SPECIFICATION PREFACE SHEET

DEPARTMENT: Engineering / Electrical SHEET 1 OF 13

AREA: Norðurál Grundartangi Reduction Plant SPEC No: 00/07/TS010 REV: C2

STANDARD TECHNICAL
SPECIFICATION
FOR
INSTRUMENTATION

INSTALLATION COMMISSIONING

This Standard Technical Specification is subject to change without prior notice. The
most current issue will at all times be located on the Nordural web site,
www.nordural.is

REV BY DATE CHK’D APPROVED REVISIONS

C1 HRY 01/03/1999 GP TMS Issued for Construction
C2 IMJ 19.4.2004 TDS ÓJ Issued for Construction

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 STANDARD TECHNICAL SPECIFICATION
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NORDIC ALUMINUM

CONTENTS
SPECIFICATION PREFACE SHEET _________________________________________ 1
TECHNICAL SPECIFICATION ______________________________________________ 3
1.0 INTRODUCTION ________________________________________________________ 3
2.0 SCOPE__________________________________________________________________ 3
3.0 STANDARDS AND CODES OF PRACTICE __________________________________ 3
40 INSTRUMENT INSTALLATION ___________________________________________ 4
5.0 INSTRUMENT AND CONTROL PANELS ___________________________________ 4
6.0 PLC AND SCADA SYSTEMS ______________________________________________ 5
7.0 INSPECTION AND TESTING______________________________________________ 5
8.0 PRECOMMISSIONING ___________________________________________________ 7
9.0 COMMISSIONING _______________________________________________________ 7
APPENDICES____________________________________________________________ 8

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TECHNICAL SPECIFICATION

1.0 INTRODUCTION

This Specification is issued to give general guidelines and to outline basic requirements
to contractors to cover the testing and pre-commissioning of instrumentation and control
systems. It is intended to ensure that the equipment installed is as specified by the
design and that installation materials are of specified type and quality correctly installed
and in all respects suitable for commissioning to the Engineer's requirements.

In this Document the following words and expressions shall have the meaning
hereby assigned to them except where the context otherwise requires:
Engineer: The Owner or any person or organization employed or engaged at
any time by the Owner and authorized by the Owner, in writing, from time to
time to act on behalf of the Owner in the execution of the items covered by this
Document, in whole or in any part, for any or all purposes provided in this
Technical Specification.
Owner: Norðurál hf (Nordic Aluminum Corporation Ltd.), an independent legal
entity owned by Century Aluminum.

2.0 SCOPE

This procedure together with its appendices covers the scope of work, inspection and
testing of all instrument equipment from arrival on site up to and including pre-
commissioning.

3.0 STANDARDS AND CODES OF PRACTICE

In addition to the requirements of this specification the installation shall comply with:

Icelandic Government Electrical Codes and Regulations no:264/1971

Icelandic Government Health and Safety at Work Act no:46/1980

BS6739 : 1986 - Instrumentation in process control systems -installation

design and practice.
IEC 61508 Functional safety of electrical / electronic / programmable
electronic Systems.

Norðurál Standard Technical Specifications as applicable

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40 INSTRUMENT INSTALLATION

The installation of all sensors shall conform to good measuring practice so that a truly
representative signal of the variable is obtained. They must be installed according to
European EN Standards. Equipment shall be positioned to permit easy access for
visual inspection and maintenance but shall be protected from damage by personnel or
passing or falling objects. The equipment shall not be bracketed directly from pipework
or handrails. Care shall be taken to ensure equipment is not damaged or obstructed by
subsequent lagging/steelwork etc.

Provision shall be made for the adequate isolation of impulse lines and for the removal
of sensors for repair or calibration.

Equipment shall in all cases be installed with due regard for the safety of personnel.

5.0 INSTRUMENT AND CONTROL PANELS

When instrument/control panels arrive at site they will normally be prefabricated and
prewired. The Contractor will be responsible for lifting such panels and it shall be the
contractor's responsibility to ensure the panel is correctly positioned and bolted down in
accordance with his requirements.

The Instrument Installation/Commissioning Contractor shall make the following checks.

