volime ii of ii instrumentation

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GAIL (India) Limited(A Govt. of India Undertaking)

BID DOCUMENTFOR

P PIPELINE FROM HANUMAN JUNCTION TO VCL

VOLUME II OF II(INSTRUMENTATION)

(BID DOCUMENT NO: 11/0330G/WGI/GAIL/01-R0)

OPEN DOMESTIC COMPETITIVE BIDDING

ISSUED BY

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Document No. Rev

11-0330G01------------------ B

LIST OF DOCUMENTS/DRAWINGS

ATTACHED

SHEET 1 of 2

CONTENTS

S.NO. DOCUMENT/DRAWING DESCRIPTION. DOCUMENT/DRAWING NUMBERNO OF

SHEETS

1. Scope of Work Instrumentation 11-0330G01-01-11-06-002 11

2. Design Criteria for Instrumentation 11-0330G0100-11-01-001 15

3. Tech. Specs. for Gas Over Oil Actuator 11-0330G01-03-08-02-009 6

4.Tech. specs for Optical Fibre Cable &HDPE Duct.

11-0330G01-01-11-02-023 25 + 15

5.Tech. Specs. for fire & gas detectionsystem

11- 0330G01- 01-11- 06- 018 11

6. Tech. Specs. for Control Panel 11-0330G01-01-11-04-008 9

7. Tech specs for telemetry interface cabinet 11-0330G01-01-11-02-031 4

8. Tech specs for field transmitters 11-0330G01-01-11-02-009 14

9. Tech specs for pressure gauges 11-0330G01-01-11-02-010 9

10 Tech. Specs for RTD/Thermo well 11- 0330G01- 01-11- 04- 016 7

11. Tech. Specs for Pressure Relief valves 11-0330G01-01-08-02-017 8

12 Tech. specs for instrument cables 11-0330G01-01-11-02-012 9

13.Tech. specs for junction boxes and cableglands

11-0330G01-01-11-02-011 7

14. Tech. specs for stainless steel tubes 11-0330G01-01-11-02-026 7

15. Tech. specs for stainless steel tube fittings 11-0330G01-01-11-02-025 6

16.Tech. specs for instrument valves &manifolds

11-0330G01-01-11-02-027 8

17. Tech specs for room temp switch 11-0330G01-01-11-02-035 2

18.Tech specs for Self Actuated PressureRegulator Valve

11-0330G01-01-08-02-016 9

19. Cable Specification 11-0330G01-01-11-02-006 2

20. List of Recommended Vendors 11-0330G01-01-11-06-01 8

21. Instrument List - SAMPLE

22. List OF Parameters to SCADA - SAMPLE

23. Instrument Index Sheet 11-0330G01-01-11-02-007 1

24. I/O Point List 11-0330G01-01-11-02-008 1

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LIST OF DOCUMENTS/DRAWINGS

ATTACHED

SHEET 2 of 2

25.. Instrument Data Sheets 11-0330G01-01-11-02-006 6

26. Data Sheet for Junction Box 11-0330G01-01-11-02-011 3

27. Data Sheet for Gas Over Oil Actuator11-0330G01-03-08-02-010

1

28. QAP -Instrumentation 11-0330G01-01-11-10-021 2

29. Inst. / Canopy installation drawings.1-11-001, 1-11-002, 1-11-003 ( 2

sheets), 1-11-0055

30. Inst. Hook-up Drawings. 1-11-006, 1-11-007(2 sheets) 3

31. P&ID Legends 11-0330G01-03-01-001 2

32. P&ID for Dispatch Station 11-0330G01-03-01-002 1

33. P&ID for SV - 1 11-0330G01-03-01-003 1

34. P&ID for SV - 2 11-0330G01-03-01-004 1

35. P&ID for Receiving Station 11-0330G01-03-01-005 1

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GAIL (INDIA) LIMITEDPIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO.SCOPE OF WORKINSTRUMENTATION

TOTAL SHEETS 11

DOCUMENT NO 11 0330G01 01 11 06 002

0 5-7-11 ISSUED FOR TENDER PS MLS MLS

REV DATE DESCRIPTION PREP CHK APPR

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Document No. Rev

11-0330G01-01-11-06-002 BSCOPE OF WORKSINSTRUMENTATION

SHEET 2 of 11

CONTENTS

1.0 GENERAL

2.0 STANDARDS

3.0 SCOPE OF WORK AND SUPPLY

4.0 EXECUTION METHODOLOGY

5.0 DOCUMENTS/DRAWINGS TO BE SUBMITTED BY CONTRACTOR

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1.0 GENERAL:

This requisition outlines the detailed requirements of supply, installation, testing & commissioning ofinstrumentation related to pipeline from Hanuman Junction (Chainage 154KM) on Tatipaka-Lancopipeline to VCL of M/s GAIL.

2.0 STANDARDS:

The instrumentation erection, calibration and testing shall be carried out in accordance with variousrelated national, international and Indian Standards in instrumentation but not limited to the following.The Standards referred herein and mentioned below shall be of the latest edition prior to the date, of thepurchaser's enquiry: -

API American Petroleum Institute

MPMS Manual of Petroleum Measuring Standards

RP Recommended Practices

BS-6739 Instrumentation in process control systems:

Installation design and practice.

ISA Instrument System and automation society of

American Standards, Recommended

Practices and Technical Reports.

RP 7.1 Pneumatic Control Circuit Pressure Test

IS-5 Colours for ready mixed paints and enamels

IS-2074 Ready mixed paint, air drying, red oxide-zinc

chrome priming.

Instrumentation Installation Standards onwards

(Process Hook-ups)

Instrumentation supports standards

Manufacturer's standards and practices

3.0 SCOPE OF WORK AND SUPPLY:

The scope of work & supply shall generally be as follows, however contractor to provide all materials /instrumentation, install & commission them as per P&IDs and other data provided in tender to completethe work in all respects.

1. Supply, installation, calibration, loop checking & commissioning of all the instruments (Pressure reliefvalves, pressure gauges, RTDs / Thermowells, Pressure transmitters, Temperature transmitters, roomtemp switch etc)as per P&IDs, Data sheets, tech/standard specs.

2. Supply, installation, testing &commissioning of control panels (with all accessories, instrumentation,microprocessor based indicators {6X3}, signal repeaters/isolators, push buttons/switches/lamps/relays,redundant power supply regulators / convertors etc.) in control room, as per tech specs.

3. Supply, installation, testing & commissioning of wall mounted telemetry interface cabinet.

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4. Supply &installation of junction boxes & cable glands in field for all instrumentation.

5. Supply, laying, termination, testing & commissioning of cables (single pair/multi pair individual shielded /overall shielded, control / power cables, RS 232/RS485) from all field instruments/gas over oil actuatorvalves, gas detectors, fire / smoke / heat detectors, horns / beacons etc; to junction boxes/control room,from junction boxes to control room, from control panel to telemetry interface cabinet, from all types ofelectrical panels to telemetry interface cabinet etc;

6. Supply, installation, testing &commissioning of all piping, tubing, instrument valves & manifolds for fieldinstruments.

7. Supply, installation, of all steel structure (Angles, Pipe stanchions, canopies, channels, plates, anchorbolts, nuts etc ;)

8. Supply, installation, of perforated GI cable trays, Road crossing sleeve pipes, MCTS for control roomentry, GI strips, Earthing wires etc.

9. Construction of cable trench in field for all locations/stations as per approved drawing.

10. Supply, installation, testing &commissioning of gas detectors (IR Type),open path &fixed type includingcontrol room panel (any junction box required between field fire detection instruments and fire alarm

panel in control room is in vendors scope)with monitors, horn, beacons, portable gas calibrator etc; asper tech specs.

11. Supply, installation, testing &commissioning of fire detection system consisting of MCPs, Heat detectors,smoke detectors, horns, beacons including fire alarm panel etc,(fire &gas alarm to be repeated in guardroom)

12. Supply ,installation of all consumables required for instrumentation job, like welding, welding materials,welding gases, studs, nuts, washers, bolts, clamps, clips, gaskets, Teflon tape, Lugs, ferrules etc;

13. All paints, primers as per painting specifications given intender.

14. Writing tags details for all instruments with Paint.

15. Furnishing all drawings, documents for review/approval as per tender document.

16. Calibration, performance checking, loop checking, commissioning of all instruments.

17. Supply, installation of all materials including but not limited to structure steel, cable trays, cables, junctionboxes & cable glands(for loose supplied ultrasonic meters/valves ,which are assembled at site bycontractor) to complete the job in all respects. The job also includes supply, installation, and terminationof cables from field to control room as per drawings/specs of vendor.

18. Making cut outs, supply & termination of wires of loose supplied flow computers, control unit, printer etc.in control panel being supplied by vendor

19. Installation of loose supplied instruments, cables, junction boxes, tubing, valve/manifolds, fittings etc, ofmetering skids / filtration skids / letdown skids as per vendors drawings. Supply, installation of structuresteel, cable trays inside metering/filtration/letdown skids. Supply, laying, termination of cables from skidjunction boxes to control rooms. Calibration, loop checking of all instrumentation of metering / filtration /letdown skids. Installation of Metering panels supplied by vendor in control rooms, including installation,testing, calibration, loop checking, and connection / termination of loose supplied instruments &accessories for metering panels.

