Page 1 of 15

HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY


DHT PROJECT SRU UNIT

LSTK CONTRACTOR 3

PART: III
SECTION: B.8

TITLE: SCOPE OF WORK INSTRUMENTATION

DOCUMENT NO: 44LK-5100-00/J.02/0025/A4















1 27.05.09 15 Issued for Amendment STK SPM KA
0 30.03.09 15 Issued For FEED STK SPM BSP
Rev No. Issue Date Pages Rev Description Prepared By

Checked By

Approved By



HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 2 of 15

1.0 INSTRUMENTATION AND CONTROL

1.1 GENERAL

1.1.1 LSTK CONTRACTOR 3 (Henceforth referred to, as Contractor) shall develop the Approved
for Construction (AFC) status taking due account of the engineering design basis, job
specifications, standard specifications, engineering standards, statutory regulations, OISD
requirements and any information given within the FEED in providing final details for the
facilities described within this overall scope of work as being a requirement. Contractor shall
be responsible for implementation of complete instrumentation and controls for SRU on
turnkey basis with scope of work as listed below, but not limited to the following.

1.1.2 Contractors scope of work for instrumentation and control system shall include but not be
limited to: -
- Design and engineering including residual engineering
- Carry out HAZOP and implement the recommendations without any cost/delivery implication
- Procurement, shop testing and supply
- Installation, field calibration / testing, Loop checking, integration and commissioning.
- Co-ordination with other contractors, package vendors, LLI (Long Lead Item) suppliers,
Licensor, PMC and client
- Obtaining statutory approvals, certificates from the authorities such as IBR, CMRI, CCE, FM,
CENELEC, PTB etc. as applicable and required to complete the work and commission the
plant/system

The descriptions and requirements contained in above specifications are concise by necessity
and cannot include all details. However, it is the responsibility of the contractor to execute the
job in accordance with the specifications and good engineering practices for smooth, safe and
successful operation of the plants.

This scope of work shall be read in conjunction with engineering design basis, job
specification, job drawings, standard specification, standard drawings, engineering standards,
process package, P&IDs and process data sheets of the bid package. The contradictions in
any of these documents shall be brought to the notice of Owner / PMC immediately for
approval.

The scope of instrumentation and controls shall include all changes due to completion of
residual engineering on P&ID / Process Package. Scope changes as a result of contractors
detailed engineering and HAZOP study, and changes w.r.t. Licensors checklist / comments
shall also form part of this contract.

Contractor shall furnish soft as well as hard copies of Basic engineering package to PMC.

1.1.3 Contractors battery limit

Battery Limits of DHT project comprising SRU Fired Heaters, Columns / Towers, Vessels /
Drums, Tanks, Reactors, Heat Exchangers, Blowers / Feed Pumps, miscellaneous
equipments etc. Plant Unit Battery limit shall include all instrumentation and control for plant
units as indicated in licensors documents, FEED documents, scope of work.

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 3 of 15


- New process units pipe rack
- Fire and Gas detection to be interfaced with control system.
- Tie-in points with existing facilities as mentioned in the FEED package
- Sub-station for Instrument / Electrical interface cabling

1.1.4 Scope of Contractor:
Supply, installation, testing, commissioning of all items related to instrumentation and Package
control system shall be as indicated on the Piping and Instrumentation Diagrams (P&ID) and
process package of respective units and other documents attached with the tender package.

The scope shall include but not limited to the following: -

All types of instruments including field transmitters, pressure and temperature gauges,
level gauges, thermowells, RTDs, thermocouples, skin thermocouple assemblies, venturi
tubes, flow nozzles, vortex meters, orifice assemblies, solenoid valves, control valves with
accessories, safety relief valves, flame arrestors, breather valves, mass flow meters,
thermal mass flow meters, ultrasonic flow meters, remote operated valves, rotameters, self
actuated pressure control valves, analyzers and other special instruments etc. as indicated
on the P&IDs, licensers package, job specifications, standard specifications, auxiliary
P&IDs and other documents of the tender package.

All installation and erection materials such as impulse piping, pipe/tube fittings and valves,
tubing, cable tray / duct, supports, fire proofing, cable glands with shrouds & accessories,
stanchions, mounting brackets, canopies, all types of consumables and accessories for
mounting.

