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RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

Rev. :

D3

Specification for Instrument Junction Boxes and Cable Glands

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RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

Document Title

 

Document Number

 

Rev. :

D3

Specification for Instrument Junction Boxes and Cable Glands

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Page: 3 of 14

TABLE OF CONTENTS

1 INTRODUCTION

4

1.1 GENERAL

4

1.2 PROJECT DESCRIPTION

4

1.3 DEFINITIONS

4

1.4 ABBREVIATIONS

5

2 SCOPE

5

3 SERVICE CONDITIONS

6

4 STANDARDS AND CODES

6

5 DOCUMENT PRECEDENCE

7

6 SPECIFICATION DEVIATION / CONCESSION CONTROL

7

7 QUALITY ASSURANCE / QUALITY CONTROL

8

8 DOCUMENTATION

8

9 HANDLING

9

9.1 PACKING FOR SHIPMENT

9

9.2 PRESERVATION AND STORAGE

9

10 INSTRUMENT JUNCTION BOXES

9

10.1 CONSTRUCTION

9

10.2 TERMINATION DETAILS

9

10.3 IDENTIFICATION

9

10.4 CERTIFICATION AND TRACEABILITY

9

10.5 PROTECTION

9

10.6 JUNCTION BOX TYPES

9

11 TECHNICAL REQUIREMENTS FOR CABLE GLANDS

9

11.1 GENERAL

9

11.2 CABLE GLAND TYPES

9

12 PAINTING

9

13 INSPECTION AND TESTING

9

14 SPARES

9

15 TOOLS

9

16 GUARANTEE

9

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

Document Title

 

Document Number

 

Rev. :

D3

Specification for Instrument Junction Boxes and Cable Glands

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1

INTRODUCTION

1.1

General

This specification defines the minimum requirements of the Instrument Junction Boxes and Cable glands to be used for the Reshadat Renovation & Development Project.

The VENDOR shall include, within a quotation, a list of any specific exclusion to this specification and all referenced specifications, otherwise the quotation will be considered to be fully in accordance with the requisition documents.

Compliance by the VENDOR with the provisions of this specification, or any omission herein, does not relieve him of the responsibility to furnish materials/equipment and accessories of a suitable and safe design to meet the specified service conditions, and/or local codes or standards.

1.2

Project Description

The Reshadat Field, formerly called Rostam, is located in the Persian Gulf 110kms south- west of Lavan Island at approximate co-ordinates of 25°54’26”N 52°54’42”E.

SADRA was awarded the EPC work (Contract No. : 3688-85-2FG) for “C2-T: Topside & Bridges” of “Reshadat Renovation and Development Project”. This involves

New Process platform (P4), Quarters platform (Q4), Wellhead platform (W4) and flare platform (F4). Q4, W4 and F4 shall be bridge connected to the P4 platform.

New Satellite well head platform (W0) to the south of the Reshadat Field.

The oil produced from the complex will be exported via a new 16” pipeline to Lavan Island. Produced gas will be compressed and exported. Interconnecting Subsea pipelines and power/controls cables from P4 to W0 and Oil export line from P4 to Lavan Island is covered under scope of a separate EPCI Contract (C3-P) contract. Substructures associated with the Platforms are part of yet another EPCI Contract (C1-S). This scope is not covered under “C2-T: Topside & Bridges” of “Reshadat Renovation and Development Project”.

1.3

Definitions

For the purpose of this document, the following definitions shall apply:

COMPANY

-

The Iranian Offshore Oil company (IOOC)

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

Document Title

 

Document Number

 

Rev. :

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Specification for Instrument Junction Boxes and Cable Glands

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PROJECT

-

The Reshadat Renovation and Development Project - Topsides and Bridges

EPCI CONTRACTOR

-

Iran Marine Industrial Company (SADRA)

ENGINEERING

-

WS Atkins and Partners Overseas

SUBCONTRACTOR

VENDOR

-

Supplier of equipment/material

shall

-

Indicates a mandatory requirement

MDP

-

Report on Master Development Plan [MDP-prepared by Tehran Energy Consultants (TEC) in June 2007]

1.4

Abbreviations

ANSI

-

American National Standards Institute

API

-

American Petroleum Institute

ASME

-

American Society of Mechanical Engineers

ASTM

-

American Society for Testing and Materials

BS

-

British Standard

ISA

-

Instrument Society of America

ISO

-

International Standards Organisation

IEC

-

International Electro-technical Commission

NACE

-

National Association of Corrosion Engineers

PVC

-

Poly Vinyl Chloride

CO2

-

Carbon Dioxide

FEED

-

Front End Engineering Design

GRP

-

Glass Reinforced Polyester

H2S

-

Hydrogen Sulphide

2

SCOPE

VENDOR shall supply Instrument junction boxes and cable glands, fully which complies with this specification. The Material Requisition defines the quantity of each item.