A proportion of these checks shall be repeated in the presence of the Engineer.

A general visual check for damage, deformation and quality of construction.

A dimensional and detailed physical check to ensure that all dimensions are
correct against specifications and drawings.

Earthing arrangement checks shall be made to ensure they are to Norðurál

requirements and that earth conductors have continuity and are adequately
rated.

Checks shall be made to ensure that gland plates are of a size sufficient to
accommodate all cabling and piping and that any internal trunking is of sufficient
size to accommodate any field wiring.

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Warning and general labels shall be checked to see if the descriptions are
correct and these are sufficient.

A function and calibration check shall be carried out on each instrument. Where
necessary the equipment shall be recalibrated.

All test equipment used shall be certified and certificates made available to
illustrate compliance.

6.0 PLC AND SCADA SYSTEMS

Microprocessor based control systems are not covered by this procedure except in so
far as the tests detailed can be applied to components of a system.

On site check-out and pre-commissioning would usually be carried out by specialist

personnel from the equipment vendor or alternatively by reference to the manufacturer's
specific instructions.

Nevertheless, the basic requirement remains that every input and output signal must be
checked through from its field initiation point to control room display unit or vice versa.
All control functions must be checked for operability in accordance with the
manufacturer's stated performance characteristics.

All checks must be recorded on loop test sheets and the forms as attached may be used
as applicable.

All test methods must be agreed with the Engineer.

7.0 INSPECTION AND TESTING

Visual checks shall be made on all primary element installations and impulse piping to
ensure equipment has been installed in accordance with specifications and drawings.
Primary elements and their impulse lines shall be examined for correct location to meet
standard flow metering codes and tank zero datum for contents.

The orientation and access to all sensors shall be inspected to verify correct location in
the plant and serviceability of installation.

Isolation provided shall be checked together with slope on impulse lines i.e. at least 1 in
12.

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Field mounted transmitters shall be check calibrated to ensure they agree with
calibration/functional test certificates, where necessary they shall be re-calibrated.

A detailed physical check shall be made against specifications and drawings.

Tagging/labels shall be inspected.

An inspection shall be made of all junction boxes, earthing checks performed, cabling
arrangements inspected for neatness and accessibility.

A check shall be made that internal connections are as per drawing and are satisfactory.

Location of labels to drawings shall be checked.

All cabling and piping shall be inspected against specification and drawings. Wiring
shall be checked for correct materials, correct identification and physical installation
ensuring that kinks and strains have been avoided. Piping shall be inspected likewise.

All fittings and connections shall be inspected for correct installation and possible
absence or misapplication of sealing compounds.

A check shall be made to ensure that signal cabling is adequately segregated from
power cabling. Cable tray, trunking and brackets shall be inspected for firm fixing, no
sharp edges, protection of cut edges and acceptable routing.

Glanding and terminations shall be examined to ensure correctness of same and correct
termination of conductors, screen or shield. All connections shall be inspected for
security.

Insulation and continuity tests shall be carried out core to core for insulation value and
continuity. Testing shall be carried out with approved equipment and before final
connection to electronic equipment.

Pressure tests shall be carried out on all pipework with suitable isolation to protect
connected equipment. For lines containing pressure above 2 bars the pressure tests
decay shall not exceed 66 millibar (1 lb/ins2) in 10 minutes. For lines containing less
than 2 bar, pressure slightly above the maximum to be encountered on normal service
shall be applied through a bubble flow indicator. The bubble rate shall not exceed one
bubble in 10 seconds. After pressure testing, test gauges and equipment shall be
disconnected, connections remade and tested with soap solution when under service
pressure.

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 STANDARD TECHNICAL SPECIFICATION
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Power supplies, electric and pneumatic shall be inspected to ensure installed supplies
are to specification and the drawings are suitable for supplied equipment. Earthing
facilities as well as fusing/circuit breaker values shall be as required.

Control valves and actuators shall be inspected to ascertain correct installation in

process pipework, accessibility, serviceability and correct flow direction.

