(e ENGINEERS

s@;al fclldlc5 (t.:,tJ INDIA LIMITED

(a-m'i'f (A Govl of India Undertaking)
DUAL FEED CRACKER UNIT & ASSOCIATED UNIT PROJECT
OPaL, DAREJ. BHARUCH, GUJARAT
Ref: 6987-LEPClilNST-01l19-42/LETI '313
Date: 9th June 2011
Mis Samsung Engineering,
Dahej Petrochemical Complex,
Dahej.
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Sub: - Dual Feed Cracker and Associated Units, Dahej Petrochemical Complex
_ Construction procedure & ITP for Instrumentation work.

Dear Sir,
Please refer your . letter no SE-EIL-L-1287 dtd 06.05.2011 approval of construction
procedure for installation and ITP for Instrument works.
Please find enclosed herewith the above documents duly reviewed and approved for
implementation for the subject work.
Further you are requested to submit construction procedure & ITP for balance job like Field bus,
PSVetc.
Thanking you,
Very truly yours,
Enclo. : As above
INCHR
fI9. Je
I Q.\tQC.. Ie..
.. : 4.':
Regd Office: Engineers fudia Bhavan, 1 Bhikaiji Cama Place, New Delhi-II 0066
Visit us at: www.engineersindia.com
CM
so
. - " ., ..
ONGC Petro additions limited
SEZ, Dahej, Gujarat, India
DAHEJ PETROCHEMICAL
COMPLEX
Dual Feed Cracker Unit
& Associated Units
CONSTRUCTION PROCEDURE
FOR
INSTRUMENT WORK

Ell
JOB NO. 6987
Page: I of 21
Reason for Issue I Remark Prepared Checked Approved
Contract No. I Po. No. :
ENGINEERING
DIVISION
SAMSUNG
ENGINEERING
Doc No: &SE-OO-W-PE-0058
Linde Project No.:
Linde Project Code:
Samsung Project
No.:
Sanisung Project
Code:
Item Name.:
3110 A9NK
DAHEJ
SC 2252
OPal DFCU &
AU
Company Doc. No.: 6987-LEPC1-SE-OO-CN-PE-0058
I ,.
Dahej Petrochemical Complex DFCU &AU
Page 20f 21
6987-LEPCl-SE-00-CN-PE-0058
Construction Procedure for Instrument
Issue: 02
work
REVISION HISTORY
REV DATE DESCRIPTION
01 04-06-2011
Letter nO.SE-EIL-L-1254&1262 dated 23.05.2011, ElL
Comments incorporated and re-submitted.
* Notes:
This page records all revisions on the specification.
Issued for
~
00 23.05.2011 Review &
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Nis(.., ..... ~ -s
Approval
Rev. DATE Purpose
Prepared by
_l
Checked hy Approved by Approved by
J
SECL SECL SECL ElL
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Dabej Petrocbemical Complex DFCU &AU PROJECT Page 30f2,
6987-LEPCI-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
-
. CONTENTS
PAGE
1 . ----------------------------------------------------------------------------------- 3
1.1 Scope of Application ----:.----------------------------------------------------------- 3
1.2 Codes and Standards ------------------------------------------------------------ 3
1 .3 R efe re n ces ---------------------------------------------------------------------------- 3
2. I S T f\L-L-f\ T ION W 0 F{ K S ------------------------------------------------------------ 3
2.1 General Requirements ------------------------------------------------------------- 3
2.2 Be n ch T est ---------------------------------------------------------------------- 4
2.3 Equipment in Control Room ------------------------------------------------- 7
2.4 I nstrum e nts I nstallation -------------------------------------------------------- 7
2.5 Main Cable Way(Duct) ------------------------------------------------------- 7
2.6 Perforated Cable Tray ------------------------------------------------"------ 9
2.7 Cabling and Wiring ---------------------------------------------------------- 10
2.8 Pressure Piping and Tubing . --------------------------------------,,;---------- 11
2. 9 Air Supply Tubing' ---------------------------------------------------------- 12
2.10 Steam Tracing 12
3. INST f\LL-f\ TION f\ND TEST ----------------------------------- 13
3.1 Inspection on Receipt and Storage -------------------------------------------- 13
3.2 Inspection during the Execution of the Works ------------------------------- 13
3.3 Control Equipment Installation Inspection ------------------------------------- 13
3.4 Instrument Installation Inspection ---------------------------------------------- 13
3.5 I nstrument Wiring Test -------------------------------------------------------------- 15
3.6 Pressure Piping and Tubing Test ----------------------------------------------- 15
3.7 Air Supply Piping Test ------------------------------------------------------------- 16
3.8 Steam Tracing Tubing Test -------------------------------------------------------- 17
4. LOOP AND FUNCTION TEST ---------------------------------------------------------- 17
4.1 Field Check and Test Preparation ---------------------------------------------- 17
4.2 Loop Test ---------------------------------------------------------------------------- 18
I