Any variations must be stated by the VENDOR, otherwise it will be assumed that the material offered are in accordance with this specification.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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Any materials failing to meet the requirements of this specification shall be subject to rejection by EPCI CONTRACTOR and shall be replaced by VENDOR at his own expense.

3 SERVICE CONDITIONS

The Instrument Junction Boxes and Cable Glands shall be designed for continuous use over a period of at least 25 years in a marine location in the Persian Gulf, which has a continuously saliferous and humid atmosphere. Traces of H 2 S and C0 2 are present in the atmosphere.

The following parameters shall be considered as the design conditions:

Air temperature

:

minimum 7 °C

maximum 41°C

Humidity

:

minimum 30%

maximum 100%

Maximum Solar temperature

:

85°C

Full details of environmental conditions are given in the project document RSH-00-PM-SP- 0001, “Specification for Environmental and Utility Data”.

4 STANDARDS AND CODES

The equipment shall be designed, fabricated and tested in accordance with the latest revision of all relevant international Codes and Standards including but not limited to the standards listed below.

In the event of conflict between codes and standards and/or this specification, the matter shall be highlighted for EPCI CONTRACTOR / COMPANY’s attention/approval.

API 552

-

Transmission Systems

API 554

-

Process Instruments and Control

ASME B1.20.1

-

Pipe threads, general purpose (inch.)

ASME B2.1

-

NPT pipe threads

BS 381 C

-

Specification for colours for identification coding and special purposes.

BS 6121-1

-

Mechanical Cable Glands - Part 1: Armour Glands - Requirements and Test Methods

BS 6883

-

Specification for Elastomer-Insulated Cables for Fixed Wiring in Ships and On Mobile and Fixed Offshore Units

BS 7671

-

Requirements of electrical installations - IEE wiring regulations

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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BS EN 50019

-

Electrical apparatus for explosive atmospheres - Increased safety ‘e’

BS EN 50262

-

Cable Glands for electrical installations

 

IEC 60079

-

Electrical Apparatus for Explosive Gas Atmospheres (all parts)

 

IEC 60092-375

-

Electrical

 

Installations

in

Ships

 

Part

375:

Shipboard

Telecommunication

Cables

and

Radio-

Frequency

Cables

-

General

Instrumentation

-

Control

and

Communication Cables

 

IEC 60331

-

Fire resisting characteristics of electric cables

 

IEC 60332

-

Test on electric cable under fire conditions

IEC 60529

-

Specification for degrees of protection provided by enclosure.

 

ISO 9000

-

Quality Management Systems – Requirements, 2000 Edition

5 DOCUMENT PRECEDENCE

It shall be the VENDOR responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The VENDOR shall notify the EPCI CONTRACTOR of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation shall be obtained from the EPCI CONTRACTOR in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be:

Requisition

This Specification

Standards and Codes (listed in Section 4)

VENDOR’S Quality Plan

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6 SPECIFICATION DEVIATION / CONCESSION CONTROL

Deviations from this specification are only acceptable where the VENDOR has listed in his quotation the requirements he can not, or does not wish to comply with, and which the COMPANY/EPCI CONTRACTOR has accepted in writing before the order is placed.

In the absence of a list of deviations, it will be assumed that the VENDOR complies fully with this specification.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Any technical deviations to the Material Requisition and its attachments including, but not limited to, Data Sheets and Specifications shall be sought by the VENDOR only through Concession Request format. Concession requests require EPCI CONTRACTOR’S and COMPANY’S review/approval prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

7 QUALITY ASSURANCE / QUALITY CONTROL

The VENDOR shall have in effect at all times, a QA/QC program that clearly establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well-defined authority to enforce quality requirements, initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.

A copy of the VENDORS QA/QC program shall be submitted to the EPCI CONTRACTOR

with its quotation for EPCI CONTRACTOR’S review and concurrence prior to award. If VENDOR’S QA/QC program and facility, where the work is to be performed, is ISO 9001:1994 or ISO 9001:2000 (including design) certified, then only a copy of the VENDORS ISO 9001 certificate is required. In addition, if VENDORS facility is ISO certified, EPCI CONTRACTOR’S QA audit requirements will be waived in favour of ISO 9001:1994 or ISO 9001:2000 (including design) registrar audits, unless the EPCI CONTRACTOR’S trend

analysis program indicates areas of concern.

