DOC. NO.

BPK-PROC-IC-001
INSTRUMENT
PT. BAHARU PAGE 1 OF 24
CONSTRUCTION
PENTA KENCANA REV. 0A
PROCEDURE

DOC. TITLE : INSTRUMENT CONSTRUCTION PROCEDURE

CLIENT : PT. GRESIK POWER INDONESIA

CONTRACTOR : PT. BAHARU PENTA KENCANA

PROJECT TITLE : SUPERHEATER PROJECT

LOCATION : GRESIK, JAWA TIMUR

NO DATE PAGE DESCRIPTION PREP'D CHK'D APP'D

0 February 11, 2010 ALL Issued for Bid

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CONTENTS

Section page

1. GENERAL................................................................................................................................ 4

2. CHECKING AND CONFIRMATION PRIOR TO WORK........................................................4

3. INSTRUMENT PANEL INSTALLATION.................................................................................4

3.1. Handling of Instrument Panel................................................................................................. 4

3.1.1. Attention to be paid prior to transportation............................................................................4

1.1.1. Handling of Packing in the Interior of Building and unpacking.............................................5

1.2. Channel Base Installation....................................................................................................... 6

1.2.1. Precaution Prior to Installation...............................................................................................6

1.2.2. Installation of Channel Base................................................................................................... 7

1.2.3. To Realize Horizontal.............................................................................................................. 7

1.2.4. Channel Base Fixing............................................................................................................... 7

1.3. Instrument Panel Installation.................................................................................................. 8

1.3.1. Precautions Prior to Installation............................................................................................. 8

1.3.2. Installation of Instrument Panel..............................................................................................8

1.3.3. Cautions after Installation....................................................................................................... 8

4. FIELD INSTRUMENT.............................................................................................................. 8

4.1. Mounting in General................................................................................................................ 8

4.1.1. Handling of Instrument............................................................................................................ 8

4.1.2. Selection of Instrument Location............................................................................................ 8

4.2. Field Instrument Stanchion Mounting.....................................................................................8

4.3. Junction Box Mounting............................................................................................................ 9

5. INSTRUMENT TUBING........................................................................................................ 11

5.1. Scope of Work....................................................................................................................... 11

5.2. Pressure Lead Tubing........................................................................................................... 11

5.2.1. Tubing Materials.................................................................................................................... 11

5.2.2. Tubing.................................................................................................................................... 11

5.2.3. Tubing Support...................................................................................................................... 11

5.2.4. Impulse Line Tubing.............................................................................................................. 12

5.2.5. A Single-core Copper Tubing............................................................................................... 12

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5.2.6. Supporting of a single Core Copper Tubing........................................................................13

5.2.7. Connecting of Copper Tubes................................................................................................ 14

5.3. Testing and Inspection of Tubing.........................................................................................15

5.4. End Treatment of Copper Tube............................................................................................16

6. CABLE LADDER INSTALLATION........................................................................................16

6.1. Cable Ladder Installation in General....................................................................................16

6.2. Cable Ladder......................................................................................................................... 16

6.3. Cable Ladder Route Selection.............................................................................................. 17

6.4. Supporting and Fixing........................................................................................................... 17

6.4.1. Supporting Method................................................................................................................ 17

6.4.2. Cable Ladder Supporting...................................................................................................... 18

6.4.3. Cable Ladder Branching....................................................................................................... 19

7. WIRING.................................................................................................................................. 20

8. CABLE INSTALLATION AND CABLE CONNECTIONS.....................................................21

8.1. Cable Installation in tray....................................................................................................... 21

8.2. Cable Connection in Junction Box.......................................................................................21

8.3. Cable Connection with Temperature Instrument.................................................................21

8.4. Cable Connection with Each Instrument..............................................................................22

8.5. Shielded Cable Grounding.................................................................................................... 22

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1. GENERAL

1.1 This specification covers the requirements and the execution procedure for the electrical

work in Superheater Project, PT. Gresik Power Indonesia.

1.2 This specification is intended to supplement the construction drawings and to serve as a

construction guide for activities not detailed on the drawings.

1.3 Details not specified herein shall conform to the individual specifications and or electrical

construction drawings, and instructions given by MAIN CONTRACTOR’s engineer.

1.4 Should any conflicts occur between this specification and any individual specification,

drawing or instruction given by MAIN CONTRACTOR, clarification is required.

2. CHECKING AND CONFIRMATION PRIOR TO WORK

The following checks and confirmation shall be made prior to starting the work.

2.1 Confirm documents (project specifications, working drawings, manufacturer’s drawings,

work specifications, etc.) required for executing the construction work.

2.2 Confirm whether the work schedules have been prepared.

2.3 Confirm whether equipment and material that will be used meet with the relevant

specifications.