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04.06.2011 I
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Dahej Petrochemical Complex DFCU &AU PROJECT Page 40[2,
6987-LEPC l-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
.
1. GENERAL
1.1 Scope of Application
1.1.1 This specification covers the general requirements for the installation work, inspection
and test of instrument and control equipment during execution.
1.1.2 The following installation work includes in this specification:
(1) Bench Test
(2) Control Equipment including DCS
(3) Instrument Installation
(4) Main Cable Way(Cable Duct)
(5) Perforated Cable Tray
(6) Cabling and Wiring
(7) Pressure Piping and Tubing
(8) Air Supply Tubing
(9) Steam Tracing
1.2 Codes and Standards
The installation of instrument and control equipment shall conform to the requirements of the
applicable codes and standards stated on the succeeding paragraphs and the references.
1.3 References
1.3.1 The following documents shall be applied as an integral part of the
requirements of this specification
(1) Drawings for Construction of Instrumentation and Control System
(2) Instrument Specification
(3) Instrument Hook-up Drawing
(4) Instrument Wiring & Tubing Connection Detail
(5) Installation Standards Instrument Mounting Details
1.3.2 In the event of conflict between the documents and drawings the order of precedence
shall be as indicated in Section 1.3.1
2. INSTALLATION WORKS
2.1 General Requirements
2.1.1 All materials shall be received, handled, and stored in a careful and prudent manner to
the components they incorporate.
2.1.2 The installation work and materials shall conform to the specified documents and
drawings.
The alternatives shall be allowed only after ElL's approval.
2.1.3 The materials used for the work shall be cleaned prior to assembling.
After completion of the work, foreign matter such as rust, scale, etc. shall be removed.
04.06.2011
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Instrument work procedure
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2.1.4 All screw threads shall be machined by a threading machine.
2.1.5 Pipes, tubes and conduits shall be cut mechanically at right angles. However, the cutting
other than by the mechanical shall be subject to ElL's approval.
2.1.6 Pipes, tubes and conduits shall be reamed and cleaned before installation.
2.1.7 Unless stated, Teflon tape shall be used for sealing of all threaded joints.
2.1.8 During construction, temporary openings of equipment, conduits, tubes, cables, etc. shall
be plugged and/or sealed to prevent entry of moisture and dust.
2.1.9 Supports shall be installed on concrete walls, steel structures, etc.
No supports shall be installed on process equipment, insulated pipes, and location
subject to vibration, high temperature or corrosive fluids
2.1.10 Unless otherwise specified, threaded connections shall not be welded.
2.2 Bench Test
2.2.1 This test is for calibration and is undertaken at the workshop
2.2.2 As the strict performance tests of instruments are to be made at the manufacturer's
shop, emphasis shall be placed upon zero and/or span checks of them rather than
accuracy.
The results of each completed test should be recorded on the appropriate calibration
sheet and witnessed by the responsible engineer.
2.2.3 Prior to the test, confirm if the utilities such as air, electrical power, etc. are under
normal conditions.
2.2.4 After completion of the tests, the instrument should be drained and, if necessary, blown
through with clean and oil-free dry air. After testing and draining, all connections and
entries should be temporarily sealed to prevent subsequent ingress of moisture and dirt.
2.2.5 The instrument to be tested should be mounted in the correct plane on a rigid and
vibration-free stand of structure.
2.2.6 Bench test procedures shall be as follows:
(1) Flow Instrument
1) D/P Transmitter
The transmitters shall be calibrated against standard water or mercury
column manometer at 0-25-50-75-100% of span.
2) Turbine and positive displacement meters
04.06.2011
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Instrument work procedure
Rev.: 01
04.06.2011
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G) The meters shall be checked by mechanical operability.
@ The characteristic of converter shall be confirmed using a
pulse-synthesizer.
3) Rotameter
All transmitting and indicating rotameters in which the float is not visible
sh!311 be calibrated by'manually positioning the float and adjusting the
indicator or transmitter output to the correct value at 0-25-50-75-100% of-
span. ~
4) Flow Switch
The action shall be checked by moving the paddle of float.
(2) Level Instrument
1) Displace Type Level Instrument
G) The instruments shall be calibrated by filling the chamber with clean
water and using clean plastic tubing connected at the bottom drain as a
gauge glass. Check calibration at 0-25-50-75-100% of span.
Reset the specific gravity adjustment to the operating conditions and
recheck zero after calibration.
@ Internal type shall be calibrated with the help of weights simulating at
~ 0-25-50-75-100% of span.
2) Capacitance Type Level Instrument
The instrument shall be put into water of bath, and the action shall be
checked.
In case of using plastic bucket, grounding shall be considered.
3) Tank Gauging System
The dimension or length of the float and wire shall be checked in accordance ,J
with vendor's drawing.
4) Float Type level Switch
The switches shall be checked by removing the side outlet plug, filling the float
chamber with water and observing the float action and the switch action.
5) DIP Transmitter
. The instruments shall be calibrated like DIP flow instruments.
(3) Pressure Instrument
1) Pressure Transmitter ~
The instruments shall be calibrated at 0-25-50-75-100% of range with a hand
pump calibrator or using dry air or nitrogen as a source of pressure.
2) Pressure Switch
The instruments shall be calibrated with a precision calibration gauge or
manometer with hand pump or using dry air or nitrogen as a source of
pressure.
3) Pressure Gauge
The instrument shall be zero-adjusted .
. - .4) Draft Gauge
Issued For
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Instrument work procedure
Rev.: 01
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The instrument shall be zero-adjusted.
5) DIP Gauge .
The instruments shall be checked against standard water or mercury at
0-25-50-75-100% of range. A precision calibration gauge shall be used to
check.
(4) Temperature Instrument
1) Temperature Tra.nsmitter Gb
CD The instruments for TIC shall calibrated at 0-25-50-75-100% of range using DC
voltage standard. A precision calibrator shall be used to check the
transmitted signal.
@ The instruments for RTD shall be calibrated at 0-25-50-75-100% of range
using a precision resistance. .
2) Filled Type Temperature Instrument
The instruments shall be calibrated at the ambient temperature-adjusted
using precision mercury gauge.
3) Temperature Switch :
The instruments shall be calibrated at 0-25-50-75-100% of range using a
temperature controlled bath and set at proper value.
4) Thermocouple and RTD
The sensor shall be checked there is no open circuit with circuit
tester and the output value corresponding the ambient temperature shall be
checked mV for thermocouple, resistance for RTD respectively using precise
multi tester.
(5) Control Valve
1) The valves shall be set at the installed condition using a chain block or pulley
at the shop for its size is bellow 4". However, its size is above 4" valves would
be stroke tested only at shop and calibration will be done at field side after
piping installation as following manner.
2) All diaphragm or piston operated control valves shall be pneumatically
stroked using a pressure regulator, test gauge and DC power supply etc.
3) The following items shall be checked and calibrated.
CD Valve action including solenoid valve