All types of cables such as such as FF Cable Type A (Trunk and spur) as per IEC 61158-
2, signal / alarm, control, thermocouple extension and power, Data cables such as
armoured Fiber optic, Serial communication link cables as required including all necessary
accessories.

FRP cable duct, FRP cable trays, MCT blocks, structural supports, cable markers,
consumables for cable laying and routing inside battery limits of process units and up to
control room / sub-station. Contractor shall refer to the overall plot plan and cable / duct
layout drawings for information such as location of various units of this package, duct
layout, pipe rack carrying main cable duct / trench routing up to control room, sub-station.
Based on the information and site survey by contractor, contractor shall estimate the
requirement of ducts/trays, cables, special cable, bulk material for complete SRU. Refer
indicative cable routing drawing (Dwg no. 44LK-5100-00/J.01/0002/A0). The cable duct /
cable trench route drawing enclosed shows only an indicative over all drawing as a
minimum. All branch cable ducts/trays Cable trays/ducts routes shall be detailed by
contractor during detail engineering. All cable routing shall be preferably overhead inside
the plant area (ISBL). Contractor shall develop detailed drawings and provide cable
ducts/tray-s and trenches as required. Wherever existing cable/pipe racks are to be
extended to install new cable ducts/trays, contractor shall in such cases strengthen the
existing structure and verify the stability of structure as required.

Cables and cable trays/ Cable ducts shall be fire proofed (openable type) inside the
plant units (ISBL). Tying & Tagging with SS wire and clamping of all cables with
aluminium plate are in the scope of contractor.

1

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 4 of 15

All junction boxes and cable glands for different types of signal cables such as FF
signal, 4-20 mA DC, thermocouple, RTD, shutdown (for solenoid valves) switch
contacts, alarm, power, intrinsically safe and non intrinsically safe instruments etc.

All pipes and pipe fittings for instrument air supply distribution and tubes and tube
fittings for instrument air supply / steam tracing etc.

Wherever suitable as per application / service pre-fabricated close couple process
hook-up shall be followed.

Access platforms/approaches shall be provided for all instruments.

FRP canopy of thickness minimum 4 mm over all field electronic instruments, Local
Panels (which are not inside the shed) and FF Junction Box along with FF field barriers
of P&F or MTL make.

Local panel, control panel and accessories (as applicable)

Redundant Green colour PVC sheathed 1.5 sq mm-copper cables for earthing of all
instrumentation items like junction boxes, thermocouple head, field instruments,
analyzers etc. as per earthing norms/standards.

Earth pits, electrodes, conductors etc. as per earthing philosophy for SRU.

Any other erection material necessary for installation and commissioning of
instruments / analyzers and special instrument items.

Power supply distribution boards: contractor shall consider feeders as required and
additionally 20% spares in Power distribution boards for all levels of power supplies.

Construction of cable trenches.

Fabrication and installation of FRP cable tray support, necessary MS structural etc.

Sand blasting, Painting with Primer, and Epoxy anti-corrosion painting for tray
support/structural/stanchions/ impulse piping etc.

Supply of drawings and documents as listed in contractors documentation
requirements in non-proprietary softcopy format as well as in hardcopy bound format.

Positive Material Identification (PMI), Hydrotesting, QA/QC for all instrumentation Job.

Steam tracing job including supply of 3/8 bare copper tube on both sides of impulse
piping, steam traps etc.

Radiography, PWHT & Stress Relieving job, wherever applicable. For all welds with
rating of 600# and above shall be 100% radiographed.

Supply of analyzer shelters / rooms / cabinets as required.


HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 5 of 15


Mandatory spares, start-up and commissioning spares for all instruments including
analyzers and any special instrument items. This shall include supply of spares and
consumables required during warranty period.

Supply and installation of MCT blocks and frames for cable entry to control room, local
control room, analyzer shelters etc.The power cables for instruments shall be suitably
separated from the other cables and shall be routed through separate MCT blocks. In
general, the MCT frame considered for instrument shall not be used for electrical
cables. The MCT shall be installed as per the recommended practice of supplier. 50%
installed spares shall be considered for MCT blocks. No spare space shall be left
uncovered in the frame.

Instruments on tie-in lines shall be supplied by others. Supply and installation of cables,
FF JBs with required hardware for Instruments on tie-in lines in utilities and offsites for
respective units shall be in respective LSTK contractors scope.