2.4 Confirm the organization required for carrying out the construction work

2.5 Confirm safety and security regulations (concerning work permit, safety training, etc.)

3. INSTRUMENT PANEL INSTALLATION

3.1. Handling of Instrument Panel

3.1.1. Attention to be paid prior to transportation

a. All person in charge shall be versed in division of work for receiving instrument
panel and necessary consultation be made with material controller and worker

about the date of delivery.

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b. Road conditions shall thoroughly be investigated for transportation of instrument

panel by vehicle. Where road is soft, remedial action shall be taken by the material

controller and persons in charge.

c. Check dimensions of entrance and floor conditions on which instrument panel is

located. All persons in charge shall be notified of the details conditions in advance.

d. Material controller shall arrange necessary equipment for unloading.

Weight of Instrument Panel by Rough Estimate (Reference)

Dimension Net Weight/ Gross Weight/lm W (kg.)

(2100mm High) Lm W. (kg.) Panel incl. Instruments

Self-Standing Open
250 300
Type (800Wx800Dx2100H)

Self-Standing Open

Type 250 300

(1200Wx250Dx1500H)

PC Desk
90 150
(900Wx800Dx700H)

Aux. Console
270 320
(800Wx800Dx1600H)

Note: The above table may differ largely depending on type of packing and crating,

where wooden frame is used, and approximately 50 kg to be above weight.

In principle, instrument panel shall be lifted as package by using a wire rope.

Since the frame shows the portions to be lifted, the wire rope shall be used in

accordance with the markings. Where there is no marking on the frame,

experienced persons shall lift the packing after checking the packaging.

In case of expert packaging, refer to packaging list for weight.

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1.1.1. Handling of Packing in the Interior of Building and unpacking

a. Before packing is delivered into control room, arrange rollers and boards on which
the packing is transferred, and pulling of the packing shall be carried out slowly to

avoid vibration and shock to instrument panel.

Where rollers are applied beneath the packing, it shall be lifted with a craw bar and

the like. Care shall be taken to bring the packing down very gently.

b. For unpacking, it shall be located at innermost part of the room and be lined up in
front of a channel base which is previously installed on the floor. Leave adequate

space between packing and others.

c. In principle, wooden crating shall be cut open with a saw for protecting an installed
instrument from shock. They will be shock-damage if opened with a craw bar and the

like

Schematic diagram as shown below illustrates procedure for opening the wooden

crating.

Figure: 2.

Note: Upper portion and front are sawed off as shown in figure 1, and then both sides

and the back are sawed off from the bottom part, and the remove the wooden

crating as illustrated in figure 2.

For unpacking, instructions by manufacturer or vendor shall be followed.

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1.2. Channel Base Installation

1.2.1. Precaution Prior to Installation

a. Supervisor shall arrange to deliver a channel base at least two (2) days prior to the
delivery of instrument panel. The date of delivery shall be arranged among

persons in charge.

b. The place of installation of channel base shall thoroughly be cleaned, and the floor
surface to place liners on shall be made thoroughly smooth.

c. Location of channel base shall be identified with reference to the drawing, and
marked with close reference to alignments level and anchor bolt positions.

1.2.2. Installation of Channel Base

a. Channel base shall be installed at the previously set location, then liners be
applied between channel base and floor to realize horizontally. The liners shall be

finished as smooth as possible on either side and more then three (3) liners shall

not be applied in pile.

b. Liners shall be applied as close as possible to the anchor bolt.

c. Liner and channel base front shall be to flush-installed.

1.2.3. To Realize Horizontal

a. Horizontal channel base shall be realized by applying liners before installing the
channel base. Overall horizontally shall be measured by a spirit level of 60 cm

long and over.

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b. Horizontal must be avoided from prodigious labor for rectifying unevenness.

1.2.4. Channel Base Fixing

a. When horizontally is realized, the liners shall be spot-welded with channel base for
fixing.

b. In principle, anchor bolts shall be applied and be tightly fixed.

c. Where no room for anchor bolt hole is available, hole-in-anchors of M12 shall be
applied.

1.3. Instrument Panel Installation

1.3.1. Precautions Prior to Installation

a. Check the channel base alignment.

b. While measuring horizontally of channel base, check the cured condition of anchor
bolts. Adjust horizontally with application of liners to get the tolerance of 1/500 and

less.

1.3.2. Installation of Instrument Panel

a. To minimize error in arrangement, place instrument panels from the centre of the
channel base, instead of from the end, before fixing with bolts. Dimensional errors

will be greatest at the channel base end, if installation starts at the end of channel

base.

b. After proper alignment, fix instrument panels with bolts exclusively provided.
1.3.3. Cautions after Installation

a. Clean up unnecessary material and free dust inside panel.