Travel indicator

Positioned calibration
@ Stroking time

Limit switch function

Failure position
4) Accessories such as hand wheel, booster, relay, lockup valve, etc. shall be
operationally checked.
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Instrument work procedure
Rev.: 01
2.3 Equipment in Control Room
2.3.1 The equipment installation shall be done based on this specification, "PLAN" DWG, and
"Instrument Wiring Connection List", and other relevant drawings.
2.3.2 Before installation of equipment, the control rqom shall be adequately cleaned.
And then the floor shall be protected temporarily with a suitable material.
2.3.3 The equipment, after completion of installation, shall be covered with a proper material.
And adhesive tape shall not be affixed directly on the equipment.
2.3.4 Channel base of the panels shall be fixed firmly and leveled horizontally.
2.3.5 Panels shall be mounted from those of center in case where there is a lot of panels.
2.3.6 Panels shall be correct-mounted horizontally, vertically using the specified liners.
2.3.7 Upper and front side of the panels shall be correct-mounted in places.
2.3.8 Panels, channel base and panel to panel shall be arranged correctly.
2.4 Instrument Installation
2.4.1 General
(1) Instruments shall not be interfered with their function, operation and maintenance.
(2) Instruments shall be installed without any interference at the time of installing,
removing them.
(3) Instruments shall be installed and protected against high temperature,
humidity, corrosive gas and dust.
(4) Instrument and its accessories for construction shall apply a standardized goods.
(5) Instrument shall be installed in a place where there is no vibration. Otherwise shall
take a measure to avoid the vibration.
(6) When the welding work are performed, instrument shall be protected against
electric spark and welding current before the works for safety.
2.4.2 Field Instrument and Equipment
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(1) The installation of field instruments and equipment shall be done based on this
specification, "PLAN" DWG, and "Instrument Wiring Connection List", and other
relevant drawings.
(2) All field instruments and equipment shall be located so that the function of them is
not affected and they are accessible from grade, platforms, walkways, etc.
However, the use of a portable ladder or a rolling platform is permitted in case of
Issued For I
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Instrument work procedure
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the instruments and valves such as a line-mounted instruments and first block
valves for instruments.
(3) Location subject to dust, excessive vibration, corrosion, and radiant heat shall be
avoided in locating the instruments.
(4) In general, instruments shall be mounted on the specified stanchion.
2.4.3 Instrument to be installed on the shall be as follows:
(1) Locate the stanchion on the designated place
(2) The stanchion shall be supported enough as specified
(3) Top side of the stanchion shall be blinded.
(4) A surface of the capillary tubes shall be protected from exterior harm.
(5) If the instrument relocation is required, it shall be shown on the drawing after
ElL's confirmation,
2.4.4 Instrument to be installed on a tower
(1) Bolts, nuts and gaskets for connection shall be used as specified.
(2) Maintenance work of instrument shall not be interfered under the hot or cold
insulation materials of process piping or equipment.
2.4.5 Instrument to be installed on piping line
(1) Instrument to be installed on pipe line such as a orifice plate, Control Valves,
Flowmeters etc. shall be confirmed of the direction of flow & Scale Plate.
(2) The orifice plate shall be correctly installed, if no tab, it will be necessary to
introduce the installation procedure before the works.
(3) The orifice plate shall not be installed before the hydraulic test and flushing works
is completed and then, it shall be installed after confirmation prior to final leak
test
(4) The orifice tap shall be blinded if it is provided as spare tap.
(5) Bolts, nuts and gaskets for connection shall be used as specified in the Drawing.
2.5 Main Cable Way(Cable Duct)
2.5.1 The Main cable way installation shall be done based on this specification, "PLAN" DWG.
and "Instrument Wiring Connection List", and other relevant drawings.
,
2.5.2 Dimension of cable duct shall be confirmed whether it is correct or not.
2.5.3 Distance from the heat source shall be confirmed whether it is enough or not
2.5.4 Connection point shall be entirely done by welding and bolting.
2.5.5 Cable shall be protected from damage due to welding and bending work.
2.5.6 Foreign materials such as oily water, rag, etc. shall be removed from cable duct.
04.06.2011 Issued For ....,/;? I \n
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Instmment work procedure
Rev.: 01
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2.5.7 Primary painting inside of cable duct shall be completely done after the welding work.
2.5.8 Separator installed in cable duct shall be made as designed.
2.5.9 The cable duct shall be routed considering the location of equipment's and the route of
process pipes. And they shall be supported with rack or bracket and shall be firmly
anchored not to be moved by wind or vibration.
2.5.10 Cable duct shall be strengthened to endure the load passing a person.
2.5.11 Unless otherwise noted, the supporting interval shall be not more than 3 meters.
2.6 Perforated Cable Tray
2.6.1 The tray installation shall be done based on this specification, "PLAN" DWG and
"Instrument Wiring Connection List" and other relevant drawings.
2.6.2 Dimension of tray shall be confirmed whether it is correct or not.
2.6.3 Distance from the heat source and other equipment and eleCtrical tray shall be confirmed
whether it is enough or not.
2.6.4 Connection point shall be entirely done by welding or bolting.
2.6.5 Cable shall be protected from damage due to welding and bending work.
2.6.6 Foreign materials such as oily water, rag, etc. shall be removed from tray.
2.6.7 Support work shall be completed prior to tray installation work, and all damaged points
shall be painted with rust inhibiting paints
2.6.8 Tray shall be finished smoothly: They shall be free of unnecessary protrusions
2.6.9 After tray installation, the welded portion shall be covered with zinc paint or other
protective means where stipulated by the project specification.
2.9.10 Tray support interval shall not be exceed maximum 2 meter.
2.9.11 For support, material shall be used after blasting and applying primer paint coat. After
support fabrication, intermediate and final paint shall be applied at site.
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6987-LEPC1-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
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2.7 Cabling and Wiring
2.7.1 The cabling and wiring shall be done based on this specification, "PLAN" DWG, and
"Instruments Wiring Connection List", and other relevant drawings.
2.7.2 In laying cables and wires, special care shall be taken to avoid any damages on cables
and wires.
2.7.3 Wires shallnot be spliced in other places than the specified point.
2.7.4 Cables installed in vertical cable tray shall be fastened at proper points.
2.7.5 Bending radius of cables shall be not less than 6 times of its outside diameter.
2.7.6 After laying of cables and wires, they shall be cut with some margin in length in both
ends.
2.7.7 Cables in cable tray shall be laid in parallel and straightly as far as possible.
2.7.8 The stripping of multi cables for wiring shall be done after clamping the cable.
2.7.9 When connecting the wires to the terminal block of instruments, junction boxes and
panels, the compression terminal shall be used.
2.7.10 Shield wires shall be grounded only at the one point.
2.7.11 Left over cables on the drum should be updated and suitably marked on the drum.
2.7.12 Cable work
(1) The cable shall not be twisted when it is being pulled from the drum.
(2) The cable work shall be carefully worked to avoid the damage on insulator of the
cable.
(3) The length of cable shall be enough prepared for the termination and maintenance
work.
(4) The electric power and electronic line shall be separated as specified on drawing so
as to be protected from the noise.
(5) The cable connection work in the cable tray shall be prohibited
(6) The cable inside of the cable .tray or pit shall be clearly arranged.
(7) Shield wire inside of the panel shall be only 1 point grounded.
(8) Wiring of the intrinsically safe circuit shall be independently installed with the
blue color and protected from the others.
(9) Joints shall be made only at terminals in instruments or approved equipment. No
, intermediate joints shall be made on cable trays.
(10) Cable shall be drawn from the drums allocated on the cable list. A record shall be
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kept of actual cut length.
2.7.13 Signal wiring work
(1) The signal wiring shall be arranged as shown on the drawings.
(2) The materials specified on drawings shall be used.
Rev.: 01
(3) The wiring route shall avoid an adverse effect from a.heat source and not be under
the process piping and equipment which are covered by the hot or cold insulation
materials.
(4) The wiring shall be arranged or supported to avoid the vibration and thermal
expansion of process piping and equipment.
(5) Wiring shall avoid an adverse effect from power cables.
(6) Sealing method shall be conformed to the specified drawings.
(7) Grounding method shall be conformed to the specified drawings.
2.8 Pressure Pipe and Tubing
2.8.1 The instrument pressure piping and tubing shall be done based on this specification,
"Instrument Piping Hook-up Detail", and other relevant drawings.
2.8.2 The lines instruments and process lines/equipment's shall be short as far as
possible.
2.8.3 Cold bending shall be applied. However hot bending may be employed subject to
approval of ElL. Bending radius shall generally be not less than 5 times of the
pipe outside diameter.
2.8.4 All block valves except equalizing valves shall be closed after installation of
pressure lead lines.
2.8.5 The lined shall be 100mm remote from adjacent structure, equipment and piping.
2.8.6 Whenever cutting or welding is necessary for rearrangement of the pressure lead line
after installation, the lines shall be removed from the instruments.
2.8.7 The proper space allowance for insulation and/or steam tracing between the lead lines
and equipment's & process pipe lines shall be considered.
2.8.8 All high and/or low pressure piping components and instruments shall be inspected prior
to assembling the lines.
2.8.9 The lines shall not be supported by instruments.
2.8.10 Welding shall be only made by welders who have been qualified as specified in the
related documents.
2.8.11 The materials specified on drawings shall be used.
2.8.12 The elevation and direction of pressure tapes and instruments shall be correct as
shown on the drawings.
2.8.13 Seal pot and/or condensate pot shall be assembled in the same of the specified
elevation.
2.8.14 The lines shall be slopped as specified on instrument hook-up drawing.
Ground lug for welding machine shall not be connected to the instrument stanchion
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2.9 Air Supply Tubing
2.9.1 The air tubing shall be done based on this specification, "PLAN" DWG, and
"Instrument "Connection Detail", and other relevant drawings.
2.9.2 The work includes tubing from air header to each control valves.
2.9.3 The tube shall be supported by perforated tray ..
2.9.4 Fittings for each tubing run shall be minimized.
2.9.5 Bending radius of tubes sha'lI be more than 5 times the outside diameter of the
tubes.
2.9.6 The cutting section of the tubing shall be reamed.
2.9.7 The seal tape shall be used for thread connection.
2.9.8 The tubing route shall avoid an adverse effect from a heat source (keep 150mm
minimum distance) and not be under the process piping and equipment which are
covered by hot and cold insulation materials.
2.9.9 The tubing shall be arranged or supported to avoid the vibration and thermal
expansion of process piping and equipment.
2.9.10 The tubing shall be used as specified and pulled arranged as shown on the drawings.
2.10 Steam Tracing
2.10.1 The steam tracing shall be done based on this specification, "Instrument Steam Tracing
"PLAN" drawing and other relevant drawings.
2.10.2 The instruments shall be traced with considering the convenience of their mounting and
dismounting.
2.10.3 If the pipe shall run straight more than 20 meters, U-Ioop shall be put in the pipe for
thermal expansion.
2.10.4 Condensate pot in the steam line shall not be traced.
2.10.5 The materials and size specified on the drawings shall be used.
2.10.6 Tracing tubing shall be arranged closely to the heating zone.
2.10.7 "U" type pocket shall not be made during the tracing work.
2.10.8 The root valve(1 st block valve) shall be easily accessible.
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6987-LEPC 1-SE-CN-PE-0058
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Rev.: 01
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3. INSTALLATION INSPECTION AND TEST
3.1 Inspection on Receipt and Storage
3.1.1 Instrument equipment received on site shall be visually inspected for damage
and shortages.
3.1.2. Instrument equipment shall be stored in accordance with the vendor's recommendation.
and protected against adverse weather conditions.
3.1.3 Equipment shall be examined on receipt into the main warehouse to confirm that they
are correctly tagged and meet with the specification of purchaser order.
3.1.4 Modular and packaged equipment shall be checked to confirm that the structure, cable
and piping runs do not conflict with equipment on adjacent modules or units. Access for
commissioning and maintenance shall be checked.
3.2 Inspection during the execution of the works
All of the inspection shall be performed during the execution of the works unless otherwise
specified to be done after completion of work, if required, shall be kept all the evidence
such as a picture and drawings.
3.2.1 underground work
3.2.2 work to be covered in the wall.
3.2.3 work to be covered in the building
3.2.4 'work to be covered in the insulation materials
3.2.5 others necessary to maintain the work history.
3.3 Control Equipment Installation Inspection(Control Panel, PLC, DCS, etc.}
3.3.1 Panels shall be located in place and fixed firmly in accordance with the related
drawings.
3.3.2 The panels shall be correct-mounted vertically.
3.3.3 The surface of panels shall be clean and have not been damaged.
3.4 Instrument Installation Inspection
3.4.1 Visual Inspection Prior to Installation
04.06.2011
Date
The inline instruments and instruments mounted on equipment shall be checked prior to
installation as it is difficult to confirm the specification or re-install the instruments after
installation. The following visual inspection shall be done.
Issued For