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20. Supply laying testing, blowing of 24 Fibre OFC of approved make in trench as shown in specifications.The job to be done by contractor who has experience of laying of OFC ,After testing of OFC the same tobe shown and handed over to Telecom equipment vendor.

21. Supply , laying , testing of permanently lubricated HDPE duct of approved make as per specifications

22. Supply, installation, termination & testing of FTC & accessories (like pigtails / connectors / DDF etc,) ofApproved make.

23. Supply, installation of jointing pits & kits as per specifications.

24. Supply, installation of Electronic marker & Electronic indicators of approved make

25. All instruments / materials shall be purchase from approved vendors only and shall be factory testedbefore dispatch to site in presence of owner / owners representative. Owner may give permission todispatch erection material after satisfying himself about credential of vendor & testing certificates etc.

26. Acceptance of instrumentation / materials, exemption of inspection at any stage does not absolve vendorof his responsibility for handing over all instrumentation in perfect working condition to owner while

handing over the site.

27. Supply, installation, testing & commissioning of all items specifically listed in the Schedule of Rates withspecifications attached else where in the tender document.

28. Supply of all hardware and residual activities not listed specifically in 'Schedule of Quantities' but arenecessary to ensure proper execution and completeness of instrumentation work.

29. As-built construction drawings and documents.

30. Arranging all necessary test and calibration equipments.

31. Residual Engineering Works / any other work, not specifically listed, but necessary for the successfulcompletion of instrumentation erection work defined in this specification.

32. Fabrication of pipe nipples as necessary including threading as per installation standards.

33. Drilling of holes in blind flanges including cutting threads as per installation standards.

34. Civil works including the casting of foundation as required for instrument supports where paved surfacesdo not exist.

35. Minor civil works like chipping of pavement, grouting of instrument panels/supports/ stanchions on thepavement, laying of conduits below pavement after chipping and refinishing of pavement as necessary.

36. Sealing of cables/tube entries into the control room after laying and testing of all cables/ tubes either byfilling with sealing compound or by installing Multi-Cable Transit block (MCT) including fixing of MCTframe, routing of cables through cable blocks, tightening of cable blocks.

37. Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts as per paintingspecification or as instructed by Engineer-in-Charge.

38. Fabrication and installation of pipe stanchion as per Instrument support standards including casting ofconcrete pedestal, grouting, welding etc. as necessary.

39. Drilling holes for providing glands/grommets on panels, shut down cabinets, power supply cabinets, local

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control panels, pneumatic enclosures, junction boxes etc., wherever required for cables entry.

40. Grounding of shields of shielded cables to respective instrument earth bus provided in the controlroom/local panel/thermocouple head etc. as required and instructed by Engineer-in- Charge.

46. Mandatory spares (10% of each type of instrument or whichever is higher for all type of instruments like;-PT, TT, RTD / TW, RELAYS, PUSH BUTTON / SWITCH, BARRIERS, GAS DETECTORS.MCPS ,HEAT

DETECTORS, SMOKE DETECTORS, PSV, PGS ETC;)minimum 1 no./commissioning spares asrequired during commissioning.

47. Following tests shall generally be included at factory &site (contractor to provide QA/QC document andget approval for all critical items of instrumentation);

i) Material test certificates, hydraulic test certificate.ii) Calibration certificate for all instruments.iii) Seat tightness test, pop-up test for pressure relief valves.iv) Test certificates for all cables.v) Certificates from statutory bodies (like FM/ Bafesa / CSA/ ATEX /CMRI etc) for meeting Ex-proof,

weather proof, intrinsic safe requirements of various instruments, Certificates are also requiredfrom CCOE for Ex-proof/intrinsic safe instruments/junction boxes etc.

vi) Calibration/loop checking at site of all instruments.

48. Submission of monthly material appropriation statements for cables, tube, piping material and fittings,indicating the quantity issued and consumed in standard Performa.

49. Incorporation of all information in owners drawings/document, as per the actual execution of work at siteincluding preparation and submission of as-built drawings.

50 Start-up and commissioning assistance as required and agreed upon with Engineer-in-Charge.

51. Submission of final material appropriation statements for all the materials issued by the Owner.

52. Residual engineering / any other work not specifically mentioned above, but required for the properexecution of the instrumentation works.

53. Following power supply will be made available to the contractor; Any other power supply required shallbe in Contractors scope.:

At SV1: 24 V DC

At VCL : 230 V , 50 Hz., 1 phase AC

4.0 EXECUTION METHODOLOGY

4.1 Instrument Impulse lines

4.1.1 All impulse lines shall be installed in the best workman like manner and shall follow installation standards

in each case. Where there is no installation standard, the instruction of the Engineer-in-Charge shall befollowed.

4.1.2 Horizontal and vertical lines shall be installed using levels and plumb bobs.

4.1.3 Unless otherwise specified in the drawings, impulse lines shall have a slope of not less than 1 in 12 onthe horizontal runs.

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4.1.4 All welding shall be carried out as per welding procedures and codes with electrodes approved byEngineer-in-Charge. Only qualified welders approved by Engineer-in-Charge shall carry out welding. Anymaterials like electrode, equipments, testing charges for various tests etc., required for initial qualificationof the welder/ welders shall be borne by the contractor. Wherever welding of dissimilar materials areenvisaged for any process hookup, the contractor's scope includes these welding along with supply ofweld materials.

4.1.5 Impulse pipes shall be bent using pipe benders only; hot bending will be totally rejected. Pipes shall becut using pipe cutting device. Hot cutting will not be allowed.

4.1.6 All threaded joints shall be jointed with PTFE tape only. No other pipe jointing compound shall be used.

4.1.7 All impulse lines shall be properly supported at regular intervals of 1 meter. Wherever insert plates arenot available, supports on concrete structures or on ceilings shall be fixed with a minimum of 10 mmexpansion bolts. Angle supports shall be fabricated from 40 mm x 40 mm x 5 mm MS angles, as aminimum.

4.2 INSTALLATION OF CABLES/PERFORATED TRAYS:

4.2.1 Multicore cables shall always be installed on trays/inside trenches and shall be properly clamped. At

every vertical drop to junction boxes, they shall be clamped at more frequent intervals (maximum of 300mm). They shall be connected inside junction boxes strictly according to the number system asmentioned in cable schedule. At bends minimum radius shall be maintained as per manufacturer'sstandard. The angle tray supports shall be fabricated from 40 mm x 40 mm x 5 mm angles, as aminimum.

4.2.2 Identification tags shall be provided on either end of multicore cables as per Cable schedules. Engravedtag plates or PVC ferrules shall be used for identification of cables.

4.2.3 All Multicore cables shall be cut after the exact site measurements are taken between ends. The cabledrums shall be selected before cutting the lengths so as to avoid any wastage.

4.2.4 All multicables laid in trenches/trays shall be properly dressed and tied with nylon wires of 3 mmdiameter.

4.2.5 In the field, the cables shall be laid in trenches and trays as per layout drawings.

4.2.6 Inside control room all cables shall be laid in trenches or below false flooring.When laid below the false floor the cables shall be properly dressed and tied as per instructions ofEngineer-in-Charge.

4.2.7 The perforated trays/angle trays shall be properly supported at a regular interval of maximum of 1 metrefrom insert plates or steel structures. Wherever insert plates are not available supports on concretestructures and ceilings shall be fixed with minimum 10 mm diameter expansion bolts. Angle supports forperforated trays/angle trays shall be fabricated from 40 mm x 40 mm x 5 mm MS angles as a minimum.

4.2.8 All supports shall be cut with hacksaw only. Any work executed by gas cutting for making holes or cuttingpieces will be totally rejected. Free ends of angle support shall not have sharp edges and shall beproperly rounded off.

4.2.9 Perforated trays/angle trays shall be used for branch cables from main trays. Width of trays shall beselected according to number of and cables. Trays shall be laid generally as per site conditions with theapproval of Engineer-in-Charge.

4.2.10 No welding on galvanised trays/angles/perforated trays shall be allowed in general. In specific caseswhere welding is unavoidable, this shall be carried out as per instructions from Engineer-in-Charge. For

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welding, if required, following procedure shall be followed as a minimum :a) Remove galvanization thoroughly from the portion to be welded.b) After welding, clean the welded portion for any slug and sharp edge.c) Welded portion shall be painted as per procedure described under para

4.2.11 Laying of Cables

4.2.12 All cables shall be laid in accordance with installation drawings and cable schedules. Before laying, cable /multicable on drums shall be meggered and tested to ascertain the transit damages.

4.2.13 All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficientamount for the final connection of the cable to the terminals on either end. Sufficient extra length of cableshall be kept at the termination points.

4.2.14 All cables shall be indicated close to their termination point by cable number as per cable schedules /junction boxes schedules. PVC ferrule/tag plate shall be used and these identification tags shall besecurely fastened to the cables.