1.1.5 General scope matrix:
Contractor shall also refer to the table below for information regarding over all scope of supply
and installation: -

DESCRIPTION SUPPLY INSTALLATION
1.0 Instruments
1.1 All field mounted instruments By Contractor By Contractor
1.2 All skid mounted instruments (wherever required) By Contractor By Contractor
1.3 Local gauge board mounted instruments By Contractor By Contractor
1.4 Local panel mounted instruments (wherever
applicable)
By Contractor By Contractor
1.5 Remote panel / console / cabinet mounted
instruments
By Contractor By Contractor
1.6 Analyzers local or analyzer shelter mounted
complete with sampling system.
By Contractor By Contractor
2.0 Panels/gauge boards/cabinets (as applicable)
2.1 Local gauge boards By Contractor By Contractor
2.2 Local panels for
a) Process units sub-packages as applicable By Contractor By Contractor
2.3 Remote panels for
a) Package units & sub-packages By Contractor By Contractor
b) Any other items By Contractor By Contractor
3.0 Special instruments and system oriented items
3.1 DCS and PLC system By Others By Others
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HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 6 of 15

DESCRIPTION SUPPLY INSTALLATION
3.2 FF mega block for plant units and LLI package
systems
By Contractor By Contractor
3.3 FF cables , FF barrier, FF JBs for plant units and
LLI package systems
By Contractor By Contractor
3.4 MMS server / software By Others By Others
3.5 Bently Nevada VMS, sensors, Cables up to
Control Room
By Contractor By Contractor
3.6 Consoles, Large video screen Display,
Engineering stations, System cabinets,
Marshalling cabinets, Barrier cabinets, PDBs and
accessories for systems engineered / supplied i.e.
HART management system, Asset Management
System, AIMS etc.
By Others By Others
3.7 Fire and Gas Detection System By Others By Others
3.8 Fire & Gas detectors (with integral transmitter and
display), hooters, Beacons, interconnecting
cabling, barriers and alarm unit etc.
By Contractor By Contractor
3.9 Hood for H
2
gas detector in compressor house By Contractor By Contractor
3.10 Fire & Gas detectors in SRU and Analyzer
shelters
By Contractor By Contractor
3.11
Any other special instrument/system item
specified in the package.
By Contractor By Contractor
4.0 Junction Boxes
4.1 For interconnection between field and local
panels, Field & control room, JBs & control room,
Local panel & control room etc.
By Contractor By Contractor
4.2 Separate junction box for
A) FF signals By Contractor By Contractor
B) For 4-20 mA DC signals (separate JBs for
intrinsic safe and non-intrinsic safe)
By Contractor By Contractor
C) For Gas Detector signals By Contractor By Contractor
D) For contact signals By Contractor By Contractor
E) For interlock and shutdown signals By Contractor By Contractor
F) For power supply to various instruments By Contractor By Contractor

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 7 of 15


DESCRIPTION SUPPLY INSTALLATION
G) For any other signal not covered but required
for completion of job
By Contractor By Contractor
5.0 Cables
5.1 Between field instruments and junction boxes /
local panel / control room
By Contractor By Contractor
5.2 Between junction boxes and local panel / control
room panel
By Contractor By Contractor
5.3 Between local panel and control room By Contractor By Contractor
5.4 Between analyzer shelter and control room. By Contractor By Contractor
5.5 Between substation / MCC and Control room/
local panel / analyzer shelter
By Contractor By Contractor
5.6 Between power distribution boards (AC/DC) and
field power distribution JB / instruments.
By Contractor By Contractor
5.7 Machine monitoring, analyzer system and gas
detection system cables as below,
By Contractor By Contractor
A) From field to control room By Contractor By Contractor
B) Within control room By others By others
5.8 System cables (Fibre optic, co-axial etc.) as
required
By Others By Others
5.9 Fire proofing of cable ducts/trays By Contractor By Contractor
5.10 Any other cable not covered but required for the
completion of the job
By Contractor By Contractor
5.11 Termination and Glanding of all cables in LCP,
shelters, marshalling racks at control room.
By Contractor By Contractor
5.12 Cabling between FF field instruments and FF
Junction Boxes in LLI package systems.
By Contractor By Contractor
5.13 Cabling between FF Junction Boxes and
marshalling racks/control room in LLI package
systems.
By Contractor By Contractor
5.14 Cabling between non-FF field instruments and
Junction Boxes/Local panel in LLI package
systems.
By LLI Vendor By LLI Vendor
5.15 Cabling between non-FF Junction Boxes/Local
panel and marshalling racks/control room in LLI
package systems.
By Contractor By Contractor
6.0 Power Distribution Cabinets (PDBs) for field
Instruments. (Refer Note 3)
By Contractor By Contractor
1