if

Approval

Purpose
Prepared Checked
I
Approved Approved
by SECL by SECL
I
by SECL by ElL

Dabej Petrocbemical Complex DFCU & AU PROJECT Page
6987-LEPCl-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
04.06.2011
Date
.
A. Flow Instrument
(1) Orifice Plate
Each orifice plate shall be checked and confirmed for Tag No., flatness, freedom
from adhesive materials, specification of gaskets, cleanness, correct bore size,
plate thickness, stamp on tab, flow direction and flatness.
(2) Flow Nozzle I Venture Tube
Each flow nozzle I venture tube shall be checked and confirmed for Tag No.,
damage, cleanness, face to face dimension and inside diameter.
(3) Pitot Tube
Each pitot tube shall be checked and confirmed for Tag No., damage, flow direction,
and insertion length.
(4) Rotameter
CD Where the float of rotameter is not visible, the action shall be checked by
positioning the float manually.
@ To be checked that the proper float is correctly installed, and that the float
moves freely.
Cleanness shall be checked
(5) Turbine and Positive Displacement Meters
Each meter shall be checked for Tag No., damage, cleanness, flow direction.
(6) Flow Switch
Each meter shall be checked for Tag No., damage, cleanness, flow direction.
B. Level Instrument
(1) Displace Type Level Instrument
1) Stiffeners shall be removed.
2) Direction of indicators or transmitters shall be confirmed.
(2) Capacitance Type Level Instrument
Direction of transmitters shall be confirmed.
(3) Tank Gauge System
Float and measuring tape shall be verified.
(4) Level Gauge
The center to center length shall be checked according to specifications and
vendor's drawing
C. Temperature Instrument
(1) Thermocouple/RTD
Insertion length and outside diameter shall be checked.
(2) Thermometer
1) The instruments may not be calibrated but dial pointer shall be adjusted to the
known ambient temperature.
2) Insertion length and outside diameter shall be checked.
Issued For


;?-.
Approval

---------
I
Purpose
Prepared Checked Approved Approved
by SECL by SECL by SECL by ElL
, '
~
Dahej Petrochemical Complex DFCU &AU PROJECT Page l ~ o f 2 '
6987-LEPCI-SE-CN-PE-OOS8
Instrument work procedure
Rev.: 0]
.
D. Control Valve
Visual Inspection of valve body inside and flow direction shall be done.
3.4.2 Instruments shall not be interfered with their function, operation and maintenance.
3.4.3 Instruments are installed according to the materials shown on the related drawings.
3.4.4 Instruments are correct-mounted horizontally, vertically or at the specified angle.
3.4.5 Instruments are cleaned and have not been damaged.
3.4.6 The terminal and indicating direction of transmitters and switches shall be
checked.
3.5. Instrument Wiring Test
3.5.1 Continuity Test
(1) Use low voltage apparatus such as testers, buzzer or telephones.
(2) Disconnect the wires from the terminal blocks to avoid excessive voltage to the
instruments and to prevent the bypass circuits.
(3) Confirm that the identification of cables and wiring is as shown on the drawings.
3.5.2 Insulation Resistance Test
Insulation resistance test shall be performed after the continuity test.
(1) Used "Meager Tester"(lnsulation resistance tester) of rated voltage 500V or 250V
meager
(2) Disconnect the wires from the terminal blocks after continuity test, and the measure
the insulation resistance between a wire and ground.
(3) Check that the measured values are greater than 100 Mohm except compensation
lead wire for thermocouples as a 5 Mohm.
(4) When specified by the manufacture of apparatuses, the value shall be governed.
(5) Reconnect the wires to terminal blocks after electric energy charged in the wire is
discharged to the ground.
3.5.3 Ground Resistance Test
(1) Grounding resistance meters shall be used.
(2) The measured value shall be less than the specified.
(3) When the grounding resistance value is specified on the special circuits such as
intrinsic safety circuits, the value shall be governed.
3.6 Pressure Piping and Tubing Test
3.6.1 Unless otherwise stated, the test shall be performed with blocking of the
lines from the instruments
3,6,2 Instruments with an operating pressure less than 900# shall be pneumatically tested.
I
04.06.2011 i
i
Date I
Issued For
Approval
Purpose
Prepared
by SECL
Checked
by SECL
Approved
by SECL
Approved
by ElL

Dabej Petrochemical Complex DFCU & AU PROJECT Page llfof2t
6987-LEPCl-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
- -
Instruments with an operating pressure more than 900# and equal shall be
pneumatically and/or hydro statically tested. .
(1) Pneumatic Test
1) Test fluid: Nitrogen, Air
2) Test pressure (the maximum working pressure times)
G) 1.25 for less than 900#.
1.1 for more than 900# & equal.
3) After pressurizing up to test pressure for 5 minutes, pressure piping and tubing
shall not have any pressure change. During the test, the leakage from pressure
piping and tubing shall be checked by soap water.
(2) Hydrostatic Test
1 ) Test fluid : Water
2) Test pressure shall be 1.5 times the maximum working pressure.
3) After feeding of fresh water up to test pressure for 3 minutes, the pressure
piping and tubing shall not have any pressure. During the test, the pressure
decreasing of the lines shall be checked by pressure gauge indication.
<Notes> 1. Pressurization of system shall be done slowly for safety.
2. The test for analyzer piping shall be performed without
disconnection of the lines from analyzers. The test method shall be
done according to process pipe line, pressure pinging and tubing.
3. All piping and tubing system shall be cleaned by air blowing or
water flushing before and/or after the test.
; 3.7 Air Supply Tubing Test
3.7.1 Continuity test and flushing
(1) Continuity test shall be done after flushing of the main header.
(2) Tube itself shall be tested after disconnecting from the instrument.
3.7.2 Leak test
(1) Leak test shall be done after continuity test.
(2) The pressure of air source shall be maintained as specified.
(3) Leak test shall be checked by well mixed soap water.
(4) The roof valve(1st valve) shall be completely opened before testing.
(5) The air shall be used as the test fluid.
(6) The working pressure shall be considered as the test pressure.
(7) After pressurizing up to test pressure for 3 minutes, piping lines shall not have any
pressure change. During the test, the leakage from piping shall be checked by
soap water.
3.7.3 Cleaning Check
04.06.2011 I
Issued For


y=-h-

Approval

t-
Date
I
Purpose
Prepared Checked Approved Approved
by SECL by SECL by SECL by ElL

-
Dabej Petrocbemical Complex DFCU & AU PROJECT Page I gof2fl
6987-I,.EPC l-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
-
(1) The instrument air shall be used as the test fluid.
(2) The working pressure shall be considered as the test pressure.
(3) Blowing out for cleaning shall be performed according to the following procedure.
1) Disconnect lines ahead the individual instrument filter.
2) Open the take-off valve on the main header.
3) Open and shut the stop valve of individual instrument and stop valves in main
header.
4) Repeat above step 1) to 3) until any matter is not found on the white paper
<Note> The blowing shall be done sequentially from instrument air header to
instruments.
3.8 Steam Tracing Tubing Test
3.8.1 Basically, the procedure shall conform to Section 3.6
3.8.2 The steam used for steam tracing shall be practically used for pressure and leak test.
3.8.3 The tubing shall not have any pressure change.
3.8.4 Tracing tubing shall be arranged as shown on the drawings.
3.8.6 No extremely crushed parts by bending shall be found on the heat tubing.
4. LOOP AND FUNCTION TEST
4.1 Field Check and Calibration
Prior to starting of check and calibration of each instrument, the following confirmation shall
be carried out.
4.1.1 Electric Power Source
First,
- If the electric power source energizes normally
- If the voltage is normal
- If the insulation is normal
- If the terminals have been tightened certainly.
In these case, main switch of instrument power source shall be cut off. Second,
- If converter linverter system is normal.
- If the right voltage is supplied.
- If the take-over system is normally functioned each other
(mechanical contractor)
- If the back-up time of each battery is more than holding up time.
<Notes> 1. Dummy load may be considered for this test.
In this case, main switch of switchboards shall be cut off.
2. Refer to "Vendor's instruction manual".
4.1.2 Instrument Air Source
i
Issued For
.
1-