4.2.15 All cores of electrical cables shall be identified by their wire numbers by means of the PVC ferrules. Wirenumbers shall be as per schedules. All temporary ends of cables shall be protected against dirt andmoisture. For this purpose, ends of all PVC insulation cables shall be taped with an approved PVC or

rubber insulating tape.

4.2.16 The bending radius of cables shall be maintained as per manufacturers' recommendation. Cablesinstalled above ground shall be run exposed on walls, ceilings, structures and shall run parallel or at rightangles with beams, walls or columns.

4.2.17 Cables shall be rigidly supported on structural steel and masonry individually or in groups as requiredusing PVC covered galvanized clips, multiple cable supports or cable trays. If drilling of steel must beresorted to, approval must be obtained and steel must be dr i ll ed where the minimum of weakening ofthe structured wall result. Cable shall be supported at every 500 mm on vertical runs and every 100 mmon horizontal runs.

4.2.18 All special cables and power supply cables will be laid direct to the held instrument without any junctionboxes, unless otherwise specified.

4.2.19 While laying cables in trenches or burying them, care shall be taken to ensure that low signal cables likealarm, gas chromatograph cables , special cables from gas chromatographs, ultrasonic meters.Compensating cable etc. are separated from other power supply cables.

4.2.20 Each underground cable (either in concrete trenches or hurried) shall be provided with identifying tag oflead securely fastened every 30 m of its underground length with at least one tag at each end before thecable leaves/enters the ground.

4.2.21 Directly buried cables shall be laid underground in excavated cable trench wherever specified in layoutdrawings. Trenches shall have sufficient depth and width to accommodate all cables correctly spaced.Pipe sleeves if required for cross over other than road like drains etc. shall be provided by contractor asper the instructions of Engineer-in-Charge. Before cables are placed the trench bottom shall be filled with100 mm layer of sand and leveled. Each layer of cables shall be covered with 150 mm of sand on topand sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall beplaced flat on the final layer of sand and cable. The remaining portion of the trench shall be then backfilled with soil compacted and leveled. On completion of every group of cable laying and before sandfilling, every cable shall be given insulation test in the presence of Engineer-in-Charge. Any cable provedto be detective shall be replaced before the next group of cables is laid. Cable route markers indicatingnumber of cables, depth and direction will be placed en-route, on crossovers/turnings etc. to mark thecable route.

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4.2.22 At each road crossings and other places, where cables enter pipe sleeves, adequate bed of sand shall begiven so that the cables do not slack and get damaged by pipe ends after back filling. After laying, the pipesleeves shall be sealed using sealing compounds.

4.2.23 At the entry into concrete blocks at road crossings cable loops shall be provided at either ends to preventany damage to cables. Each cable shall have one tag at each end before the cable enters/leaves conduitpipes.

4.2.24 After laying of all the cables, the cable entry to control room shall be suitably filled and sealed so as toachieve a positive seal against the entry of gas/water.

4.3 Earthing

4.3.1 Earthing of junction boxes, local panels / cabinets, gas chromatographs etc as required shall be carriedout as per the documents and instruction from Engineer-in-Charge.

4.4 Painting

4.4.1 This part of the specification is applicable to cable ducts, MS cable ways, angle trays. instrumentsupports/perforated trays, all structural supports for the above items, etc.

4.4.2 The surface to be painted shall be thoroughly cleaned with wire brush, sand paper to remove all scales.After cleaning, the surface is painted with one coat of red oxide zinc chromate primer conforming to IS-2074 and allowed to dry completely.

4.4.3 Primer coated surface is painted with one coat of paint to the color nearest to the final paint and allowedto dry. The color number shall be specified from IS-5.

4.4.4 Final second coating, shall be with the paint of desired colors and shall be selected from IS-5.

4.4.5 It shall be noted that final second coating on external surfaces not covered by cables, etc. shall beapplied just before handing over the plant or commissioning of the plant whichever is earlier.

4.4.6 The name of manufacturer, color and quality of all types of primer paint shall be subject to approval ofEngineer-in-Charge.

4.5 Testing

4.5.1 Electrical cables for signal power supply alarms shall be checked for megger values and continuity beforefinal termination and ferruling.

4.5.2 Testing shall be carried out after the Installation of instrument with primary piping complete in all respectsand approved by Engineer-in-Charge.

4.5.3 Primary piping shall be tested hydraulically to 1.5 times the operating pressure after isolating theinstruments. Flushing of piping shall be carried out as per instructions of Engineer-in-Charge. Lines shallbe blown after hydro-testing.

4.6 Calibration

All instruments shall be calibrated as per instructions given in manufacturers manuals/engineer-in-charge. Standard test instruments shall be used for calibration of instruments.

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4.7 Loop checking

4.7.1 Loop checking shall be performed after calibration; interconnection of signal lines is carried out for allinstruments. Loops tests are conducted to check the functional performance of all elements comprisingthe loop, thereby ensuring proper interconnections and operations.

4.7.2 Before proceeding for loop checking, the calibration results of individual elements shall be recorded on

the Performa and shall be approved by Engineer In Charge for correctness of installations,measurements and calibration results.

4.7.3 Loop testing for all control loops shall be simulating process conditions for at least 0%, 25%, 50%, and100% of full scale inputs. Detailed procedure shall be admitted by Engineer In Charge for approvalbefore proceeding for loop checking.

4.7.4 In case of shutdown systems, field/receiver switches are simulated for abnormality by disconnecting thewires at terminals. Function of all associated systems are checked including performance of solenoidvalves, On/Off type control/shutdown valves including proper functioning of limit switches and otheraccessories. Adjustment of limit switches wherever necessary also form part of checking of loopperformance.

4.7.5 Performance of individual loops shall be accepted for an overall accuracy of 1.5%. Where deviation is

found to exist more than specified limit, contractor shall recalibrate the instruments which shall also formpart of loop testing, at no extra cost.

4.7.6 After the loop test is complete, the contractor shall connect back any terminations and connectionsremoved for loop checking.

4.7.7 A loop shall be considered as handed over only after measurements in that particular loop are completedand certified by Engineer-in-Charge, in addition to loop sheets being duly filled in all respects, approvedand accepted by Engineer-in-Charge and Client. In case of loops in which certain instruments of theloops are calibrated by other agency, loop checking shall be performed in coordination with the agencyinvolved. If a defect in the calibration of the instruments in contractors scope is observed, same shall berectified to the satisfaction of the Engineer-in-Charge. However, if detect is detected in the calibration ofthe instruments in the scope of other agency, same shall be rectified by the agency involved. After thecalibration has been rechecked by other agency/agencies, the loop checking would be performed to thesatisfaction of Engineer-in-Charge. This is part of the contractor scope of work.

4.7.8 Final certified loop sheets shall be submitted in 4 copies.

5.0 DOCUMENTS/DRAWINGS REQUIRED FROM CONTRACTOR:

Following drawings and documents are to be generated by contractor and submitted forreview/approval/records. Signed &stamped Tech. specs of each item to be submitted along with otherdocuments of the item. (all documents related to particular item to be submitted in one lot).QA/QPdocument of each item/system to be submitted.

i) Purchase order, data sheets, model no. details, catalogs, and manuals, vendor drawingsdocuments:-For review/approval.

ii) Control panel/Telemetry interface cabinet GA drawings, Detailed wiring drawing, catalogs, modelno. details of various items, Functional schematics etc;:-For review/approval.

iii) Fire detection system, details of each item with catalogs/model no. details, fire alarm panel GA,wiring drawing, Functional schematics, Zone layout drawing, Location drawing of each item.:-Forreview /approval.

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iv) Gas detection system, details of each item, catalogs, Panel GA, wiring drawing, functionalschematic, location drawings of each item.:-For review/approval.

v) Instrument location drawing, trench layout, control room entry drawing:-For review/approval.

vi) Junction box, cable schedule:-For review/approval.

vii) Control room equipment layout drawing:-For review/approval.

viii) Manufacturers test reports, certificates, statutory certificates:-For review/records.

ix) Test procedures:-For review/approval.

x) Hydraulic test, calibration, loop check reports:-For records.

xi) Sizing calculations of pressure relief valves:-For review/approval.

xii) As built drawings:-For records.

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Document No. Rev

11-0330G0100-11-01-001 BDESIGN CRITERIA

FOR

INSTRUMENTATION SHEET 2 of 15

TABLE OF CONTENTS

PART-I: GENERAL Page No.1. General 4

2. Applicable national/international standards ... 4

3. Protection .....54. Certification Requirements ..6

5. Units of Measurement ..66. Utility Requirements 6

7. Process & Electrical connections .78. Major Components of Control & Instrumentation ...7

9. Material Selection Philosophy .8

10. Instrument Earthing 8

PART-2: INSTRUMENTS & SYSTEMS1.0 Pressure Instruments..102.0 Temperature Instruments ..11

3.0 Isolation Valves.11

4.0 Safety and Relief Valves ..125.0 Control/Metering Panel 136.0 Instrument cabling and wiring ..14

7.0 Junction Box .14

8.0 RTU/SCADA ..159.0 Telecommunication System.. 15

10.0 Filtration/Metering/Letdown Skids. 1611.0 Others...16

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1.0 GENERAL

The purpose of this design criterion is to furnish the minimum requirements on the Instrumentation,

Controls, and SCADA &Telecommunications. For detailed scope of work, refer SCOPE OFWORK documents

The objective of this document is to provide guidance to the contractor undertaking the detailed

design for instrumentation system of the Gas pipeline.