The VENDOR shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the EPCI CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance

of its SUBVENDORS activities.

The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily.

The COMPANY/EPCI CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR, 30 days after award but prior to the pre-inspection meeting, shall provide the EPCI CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory COMPANY/EPCI CONTRACTOR witness points.

8 DOCUMENTATION

The VENDOR, as bidder, shall include in his bid sufficient technical details on components and materials offered including manufacturer's exact model numbers, specifications and description sheets, preliminary schematic/dimensional drawings, etc. and any other details

to support their compliance statements.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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The VENDOR shall provide full components details, assembly and construction drawings and details for EPCI CONTRACTOR's approval.

The VENDOR shall provide with the equipment a full set of manuals that shall include but not limited to the following:

A general description of item / equipment / system

A complete set of technical data sheets including the manufacturer details, specifications, spare parts list, exploded views, maintenance and operational details etc.

A complete set of materials certificates

Dimensional / GA Drawings including installation details

The above list is not exhaustive. The VENDOR shall refer to specific document / drawing requirements in the material requisition, raised by the EPCI CONTRACTOR, for completeness.

9

HANDLING

9.1

Packing for Shipment

Preparation for shipment shall be in accordance with the VENDORS standards and as noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site.

Preparation for shipment and packing will be subject to inspection and rejection by COMPANY’S/CONTRACTORS inspectors. All costs occasioned by such rejection shall be to the account of the VENDOR.

After inspection and test, equipment shall be completely free of water and dry, before start of preparation for shipment.

Equipment shall be packed and securely braced to prevent damage during transit, lifting, or unloading.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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9.2

Preservation and Storage

Equipment and materials shall be protected to withstand ocean transit and extended period

of

storage at the jobsite for a minimum period of 18 months. Equipment shall be protected

to

safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt,

sand, mud, salt air, salt spray, and seawater.

10

INSTRUMENT JUNCTION BOXES

10.1

Construction

Field junction boxes shall be manufactured of impact resistant and flame retardant GRP material up to 300mm enclosure size. Above 300mm, junction boxes shall be manufactured from 316-stainless steel, and shall have hinged and detachable lids.

All stainless steel Junction Boxes shall have an internal/external brass M10 earthing stud. GRP boxes shall be fitted with a tinned or nickel plated brass earth continuity plate and earth bonding connection.

All stainless steel Junction Boxes shall be provided with full width, undrilled gland plates on each side for incoming field cables, and on the base for exiting multi-core cables. Gland plates are not permitted on the top of the box; cable entries to junction boxes will be from the bottom or side ONLY, top entry of cables is strictly forbidden. All Gland plates shall have internal earth bonding facilities suitable for termination of 6mm² wires. Gland plates will be drilled to suit at site except for EExd junction boxes which shall be provided with the required gland entries fitted with certified plugs.

GRP Junction Boxes to be fitted with internal earth continuity plates and have cable entries pre-drilled and plugged without affecting the IP rating or certification.

A

rain lip shall prevent drip ingress into the box when the door is opened.

All Junction Boxes shall be provided with an approved IP-65 rated breather device to prevent condensation.

All Junction Boxes shall have external fixing lugs provided for installation.

10.2

Termination Details

Junction boxes shall be supplied, complete with terminals and links, assembled on terminal rails as indicated in the requisition document. Links are for use when terminating overall screen cables only.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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All Junction Boxes shall be provided with Weidmüller (Klippon) type WDU 2.5 or similar terminals with flat head screws. Intrinsically Safe terminals shall be light blue.

Terminals shall be mounted on Weidmüller (Klippon) type TS-35 rail or similar DIN rail. Terminals shall be supplied assembled on terminal rails.

Each terminal row shall be headed by an identifying label, which will be affixed to a rail mounted label carrier. Terminals shall be labelled on both sides as indicated in the Requisition document.

10.3 Identification

The junction boxes shall be provided with two black engraved, white laminated plastic (Gravoply or similar) labels per junction box, marked in accordance with the junction box schedule. One label shall be affixed to the junction box lid and the other shall be affixed inside the junction box, such that the correct lids may be replaced when removed from the boxes. Fixture of the labels shall be by a method which does not impair the IP rating of the box, whilst ensuring that the labels do not fall off under environmental conditions. Double sided tape shall NOT be used.