I
04.06.2011 .j
Approval
. I
-_.
Prepared
I
Checked
I
Approved
Date
i
Purpose
Approved
i
by SECl by SECl by SECl by Ell
-
Dabej Petrochemical Complex DFCU & AU PROJECT Page 1,0[2,
6987-LEPC I-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
.
-
(1) Instrument Air Source
The following items shall be confirmed carefully:
1) Loading/unloading of compressor
2) Starting stand-by compressor Refer to "Vendor's Instruction Manual".
(2) Supply of Instrument Air
Upon completion of various kinds of tests, the required supply air pressure of each
kind of instrument shall be confirmed and setting of the pressure regulator (air set)
shall be made. .
4.1.3 Outline of Field Check and Calibration
Check and calibration of the following equipment shall be in accordance with vendor's
standard procedure.
(1) DCS operator console
(2) DCS cabinet
(3) Control panel and rack in control room
(4) PLC
(5) Local panel supplied by package vendor
(6) Power distribution board
(7) Analyzers including Gas-chromatograph
4.2 Loop Test
After each component of a control loop has been calibrated individually, an operational test of
the individual loop shall be carried out.
4.2.1 DCS
(,1) Functional Test
Each loop shall be operated to simulate actual operation from transmitter to final
control element. The complete loop as well as each component in the loop shall
be checked for proper operation and control action (direcUreverse).
(2) Calibration Check
0% of scale for each transmitter shall be verified and calibrated on DCS console.
(3) Action Check
The action of switches and valves shall be checked on DCS console.
(4) Alarm Check
Alarm point shall be confirmed at the above function test.
4.2.2 SIS/ESD and Sequence Control System
04.06.2011
Date
(1) The operational confirmation for input signals, from field instruments to the system,
shall be done at the final output end.
(2) If the operational confirmation of an loop has already been done and an input to
SIS/ESD and sequence system is duplicate to alarm system, it is permissible to
check input to system without operational confirmation from field instruments.
(3) The stroking time of the on-off valve shall be measured using a stop watch.
Issued For
Approval
Purpose
Prepared
by SECl
Checked
by SECl
Approved
by SECl
Approved
by Ell
- -
Dahej Petrochemical Complex DFCU & AU PROJECT Page 2J)of2t .
6987-LEPCl-SE-CN-PE-0058
Instrument work procedure
Rev.: 01
.
4.2.3 Field Signal Input
04.06.2011
(1) Flow Instrument
1) DIP Transmitter
CD The instruments shall be calibrated using a portable signal generator or
HART communicator.
@ 00% of full scale shall be verified on DCS.
@ Hard-wired alarms for the loop shall be confirmed at console.
2) Turbine Meter and PID Meter
0-25-50-75-100% offull scale shall be verified on DCS by the simulated signal
such as pulse or mA generator.
3) Flow Switch
Alarms on the DCS or the console shall be confirmed by giving open or closed
signals at the terminal of the instruments.
(2) Level Instrument
1). Displace Type and Capacitance Type
CD The loopsshall be tested using a potable Millie ampere simulator
connected to the terminal of the instrument.
@ 0-25-50-75-100% offull scale shall be verified on DCS .
.&c..
@ Hard-wired alarms for the loop shall be confirmed at console.
2) Tank Gauge System
Zero point shall be verified on DCS raising the float electrically.
(3) Pressure Instrument
1) Pressure Transmitter
CD The instruments shall be calibrated using a portable signal generator or
HART communicator.
@ 0-25-50-75-100% of full scale shall be verified on DCS.
&
@ Hard-wired alarms for the loop shall be confirmed at console.
2) Pressure Switch
Alarms on the DCS or the enunciator console shall be confirmed by giving
open or closed signals at the terminal of the instruments.
(4) Temperature Instrument
1) Temperature Transmitter
Issued For
Approval
CD The loops shall be tested using a potable milliampere simulator
connected to the terminal of the instrument.
@ 0-25-50-75-100% of full scale shall be verified on DCS.
@ Hard-wired alarms for the loop shall be confirmed at enunciator console.


---.... -
Prepared I Checked Approved
by SECL
Approved
by ElL
Date Purpose
by SECL by SECL
-
Dahej Petrochemical Complex DFCU & AU PROJECT Page 2,0[2,
6987 -LEPCl--SE--CN-PE-0058 Instrument work procedure
Rev.: 01
APPENDIX:
04.06.2011
Date
-
2) Thermocouple and RTD
<D Thermocouple loops shall be tested using a potable mill volt simulator
connected to the terminal of the element. RTD loops shall be tested using
a resistance simulator connected to the terminal of the element.
of full scale shall be verified on DCS.
@ Alarms for the loop shall be confirmed at enunciator console.
3) Temperature Switch
Alarms on the DCS or the console shall be confirmed by giving open or closed
signals at the terminal of the instruments.
(5) Control Valve
1) The following items shall be verified by giving signal by DCS and/or PLC.
<D Valve action (smooth)
@ Travel of full scale)
@ Limit switch action (to be confirmed on DCS by answer back)
@ Solenoid valve action
Air and electrical failure position
2) If the control valve has a solenoid valve and the test is impossible, this test
may be performed at the same time off the operational confirmation of
interlock system or sequence system.
1. ITP for Instrument,
2. Calibration Reports
3. Inspection Record Sheets
Issued For
Approval
Purpose
Prepared
by SECL
Checked
by SECL
Approved
bySECL

DAHEJPETROCHEMICAL
e)
COlVIPLEX
Dual Feed Cracker Unit
ONGC Petro additions Limited
& Associated Units
ElL
SEZ, Dahej, Gujarat, India
JOB NO. 6987
Page: I of 4
INSPECTION AND TEST PLAN
02 04-Jul1e-2011
01 n-May-2011
Dalc
0-
-.:! ...
. .
'. .
Contract No PO No.:
I t '."llractor noc. No.:
I &SE-OO-Q-PQ-042
L_.
FOR
INSTRUMENTATION
For Approval
For Re\'icw & Approval
Rc,lsnn 1(1)" IsSlIC Rcmark
ENGINEERING
DIVISION
SAMSUNG
ENGINEERING
Prcpared
Linde Project No.:
Linde Project Code:
Samsung Project No.:
Samsung Project Code:
Item No.:
l.,mpany Doc. No.:
Y.K.Park
Y.K.Park
Chccked :\ppnwcd
3110 A9NK
DAHEJ
SC 2252
OPaL DFCU & AU
6987-LEPC I-SE-OO-QC-PQ-042
Dahej Petrochemical Complex DFCU &AU
Page 2 of4
6987-LEPC 1-SE-00-QC-PQ-042
INSPECTION AND TEST PLAN FOR
Issue: 02
INSTRUMENTATION
REVISION HISTORY
REV DATE DESCRIPTION
01 04-June-2011
Letter no.SE-EIL-L-1254&1262 dated 23.05.2011, ElL
Comments incorporated and re-submitted.
* Notes:
This page records all revisions on the specification.
23-05-2011
Date
Issued for
Approval
Purpose
Prepared by
SECL
Checked by
SECL
Appro\'cd by ElL
I
I
Dahe.i Petrochemical Complex DFCU & AU Page 3 of4
,()X7-1.1:PC I-S E-OO-QC-PQ-042
INSPECTION AND TEST PLAN
Issue: OL
INSTRUMENTATION
L ............. _ ... ___ .
0' In'p"tion T."
I nspectionffest
Reference Document Remarks
Report Format
I M.ATERIAL RECEIVING IMIR H H IIMIR
.--------
- Calibration should be bench tested
CALIBRATION basically but where bench test is not
2.1 Transmitters INC-CAL-OO I suitable such as flow element, control
'1 '1 S . I
INC-CAL-002 valve above 4" etc., t1eld calibration
2
I wltC les
IIR W V/RC -Instrument Data Sheet
2.:> Thermocouple/RTD INC-CAL-003 would be adopted.
2.4 Control Valves INC-CAL-004 - Gauges will "0" adjusted but ifnot
2.5 Gauges(Pressure/Temperature) No Record possible to calibrate, that gauge will be
substituted by new ones.
I.UC /\L PANEL
r ["()NTROL ROOM EQUIPMENT