2.0 APPLICABLE NATIONALIINTERNATIONAL STANDARDS:

2.1 Design and terminology shall comply, as a minimum, with the latest edition prior to the date ofpurchasers enquiry of following codes, standard practices & publications.

ANSI/ASME:B 1 20. 1 Pipe Threads

B 16.47 Steel pipe flanges and flanged fittings.B 16.20 Ring joint gaskets and grooves for steel pipe flanges.

FCI 70.2 Control valve seat leakage classification.

API:RP 520/521/526/527 Sizing/selection/installation of pressure relieving systems.

RP 551 Process Measurement Instrumentation.

RP 552 Transmission Systems.

BS:

BS 5308 Specifications for PVC insulated cables.

DIN-43760: Temperature vs. Resistance curves for RTDS.

IEC:

IEC 79 Electrical Apparatus for Explosive Gas atmosphere.IEC 332 Test on bunched wires or cables.IEC 529 Degree of protection provided for enclosures.

IEC 534-2 Industrial process control valves-flow capacity.IEC 751 Platinum resistance temperature sensors.

IEC 801 Electromagnetic compatibility for industrial process measurementand control equipment.

ISA:

S-75.01 Flow equations for sizing control valves.

IS:IS-5 Colors for ready mixed paints.

IS-1554 PVC insulated (heavy duty) electrical cables wiring.

(Part-1)IS-2147 Degree of protection provided by enclosures for low

Voltage switchgear and control gear.

IS-2 148 Flame proof enclosures for electrical apparatus.

IS-3624 Specification for pressure and vacuum gauges.IS-583 1 PVC insulation and sheath of electrical cables.

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IS-15729 Natural gas pressure regulating and metering terminals.

EN:

EN-334 Pressure regulators.

EN-i4382 Slam shut valves.

AGA

AGA-5 Energy calculations in natural gas

AGA-7 Measurement of gas by turbine meters

AGA-8 Compressibility factors of natural gas & other related

hydrocarbon gases

AGA-9 Measurement of gas by ultrasonic meters

AGA-10 Speed of sound in natural gas & other related hydrocarbon

gases

GPA

GPA-2145-2172 Gas chromatographic analysis/heating value

3.0 PROTECTION

All instrument internal and external parts which are not inherently corrosion resistant by choice

of instrument and construction material shall be prepared and finished by suitable protectivecoating and paint finish.

All equipment shall also be able to withstand these conditions during shipment, storage andinstallation prior to commissioning

3.1 TYPE OF INSTRUMENT PROTECTION

Instrument Explosion proof Intrinsicallysafe

IncreasedSafety

Others

Field Switches

2-wire Transmitters

Solenoid Valves

Proximity Switches

All field instruments & junction boxes shall be weather proof to NEMA-4.

All intrinsically safe instruments shall be provided with isolator barriers in control panel.

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4.0 CERTIFICATION REQUIREMENTS

All instrumentation items used in hazardous areas shall be certified as indicated above, byinternational agencies like UL, FM or BASEEFA. As a minimum all the field instruments shall

be suitable for the use in Zone 1, Gr. IIA/B, temperature Class T3. All instruments to be used in

the classified area shall comply with IS-5571I IEC 60079. In case of discrepancy IS-5571 shallgovern. Also certificates (for all instrumentation used in hazardous areas) from BISICCOE shall

be furnished. In case of indigenous instruments hazardous area certificate from CMRI shall befurnished. Calibration /carrier gas cylinders for gas chromatographs shall be CCOE approved

5.0 UNITS OF MEASUREMENTS

a) Flow Gas: Kg/HrI sm3 /hrb) Pressure: Kg/cm2gIbargc) Temperature: DegC

d) Heating value: Kcal/SCM (BTU/SCM)

6.0 UTILITY REQUIREMENTS

Following power supply will be made available to the contractor; Any other power supply

required shall be in Contractors scope.:

At SV1: 24 V DC

At VCL : 230 V , 50 Hz. 1 phase AC

6.1ELECTRONIC INSTRUMENTS

6.1.1Power Supply requirementTransmitters: 24 V, DC

Solenoid valves: 24 V, DC

RTU/Telecomm. System: 24 V DC, -UPS, Unearthed (UE)Alarm Annunciators: 24 V DC, -UPS, Unearthed (UE)

Control Panel: 24 V DC, -UPS, Unearthed (UE)

F&G Panel: 24 V DC, -UPS, Unearthed (UE).

Gas Chromatograph: 24 V DC, -UPS, Unearthed (UE).

Any other power supply required for any Control/lnstrumentlRtulTelecomm. system shall be

derived from 24V DC Supply provided.

6.1.2 Signal transmission: 4-20 mA DC, 2 wire.

6.1.3 Switching: DPDT dry contacts

Normal: Close

Alarm/ Shutdown: Open

6.1.4All valves requiring Power supplies shall be directly powered and controlled from the

Instrumentation Panel. There shall be no interface with electrical except for the main

power supplies.

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6.1.5One UPS power feeder and one NON-UPS power feeder (for non-critical loads such as

panel light, fan etc.) shall be provided for control panels by contractor. Distribution to

panel instruments and field instruments shall be provided within the control panel.

Power supply to gas over oil-actuated valve shall be from control panel.

6.1.6 Electromagnetic Interference:

All instruments & systems shall be immune to electromagnetic interference as per IEC

801.

7.0 PROCESS & ELECTRICAL CONNECTIONS

7.1 PROCESS CONNECTIONS

The Nozzle length on Vessels for all instruments and on Piping for temperature instruments

shall be 8

Process connection for Thermowell shall be 1.5 FlangedMinimum Pipe size for thermo well installation is 4

7.2 ELECTRICAL CONNECTIONS (CABLE ENTRY)The cable entry for all field instruments shall be 1/2NPT (F) size, unless otherwise required bythe specific application.

8.0 MAJOR COMPONENTS OF CONTROL & INSTRUMENTATION

The major components of the Control & Instrumentation package include the following:

i) Local Gauges (Pressure)ii) Safety? Relief Valves

iii) Transmittersiv) Main Line Sectionalizing Valve? Isolation Valves /Actuators & accessories.

v) Local Control Panels and accessories.vi) Pig signaler.

vii) Fire and gas detection and monitoring system.

viii) Cables

On Vessels On Piping

Instrument

type Nozzle size Isolationvalve

Nozzle size Isolationvalve

Instrument

side

Pressure

Instruments2 Flanged 2 - 2

NPT(M)for

gauges, (F) for

Transmitters&

switches

Temperature

Instrument1 .5Flanged --- 1 .5Flanged - 1 .5Flanged

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ix) Junction boxes and cable glands

x) SS Tubes and fittings

xi) Instrument valves and fittings

xii) RTU/SCADAxiii) Telecom System.

xiv) Ultrasonic Flow Metering System/Filtration Let Down Skid & Metering Panel.

8.1 FIRE & GAS DETECTION SYSTEM

Fire & gas detection system shall be provided at the dispatch station, receiver stations. Each

system shall consist of smoke detectors, heat detectors & manual call points. Flashing light willbe provided at prominent point. Hooter will be provided on fire & gas detection panel. Also horn

will be provided in guardroom in unmanned stations.Minimum two open path gas detectors (IR absorption type) and minimum two fixed point gas

detectors (IR type) shall be provided near each pig launcher/pig receiver

Minimum four Nos. of open path gas detectors (IR t7e) and minimum four Nos. of fixed-pointgas detectors shall be provided for each metering station

8.2 INTERFACES TO OTHER SYSTEMSIsolated hardwired signals from field! electrical panels shall be terminated at local control panel

as well as fire & gas alarm panel. All the repeat signals for RTU/SCADA shall be made availableat the terminal end of the local control panel/telemetry interface cabinet. Necessary cables from

terminal strip of control panel to RTU / SCADA to be carried out by contractor.

9.0 MATERIAL SELECTION PHILOSOPHY

9.1 MATERIAL OF CONSTRUCTIONIn general, material of construction for the enclosure for transmitters, switches, solenoids, gas

detectors, junction boxes shall be cast aluminum (LM-6/LM25). Stainless steel enclosures shallbe provided for local gauges.

All wetted part material for the instruments shall be minimum SS 316.

10.0 INSTRUMENTATION EARTHINGNecessary earth pits shall be provided for signal earth and equipment earth as per relevant

standards. GI strips and COPPER wires shall be provided for instrumentation earthing

system.

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INSTRUMENTS & SYSTEMS

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1.0PRESSURE INSTRUMENTS

1.1 GENERALa) Process connections for pressure instruments shall normally be 1/2NPT

b) Static pressure sensing connections on horizontal lines are normally made at the top

c) Impulse connection between primary process taps and pressure instruments shall generally

be % OD 316 SS seamless tubing. The tubing wall thickness shall be determined bypressure and temperature design limits of the process for that particular fittings shall be of

compression type with double ferrule, Swagelok or Parker.

d) All pressure instruments shall be suitably mounted so as to minimize the length of impulse

lines.