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 8 of 15

DESCRIPTION SUPPLY INSTALLATION
6.1 Cabling from UPS DB to PDB cabinets within SRR
as well as UPS DB to PDB cabinets in field.
By Contractor By Contractor
6.2 Cabling from 415V auxiliary service board located
near substation to Analyser shelters air
conditioning.
By Contractor By Contractor
7.0 Installation Materials
7.1 Impulse tubing/piping, tube/pipe fittings, valves
and valve manifolds, steam traps etc. as required.
By Contractor By Contractor
7.2 Instrument air valves, pipes and fittings By Contractor By Contractor
7.3 Cable trays, cable duct, conduits, cable glands,
gland shrouds and accessories etc.
By Contractor By Contractor
7.4 Instrument stanchions, supports, canopies/
sunshields, supports for cable tray/duct, all
consumables.
By Contractor By Contractor
8.0 MCT Blocks & frames for cable entry in
analyzer shelters/Control Room, Satellite Rack
Room .
By Contractor By Contractor
9.0 Earthing system for, local panels, PDBs field
instrumentation, JBs, including earthing
strips, earthing cable, earthing electrode and
earthing pit.
By Contractor By Contractor
10.0 Earthing system for control system. By Others By Others
11.0 Power supply distribution for local panels By Contractor By Contractor
12.0 Special tools and tackles By Contractor -
13.0 Mandatory spares and commissioning spares By Contractor -
14.0 Documentation required as per this package By Contractor -
Notes: - 1. The scope of supply and installation indicated above is to identify broadly the scope for major
instrumentation items. Contractor to read the same in conjunction with various requirements,
specifications and standards for the overall scope. However, wherever there is a need to
interface/use the existing system as specified in relevant documents/drawing, The contractor to
co-ordinate with the Existing system supplier for carrying out the required job.

2. List of LLI items is attached elsewhere in tender document.

3. Please refer the following attached drawings:
a) 110VAC Power Distribution Schematic for Third Party Interfaces (Doc no. 44LK-5100-
00/J.01/0035 no. of shts.1)
.
1

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 9 of 15


1.2 DETAILED ENGINEERING

1.2.1






Contractor shall carryout design and engineering of instrumentation and controls based on the
process package and other technical requirements described in various volumes of this bid
package specification. In carrying out design and engineering, Contractor shall prepare detailed
calculation / sizing, residual engineering, update licensers data sheets, prepare new data sheets as
required, verification of sizing etc. for all types of supply items and for construction. Contractor shall
duly check all the documents/drawings before submitting them to PMC/Owner. The drawings/
documents shall include following as minimum:-
i. Drawing and document schedule.
ii. Instrument Index
iii. DCS/PLC Input / output list
iv. FF segment design
v. FF cable schedule
vi. FF JB schedule
vii. Non FF cable schedule
viii. Non FF JB schedule
ix. Instrument sizing calculations for control valves, orifice plates, safety valves, breather
valves, self actuated pressure control valves.
x. Instrument data sheets
xi. Level sketches
xii. Instrument Hook-up drawings
xiii. Logic diagrams, logic description / cause and effect list.
xiv. Set point, Alarm & trip schedule
xv. Functional loop schematics and its detailed description
xvi. Dynamic graphic display drawings including package vendors
xvii. Instrument details (Point data base) including package vendors
xviii. Machine Monitoring system.
xix. Hardwired console layout
xx. Dimensional & GA drawings for JBs, panels & racks
xxi. Purchase requisition for all items and sub-packages
xxii. Instrument and junction box location plan
xxiii. Instrument cable tray / duct/ trench layout
xxiv. Earthing layouts
xxv. Instrument cable and junction box schedule
xxvi. Cable block diagram
xxvii. Instrument air consumption / requirement.
xxviii. Instrument air supply layout
xxix. Layout of local panel, Analyzer panel and Analyzer / Gas Chromatographs shelter, Analyzer
shelter layouts.
xxx. Wiring & termination drawings for JBs, panels & racks.
xxxi. Instrument-Electrical interface wiring drawing
xxxii. UPS power consumption / requirement.
xxxiii. UPS power feeder list.
xxxiv. Power supply distribution detail drawings
xxxv. Single line Power supply distribution diagrams