I-RIB Equipment & Wiring Layout
4 "Jl BOX IINC-INSP-OO 1
.5 Cable Duct INC-INSP-002
(j
PERFORATED TRAY INC-INSP-002
7
I IIR
IIR
I/R
IIR
I/R
I H
H
H
W
W
W
W
W
W
V/RC
I-Instrument Main Cable Plan
Main Cable Way
-Instrument Main Cable Plan
-Instrument Wiring Plan
-Instrument Air Tubing Plan
-Inspection Connection List
Partial inspection request is acceptable
Inspection should be done before cable
pulling or tube laying on tray
Inspection should be requested after
rack & JB both side termination done
MULTI-CABLE INC-INSP-003 " """d 8.1 + 8.2
7 I C,blo p"mng INC-INSP-004 -I"pootion bo q
) INC-INSP-005 In,'mmo.' W;ri.g PI,. . altho b"oq",,'od afto"B
(C.",;"",,,Ii.," a .0. W :I.","mo., W;".g & T"b .. g -1.'pOO"0.' ,;do ",m;.atod
>----------+-,;, N G L CoCA B LEV IRC . Co o"; eo Dotail & .. "rumo.'
I
X J H.I Cable Pulling
{ X.2 Cable Termination
_____ _ (Continuity/Insulation)
INC-INSP-004
INC-INSP-OOS
IIR
IIR
W
W
Issued for I I /"\ ... .. :A' :;;;;>'
Approval
01 04-06-20 II

Rev.
Date
Purpose Prepared by SECL Checked by SECL Approved by SECL Approved by ElL
Dahe.i Petrochemical Complex DFCU & AU Page 4 of 4
.
E
6987-LEPC I-SE-00-QC-PQ-042 INSPECTION AND TEST PLAN INSTRUMENTATION Issue: 02-
-----'1NSTRUMENT
9.1 Stanchion
9 I 9.2 Instrument Installation
9 . .1 Pressure Piping & Tubing
9.4 Others(such as Steam Tracing)
LEi\K TEST
10 I 10.1 Pressure Piping/Tubing
INC-INSP-006 I
fNC-fNSP-007 I
-Instrument Wiring Plan
IIR I H H
I -Piping Arrangement(if needed)
-Instrument Hook-up Detail
-Steam Tracing Plan
f/R I W
I V/RC I -Instrument Data Sheet
-Instrument Air Supply Tubing Plan
-Instrument Calibration Record
____ ________ +-__________ -+ ____ +-__
II I I.OOP TEST INC-INSP-008 I f/R I H H
I -Instrument Termination Test Report
-Other Logic/Control Diagram as
required
NOTE
I Stanchion location should be decided
with the coordination with ElL
The aclditional rei'erence drawing and/or document may be required while inspectionitest if necessary other than listed above Reference Document.
PARTICIPATIENT
SC - Sub Contractor
SS - Samsung Engineering & Construction Co., Ltd.
EI L - Engineering India Limited
LEGEND
I - Responsible to request/undertake the inspection/test
R - Responsible to generate/maintain the inspection/test record
V - Verify/Review of InspectionfTest Record
W - Witness of InspectionfTest(lf not il! attendance of specified time, inspection/test may proceed
RC - Random check: may request the test for few %(Iess than 10%) or items among tested items for
verification.
H - Hold InspectionfTest till SECLIEIL attend(may not proceed inspection/test by themselves)
[0'-- 04-06-'011 I""d foc
Approval ,,).';;t ... .J. < If ."
Date I
Rev. Purpose Prepared by SECL Checked by SECL I Approved by SECL I Approved by ElL
Owner PMC
DAHEJ PETROCHEMleAL COMPLEX
Contractor
II

Dual Feed Cracker Unit
.-
SAMSUNG
=:
& Associated Units
ENGINEERING
OPaL ElL
-
CALIBRATION REPORT
(TRANSMITTERS)
Report No.: Calibration Date:
Tag No.:
Eng. Spec. No.:
Tag Description
Range on Spec.:
Location I Area:
1. Instrument data
Function: Range:
Manufacturer: Test Voltage:
Type I Model No.:
/iTem
p
Serial No.:
r(/)
2. Visual Checking
" if>
No.
ITEM DECRIPTION OK

1I!Aj'
REMARKS
1 Accessories(Block Valve, Cable Entry Blocking, etc.)
A b:J
2 Instrument check against data sheet

II
3 Instrument checked for damage

,,)
4 Instrument tag number attached to instrument

,--) J
5 Calibration tag or sticker attached to instrument
Ac"-.

3. Calibration Results .

ACTUAL INPUT

FINALmA % ERROR(FINAL)
% INPUT

Rising . Falling Rising Falling
0%

25%

J
50%
1
75%
r
V" " "t'
h"'I.
100%
"
//)
_.-r... .) ,!
pr .'

4. Test Equipment
Description Manufacturer I Model Serial No. Calibration Expiry Date
Remarks:
.-....... __ ... _ ... __ ................ -................. _ ...... _-._-_ ...... _ ....... __ ......... -.... _ ....... ............. __ ........................ _ .......... _-_.-._.-_ .... _._---_._-----_ ..... _ ... _.-_._. __ .. -. __ .. _ .. __ ............... _.---.. _--
........................................... -. .................... __ .... -..... _ ..... -.. --.. _ ...... ....... -........ . ........... _ ......... .................. -............ _ ....... _ ..... __.. _._ ... _ ........... -._-_ ........ -.--_ ............. . .......... _ ................. _ ..... ............ .. ..... -.....
Company Sub-Contractor Samsung

EWOPaL
Name
N'Sh",d..s

Signature
cntQ
Date
'-"
j{(dl\
Ot., - Iu If\.( - 20 It
Form No.: INC-CAL-001
i
Owner PMC
DAHEJ PETROCHEMICAL
Contractor


COMPLEX
-
SAMSUNG
(I.1M)
Dual Feed Cracker Unit
ENGINEERING
&-
& Associated Units
OP::l1 Ell
CALIBRATION REPORT
(SWITCHES)
Report No.: Calibration Date:
Tag No,:
Eng. Spec. No.:
Tag Description:
Set point on Spec.:
Location I Area:
1. Instrument data
Function: Range:
Manufacturer: T
((-
,tage:
,
Type r Model No.: b' nve ..
--
!
1/
/1
Serial No.: /' T
,r
2. Visual Check
""-
No.
ITEM DECRIPTION
,"'
",-oJ! I..INO
"
N/A
REMARKS
1 Accessories(Block Valve, Cable Entry

2 Instrument check against data sheet
/rb 1
'''''
3 Instrument checked for damage
,""H l.
4 Instrument tag number attached
5 Calibration tag or. sticker attached
3. Calibration Results
{.



As Left
Set Point RiSing!

a '
I '"" ,
mead Band Rising Falling Dead Band
\

)
(
- : M
\V'
'= z,r
.d if

4. Test Equipment
Description Manufacturer f Model Serial No. Calibration Expiry Date
Remarks:
....................... -.... _ .............. -............... -......... -........................................................... _ ..................... _-............ _ ............ -.-....... -..... -... -............... _ ............. -.... _ ....................... _ ....... _ ..
.......................................................................................................................... .................... _ ......................................... _ ....................................................................................................
............... ....................................................................................
"
.... . ....................................................................................................................................................
Company Sub-Contractor Samsung EIUOPaL
Name


VAL.
Signature
?dQ. RP../)

- -

Date
04- Jc..AlfU - 2.011
Form No.: INC-CAL-002
-
PMC
DAHEJ PETROCHEMICAL COMPLEX
Contractor
II


Dual Feed Cracker Unit
-
SAMSUN.G
.
& Associated Units
ENGINEERING
L
OPaL ElL
CALI BRA TION REPORT
(Thermocouple/RTD)
Report No.: Calibration Date:
Tag No.:
Eng. Spec. No.:
Tag Description:
Range on Spec.:
Location! Area:
1. Instrument data
Function: ge:
c
".I
Manufacturer:
i 'V. It e:

{I
Type I Model No.: Am n "' p.:
Serial No.:
2. Visual Check

;ti-
No.
ITEM DECRIPTION

NO NIA
REMARKS
1 Accessories(Union, Cable Entry Blocking, etc./, /"'\, ) t"#
2 Instrument checK against data sheet
"J'J
3 Instrument checked for damage

4 Instrument tag number attached to v
5 Calibration tag or sticker attached 'Y
3. Calibration Results
: . .:::ss

Measured Value Error
Input

As Found As Left %
c fC&P" c Q/Mv
c
Q/Mv
Ambient
\..J
Ij)j
?' ,
URV
"
l/'
,,'
4. Test Equipment
Description Manufacturer I Model Serial No. Calibration Expiry Date
Remarks:
........... __ ............... _ .... -.. _ ............. -.... _ ... _ ... __ ......... _ ... _ ................................................. _ ..................................... __ ._ ................... _ ... _ ......... _ .... _ ................. _ .......... __........ _-.. -._ ........ -
............................................... __ .......................................... -............................................................ - ......... _ ..... __ ...... -... _ .. _ .......... -.... _ ... _ ............ _ ..... -.................................... -.... -..................... -
.Ji ................................................................................................................ ............ . ................................................................. _ .................... -................. -.......................................................................
Company Sub-Contractor Samsung
i
EIUOPaL
Name
Nisl".,.d5

Signature
_MJ.r-vAL
-
q1g\ \\
Date
'j'aw. - 2.0',
- Form No.: INC-CAL-003
Tag No.:
COMPLEX
Dual Fel!d Cracker Unit
& Associated Units
CALIBRATION REPORT
(CONTROL VALVE I ON-OFF VALVE)
Eng. Spec. No.:
Contractor
SAMSUNG
ENGINEERING
Tag Description: Air Supply Press.: _________ _
Location I Area:
1. Valve data
Manufacturer:
Type I Model No.:
2. V isual Checking
S. No.
ITEM DECRIPTION
1 Accessories Status(I/P Converter, Solenoid, etc.)
2 Valve check against data sheet
3 Cable entry and air connection blocking check
4 Valve flow direction correct
./
5 Calibration tag or sticker attached to
Serial No.:

A
OK N, 1/".1'
"-
.I'
'"

"'
"\
,.
i)J
"'I
3.C alibration Results

. INPUT

REMARKS
CLOSING ACTION
TRAVEL %



TRAVEL % lIP Conv.
% mA As Found As Left

As Left As Found As Left As. Left
0%
<;:
b
V

..,..
25%
/
50%
(C

75%


1<" ,/
-
100%
STROKE TIME: Air Fail Action:
ACCESSORIES FAIL FUNCTION OK NOT OK
SOLENOID A
SOLENOID B
LIMIT SWITCH CLOSE
LIMIT SWITCH OPEN
LOOK-UP DEVICE
OTHER
4. Test Equipment:
ERROR %
As Left
Description Manufacturer I Model Serial No. Calibration Expiry Date
Remarks:
Company Sun-Contractor
Name
Signature
Date
Form No.: INC-CAL-004


DAHEJ PETROCHEMICAL COMPLEX
.,
SAMSUNG
(ilIIt11PIl
Dual Feed Cracker Unit
ENGINEERING

& Associated Units
INSPECTION & TEST REPORT
.
(PANEL I JUNCTION BOX)
.
Report No.: Inspection Date:
Tag No.:
Ref. Spec.lDWG No.:
Name
Location I Area:
Panel I Junction Box Installation Check list
No. CHECK ITEMS
11hA
SAT.
UN
N/A Remarks
SAT.
1 Labelling I Identification correct
2 Check mechanical damage
A
'':::/
3 Check panel leveled properly and stand in a row

4 Check paint condition
/,,',\V
5 Tblllllllc:ltivi peripherals good condition
,"1/
6 Check for accessibility and correct
'''\,;:
7 door opening is smooth and not object

8 Spare entries plugged

9 ICheck internals for cleanliness

10 Check panel against drawing, Specification
11 Check manual operation

push button, Lamp, etc.

Jft' Ar'


'=/:;/)'
"V ..
Remarks: .
-..... _ ...... -.. _ .......... _-...... __........ -_ ........ --..... _ ................ _ .......... _.--_ .. _ ... _ ...... _. __ ...... __ . __ .. _ ............. _--... __ .......... _._._--_ ..... -. __.. _ ....... - ..... _ .. _._._ ..... _. __ ... _--_ .. _--
__ _ ........... _ _ .................................. __ __ n _ .................... _ _ _ ............................ _ .......................... _ ......... _ ................. __ _
.................................................................................................................. _ ................... _ ......................... _ .................................... _ ......................................................................... -_ .. __ ..... _ ...
Company Sub-Contractor Samsung EIUOPaL
Name
Nts "'c.olJ'
Signature


,.
Date
- 04 - jo "'l- 2.11 -
"
Fnrm Nn . INl.-INSP-001

DAHEJ PETROCHEMICAL COMPLEX

.
Dual.Feed Cracker Unit .,
SAMSUNG
-
ENGINEERING

& Associated Units
INSPECTION & TEST REPORT
.
(CABLE DUCT I PERFORATED TRAY)
.
Report No.: Inspection Date:
. Location I Area:
Ref. Spec'/DWG No.:
Cable Duct Installation Check List
No. CHECK ITEMS SAT.
UN
N/A Remarks
SAT.
Cable duct size and layout as per approved drawing
/)A
Support and hanger installed properly
!...VLh
Bending radious acceptable
,V/
Cable duct is free from mechanical damage

b'V
Joint plates correctly installed with proper bolt &
{Qi
....



Perforated Tray Installation .
Tray size and layout as
Tr is properlysu!-,!-,vi \
a
Spacing from hot
Spacing from
\
Joint plates correctly bolt & nuts
Welded portion is properly zinc painted
IWelded portion is properly zinc painted
Remarks:
_ .. __ ..................... __ ................ -............ -_ ............................ -........ _ .............. _--......................................... -_ .. -... _--..................... -.. _ ... __ ........ __ ..... -_._ ... -....... --.-........ _--_ ... _ .... _ ....
......... -_ .................... _-_ ................ -.......................................................... -....................... .............................. -..................... ................ -..... -............ _ .......... _ ........................... _._ .. _-.. -
.. _ ............ -................................................................................................ _ ............. __ ................... _ ... _ ................................................................................ _ ............. - .. _ ............ _ ......... - ....... -....
Company Sub-Contractor Samsung ElL/OPal
Name
N,s

Signature


-
Date
Q -4 - jCAIIV - 2-o!l
9
l61 II
Form No : INC-INSP-002


DAHEJ PETROCHEMICAL COMPLEX
(I'B'W
Dual Feed Cracker Unit
.-
SAMSUNG
& Associated Units
ENGINEERING

INSPECTION & TEST REPORT
.
(INSTRUMENT CABLE)
Report No.:
Inspection Date:
JB No. I Panel No.
Ref. Spec.!DWG No.:
From:
To:
Drum No:
Cable(Multi-Cable) Installation Check List
Cable size:
No. CHECK ITEMS
/)
SAT.
UN
N/A Remarks
SAT.
1 Cable trench status(Tile Brick, Sand, Warning Tape, etc.)
2 Cable duct bank status ,'{/j
3 Cable route and cable transit assembly status
h
V
4 Cable different voltage level segregated, dressed
#'

5 Cable size and type as per cable schedule
/()j
'V
6 Cab'le physically not damaged

7
ICable tag is correct.




"'"



t
V
./11
=<-!y;
Remarks:
...... _ ...... -......... _-.. - ........ _ ............ _ ... _ ...................... -...... _ .... __ ................... _-._-_. __ ............ _._ ................ _---_.-._ ... -._ .. _ .......... _ .. _ .. _--_ ........ _ ... _ ......... -..........
_ ....... -.......... -... __.......................... -_................. -........................... _ ...... _ ........... __ ._-...... _._ ..... _ .. _ ... -..... _ .. --_._. __....... -._ .. _ .... _._... __ ._-_ .......... -........ -................... _--_ ... _ ..
............. _ ........................... . ............................................................ _-_........................ _ ......................................................... _ .................................... -... _ ... _ ........ _ .......... __.. _ ...........
Company SUb-Contractor Samsung EIUOPaL
Name
Nt's \., 5
Signature