10.4 Certification and Traceability

All junction boxes shall be certified EEx(e) or EEx(d) in compliance with IEC-60079 for use in Class-1,Division-1,Group IIB, T3 hazardous areas. Those for intrinsically safe circuits need only have component certification for the enclosure.

D3
D3

All junction boxes shall be supplied with an approved certificate and certification label. Intrinsically safe junction boxes shall have the EEx(e) label removed and be supplied with a light-blue “Intrinsically Safe” label only.

10.5 Protection

All Junction Boxes shall be suitable for use in the environmental conditions stated in the Section 3. The VENDOR shall confirm that all fittings used conform.

All junction Boxes shall have a rating of IP 65 minimum when fitted with cable glands having Integral Entry Thread Seal (CMP Type RP2K or equivalent) as defined by IEC-60529.

10.6 Junction Box Types

ITEM

Size

No of Terminals

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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1

225 x 250 x 120D

2x25

2

510H x 372W x 120D

2x50

3

780H x 510W x 155D

2x90

11

TECHNICAL REQUIREMENTS FOR CABLE GLANDS

11.1

General

All cable glands shall be type E1X dual certified (EExd/EExe) glands for armoured cables as defined by BS 6121-1.

The E1X gland shall also include a deluge seal on the armour, fully inspectable armour clamping and Integral Entry Thread Seal.

Shrouds shall not be used with deluge seal glands.

All glands, adapters and plugs shall be manufactured from nickel plated brass.

All cable glands shall be provided complete with back nuts, serrated washers, in addition those glands without adaptors shall have earth tags provided.

Thread form shall be ISO metric.

Cable armour type Galvanized Wire Braid.

IP Rating shall be IP-65 Minimum

11.2

Cable Gland Types

Where the armour is to be insulated from earth the glands are to be complete with an insulating adapter.

ITEM

SIZE

DESCRIPTION

TYPE

Gland

20S

EEx’d/e’ cable gland

E1X

Gland

20

EEx’d/e’ cable gland

E1X

Gland

25

EEx’d/e’ cable gland

E1X

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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Gland

32

EEx’d/e’ cable gland

E1X

Gland

40

EEx’d/e’ cable gland

E1X

12 PAINTING

Vendor shall follow project painting specification RSH-00-MW-SP-0003 and shall highlight the deviation in his quotation (if any) for review and approval.

13 INSPECTION AND TESTING

VENDOR to confirm in the quotation that the workshop contains all facilities required to perform the necessary shop tests.

It is a prior requirement to any final inspection that the drawings be certified / approved by EPCI CONTRACTOR / COMPANY / Certifying Authority where appropriate.

VENDOR shall complete all required internal shop tests for all equipment and provide all test reports, final inspection certificates, etc, to EPCI CONTRACTOR for review / approval prior to commencement of witness testing.

VENDOR shall notify the EPCI CONTRACTOR at least ten (10) calendar days in advance of each scheduled inspection, and as required COMPANY's Representative.

VENDOR shall provide adequate facilities for EPCI CONTRACTOR inspector, to verify bulk materials for compliance with the specification / data sheet included with the material requisition.

Any rejection made by the inspector, based on inspection or test, will be final; however the inspection shall in no way release the VENDOR from guarantees as to materials, apparatus, workmanship and performance.

The cost of rectification and replacement of defective equipment shall be borne by VENDOR.

Acceptance of shop tests shall not constitute a waiver of requirements to meet field test requirements.

The equipment shall not be despatched by the VENDOR until it is released by EPCI CONTRACTOR.

RESHADAT RENOVATION AND DEVELOPMENT PROJECT Irani an O ffsh ore O il Com pany

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Irani an O ffsh ore O il Com pany

Iranian Offshore Oil Company

C2-T: Topside & Bridges Contract No. : 3688-85-2FG

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Document Number

 

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All bulk materials shall be subjected to physical and dimensional checks for conformity with the specification.

The material test certificates, internal shop test reports etc. shall be verified during inspection.

14 SPARES

The VENDOR shall provide with his quotation, separate price lists of recommended commissioning and operating spares in accordance with the forms supplied with the material specification.

15 TOOLS

The VENDOR shall submit, with his quotation, his recommendations for one set of special tools required for installation and maintenance of the supplied equipment.

16 GUARANTEE

VENDOR shall warrant that all materials are fit for purpose and fully compliant with specification requirements.