4. FIELD INSTRUMENT

4.1. Mounting in General

4.1.1. Handling of Instrument

a. When transferring instrument from warehouse to the place of mounting, extreme

care shall be taken not to give shock to the instrument.

b. When instrument is loaded on board without protection, protecting measure shall

be taken to protect the instrument from damage.

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4.1.2. Selection of Instrument Location

a. The instrument shall be installed in existing location.

4.2. Field Instrument Stanchion Mounting

2.2.1 In principle, instrument shall be mounted with stanchion made of 2” SGP. Process
requirements sometimes allow integral mounting. For proper selection of the type

of stanchion shall be in accordance with the class of instrument.

2.2.2 In principle instrument shall be mounted in vibration free area and may require
foundation for its stanchion.

2.2.3 Where stanchion is fixed on the concrete floor or concrete pillar, hole-in-Anchor
shall be applied instead of Drive-it. Otherwise, anchor bolts shall be applied in the

concrete.

2.2.4 Where stanchion is fixed on the metal floor, carry out the work in accordance with
the following schematic diagram with particular care to realize horizontally.

2.2.5 For mounting instruments such as local pressure gauge with contact and
temperature indicator equipped with capillary tube not specified in the drawing,

stanchions may be mounted by applying adequate supporting metal fixture.

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Note: Mounting method depends on the location.

4.3. Junction Box Mounting

In principle, junction box shall be mounted on structural steel, concrete, pillar, concrete wall,

etc. It shall not be mounted on concrete block wall.

a. Mounting on Structural Steel

b. Mounting on Concrete Pillar and Concrete Wall

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c. Mounting on Concrete Beam

5. INSTRUMENT TUBING

5.1. Scope of Work

Pressure lead tubing work by instruments installation in general shall be from take-off

existing point on process Tubing to instrument.

5.2. Pressure Lead Tubing

5.2.1. Tubing Materials

Materials, standard and pressure rating of pressure lead Tubing shall conform to Tubing

Specifications for Process Tubing.

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5.2.2. Tubing

a. Steel tube of ½” O.D. or tubes of 10 - 20 O.D. shall be used for pressure lead
tubing.

b. Tubing from detecting end to instruments shall be as short as possible.

c. Proper slope be designed for Tubing in accordance with hook-up Drawing.

d. Bending radius of pressure lead Tubing shall be 5 O.D. and above.

e. Tube cutting shall be made with tube cutter, high-speed tube cutter, etc. All tubes
shall be reamed after cutting and blown clean of burs and other foreign materials.

f. In case of differential pressure transmitters, make high and low-pressure tubes and
their lengths uniform for good outside appearance. They shall run the shortest

possible distance to minimized unnecessary bending.

5.2.3. Tubing Support

a. Support materials shall be steel of 40 x 40 angle steel x 5t or of 50 x 5t. Pressure

lead Tubing shall be fixed by clamp and nut, etc.

b. Metal supports shall be welded to steel structure and burs shall be removed, and
then be coated with corrosion resistant paint.

5.2.4. Impulse Line Tubing

a. For supporting multi-core copper tube, U-bolt shall not be used.

Bending radius of copper tube cable shall be over 5 O.D.

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5.2.5. A Single-core Copper Tubing

a. Since a single-core copper tube is smaller in size and not as harder as a steel
Tube, great care shall be taken for protection and support.

b. Single core copper tubing shall be installed in a Tube rack, structural steel, etc. 1
to 2 single core copper tubes shall be installed along shaped steel or the like.

Routing single core copper tubing shall be coordinated with each person in

charge.

c. Over 5 single core copper tubing shall be installed in a Cable Ladder. A single
core copper tubing consisting of 4 and less cores shall be installed in a Tubing

installed along angle steel or steel flat bar.

d. A single core copper tube shall be connected neither in Tube rack nor in Cable
Ladder.

e. A single core copper tubing branching-off shall not cross the other single core
copper tube.

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f. Single core copper tubing shall be installed in a location not subject to heat affect
by other facilities, and over zero degree C temperature.

5.2.6. Supporting of a single Core Copper Tubing

a. Tubing methods very depending on number of Tubing and location. The following
schematic diagrams show some examples.

b. Where single core tubing is branched off from a Cable Ladder, the shaped steel
shall not be welded to the Cable Ladder.

c. Intervals between metal fixtures for tube shall be less than 1.5 m.

d. Bending radius of copper tube shall be over 5 O.D.

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5.2.7. Connecting of Copper Tubes

a. In cutting a copper tube, use a Tube cutter. When hacksaw is used, more attention
shall be taken to prevent ingress of metal dust into copper tube, and cut section be

smoothed.

b. Vinyl sheath shall be removed by either a Tube cutter or a knife. No incision on

copper tube outside is allowed, which will produce breakage on copper tube.

c. For connection of junction box.