1.2 PRESSURE TRANSMITTERa) Pressure transmitter shall be electronic SMART type, two wire loop powered at 24 VDC

with 4-20 mA output and integral digital output meter. Transmitters shall have HARTprotocol for digital communication.

b) Material of construction for wetted parts shall be SS 316.

c) Pressure transmitters shall have minimum accuracy +1-0.025% of the calibrated span.

d) Pressure transmitters shall be installed as close as practical to the primary taps.

Transmitters shall be installed in accessible places.

1.3 PRESSURE GAUGESa) Gauges shall be bourdon tube type.

b) Pressure gauge accuracy shall be 1.0% of full range.

c) Dial size shall be 150 mm and cases shall be stainless steel screw on or bayonet bezel type.Blow out disc and solid front protection shall be provided and gauges shall be orientated

such that they vent safely.

d) Gauge saver/snubbers shall be used as required.

e) Gauge windows shall be constructed from safety pattern/toughened glass.

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f) Bourdon tube material shall be type 316 Stainless steel,

g) Over-range protection shall be 1.3 times the maximum scale range. Where a gauge issubject to greater pressure, a gauge protector shall be used.

h) To facilitate pressure gauge removal and alignment, gauges shall be connected to thepiping by means of gauge adapter and not directly into valves.

2.0 TEMPERATURE INSTRUMENTS

2.1 THERMOWELLSa) Temperature measuring instruments shall be provided with thermowell. The process

connection size of thermowell shall be 1.5 flanged. Minimum line size for thermowellconnection shall be 4. For lower size line, same shall be expanded to 4.

b) The thermowell shall be constructed from drilled bar stock SS 316 material. Thermowell shall

have a sufficient internal bore to properly accommodate the devices placed in the bore.

c) Thermowell to be fabricated as per standard drawing for thermowell

d) All thermowells shall be stress analysed for velocity conditions. Calculation shall be done asper ASME PTC 19.3 code. 100% radiography shall be conducted for all fabricated

thermowells.

2.2 TEMPERATURE TRANSMITTERS

a) The sensor shall be RTD PT-100, 4-wire system. The transmitter shall be head mounted

SMART type, two wire loop powered at 24V DC with 4-20 mA output with digital outputmeter. Transmitters shall have HART protocol for digital communication. The 4-20 mA

output signals must be directly proportional and linear to temperature. The RTD shall be 4

wire, Class A type.

b) Transmitters shall have independent external screws for zero and span adjustment.

c) The accuracy of the transmitter shall be minimum 0.25% of calibrated span.

2.3 HART COMMUNICATOR

One No. of latest version of HART communicators alongwith one set of battery and battery

charger unit shall be provided along with carrying case for each individual metering skid.

3.0 ISOLATION VALVES

3.1 OPERATION PHILOSOPHYThe operating and closing philosophy for Actuated valve shall be as follows:

The actuated valve shall be operated from the Local! Remote Selection from the Actuator. If it

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is selected for the Remote, the valve can be operated from Panel or SCADA depending upon

the Panel/Scada. Remote manual operation from panelI SCADA shall be ensured without anymanual intervention, if all the process interlocks are met. But if the selector switch is selected

on the LOCAL from the valve then valve can only be operated from the field. Necessary logic

shall be relay based provided on the actuator.

3.2 VALVE ACTUATORS

3.2.1 Actuator shall be Gas-over-Oil actuator or gas actuated with quarter turn operation.

3.2.2Actuator torque shall be 1.25 times the valve torque required at full rated differential pressure of

valve.

3.2.3The actuator shall be suitable for operation using gas supply from up stream and down stream ofthe valve. Tapping for gas supply shall be provided on up stream and down stream piping of

the valve. Pneumatic cylinder storing gas with non-return valve shall be provided foremergency operation of valve.

3.2.4Tubing shall be 316 SS.

3.2.5Valve with actuator shall be suitable for installation in horizontal/ vertical lines

3.2.6Protective coating as per relevant painting specifications shall be provided.

3.2.7All Pneumatic tube fittings shall be of SS 316 compression type with double ferrules. and of

SWAGELOKI PARKERIHOKE/HAMLET make.

3.2.8All accessories as applicable duly tubed shall be mounted on the SS back plate which in turnshall be mounted on the actuator.

3.3 ACCESSORIES

3.3.1 Valve Position SwitchValve position switches for open? close position indication shall be proximity switch with

NAMUR design. The switch enclosure shall be copper free cast aluminum; weather proof(NEMA 4X) and it shall be intrinsic safe suitable for Zone-I Gr.II AIB temperature class T3.

3.3.2 Solenoid ValvesThe solenoid valve shall be double acting type. The body and internals shall be of SS 316.

Valve shall be made leak proof with 0 ring seals. The Solenoid valve shall be weatherproof to

NEMA-4X and Ex-proof type, suitable for Zone-i Gr. II A/B temperature class T3. No manualreset shall be provided for the solenoid valves.

The power supply shall be 24V DC.

3.3.3 Differential Pressure Switch

The high differential pressure switch set at 3.0 bars shall be provided with interlock to inhibitremote actuation on high differential pressure. The switch enclosure shall be copper free cast

Aluminium, weather proof (NEMA 4x) & it shall be intrinsic safe for Zone-I, Gr.ll A/B,temperature class T3. Differential pressure switch shall provide potential free contact for use in

control panel.

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3.3.4 Local/Remote Selector Switch

The L/R switch shall be provided on the valve actuator for selection of local operation from thevalve or remote operation from the control panel or SCADA.

4.0 SAFETY AND RELIEF VALVES

4.1APPLICATIONSafety valve shall be provided for Pig Iauncher/ pig receiver in accordance with API CODE.

a) ASME and API RP 520 formulae shall be used to calculate nozzle sizes of the safety reliefvalve.

b) Valves shall be sized for maximum requirements at design rates that would occur from

external fire.

4.2 MATERIALS AND CONSTRUCTION

All relief valves shall be standard disc and full nozzle full lift type with guided stem and discholder, and closed bonnet.

All relief valves shall be equipped with a manual test lever and the discharge shall be to a safearea.

4.3 INSTALLATION

Relief valves shall be installed with the spring in the vertical position

5.0 CONTROL / METERING PANEL

5.1 Control panel shall be free standing type of size 2100 mm x 1000 mm x 800 mm (H x W x D).

Fire and gas panel shall be wall mounted approx size 600mmX 600mmX300mm (HXWXD)

5.2 Control panel shall be suitable for installing in a control room. Panel shall be with a minimum

protection of IP 42.

5.3Control panel shall have bottom cable entries.

5.4Power distribution shall be provided with in the panel for all field instruments, panel mountedinstruments, annunciator, lamps, Relays, Active Barriers, etc.

5.5All the ferruling in the panels for the internal and field wiring shall be strictly cross-ferruled.

5.6The color of the control panel shall be RAL 7032.

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5.7Control panel shall be fabricated as per standard specification for Control Panel,

5.820% spare or minimum one (01) number (whichever is greater) of each type of instruments,relays, active barriers, all hardware inside the panel etc. shall be provided on each panel.

5.9Control panel shall be provided with document pouch.

6.0 INSTRUMENT CABLING AND WIRING

6.1 All cables shall be flame retardant type of IEC-60332 (Type-Ill, Category A) Cables for fire

& gas systemapplications shall be additionally fire resistant type to IEC-60331, and shallbe listed by UL/FM or equivalent in fire service.

6.2Cables for analog signals shall have both individual pair screen and overall screen, and

the pairs (or triads) shall be uniformly twisted together. Cables for discrete signals shall

have an overall screen, and the pairs shall be uniformly twisted together. 1 P cable shall

be used for field instruments from instruments to junction box one panel,

IP,2P,4P,6P,12P. Suitable conductor size considering voltage drop shall be used. 3C X

2.5 mm2 cable shall be used for 24 VDC power supply.

6.3Power supply cables (for 24V DC.) shall have stranded copper 2.5-mm2 conductor size.

6.4In general, cable shall be armoured type.

6.5Wiring inside the control room/local panels shall be 1.0 mm2 copper stranded conductors

with PVC insulation. Wiring shall be flame retardant & termination shall be via insulated

crimp pins. Panel wiring raceways and terminal blocks shall be flame retardant type

(FRLS). All terminal blocks shall be with screw clamp type and shall be UL listed 25%

spare to be provided for future expansion.

6.6All terminals shall be suitable for minimum 1 .5-mm2-conductor size excepting those on

main power supply distribution arrangements. The cable shields shall be grounded at one

location only. Only one junction box shall be allowed in the way of any interconnecting

cable between the field instruments and the final termination point both for skid and non-

skid equipment. Special signal cables shall be wired without Junction Boxes. All the field

terminal block in the local panel shall be provided with fuse and LED on the positive

(power) supply side only.

7.0 JUNCTION BOX

7.1Junction boxes shall be weatherproof to NEMA 4X. Junction boxes located in explosion

proof circuits shall be certified explosion proof to NEMA 7 suitable for the specified areaclassification.

