BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [racesorss | SPECIFICATION FOR INSTRUMENTATION JUNCTION BOX AND CABLE GLANDTABLE OF CONTENTS 1. GENERAL .. 1.1 Purpose.. 1.2 Definitions and Abbreviations 1.3 International Standards and Codes 1.4 Order of Precedence. 2. VENDOR'S QUALIFICATION & RESPONSIBILITY. 2.1 Vendor Qualification 2.2 Vendor Responsibility... 2.3 Field Proven. 2.4 Planning 3. ENVIRONMENTAL CONDITIONS 4, DESIGN REQUIREMENTS 4.1 General . 4.2 Construction. 4.3 Terminals . 4.4 Terminal Blocks 4.5 Earthing 4.6 Cable Glands 4.7 Nameplate and Labels 5. INSPECTION. . 6. PACKING .. 7. SPECIAL TOOLS AND SPARE PARTS. 8. DOCUMENTATION .. ‘9. APPENDIX JB NUMBERING.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [racesorss | 4. GENERAL 1.1 Purpose This specification details the basic minimum technical requirements of the instrumentation junction boxes and gland to be installed for the HALFAYA oil field development Project. The specification and related documents define the minimum requirements for instrumentation junction boxes and gland, scope of work, technical specifications, design, manufacture, test, supply and shipping and after sale service support. Any items or activities not included in this specification but which may be required to achieve a fully function will also be the responsibility of the vendor. ‘The documents and parameters necessary for instrumentation junction boxes and gland. design and manufacture shall be prepared by vendor and approved by Company. 1.2 Definitions and Abbreviations 1.2.4 Definitions WORD MEANING. COMPANY PetroChina Intemational Iraq FZE Iraq Branch “The organization selected and entrusted by COMPANY to perform the CONTRACTOR Engineering, Procurement, Construction, Startup, pre-Commissioning and Commissioning of the Project. “The party who is in charge of awarding agreement on behalf of PURCHASER COMPANY I CONTRACTOR for the supply of goods and services in ‘connection withthe work “The party to the contract andlor purchase order which has undertaken eee BAC TOR | the obligation to supply the goods andior services which are ordered and specified herein. Shall Indicates a mandatory requirement Indicates a strong recommendation to comply with the requirements of this document 1.2.2 Actonyms AC Alternating Current CPF Central Production Facilities cal Control and Instrumentation COR Central Control Room pc Direct Current bcs Distributed Control SystemEngineering Procurement Construction Emergency Shut Down Electro Magnetic Compatibility Factory Acceptance Test Fire and Gas system Field Surface Facilities Instrument Earthing Inputs/Outputs Intrinsic Safety Motor Control Centre Process Control System Piping and Instrumentation Diagram Programmable Logic Controller Resistance Temperature Detector Solenoid Operated Valve Stainless Steel Uninterruptible Power Supply system 1.2.3 Units ‘The UNITS shall be based on international standard of units (SI) except for temperatures which shall be in degrees Celsius instead of Kelvin, and for pipes and fittings threads which shall be in inches of NPT: Temperature Degrees Celsius ('C) Pressure (gauge) MPa (6) Pressure MPa (A) (absolute) Power Kilowatt (kW) Level/Length Meter (m), millimeter (mm) Size for Junction millimeter (mm) Box & Gland Weight (mass) Kilogram (kg), Metric Ton (t) also Ton 1.24 Standard Reference Conditions In the project, the standard reference conditions shall be as following: Absolute Pressure: 101.325kPa;BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [racesorss | Standard Temperature: 15.56°C. 1.3 International Standards and Codes ‘The instrumentation junction boxes and gland shall be compliant with the Laws and Regulations of Iraq and shall be designed, built, installed and tested in accordance with the Project Specifications and Requisitions and with the following Acts, Regulations, Standards, Recommendations, and Publications: ATEX 100a (98a) European directive 94/9/EC on the approximation of the laws of the Members states concerning equipment and protective systems intended for use in potentially explosive atmospheres. 137a(118a) | European directive 1999/92/EC on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres. Hew 60079 Code of Practice for the Selection, Installation and Maintenance of Electrical Apparatus for use in Potentially Explosive Atmospheres. 