A check against specification for type and accessories shall be made to ensure they are
correctly assembled and calibrated. Control valves shall be stroked to verify they
operate correctly over the full range, if incorrect they shall be adjusted accordingly.
Wherever possible they shall be check-calibrated in the contractor's workshop.

Generally all instruments shall be inspected, checked and calibrated/function tested

before installation.

8.0 PRECOMMISSIONING

Loop testing shall be carried out to prove the installed instrument system functions
correctly. In general each complete instrument loop shall be tested as a system, where
necessary adjustments shall be made to the calibration. Associated alarms and trips
shall be checked during loop testing.

As part of loop testing various parameters of the panel mounted instruments may
require configuring. This shall be carried out utilising an acceptable configurator.

When loop testing is complete and 'signed off' by the Engineer the complete system
may be considered suitable for hot commissioning.

9.0 COMMISSIONING

Following pre-commissioning and at a time agreed with the Engineer the Contractor
shall have an instrument commissioning engineer available to assist in plant
commissioning.

Test certificates shall be issued to illustrate that complete testing has been completed.
Certificates shall take the form of certificates as illustrated in Appendix A.

The contractor shall provide these sheets or his own equivalent to the Engineer before
testing for client verification.

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The certificates must highlight test equipment used with its manufacturer's name, model
number, serial number, test certificate number and issue date as a minimum.

APPENDIX A

Alarm System Check Sheet

Instrument Pre-Installation Calibration Sheet
Calibration Check Sheet
Instrument Loop Check Sheet

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NORDIC ALUMINUM

NORÐURÁL hf ALARM SYSTEM CHECK SHEET

PROJECT TITLE: PACKAGE TITLE
AREA: PACKAGE No:

TAG No: LOCATION:

ANNANCIATOR TYPE SIZE SERIAL No

MANUFACTURER ORDER No SPEC.No

GENERAL CHECK GENERAL CONDITION SATISFACTORY AUDIABLE ALARM OPERATES

ENGRAVING CORRECT TO SPEC ACK & TEST BUTTONS OPERATE
ELECT. SUPPLY SETTING CORRECT ____________________________
ALARM SEQUENCE CORRECT ____________________________
ALARM LOOP CHECK
ALARM ACTUATOR CHECK
POINT ALARM
TAG ALARM OPERATION INSTALLATION ALARM OPERATION
No No DESCRIPTION
No SETTING CORRECT CORRECT CORRECT

REMARKS

TEST EQUIPMENT USED MANUFACTURER MODEL SERIAL No CERTIFICATE No DATE

CHECKED BY DATE WITNESSED BY DATE

ACCEPTED BY FOR DATE

ALARM SYSTEM No

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GRUNDARTANGI REDUCTION PLANT

INSTRUMENT PRE INSTALLATION,

NORÐURÁL hf CALIBRATION SHEET
PROJECT TITLE: PACKAGE TITLE
AREA: PACKAGE No:

TAG No: LOCATION:

TYPE SIZE SERIAL No
MANUFACTURER ORDER No SPEC.No
SIGNAL RANGE DIAL/CHART RANGE
PHYSICAL CHECK PROCESS CONNECTION CORRECT PNEU/ELECT. CONN.CORRECT
BODY MATERIAL CORRECT RANGE/SPAN CORRECT
ELECT. SUPPLY SETTING CORRECT AIR SUPPLY CORRECT
GENERAL CONDITION SATISFACTORY ANCILLARY EQUIPMENT SUPPLIED
SHIPPING STOPS REMOVED ____________________________

CALIBRATION CHECK
INPUT READING OR OUTPUT

RISING FALLING
% SPAN ACTUAL
ACTUAL % SPAN ERROR % ACTUAL % SPAN ERROR %

25

75

100
MANUFACTURERS QUOTED ACCURACY %
CONTROLLER CHECK
CONTROL MODE: PROPORTIONAL INTEGRAL DERIVATIVE
ON/OFF DIFF. GAP
CONTROLLER ALIGNMENT CORRECT AUTO/MANUAL CORR.
CONTROL ACTION DIRECT REVERSE