(1) Sealing tape shall be applied around screw threads of a half union, in
the opposite direction of the half unions screwing in.

(2) For branching of copper tube, T-union shall be applied.

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d. Half Union Screwing

(1) Half union shall not be screwed too tight.

(2) Final screwing shall be made to an extent that does not cause leakage.

5.3. Testing and Inspection of Tubing

5.3.1. Tubing shall be flushed for over 10 minutes with dry air from blow valve. Copper shall be

flushed for over 2 minutes after disconnecting a half union after each valve, and connect the

Tubing back after the flushing.

5.3.2. Air tightness test shall be made with pressured air. Each connection shall be leak checked

with soap water. In case leak, the sealing tape shall re-wound around threaded portion of

the Tube and gasket shall be replace where union is applied before re-screwing. If leak is

still found, the union itself shall be replaced.

a. For air supply, primary air pressure shall be applied up to the reducing valve.

b. Signal air tubing shall be function tested independently to associated instrument

being put in operation.

5.3.3. On completion of the work, continuity and air supply test shall be carried out. Air tightness

test shall be carried out by disconnecting each union while instrument is in operation, then

flushed for over 2 minutes, and then connect the union back in accordance with the hook up

Drawing. Air tightness test shall be carried out simultaneously in accordance with the above

procedure.

5.4. End Treatment of Copper Tube

Copper tube end is a very delicate part. Care shall be taken in the Tubing work. The

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following schematic diagram shows completed condition.

6. CABLE LADDER INSTALLATION

6.1. Cable Ladder Installation in General

In principle, aerial wiring shall be housed in a ladder for protection from mechanical

damage.

6.2. Cable Ladder

In Cable Laddering installation, the following criteria shall be followed unless specified

otherwise.

a. Total cross-sectional area of wiring and copper tubing including insulating

material shall be less than 20 % of the inner cross-sectional area of the Cable

Ladder.

b. Check if the Cable Ladder is perforated in accordance with the specifications.

c. Where elimination of mutual in Cable Ladder is required, Cable Ladder shall be

provided with a separator.

6.3. Cable Ladder Route Selection

a. Cable Ladder route shall be selected in the location not subject to heat affect.

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b. Cable Ladder route shall be selected in the location not subject to interference with
operation, maintenance, and servicing of systems.

c. Cable Ladder route shall facilitate simple maintenance and checking and shall have an
easy access.

6.4. Supporting and Fixing

6.4.1. Supporting Method

a. Main route shall be supported specified by construction drawing.

b. Cable Ladder supporting by means of bracket shall be carried out as illustrated below
on conditions at job-site.

(1) Mounting on Structural Steel

(2) Mounting on Concrete Pillar or Wall

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(3) Mounting beneath structural steel

c. Supporting of Cable Ladder shall made at 3 m intervals and less.

6.4.2. Cable Ladder Supporting

Cable Ladder shall be spot-welded to support and bracket not to cause swing or vibration

due to wind pressure, vibration, etc.

6.4.3. Cable Ladder Branching

a. When Cable Ladder is branched off, welded portion shall be smoothed by grinder
to protect electric cable or copper tube from damaged by the corner.

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b. Installation of separator at branching point shall be in accordance with the above

schematic diagram.

c. In case of vertically falling branch.

(1) Vertically rising or falling Cable Ladder shall be fabricated according to the

following schematic.

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Vertically rising or falling Cable Ladder straight section longer than 5 m shall be

provided with a metal fixture to hold a cleat in the Cable Ladder, the Cable Ladder

straight section longer than 10 m shall be provided with the same at every 10 m

intervals.

7. WIRING

Electrical wiring for measuring instrument and apparatus is broadly called instrument wiring,

which can be classified by electric current through electric wire and its function.

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8. CABLE INSTALLATION AND CABLE CONNECTIONS

8.1. Cable Installation in tray

a) Before installing cable in cable tray, make sure route of cable tray up to end of

point. Installation work shall be carried out slowly and carefully.

8.2. Cable Connection in Junction Box

a. In principle, cables shall enter and leave from the bottom of junction box.

b. Cable connection where lead wire is provided as in the case of junction box.

8.3. Cable Connection with Temperature Instrument

a. Thermocouple

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b. Resistance Bulb

8.4. Cable Connection with Each Instrument

For color coding, plus side cable shall be black, and minus side be white. Color coding for

multi-core cable shall be uniform in each junction box.

8.5. Shielded Cable Grounding

8.5.1. Among those cables which are widely applied for instruments installation consisting of

braided cable and tape shielded cable.

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8.5.2. After grounding cabling is connected to the end of shielding, wind insulating tape over the

connected part.

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