7.2Material of construction of junction box shall be LM-6 cast aluminum.

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7.3Terminals shall be vibration proof, clip on type mounted on nickel-plated steel rails

complete with end cover and clamps for each row.

7.4All terminals shall be suitable for accepting minimum 1.5 sq. mm-copper conductors in

general. Sizing shall be done with due consideration for accessibility and maintenance.

7.5Plugs shall be of Nickel platted brass/SS

7.6Cable glands shall be double compression type for use with armoured cables. They shall

be of Nickel platted brass/SS.

7.7All cable glands shall be weatherproof to NEMA 4X. They shall be supplied to suit the

cable dimensions. Various components like rubber ring, metallic ring, metallic cone and

the outer! inner nuts etc. shall be capable of adjusting to the cable tolerances.

8.0 Not Used

9.0 Not Used

10.0 FILTERATION / METERING / LETDOWN SKIDS.

10.1Turbine Flow Metering based metering system along with filtration and letdown skids

and metering panels and Gas Chromatograph shall be supplied by Owner.

10.2Contractor shall install and commission the complete metering system under the supervision ofmetering system vendor.

11.0OTHERS.

11.1All cable entries to control room/-closed building shall be through MCT blocks. MCT shall have

25% spares with solid blocks Mm. 2 Nos. of each type of MCT block shall be supplied as loose

block for future entry of cables.

11.2Cable trays shall be shall be aluminum perforated type Maximum width of the cable tray shall bewith spare capacity shall be provided for cable trays.

11.3A minimum of wired 20% spare capacity shall be provided in terminals in junction boxes.Control panels, and multicore cables, cable entries in junction boxes, cable tray etc.

11.4In general, instrument Installation shall be as per specification for instrument installation works

and typical installation hook-up drawings.

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GAIL (India) LimitedPIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO. -TECHNICAL SPECIFICATION

FORGAL OVER OIL ACTUATOR TOTAL SHEETS 6

DOCUMENT NO 11 0330G01 03 08 02 009

A 16.06.11 ISSUED FOR IDC NC ASD AD


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TECHNICAL SPECIFICATIONFOR

GAS OVER OIL ACTUATORSHEET 2 of 6

TABLE OF CONTENTS

CONTENTS PAGE NO.

1.0 GENERAL 3

2.0 REFERENCE DOCUMENTS 3

3.0 DEFINITIONS 3

4.0 SCOPE 3

5.0 TECHNICAL REQUIREMENTS 4

6.0 TAG PLATE 6

7.0 SHIPPING PROTECTION 6

8.0 DATA SHEET ANNEXURE-A

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1.0 GENERAL

1.1 SCOPE

This specification together with the attached data sheets covers the Purchasers requirements for thedesign, materials of construction, manufacture, testing and shipping of Gas Over Oil Actuators.In case of contradiction, the data sheets overrule the general requirements of this specification.

2.0 REFERENCE DOCUMENTS

Reference is made in this specification to the latest edition of the following codes. standards andspecifications:

Codes and Standards

ASME B31.8 : Gas Transmission and Distribution Piping Systems.

ASME B16.5 : Steel Pipe Flanges and Flanged Fittings.

ASME B16.47 : Large Diameter Steel Flanges: NPS 26 through NPS 60

ASME SEC. VIII : Boiler and Pressure Vessels Code.

ANSI B 1020.1 : Pipe Threads, General Purpose

SA 370 : Mechanical testing of steel products

SA 530 : General requirements for specialized carbon and alloy steel pipes.

API 1104 : Welding of pipelines and related facilities.

BS 5351 : Steel ball valves for the petroleum, petrochemical and allied industries.

EN 473 : Qualification and certification of NDT personnel general principles.

EN 10204 : Metallic product: type of inspection document

50020 : Electric apparatus for potentially explosive atmosphere Intrinsic safety (I)

NEC : National Electric Code

IEC : International Electrotechnical Commission

3.0 DEFINITIONS

Shall : This verbal form indicates requirements strictly to be followed in order toconfirm to the standards and from which no deviation is permitted.

Should : This verbal form indicates that among several possibilities one is particularly

suitable without mentioning or excluding others or that a certain course ofaction is preferred but not necessarily required.

May : This verbal form indicates a course of action permissible within the limits of thisstandard.

Can : This verbal form used for statements of possibility & capability, whethermaterial, physical or casual.

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4.0 SCOPE

4.1 Vendors shall submit a detailed specification sheet for each item offered which shall provide allthe details regarding type, material of construction, electrical/hydraulic scheme, etc of theactuator and their accessories.

4.2 Vendor shall highlight the deviations, if any, from the purchasers data sheets and shall providereasons for the same. In case no deviations as indicated, it shall be assumed that allspecifications are met by vendor.

4.3 Vendor shall separately quote for two years operational spares for each instrument and itsaccessories.

4.4 The model number is solely the responsibility of the vendor. In case of contradiction thecontents of data sheets has priority over the model number.

4.5 Prior to shipment, Manufacturer shall submit one reproducible and six copies of following:

a) Test/ calibration/ inspection certificate for all items.

b) Manual for installation, erection instructions, maintenance and operation instructions.

4.6 All documents shall be in English Language.

4.7 Final documents shall be submitted in CD.

4.8 Statutory body certificates for offered instruments as applicable.

5.0 TECHNICAL REQUIREMENTS

5.1 The basic requirements of Gas Over Oil Actuator are as follows:

a) Actuator shall be gas over oil type, quarter turn operation type.

b) Actuator torque shall be minimum 1.25 times the maximum valve break torque required atfull rated differential pressure of valve.

c) Vendor shall indicate actuator model no., valve torque and actuator torque in tabularform.

d) Pneumatic connections shall be of min OD size and rating suitable for pressureconditions and shall be SS316 . Suitable connectors shall be used wherever required.

e) All tube fittings shall be SS316.

f) Valve with actuator shall be suitable for installation in horizontal pipeline.

g) All accessories as applicable shall be mounted on SS back plate, which on turn shall bemounted on actuator.

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h) Actuators shall be equipped with adjustable stoppers for opening and closing of valves. Atnormal operating conditions these stoppers at the actuator shall be limiting the openingand closing of valves.

5.2 The actuators control panel shall be weatherproofed to IP-66 .

The logic components / tubing inside the panel shall be SS316 material as minimum. All

electrical components mounted inside the panel shall be intrinsic safe and shall be certifiedby a statutory body like UL/BASEEFA/ATEX ETC.

5.3 The control logic shall enable the following:

a) Local and remote selection in field.

b) Maintenance/panel/SCADA selection in local panel.

c) Logic function shall include open/ close facilities. Logic may be implemented using relay logic incontrol panel. Panel / SCADA contacts shall be momentary, hold on contacts shall be used inlogic.

d) Remote function shall facilitate remote closure and opening of valve (without any manual

intervention if all process interlocks are met). In case electr ical signal to solenoid valvesfail, the valve shall remain in the last position (Stay put).

e) Manual local hydraulic operation of valve , with hand pumps, in case of non availability ofpneumatic (gas) operation.

f) High differential pressure inhibit switch shall inhibit the remote operation of the valve, whendifferential becomes high (more than 3 bars). However it shall be possible to operate thevalve locally.

g) Close command (or open command) shall be inhibited during valve opening (or valveclosing) and be made effective only after 100% opening (or closing ) is achieved.

5.4 Gas storage tank and hydraulic cylinders shall be sized so that the actuator / operator shall becapable of minimum two open/ close operations in the event of loss of line pressure.

5.5 Contractor shall supply gas filter regulators to derive power gas pressure to required level(min 5 bars) for the operation of the logic. Actuator sizing shall be based on minimum gaspressure available in pipeline.

5.6 Solenoid valves shall be mounted inside the actuator control panel for the remoteopen/close operation of the valve actuators. Solenoid valves shall be intrinsically safe andcertified.

5.7 All equipment and accessories shall be tropicalised and provided with anti-corrosionprotection, suitable for use in corrosive atmosphere.

5.8 All material shall be new, clean and free from rust, pits, and obvious defects.

5.9 The range (min/max) of opening/closing timings for gas over oil actuator valves shall be36-55 seconds.

5.10 Material for studs shall be ASTM A193 GR. B7 and nuts shall be ASTM A 194 GR. 2H.

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5.11 Contractor shall provide the following potential free contacts.

a) Local / remote selector switch in local position and remote position.

b) Maintenance / local / SCADA selector switch indication in maintenance / panel / SCADA mode

c) High Differential pressure.

d) Valve open position.

e) Valve close position.

All potential free contacts and remote open / close commands shall be provided in a terminal block inactuator control panel. Suitable provisions for cable entry / exit shall also be provided.

6.0 TAG PLATE

Actuator shall have SS name plate permanently fastened to the superstructure, which shallbe visible when it is in service.

The name plate shall have following information:

a) Manufacturers name and trade mark.

b) Valve tag number.

c) Actuator model no. & serial no.

d) Order no. (Optional).

7.0 SHIPPING PROTECTION

7.1 All openings shall be suitably protected and all exposed surfaces suitably coated to prevententry of foreign material and avoid damage during shipment.