SETTINGS ALARM SETTING TIME DELAY SETTING

LIMIT SWITCH SETTING –HIGH LIMIT SWITCH SETTING –LOW
OUTPUT LIMIT SETTING.-HIGH OUTPUT LIMIT SETTING.-LOW
DIFF. GAP %

CORRECTIONS AUTOMATIC TEMERATURE CORRECTION RANGE

S.G. DENSITY CORRECTION SETTING
ZERO ELEVATION/SUPPRESSION SETTING
THERMO COUPLE BURN OUT DRIVES UPSCALE DOWNSCALE
SHIPPING STOPS REFITTED
ANCILLARY EQUIPMENT LIST

REMARKS

TEST EQUIPMENT USED MANUFACTURER MODEL SERIAL No CERTIFICATE No DATE

CHECKED BY DATE WITNESSED BY DATE

ACCEPTED BY FOR DATE

INSTRUMENT TAG No

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GRUNDARTANGI REDUCTION PLANT

INSTRUMENT IN SITU,
NORÐURÁL hf CALIBRATION CECK SHEET
PROJECT TITLE: PACKAGE TITLE
AREA: PACKAGE No:

TAG No RANGE CHECKED WITNESSED DATE TAG No RANGE CHECKED WITNESSED DATE

TEST EQUIPMENT USED MANUFACTURER MODEL SERIAL No CERTIFICATE No DATE

CHECK SHEET No

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GRUNDARTANGI REDUCTION PLANT

NORÐURÁL hf INSTRUMENT LOOP CHECK SHEET

PROJECT TITLE: PACKAGE TITLE
AREA: PACKAGE No:

LOOP No: LOCATION:

SYSTEM No LINE No EQUIPMENT No

MECHANICAL/ELECTRICAL CHECKS
MEASURING ELEMENT: INSTALLATION CORRECT LOCATION CORRECT
ISOLATING VALVES CORRECT MATERIALS CORRECT
TAPPING(S) POSITION CORRECT ORIFICE DIAMETER
IMPULSE CONNECTIONS:
CORRECT TO HOOK UP MATERIALS CORRECT
PRESSURE TESTED TEST PRESSURE
CONNECTIONS: TRACED LAGGED

FIELD INSTRUMENTS
INSTALLATION CORRECT AIR SUPPLY CORRECT
WEATHER PROTECTED POWER SUPPLY CORRECT
PANEL INSTRUMENTS
INSTALLATION CORRECT AIR SUPPLY CORRECT
SCALE/CHART CORRECT POWER SUPPLY CORRECT
CONTROL VALVES
INSTALLATION AND LOCATION CORRECT SIZE AND TYPE CORRECT
STROKE TESTED POSITIONER CHECKED
LIMIT SWITCHES SET I./P. TRANSDUCER CHECKED
AIR SUPPLIES
CONNECTIONS CORRECT TO DRAWINGS BLOWN CLEAR AND LEAK TESTED
TRANSMISSION
PNEU. LINES INSPECTED, BLOWN CLEAR & LEAK TESTED
ELECT. INSULATION CHEKED-CORE TO CORE CORES TO EARTH
CONTINUITY CHEKED LOOP IMPEDANCE CHECKED
EARTH BONDING CHECKED ZENER BARRIERS CORRECT
TEMPERATURE LOOPS
T/C OR R/B CHECKED CABLE TO SECIFICATIONS
CONTINUITY CHECKED LOOP IMPEDANCE CHECKED
GENERAL
SUPPORTS CHECKED TAGGING CORRECT
CHECKED BY: DATE WITNESSED BY DATE

LOOP TEST
TRANSMITTER INPUT TRANSMITTER OUTPUT LOCAL INST. READING PANEL INST. READING

MEASUREMENT

CONTROLLER OUTPUT TRANSDUCER OUTPUT VALVE POSITION O/P CONTROL VALVE POS.

CONTROL

TEST EQUIPMENT USED MANUFACTURER MODEL SERIAL No CERTIFICATE No DATE

CHECKED BY DATE WITNESSED BY DATE

ACCEPTED BY FOR DATE

INSTRUMENT TAG No

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GRUNDARTANGI REDUCTION PLANT

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