60529 Degrees of protection provided by enclosures (IP Code) 61000 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment API RP-552 Transmission Systems 1.4 Order of Precedence The following order of precedence for technical requirements shall apply; listed in decreasing ranking of precedence: > Project Specifications Project Philosophy Iraq laws, codes and regulations > International standards / Codes Where conflicts exist between this Specfication and any of the referenced Standards, Codes and Specifications, the most stringent shall be applied and Company's decision shall be final Any deviation from established Codes, Standards, Specifications and Requirements shall be duly notified by the Vendor in writing and approved by the Purchaser. Compliance with this Specification shall not relieve the Vendor of the responsi supply Systems and Equipment of correct design, materials, workmanship andBASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | reva_| PAGE 6 OF 13 performance suited to meet the specified services, conditions and regulations. Vendor shall verify stated requirements during bid. Elements, Equipment, Subsystem and ‘System shall conform in design, material, workmanship and performance, except where otherwise specified, with the current issue and amendments of the referenced Codes, Standards and Regulations prevailing on the effective date of the Contract 2. VENDOR'S QUALIFICATION & RESPONSIBILITY 2.1 Vendor Qualification Vendor shall have at least 5 years’ experience of similar engineering applications where the product has been in use. ‘Vendor shall provide user list included user name, site location, running time, and brief project summary in the bid 2.2 Vendor Responsibility Vendor shall be responsible for designing, material procurement, manufacture, assemble, supply, test, commission and training. Vendor shall also be responsible for drawing, Providing data and coordinating sub-vender, guaranteeing instrumentation junction boxes and gland to meet the requirement of standard and code. ‘Vendor is capable to provide service for site. 2.3 Field Proven Instrumentation junction boxes and gland to be provided will be from vendors who have supplied junction boxes of the same type for use on similar oilfield project in the last 5 years. The instrumentation junction boxes and gland will have a proven history of operation. 2.4 Planning Amnilestone schedule shall be set-up by Vendor and approved by PURCHASER before system execution. This schedule shall show all target dates for implementation. Any deviation to the established schedule must have the Company's approval. The Vendor shall report job progress in writing on a monthly basis. 3. ENVIRONMENTAL CONDITIONS All instrumentation junction boxes and gland shall be designed and supplied suitable for use in a hot, humid, dusty, desert environment and protected against wind, lightning, sand and stormy weather conditions. Altitude mASL 05-6 ‘Atmospheric Pressure kPa 102 Max. Temp. °C 55BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 a PAGE 7 OF 13 Black Bulb Temp. Min. Temp. = 2 Max. Speed Wind ms 40 Prevailing Direction Wind (Winter) NW-SE Prevailing Direction Wind (Summer) NW-SE Max. Relative Humidity 80% Min. Relative Humiaity 25% Rainfall W774 Soil Temp. @ Depth 1.2-1.6m 15 (in winter) Seismic Zone 28 Evaporation Rate 3054.4 4, DESIGN REQUIREMENTS 4.1 General General, junction boxes and their associated multi-pair cable shall be dedicated to one ‘System and one Signal Type: “System”: > D: PCS(DCSIPLC). > E:ESD. > FLFR. » P: Package Equipment Control System (UCP/LCP). “Signal Type": > A: Analogue. D: Digital P: 24VDC Power. PU: Pulse > Thermocouple > RTD Digital Input and Digital Output Junction boxes could be combined for DCS signals if the signals are same voltage level (such as MOV signals). While for SIS signals, such as SDV (SOV and ZSC/ZSO), the DO and DI is not allowed to be terminated in the same JB. And this is as per standard design practice and Operation & maintenance prospective. intrinsically safe circuits and non-intrinsically safe circuits shall not be marshalled in the same junction box.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | reva_| PAGE 8 OF 13 Signals of different voltage levels shall not be marshalled in the same junction box. Cables may enter junction boxes from the bottom or sides via cable glands. Cable entries shall be designed in such a way that no transmission of stress into the individual terminal shalll occur. 