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 10 of 15

xxxvi. Fire & Gas detectors location layout
xxxvii. Fire & Gas detector cable routing layout.
xxxviii. Cable entry sizing and arrangement of MCT Blocks for the control room, analyzer shelters
etc.
xxxix. Installation standards and bill of material.
xl. Updating of existing drawings if used for contractor package facilities.
xli. Drawings/documents for Special instruments like Multipoint temperature elements, Skin
thermocouples, Analyzers etc.
xlii. Any other document / drawing not listed above but required to carry out the engineering,
construction, for better understanding and for integration of other equipment packages,
sub-ordered by Contractor shall also be prepared and furnished to Owner / PMC. And also
any other document/drawing requested by PMC/Owner related to contractors scope of
work shall be submitted by contractor.
xliii. As built documents / drawings

A common control system for process units and office area are to be supplied by owner.

1.2.2 Details of drawings / documents required are identified elsewhere. The design and engineering
shall be carried out as per various specification and standards.
The indicative list of contractors documents / drawings required for submission to owner / PMC
along with review / approval category is attached elsewhere.

1.2.3








DCS and safety PLC shall be designed, supplied and installed by PMC. The control system
related documents such as I/O List, functional loop schematics, logic diagrams, instrument details
(point data base) for DCS configuration, dynamic graphic display drawings etc. including for sub-
package items shall be prepared by Contractor for SRU and the same shall be forwarded to
owner for further engineering and implementation. For DCS and PLC sizing, the Contractor
himself shall work out the I/O requirements for SRU. The I/O list shall also account for the
requirements of sub-package items and other equipments such as Fired Heaters, Columns /
Towers, Vessels/Drums, Tanks, Reactors, Heat Exchangers, Blowers / Feed Pumps,
miscellaneous equipments.

1.2.4

The design and engineering work shall also include review of post order vendor drawings and
documents for all instrumentation items.
The Contractor shall thoroughly review and approve vendor drawings for all instruments including
sub-package items, before forwarding to Owner / PMC. Only the approved drawings duly stamped
and signed by a competent engineer of Contractor shall be sent to Owner / PMC.





1.2.5
The Contractor shall also review documents supplied by DCS / PLC vendor such as I/O
assignments, logic diagram, loop diagrams/segment diagram, dynamic graphic display drawings
etc. These documents shall be reviewed and approved by Contractor based on general
philosophy agreed for control system before forwarding to Owner / PMC.

The Contractor shall carry out the PDS / PDMS modelling of SRU.

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 11 of 15


1.2.6











Contractor shall be fully responsible for co-ordinating all instrument related activities with the
agencies concerned to ensure proper, uniform and smooth engineering.
This shall include co-ordination with:

All sub-package unit suppliers for uniformity in engineering and documentation supplied
by them including P&IDs, instrument specifications, installation standards etc and
obtaining all requisite drawing and documents for review, record and final documentation.
System / sub-system vendor for system oriented items and database generation for the
items / systems to be supplied by the contractor.
With EPCM contractor / owner for control system integration / plant level integration.
Co-ordination with all other contractors for respective unit tie in points of duct / RCC
trench from their respective battery limits.
1.2.7 Contractor shall be responsible for all As-Built drawings and documents including:
All purchase documents.
All construction related documents.
All system documents including hardware and software documentation. In addition to the
above, contractor shall also be responsible for certifying the logic diagram for unit and
equipment as final and correct.

1.3

1.3.1





1.3.2




PROCUREMENT, SHOP TESTING AND SUPPLY

Engineering for procurement shall include selection and preparation of technical specification for
instruments based on process data sheets, process package, job specification, other
specifications, standards etc, enclosed in this tender specification, evaluation of offers received
from different vendors, preparation of purchase requisition and review / approval of vendor
drawings.

