exist with commissioning.
CONTRACT DURATION:
18.0 GUARANTEE
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19.0 TRAINING
CONTRACTOR shall provide formal training to QP personnel on operation,
maintenance and safety aspects of new Radioactive Level Measurement Systems at
QP Refinery site for one day during commissioning.
Appendix A
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