4.2 Construction Junction boxes shall be sized to suit their associated main multipair cable, with all cable entries from the bottom side. Branch cables entry shall be from side and bottom of junction box. Junction boxes shall be SS or cast aluminum alloy where available. Boxes shall be ‘weather proof and watertight. Covers shall be provided with gaskets. Junction box installation shall be within centerline of the box about 1200 mm above grade. Junction box Installation shall be at clear space where easily maintenance can be performed. Alljunction boxes shall be generally built in accordance with safety requirements EEx “d” and weather proof IP 65 in accordance with IEC 60079 and IEC 60529. Allljunction boxes and accessories shall be ATEX/IEC certified for Zone 2, Gas Class IIB, ‘Temperature Class T4, even for general service, i.e. also applicable for non-hazardous, areas. This is Vendor responsibility to provide suitable cable gland size as per selected cable size. Junction boxes shall be supplied and fitted complete with all necessary terminals and accessories such as bottom plate (when necessary for stiffening purpose), mounting rails, terminals, earth bars, earth stud, etc. ‘Terminals and accessories will make part of an approved manufacturer and assembly, Tegarding the specified service conditions. Junction boxes should be equipped with a hinged lid on front and shall be lockable with screws. The lid shall be linked to the enclosure by an earth cable (or braid) of 4/6 mm2. The interior color of junction boxes may be white to improve visibility. All junction boxes shall be earthed at fied. IS JB should be painted with Blue color {if existing), NON-IS JB should to be painted with gray color. All field instrument Tag and Cable Tag information should be in Junction box ferrule details. 43 Terminals Terminal widths shall be 8 mm for signais and power supplies and solenoid valves except otherwise specified in the junction boxes list. All terminals shall be screw-in terminals clamp type where the screw is not in direct contact with the wire and suitable for size 2.5 mm2 (or otherwise as specified).BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | reva_| PAGE 9 OF 13 The terminals shall be of rail mounted clip-in type construction, material shall be high- grade track-resistant melamine. Terminal blocks should be Weidmuller make or equivalent. Cross connection to assure screen continuity through the terminal block shall be done with screen lugs provided by vendor. The terminal ends shall be provided with end plates. Cross connection block shall be provided by vendor. The number of terminals in each box shall be sufficient to terminate all signal wire (including spares). Terminals in the junction boxes shall be numbered consecutively from 1 to N. At least 20% spare terminals shall be provided. 4.4 Terminal Blocks For Junction Boxes where a high number of terminations are required additional terminal blocks can be provided. All terminal blocks shall be clearly identified and labeled. 4.5 Earthing All power supply junction boxes shall be equipped with ground bus typically 6 mm thick and 25 mm to 40 mm wide and constructed of copper material and an earth stud with a minimum diameter of 10 mm. Junction Box will be filled with additional earth terminal. Earth terminals shall be supplied with their respective washers and nuts. Accidental shorting or grounding of shield within a terminal box must be avoided, by insulating both the shield end and the shield drain wire between the end of the cable jacket and the terminal strip or the earth lug. 4.8 Cable Glands Cable glands shall be sized to suit their associated multipair cable. Glands to be arranged in not more than two rows for ease of cable installation. Explosion-proof plugs should be provided by vendor. Cable glands shall suit the diameter of the cable. Nickel plated brass glands or SS glands shall be specified Cable gland shall be equipped with earthing ring and relative bolts, nuts and lugs. Cable glands shall be with certification EEx'd'/IP65 and shall comply with IEC 60079, ‘They shall be temperature classified as T4 and suitable for gas class II B. ‘They shall be removable / reconnectable without degrading the tightness. The following general requirements are applicable to all gland installations: > Weather proofing ring on inner sheath. > Clamping and earthing of armour. > Sealing ring of outer jacket. All gland installations shall maintain the IP65 rating of the associated equipment. Gland threads shall be in inches of NPT. Use of thread adaptors may be minimizedBASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | reva_| PAGE 10 OF 13 All cable glands in the field shall be protected, using shrouds and seals. Shrouds shall be zero halogen, oil resistant and flame resistant. VENDOR shall take into account the cable characteristics to size the stuffing boxes and their relevant packing. Seals, insert and rings material should be neoprene as min. For alll cable glands, a locknut inside the terminal box is required to ensure at least 5 engaged threads for mechanical strength. Unused cable entries shall be equipped with plugs according to classification and protection class of the junction box. 4.7 Nameplate