All instruments and instrumentation items shall be procured from approved vendors furnished in
the tender package. In case, any item is to be supplied from a vendor other than mentioned in the
list, the Contractor shall have the written approval from Owner / PMC for the same. Any change
required shall be discussed and approved during the Kick-off meeting.
1.3.3

The Purchase Requisition (PR) for each item shall be prepared and shall contain all information
including the make and model no. of each instrument, in addition to the material specification and
other details. In case, the Contractor intends to follow their own format, it shall necessarily contain
all information as in ISA format, as a minimum. All such data sheet formats shall be approved
during Kick-off meeting.

1.3.4 Shop testing and calibration of all instruments shall be carried out by contractor / instrument /
system vendor. Owner / PMC and/or third party as the case may be may witness any or all items
testing in stages during manufacture and /or at final stage before shipment.





HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 12 of 15

1.4

1.4.1




INSTALLATION, FIELD TESTING / CALIBRATION / LOOP CHECKING AND COMMISSIONING

Installation
Contractor shall carry out installation of all instruments as per standard specifications/ guidelines/
various drawings/documents included in this contract document and recommendations of vendors
for special items.

1.4.1.1

















1.4.1.2
This activity shall include but not be limited to fabrication/installation of instrument supports,
stanchions, canopies, instrument sheds & shelters, installation of all field instruments and
instrumentation items including sub-package items, installation of junction boxes, local panels,
package / remote mounted equipment, interconnection between instruments and junction boxes,
ladder trays, cable racks, cable ducts, construction of cable trenches, laying of cables from field to
control rooms, laying of cables between existing control rooms / Field for interface with
package/unit, tagging, ferruling and pair/core identification of all field cables including cables to
and from substation / Switchgear, inside the package and instrumentation complete in all
respects.

All system cables / fiber optic cables shall be routed in HDPE Hard pipe. Fittings shall be used for
joining the HDPE pipe. The HDPE conduits shall be as per IS-4984 or equivalent IEC standard. All
system cables / fiber optic cables shall be routed in the middle 150 mm portion of the duct.
Wherever it is absolutely necessary to route these cables underground, it should be routed in the
RCC trenches only.

For special instrumentation systems such as fire and gas detectors, machine monitoring,
analyzers etc. the cable laying, dressing & termination shall be done under vendors supervision.
Contractor shall coordinate for providing details to field contractor.
Provide new over head cable ducts/trays and new trenches wherever required, modification of
existing cable racks and trenches if required for laying cables, reclosing the existing trenches after
laying of cables. Buried trenches shall have a minimum width of 600 mm and depth of 1000 mm.
One layer of sand is to be laid at the bottom, over which cables shall be laid with approximate
segregation between signal and other cables. Trenches shall have sufficient depth and width to
accommodate all cables correctly spaced. Existing cable rack/pipe rack structures shall be
strengthened and the structure stability verification shall be done by Contractor when existing
cable racks/ pipe racks are extended for installing cable ducts/trays. All cables inside the control
rooms shall be properly dressed and routed in perforated trays under false flooring which will be
supplied & installed by the Contractor. Separate cable route and trays shall be used for signal and
alarms in control room.
3-way junction boxes shall be used for connecting the field transmitter and field mounted analog
intrinsic safe indicator in series with control room receiver.
Any damages done to existing facilities, while carrying out work by Contractor shall be repaired or
replaced by Contractor.

1.4.2 Testing and calibration


Testing of impulse lines, instruments, instrument air lines, pneumatic signal tubes and instrument
cables, control / power cables, Data cables, Fibre optic cables including special instruments /
items if any, and calibration of all instruments shall be carried out as per the requirements in
various specifications in the bid document.
Contractor shall provide inspection & calibration report duly filled-in with Tag numbers, test
pressures and results to Owner / PMC for approval.

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 13 of 15


1.4.3 Loop checking
Loop checking of Contractor scope of supply of instruments and also loop checking of other
package units / free issued items. Where required Contractor shall co-ordinate with other
agencies / contractors in performing successfully loop checking.

1.4.4 Commissioning
Co-ordination and assistance for start-up, commissioning and stabilization of plant, with PMC /
Owner / Licensor / system vendor shall be the total responsibility of Contractor.

It is the responsibility of Contractor to co-ordinate and to make available the specialists services
from vendors at the time of installation, testing and commissioning.

All package systems (PLC) subsystems, Analyzers, special instruments shall be installed, loop
checked and commissioned by respective system/instrument vendors under the coordination,
supervision and responsibility of Contractor.