7.2 All items shall be adequately packed to withstand shipping conditions without damage.

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GAIL (INDIA) LIMITEDPIPELINE FROM HANUMAN JUNCTION TO VCL

CLIENT JOB NO. -TECHINCAL SPECIFICATIONFOR

OPTICAL FIBRE CABLE AND HDPE DUCT TOTAL SHEETS 25

DOCUMENT NO 11 0330G01 01 11 2 023

A 20-06-11 ISSUED FOR IDC PS MLS MLS


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FOR OPTICAL FIBRE CABLE ANDHDPE DUCT

SHEET 2 of 25

CONTENTS

1.0 INTRODUCTION.................................... ........................................... ............................................... 3

2.0 QUALITY REQUIREMENTS ..................................... ......................................... ............................. 3

3.0 CABLE MARKING....................................... ......................................... ........................................... 3

4.0 RAW MATERLAL .................................. ......................................... ................................................ .3

5.0 DOCUMENTATION ..................................... .............................................. ...................................... 4

6.0 SAFETY REQUIREMENT................... ............................................ ............................................ .....47.0 OPERATING REQUIREMENT ..................................... ...................................... ............................. 4

8.0 CABLE ENDS ............................... ............................................ ............................................ ........... 4

9.0 THE NOMINAL DRUM LENGTH.............................................. ............................................ ........... 4

10.0 COLOUR CODING IN OFC CABLES ............................................ ............................................ .....5

11.0 SPECIFICATION OF OPTICAL FIBRES ....................................... .............................................. ...5

12.0 OFC PIT .................................. ............................................ ............................................... .............. 6

13.0 OPTICAL FIBRE CABLE CONSTRUCTION SPECIFICATIONS...................................................7

14.0 MECHANICAL CHARACTERISTICS, AND TESTS ON OPTICAL FIBRE CABLES.................... 8

15.0 CHECK OF THE QUALITY OF THE LOOSE TUBE (CONTAINING OPTICAL FIBRE) METHOD:13

16.0 DRAINAGE TEST FOR LOOSE TUBE.........................................................................................13

17.0 OPTICAL FIBRE CABLE LAYING................................................................................................1418.0 TILE SCOPE OF WORK FOR LAYING ........................................ ............................................... .15

19.0 CABLE PROTECTION DURING INSTALLATION ......................................... .............................. 15

20.0 CABLE LAYING PROCEDURE ...................................... ......................................... ..................... 16

21.0 LUBRICATION...............................................................................................................................17

22.0 JOINTING / INSTALLATION AT PULL BOXES....................................... .................................... 17

23.0 CROSSING ......................................... ............................................ ............................................ ...18

24.0 BACKFILLING & TESTING...........................................................................................................18

25.0 HDPE CONDUIT ............................................ ......................................... ....................................... 1926.0 FIBRE TERMINATION CLOSURE & EARTHING 25

27.0 STANDARDS APPLICABLE........... ......................................... ............................................ ......... 20

28.0 APPROVAL OF DOCUMENTS .......................................... ............................................ ............... 2029.0 GENERAL GUIDELINES........................................ ......................................... .............................. 21

30.0 SOLID PERMANENTLY LUBRICATED PIPE CONDUIT.............................................................21

31.0 PACKING......................................... ............................................ ............................................ ...... 22

32.0 QUALITY ASSURANCE PROGRAMME & TESTING .................................... .............................. 22

33.0 SUMMARY OF REQUIREMENT ........................................ ...................................... ..................... 23

34.0 LIST OF ABBREVIATIONS...........................................................................................................23

35.0 LIST OF DOCUMENTS REFERED .......................................... ............................................ ......... 24

36.0 SCHEMATIC CONST. FOR OFC. ANNEXURE-A.

37.0 QAP FOR OFCANNEXURE-B.38.0 QAP FOR HDPE DUCT..ANNEXURE-C.39.0 PLB HDPE DUCT PARAMETERSANNEXURE-D.

40.0 LAYING OF OFC, HOP TESTING OF OFC, DUCT INTEGRITY TESTS ANNEXURE-E41.0 LEGENDS, OFC AND DUCT TRENCH DETAILS. ANNEXURE-F

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1.0 INTRODUCTION

This document describes the specification of CSTA (Corrugated Steel Type Armoured) Optical FibreCable for Pipelines from VCL Receiving Station to Hanuman Junction on Tatipaka Lanco pipeline. TheOFC for underground installation in ducts, which shall conform to TEC spec. No_ Gl01 C.-01l03 withlatest amendments. The optical fibre cable shall have low weight. Small volume and high flexibility. Theoptical fibre cable shall be suitably protected for the ingress of moisture by flooding belly and by waterswellable tape. The raw material used in the cable shall meet the requirements of the specs for the rawmaterials.

2.0 QUALITY REQUIREMENTS

The cable shall be manufactured in accordance with the international quality standards, ISO 9000 seriesof standards for which the manufacturer should be duly accredited.

3.0 CABLE MARKING

3.1 A suitable marking, which can last long, shall be applied in order to identify this cable from other cables.The cable marking shall he imprinted' indented. The marking on the cable shall be indelible of durablequality and at regular intervals of one meter length. Alternatively, permanent printing with the laser (theimpression shall not exceed the depth of 0.15 mm) shall also be acceptable.

3.2 The markings must clearly contrast with the surface. The colours used must withstand the environmentalinfluences experienced in the field.

3.3 The marking shall be in black colour over the orange colour nylon jacket and shall he done by hot oilindentation method.

3.4 The accuracy of the sequential marking must be within -0.25% to +0.5% of the actual measured length.The sequential length markings must not rub off during normal installation. The total length of the cablesupplied shall not be in negative tolerance.

3.5 The type of legend marking on OFC cable shall be as follows:

Name of manufacturer.Part number."OPTICAL FIBRE CABLE".

Type of Fibre.Number of Fibers.Year of manufacture.Sequential length marking.Drum number

4.0 RAW MATERlAL

4.1 The cable shall use the raw materials approved against the TEC specs No GIOR M-01/02 March 99 andthe subsequent amendment issued if any.

4.2 The materials used other than the above materials shall be clearly indicated by the manufacturer. TheManufacturer shall furnish detailed technical specifications of such raw materials used.

4.3 The source / sources of raw materials from where these have been procured shall be submitted by themanufacturer.

4.4 The change of raw materials from one approved source to other approved source shall be allowed,provided there is no change in the design of the cable. However change in design or construction of themetal free optical fibre cable requires approval from owner/consultant.

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4.5 The HDPE Red/Black in colour used for sheath shall be UV stabilized. A test certificate from arecognized laboratory or institute may be acceptable for the UV stability of the HDPE sheath material.

4.6 The material used in optical fibre cable must not evolve hydrogen that will affect the fibre loss.

5.0 DOCUMENTATIONComplete technical literature in English with detailed cable construction diagram of various sub-

components with dimensions & test data and other details of the cable shall be provided. All aspects ofinstallation, operation, and maintenance shall also be covered in the handbook.

6.0 SAFETY REQUIREMENT

The material used in the manufacturing of the armoured optical fibre cables shall be non-toxic anddermatologically safe in its lifetime.

7.0 OPERATING REQUIREMENT

7.1 The design and construction of metal free optical cable shall be inherently robust and rigid under allconditions of operations, adjustment, replacement, storage and transport.

7.2 The optical fibre cable shall be able to work in a saline atmosphere in coastal areas and should be

protected against corrosion.7.3. Life of cable shall be better than 40 years. The bidder shall submit necessary statistical calculations.

7.4 It shall be possible to operate and handle the metal free optical fibre cable with tools as per TEC specsNo. G/OFT01/02 Mar.'99 (or Latest) and subsequent amendment, if any. In case any Special toolrequirement for operating and handling the optical fibre cable. The same shall be provided along with thecable.

8.0 CABLE ENDS

8.1 Both ends of the cable shall be kept inside the drums and shall be located so as to be easily accessiblefor the test. The drum (confirming to TEC specs No. G/CBD-01/02 Nov. 94 and subsequent amendment)should be marked to identify the direction of rotation of the drum. Both ends of cable shall be providedwith cable pulling (grip) stocking and the anti twist device (free head hook)

8.2 An anti twist device (Free head hook) shall be provided attached to the front end of the cable pullingarrangement. The arrangement of the pulling eye and its coupling system along with the anti twist systemshall withstand the prescribed tensile load applicable to the cable.

9.0 THE NOMINAL DRUM LENGTH

9.1 To supply OFC cable in 4 km drum with no negative tolerance on length for one cable drum. Shorterlength (not less than 1KM) may be accepted to arrive at the total quantity to be supplied. There shall beno tolerance on the total cable quantity to be supplied. Measurement for the purpose of payment shall bephysical length of the cable.

9.2 The fibre in cable length shall not have any joint.

9.3 The drum shall be marked with arrows to indicate the direction of rotation.

9.4 Packing list supplied with each drum shall have at least the following information:

Drum No.