Date
o li - 1't.t "'" - 20 \I '11 s{ \\
Form No.: INC-INSP-003
DAHEJ PETROCHEMICAL
-


- -
('Bij
COMPLEX
.,
SAMSUNG
ENGINEERING

Dual Feed Cracker Unit
INSPECTION & TEST REPORT
(INSTRUMENT WIRING)
-
r---
Report No.:
Test Date: Page:
JB or Local Panel No:
1. Visual Checking Drum No: Cable Size
No ITEM DECRIPTION OK NO NfA Remarks
1 Bending Radious Status
2 Labelling f Numbering f Ferruling
3 Earth or sheild wire connection correct
4 Cable gland suitable for area classification
5 CablelWire length is long enough to fress from stress
6 CablelWire is tied properly
7 Cable tag is correct
8 Terminal lug and bolt tightened
2. Test Results
FIELD INSTR. JBfLOCAL PNL
CABLE
CONTROL ROOM CONTIN- INSULATION(MQ)
No TAG NO. TIM NO. WIRE NO. TERM
NO,
PANEL WIRE NO.

UITYOK CORE TO CORE TO CORE TO
(+ OR-) fCOLOR NO. NO. fCOLORA
OR NOT
CORE ARMOUR SCREEN
,!l II'#]t
"-
I'V;"
').

./
&.
!,
/'n

WI'


1#
) ,

,
..





!J


N
j'

\

tf
\
/.
7')..
:i'
IF

D '
..
t (
1#' /.?\
'-.. /1
/-/A
'Y"
Continued
Company Sub-Contractor Samsung EIUOPaL
Name 1--.1; 0:::. l,..." d. c: 1\1\1\ LU
Signature

Date
nJ.t:''Tt'.J1A1
..... ;::
W bt 1\
\.
-
Form No.: INC-INSP-004

DAHEJ PETROCHEMICAL

COMPLEX
.,
SAMSUNG
ENGINEERING

Dual Feed Cracker Unit
INSPECTION & TEST REPORT
- -
(INSTRUMENT WIRING)
Report No.: Test Date: Page:
2. Test Results Drum No: Cable Size
FIELD INSTR. JBfLOCAL PNL
CABLE
CONTROL ROOM CONTI INSULA TION(MQ)
No. TAG NO. TfM NO. WIRE NO. TERM PANEL WIRE NO. TERM
N-UITY
CORE TO CORE TO CORE TO
(+ OR-) fCOLOR NO.
NO,
NO. fCOLOR NO.
OKOR
CORE ARMOUR SCREEN
i'>...
;
'#'A
/Jl
""'-
{II
"
"", 'V "
A ,,:V
I, "
lI}

r-......'v
j'
'\
,
111

'P'
<


V



S
r-
/!

\

f
\


x
I/I?
/ ......
;'
t""


,p' ..;'
!
.<;(/./
Company Sub-Contractor Samsung
k

Name
S

Signature

-t\<h\ WL.
Date
';.,J.t'-:' T"uw - 2-011
Form No.: INC-INSP-005\

Report No.:
DAHEJ PETROCHEMICAL COMPLEX
Dual Feed Cracker Unit
& Associated Units
INSPECTION & TEST REPORT
(INSTRUMENT)
Inspection Date:
SAMSUNG
ENGINEERING
Tag No.: Hook-up DWG No.: ________ _
Field Instrument Installation Check List
Case
c
o
:.c
u
c
2
en
c
OJ
E
2
iii
c
CHECK ITEMS
Stachion is free from vibration
Fixed properly on floor or structure A
Galvinizing condition /'U'2
Sunshade installed in place of required(direct sunlight) " V),
Name plate / Labelling /Identification tag is '.;:;:vI'
Mount on location as per plan drawing V/
Location is suitable for accessiblity and!(...LO}- V
Instrument flow direction is correct (FIe. (II'" A COntrol Valve)
Isolation valve is i ,r! unused tapping pluged.
Tapping O'!""LCn,Ul' PipinnlJ!Hhinn is correct
'W ."'" 2'
Gasket,bolt-nut&MOC
Correct size of no missing bolt.
III
in
.c
Impulse slop is correct as per hookup drawing.
Material of per drawing.
Correct size and materi;1 for steam tracing if required.
Check proper glanding(gland size/type) and termination. Unused entries
plugged&unused wires are terminated. No exposed armour/wire at point of gland .
o
o1l Wiring,earthing connection as per drawing.

U
lugs/sleeves &ferrules are proper and termination tightened.
OJ
iii
Extra cable loop,cable marking is provided near instrument.
[shield wire is cut&insulated to avoid grounding.
Remarks:
Sub-Contractor Samsung
Name
Signature
Date
SAT. UN N/A Remarks
SAT.
\ f3!.1
0PaL
-
Form No. INC-INSP-006


DAHEJ PETROCHEMICAL COMPLEX
SAMSUNG
Dual..Feed .Cracker Unit
.,
W
ENGINEERING
& Associated Units
INSPECTION & TEST REPORT
-
(PIPEITUBING)
-
Report No.: Insp./ Test Date: T est Duration:
Area / Location Ref. Spec. / DWG. No.
I." Inspect:
II I::' ld lid LU II ;LlUIi Test
HYDROSTATIC TEST PNEUMATIC TEST
No. TAG No. SUPPORT MATERIAL TEST TEST RESULT TEST TEST RESULT
TEST
REMARKS
& FLUID PRESS PRESS FLUID PRESS PRESS
RESULT
RATING I (kg/cm
2
G) (kg/cm
2
G) (kQ/cm
2
G) (kg/cm2G)

f fA
e V/A
"-
{f jt
I'
....... /

,
/AY
....,.,
"-
'-.

/,.
''\ "-
w
fI'
} V
"-
"J
'"
/"\",
"'
"-
\ ."-
'"
.#

"- "'-



."""
"-


'"

"'"
... 'V
\ \

L \ 1/
[If

}
[
P'
...."".
lW
'---
J




FLUID A = AIR ,N = N2 W=WATER
Remarks:
.... __............. _ ........... _-_._-................... -.. _._._ ................... _ .... -.. _ ......... -.................. _ ........... -.. _--_._ .. _._ ....... -.. _ ................. -_ .. _ ........... _._ ... _ ...... - ..
_ .............. -....... _ ............... _._ ................................................. -............................. _ ...... _ ... _ .. __ ... __ .... _.-................ __ ..... -....... _ ....... _ .. _ ......... __ .. -
.................... _ ... _ ............................................................................... _ ................................. _ ....... -...... -.................. -..... __ .......... _ ......... -.......................................
.... _._ ................. _ ............................................. _ ........ _._ ................. _ ............................................ _-._ ... -........... _ .................................. -_ ........................ -... _ .
L-omf-'ol Sllh-r.lmtractor . vdlnsung EIl)OPaL
Name
Ni.sL.""d ('
!\rt\, \UL
Signature
9:1r.:::L
Qate
OJt- '2011
'-'"


Form No.: INC-INSP-007
\ 1

2 DAHEJ -
Dual Feed .Cracker .Unlt _ mGINmlNG
& & ASSOCiated Units
INSPECTION & TEST REPORT
(LOOP TEST)
Date:
Report No:
Loop No.
o Digital Input/Output
Type
o Proximity Switch o Switch 0 Push Button
o Solenoid Valve
Indication/Com m and
o DCS/ESD Command
o Close 0 Start
o Open 0 Stop
Status
OOk o Not OK
o Transmitter
Type
o Flow
OLevel
.Range:
Eng.Unit
OPressure
OTemperature
-------
o Control Valve 0 ON/OFF Valve
Control Valve
o AlarmlTrip
Status
OOk
ON/OFF Valve
o Others
o Not OK
o Not OK
DCS Command Des Command Valve Position
% mA
0
25
50
75
100
Remarks:
Risin
Fail Position
o Fail Close
o Fail Open
Stroke Time:
o Fail Lock
.---- . Ihlr"' IhieD n"Q
sec.