and Labels Each junction box shall be allocated a number. All these numbers shall be shown on the detailed drawings and shall be marked in a Stainless Steel nameplate on the junction boxes. Junction boxes shall have a stainless steel manufacturer nameplate which shall contain at Ieast, when applicable: > Manufacturer name, Manufacturer mode! number. Manufacturer serial number. Electrical classification EEx ‘d” as appropriate 5. INSPECTION Inspection and acceptance test shall be carried out by the VENDOR on the Junction Boxes and Gland and its accessories included in VENDOR’ scope of supply at the applicable manufacturer's works and as required as per applicable specifications, codes and standards. ‘The VENDOR shall provide with his proposal a Quality Control Plan including all inspections and control actions to be approved by the PURCHASER prior to start of manufacturer. Unless otherwise specified by the requisition, the following tests shall be carried out as minimum: > Visual inspection ‘Supply compliance Check of correct installation of components and accessories. Check of cable entries. Check of mounting arrangement. Check of name plates, numbering of each junction boxes.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [race sora | Check of earthing arrangement. Dimensional check > Check of certifications » Material certificates > Mechanical Construction certificates. > Electrical Construction Certificate. Junction boxes and gland will be subject to PURCHASER representative during fabrication, testing and before shipment. Throughout the duration of junction boxes and gland fabrication, PURCHASER representative shall have free access to all parts of the shop where fabrication is in progress. ‘The VENDOR will aid th e inspector with the reasonably necessary appliances to verify that the junction boxes and gland and their components are in full compliance with the contractual documents. ‘The VENDOR's assistance to perform the required inspections and tests shall be also at \VENDOR's cost. Inspections and drawings approved by PURCHASER and/or his agent will not exclude VENDOR of his own obligations and responsibilities. 6. PACKING Packing shall be suitable for shipment and prolonged storage under tropical conditions to a desert location. For each case it must be shown, outside of the packing, the detailed content with designation and tag numbers. ‘The gasket faces, machined, must be carefully protected against corrosion (grease or silicone). Rubber gaskets will be protected to avoid sticking. Any bolting will be protected in order to give a trouble free use, even after been stored outside for a prolongated period 7. SPECIAL TOOLS AND SPARE PARTS The manufacturer must supply five (6) sets of any special wrenches to be used. Different types of terminals (100 of each type) shall be supplied in spare parts. 8, DOCUMENTATION VENDOR shall provide documents as listed in VENDOR document list attached to the relevant requisitions. Vendor shall submit drawings for approval before proceeding with fabricationBASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [race zor a | All documents & drawings shall be provided in English. ‘As a minimum, VENDORS shall provide at the bid stage the following documents: > Details of any special tools required. > Completed junction box and gland data sheets. General arrangements drawing Dimensional drawings including accessories and weights. Deviation list if any. ‘Sub VENDOR list. Inspection and test reports. Material and tests certificates. Preliminary packing list. Procedures for handling, transportation, preservation and storage. Hazadrous certification. Certificates of origin. > Mannul or catalogue. ‘The VENDOR shall provide technical information necessary for design and completion of the work, a time schedule for the submission of documents, fabrication, delivery, tests, inspections, ready for shipment and a monthly status report. All drawings and documents may be subject. ‘The VENDOR shall be responsible for supplying documentation revisions or changes due to inaccuracies, installation requirements, omissions determined by usage, and design or production alteration to the system. All changes shall be issued in the form of Teplacements for the affected drawings, diagrams, charts, tables, lists, and pages in the various manuals.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0019 | neva [race ssor a | 9. APPENDIX JB NUMBERING JB LL sum ‘Symbol (‘I for Intrinsic Safety) Serial Number {___________ unit Number Zone Number A: Analogue D: Digital Signal Type ] p: 24'VDC Power PU: Pulse TC: Thermocouple R:RTD ¢ D: DCS/PLC/RTU F:F&G Control ante E: ESD \ P: Package Equipment Control System