Type of cables

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Physical cable length

No. Of fibers

10.0 COLOUR CODING IN OFC CABLES

The colorant applied to individual fibers, fibre units and hinders shall be readily identifiable throughout the

lifetime of the cable and shall match and confirm to the MUNSELL COLOUR STANDARDS (FOR EIASTANDARD EIA-359M and IEC Publications 304 (4)).

11.0 SPECIFICATION OF OPTICAL FIBRES

Single Mode Optical Fibre used in manufacturing optical fibre cables shall be as per ITU - T (earlierCCITT) Recommendation G-652. The specification of optical fibers is as below:

11.1 Type of Fibre Single mode11.2 Number of fibers Twenty Four11.3 Wavelength and band optimized 1300 nm & 1550 nm (2nd

window)GEOMETRICAL CHARACTERISTIC

11.4 Nominal MFD

For depressed CladFor Matched CladTolerance

9 um10 um+/- 10% of the nominal

value11.5 Nominal Cladding Diameter 125 um +/- 0.7um11.6 Cladding Non-Circularity


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less than 0.1 dB.The spectral attenuation shall be measuredon uncabled fibre.

11.14 A) Total DispersionIn 1285 1330 nm bandIn 1270 - 1340 nm bandAt 1550 nmB) Polarization mode dispersion at 1300& 1550 nm

FibreCabled FibreNote: measurement on uncabled fibre maybe used to generate cabled fibre statisticsand correlation is establishedC) Zero Dispersion SlopeD) Zero Dispersion wave length range

< 3.5 ps/nm. Km< 6.0 ps/nm. Km< 18.0 ps/nm. Km

< 0.2 ps/Km< 0.3 ps/Km

< 0.092 ps/(nm2.Km)1300 1342 nm

11.15 Cut off wavelength of optical fibersFor Coated Fibre (For 2 m samples length offibre)For Cabled Fibre (For 22 m sample length ofcable)

1320 nm maximum

1270 nm maximum

MECHANICAL CHARACTERISTICS

11.16 Proof test for minimum strain level

Strippability force to remove primaryNote:The force required to remove 30 +/- 3 mm of

the fibre coating shall not exceed8.9 N and shall not be less than1.3 N

Dynamic Tensile StrengthUnagedAgedDynamic FatigueStatic Fatigue

1%

1.3 440 KPSI (3.00 Gpa)>/=20>/=20

11.17 Change in attenuation measured at 1550 nmwhen fibre is coiled with 100 turns on 30+1.0mm radius mandrel.

< 0.10 dB

11.18 Fibre Curl >4 Meter radius ofcurvature11.19 Fibre micro bend (1 around 32+0.5 diameter

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Joining pit at every 4 Km.

The pit shall be provided with a concrete cover slab with a man-hole. The top of this slab shall beminimum 300mm above the finished ground level or depth of water logging during monsoon whichever ishigher.

A cat ladder shall be provided if depth of pit is more than 1 m.

The details of Pit and location of permanent lubricated HDPE duct are given in annexure-6.

13.0 OPTICAL FIBRE CABLE CONSTRUCTION SPECIFICATIONS

13.1 SECONDARY PROTECTION

The primary coated fibres may be protected by loose packaging within a tube, which shall be filled withthixotropic jelly.

Number of fibres: 24

Number of loose tubes: 4

Number of fibres per loose tube: 6 (Six)

Material for loose tube: PBT (Polybutylene terephthalate)Outer diameter of loose tube: 2.5 mm nominal

13.2 STRENGTH MEMBER

Solid FRP non-metallic strength member with a minimum diameter of 2.5 mm nominal in the cablecore shall be provided. The strength member(s) in the cable shall be for strength and flexibility of thecable and shall have anti buckling properties. These shall also keep the fibre strain within permissiblevalues

To achieve the required tensile strength of the optical f ibre cables, the manufacturer may use AramidYarn along with solid Rigid FRP Rod. The use of solid rigid FRP Rod(s) is mandatory in Optical FibreCable design. The Aramid yarn shall be equally distributed over the periphery of the cable core. Thequantity of the Aramid yarn per km length of the cable along with its dimensions shall be indicated bythe manufacturer.

13.3 Cable Core Assembly: Primary coated fibres in loose tubes stranded together around Centralstrength member using helical or reverse lay techniques shall form the cable core.

13.4 Core Wrapping: The main cable core containing fibres shall be wrapped by layer/layers of Polyesterwrapping tape. Minimum thickness of Polyester wrapping tape shall be 250 um. The nylon/ polyesterbinder thread shall be used to hold the tape.

13.5 Moisture barrier (protection): The main cable core (containing fibres core wrapping) shall beprotected by flooding compound (Jelly) having properties of non-hygroscopic dielectric material andby water swellable tape. The core wrapping shall not adhere to the secondary fibre coating.

13.6 Filling compound: The filling compound used in the loose tube and to the cable core shall becompatible to fibre, secondary protection of fibres core wrapping etc. The drip point shall not be lowerthan 71 degree C. The fibre movement shall not be constrained by stickiness & shall be removableeasily for splicing. Reference material test method to measures drop point shall be as per ASTM D556. The filling and the flooding jelly compound shall be as per the TEC specs No. G/ORM-01/02MAR'99

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13.7 Sheath: A non-metallic moisture barrier sheath may be applied over and above the cable cores. Thecore shall be covered with tough weather resistant High Density. Polyethylene (HDPE) sheath redblack in colour with minimum outer diameter of 1.5mm (UV stabilized) and Colour shall conform toMunsell Colour Standards. Thickness of the sheath shall be uniform & shall not be less than 1.5 mmincluding the. Strength members it used in the sheath. The sheath shall be circular, smooth, and freefrom pinholes, joints. Mended pieces and other defects. Reference test method to measuresthickness shall be as per IEC 189 para 2.2.1 and para 2.2.2.

Overall cable diameter shall not exceed 16mmNote: in case HDPE: material black in colour is used; the material from finished product shall be

subjected to following tests (on sample basis)

1) Density

2) Melt Flow Index

3) Carbon Black Content

4) Carbon Black Dispersion

5) ESCR

6) Moisture Content

7) Tensile Strength and Elongation at break

13.8 Outer Jacket: A circular Sheath I Jacket of not less than 0.65 mm thick of polamide-12/ nylon - 12material (orange colour), free from pin holes, scratches and other defects etc. shall be provided overand above the HDPE sheath, The nylon Jacket shall have smooth finish and hydrocarbon resistant.

13.9 Cable diameter: The manufacturer shall specify the over-all cable diameter.

13.10 RIP Cord: Suitable rip cord(s) shall be provided which shall be used to open the HDPE sheath of thecable. The ripcords shall be properly waxed to avoid wicking action.

13.11 Optical fibre cable shall be having armoire for mechanical protection.

14.0 MECHANICAL CHARACTERISTICS, AND TESTS ON OPTICAL FIBRE CABLES

14.1 TENSILE STRENGTH TEST

Objective: This measuring method applies to optical fibre cables, which are tested at a particulartensile strength in order to examine the behaviour of the attenuation as a function of the load on acable, which may occur during installation.

Method: IEC 794 - l - E l

Test Specs: The cable shall have sufficient strength to withstand a load of value T (N) = 9.81 x 2.5W Newton or 2670 N which ever is higher. (Where W=mass of 1 km of cable in Kg) The load shall besustained for two minutes and the strain of the fibre monitored.

Requirement: The load shall not produce a strain exceeding 0.25% in the fibre and shall not causeany permanent physical and optical damage to any component of the cable. The attenuation shall benoted before strain and after the release of strain. The change in attenuation of each fibre after theTest shall be < 0.05 dB both for 1300 nm and 1550 nm wavelength.

14.2 ABRASION TEST

Objective: To test the abrasion resistance of the sheath and the marking printed on the surface ofthe cable.

Method: IEC - 794-1-E2 or by any other international test method.

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Requirement: There shall be no perforation & loss of legibility of the marking on the sheath

14.3 CRUSH TEST (COMPRESSIVE TEST)

Objective: The purpose of this test is to determine the ability of an optical fibre cable to withstandcrushing

Method: IEC 794-1-E3.

Test Spec.: The fibres and component parts of the cable shall not suffer permanent damage whensubjected to a compressive load of 2000 Newton applied between the plates of dimension 100 xl00mm. The load shall be applied for 60 secs. The attenuation shall be noted before and after thecompletion of the test.

Requirement: The change in attenuation of the fibre after the test shall be < 0.05 dB/Kmboth for 1300 nm and 1550 nm wavelength.

14.4 IMPACT TEST

Object: The purpose of this test is to determine the ability of an optical fibre cable to withstandimpact

Method: IEC 794-1-E4Test Spec.: The cable shall have. Sufficient strength to withstand art impact caused) by a massweight of 50 Newton, when falls freely from a height of 0.5 meters. The radius R of the surfacecausing impact shall be 300 mm. ten such impacts shall be applied at the same place with a gapbetween one impact to another of approximately at 60 seconds.. The attenuation shall be notedbefore and after the completion of the test.

Requirement: The. Change in attenuation of the fibre after the test shall be < 0.05 dB/Km both for1300 nm and 1550 nm wavelength.

14.5 REPEATED BENDING

Objective: The purpose

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