1.5 The responsibility between Contractor and others are as given in the tables below: -

SR.
NO.
DESCRIPTION BY
CONTRACTOR
BY OTHERS

1.0 Residual engineering of FEED Packages X
2.0 Design of DCS and Safety PLC system X
3.0 Design, sizing, selection (type and material) etc.
for instruments as per job requirement.
X
4.0 Detailed engineering, procurement & supply of
instruments and erection of material as per job
requirements.
X
5.0 Integration of systems like analyzer system, fire
and gas detection system, machine monitoring
system etc. with DCS/ PLC control systems as
applicable.
X
6.0 Installation of:
a) All instruments & accessories. X
b) Sub-packaged instruments, panels and other
accessories in field
X
c) All systems oriented items like machine
monitoring system, fire & gas detection, FF
instruments.
X
d) All instrument installation accessories such as
junction boxes, cable glands, cables, hook-up
hardware, terminating up to marshalling racks
at control room.
X

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4 Page 14 of 15

SR.
NO.
DESCRIPTION BY
CONTRACTOR
BY OTHERS

e) Installation of MCTs for cable entries into
control room, analyzer shelter.
X
7.0
a) Provision of instrument road crossings
(IRCs), culverts, ducts, trays and their
supporting structures (as applicable).
X



b) Cable trenches wherever necessary including
cable laying and back filling with sand etc.
X

c) Branch cable racks, duct/cable tray from main
duct/trays to field instruments, local panels,
Junction Boxes etc. along with their
supporting structure.
X

d) Provision of Pipe rack/cable rack/ trenches
inclusive of sub racks as per guidelines shown
on cable tray layout drawing.
X

e) Provision of cable duct for entire length
between JB and plant battery limit.
X
8.0
Supply and Laying of all type of cables including
FF cables, special cables, fibre optical cables with
adequate protection between field instruments &
marshalling rack.
X


9.0
Supply and Laying of power cables from feeders
to field instruments/analyzers/any other package
X
10.0
Instrument air and its distribution within the SRU
limits.
X
11.0
Heat tracing and insulation as required
X
12.0
Painting of instruments, impulse lines etc.
X
13.0
Provision of various utilities and their distribution
as required.
X
14.0
Fire proofing system for all cable ducts supplied by
contractor (ISBL & OSBL up to SRR) .
X
15.0
Shop testing, Factory Acceptance test by
owner/consultant for package /PLC/Analyzers/Fire
& Gas System & Special Control Valves and third
party inspection for all other items / integrated
testing as applicable.
X
16.0
Positive Material Identification (PMI), Hydrotesting,
QA/QC for all instrumentation Job
X
17.0
Radiography, PWHT & Stress Relieving job,
wherever applicable.
X
18.0
Field testing, calibration, loop checking,
commissioning and site acceptance of all
instruments and systems.
X
1

HPCL, MUMBAI SCOPE OF WORK - INSTRUMENTATION PART III
LSTK CONTRACTOR 3

SECTION B.8.1
44LK-5100
Doc. No. 44LK-5100-00/J.02/0025/A4
Page 15 of 15


SR.
NO.
DESCRIPTION BY
CONTRACTOR
BY OTHERS

19.0
Preparation and review of engineering
drawings/documents
X
20.0
Participation in kick-off meeting, system and
software definition meetings; at vendors
works/PMC/owners office.
X
21.0 Factory acceptance test at vendors works. X
22.0 Site acceptance test at site X
22.0 Documentation X
23.0 Documentation for documentation node. X
24.0
Co-ordination with various vendors /other site
contractors/manufacturers/package vendors/
owner/Consultant /licensor etc.
X
25.0
Ensuring the availability of suppliers specialists
services for all system oriented items like Package
PLC, Machine monitoring system, Fire & Gas
detection system etc. during start-up and
commissioning.
Similar services shall be provided for special
instruments such as Analyzers, Ultrasonic flow
meters, Special control valves, etc. during start-up
and commissioning.
X
26.0 Documentation as per project requirements X
27.0
Training as required for various systems and for
special instruments. X

28.0
Spares and spare parts (all types)
X

Note: As part of safety during construction stage, Contractor shall arrange to keep portable
H
2
S/H
2
/HC gas detectors/monitors as applicable to the working area/equipment along
with alarm & Hooter facility. Contractor shall periodically get these instruments
calibrated/tested.