RSH 00 in SP 0030 D3

Pranob Samson
RESHADAT RENOVATION AND DEVELOPMENT PROJECT

C2-T: Topside & Bridges Contract No. : 3688-85-2FG Document Number PRO
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Iranian Offshore Oil Company
Document Title
Specification for Instrument Junction Boxes and Cable Glands
Rev. : D3 Page: 2 of 14
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TABULATION OF REVISED PAGES

Sheet 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 D0 D1 D2 REVISIONS D3 D4 D5 D6 D7 Sheet 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 D0 D1 D2 REVISIONS D3 D4 D5 D6 D7
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TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................ 4 1.1 1.2 1.3 1.4 2 3 4 5 6 7 8 9 GENERAL ................................................................................................................................................. 4 PROJECT DESCRIPTION ............................................................................................................................ 4 DEFINITIONS ............................................................................................................................................ 4 ABBREVIATIONS ....................................................................................................................................... 5
SCOPE ........................................................................................................................................................... 5 SERVICE CONDITIONS ................................................................................................................................ 6 STANDARDS AND CODES .......................................................................................................................... 6 DOCUMENT PRECEDENCE......................................................................................................................... 7 SPECIFICATION DEVIATION / CONCESSION CONTROL ......................................................................... 7 QUALITY ASSURANCE / QUALITY CONTROL .......................................................................................... 8 DOCUMENTATION........................................................................................................................................ 8 HANDLING..................................................................................................................................................... 9 9.1 9.2 PACKING FOR SHIPMENT........................................................................................................................... 9 PRESERVATION AND STORAGE .................................................................................................................. 9
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INSTRUMENT JUNCTION BOXES ............................................................................................................... 9 10.1 10.2 10.3 10.4 10.5 10.6 CONSTRUCTION ....................................................................................................................................... 9 TERMINATION DETAILS ............................................................................................................................. 9 IDENTIFICATION ........................................................................................................................................ 9 CERTIFICATION AND TRACEABILITY ............................................................................................................ 9 PROTECTION ............................................................................................................................................ 9 JUNCTION BOX TYPES .............................................................................................................................. 9
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TECHNICAL REQUIREMENTS FOR CABLE GLANDS .............................................................................. 9 11.1 11.2 GENERAL ................................................................................................................................................. 9 CABLE GLAND TYPES ............................................................................................................................... 9
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PAINTING....................................................................................................................................................... 9 INSPECTION AND TESTING ........................................................................................................................ 9 SPARES ......................................................................................................................................................... 9 TOOLS ........................................................................................................................................................... 9 GUARANTEE ................................................................................................................................................. 9

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1 1.1
INTRODUCTION 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 southwest of Lavan Island at approximate co-ordinates of 255426N 525442E. 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)

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PROJECT EPCI CONTRACTOR ENGINEERING SUBCONTRACTOR VENDOR shall MDP 1.4 Abbreviations ANSI API ASTM BS ISA ISO IEC NACE PVC CO2 FEED GRP H2S 2 SCOPE
- The Reshadat Renovation and Development Project - Topsides and Bridges - Iran Marine Industrial Company (SADRA) - WS Atkins and Partners Overseas - Supplier of equipment/material - Indicates a mandatory requirement - Report on Master Development Plan [MDP-prepared by Tehran Energy Consultants (TEC) in June 2007]
- American National Standards Institute - American Petroleum Institute - American Society for Testing and Materials - British Standard - Instrument Society of America - International Standards Organisation - International Electro-technical Commission - National Association of Corrosion Engineers - Poly Vinyl Chloride - Carbon Dioxide - Front End Engineering Design - Glass Reinforced Polyester - Hydrogen Sulphide
ASME - American Society of Mechanical Engineers
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.

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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 H2S and C02 are present in the atmosphere. The following parameters shall be considered as the design conditions: Air temperature Humidity Maximum Solar temperature : minimum 7 C : minimum 30% : 85C maximum 41C maximum 100%
Full details of environmental conditions are given in the project document RSH-00-PM-SP0001, 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 / COMPANYs attention/approval. API 552 API 554 ASME B1.20.1 ASME B2.1 BS 381 C BS 6121-1 BS 6883 BS 7671 - Transmission Systems - Process Instruments and Control - Pipe threads, general purpose (inch.) - NPT pipe threads - Specification for colours for identification coding and special purposes. - Mechanical Cable Glands - Part 1: Armour Glands - Requirements and Test Methods - Specification for Elastomer-Insulated Cables for Fixed Wiring in Ships and On Mobile and Fixed Offshore Units - Requirements of electrical installations - IEE wiring regulations

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BS EN 50019 BS EN 50262 IEC 60079 IEC 60092-375
- Electrical apparatus for explosive atmospheres - Increased safety e - Cable Glands for electrical installations - Electrical Apparatus for Explosive Gas Atmospheres (all parts) - Electrical Installations in Ships Part 375: Shipboard Telecommunication Cables and RadioFrequency Cables - General Instrumentation - Control and Communication Cables - Fire resisting characteristics of electric cables - Test on electric cable under fire conditions - Specification for degrees of protection provided by enclosure. - Quality Management Systems Requirements, 2000 Edition
IEC 60331 IEC 60332 IEC 60529 ISO 9000 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) VENDORS Quality Plan
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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.

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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 CONTRACTORS and COMPANYS 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 CONTRACTORS review and concurrence prior to award. If VENDORS 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 CONTRACTORS QA audit requirements will be waived in favour of ISO 9001:1994 or ISO 9001:2000 (including design) registrar audits, unless the EPCI CONTRACTORS 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.

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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 9.1 HANDLING 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 COMPANYS/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.

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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 10.1
INSTRUMENT JUNCTION BOXES 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 6mm 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.

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All Junction Boxes shall be provided with Weidmller (Klippon) type WDU 2.5 or similar terminals with flat head screws. Intrinsically Safe terminals shall be light blue. Terminals shall be mounted on Weidmller (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. 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
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ITEM Size
No of Terminals

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1 2 3 11 11.1
225 x 250 x 120D
2x25
510H x 372W x 120D 2x50 780H x 510W x 155D 2x90
TECHNICAL REQUIREMENTS FOR CABLE GLANDS 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 Gland 20 Gland 25
EExd/e cable gland E1X EExd/e cable gland E1X EExd/e cable gland E1X

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Gland 32 Gland 40 12 PAINTING
EExd/e cable gland E1X EExd/e cable gland E1X
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.

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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.

RSH 00 in SP 0030 D3

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Pranob Samson

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

TABULATION OF REVISED PAGES

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

ASME - American Society of Mechanical Engineers

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

BS EN 50019 BS EN 50262 IEC 60079 IEC 60092-375

IEC 60331 IEC 60332 IEC 60529 ISO 9000 5

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

225 x 250 x 120D

510H x 372W x 120D 2x50 780H x 510W x 155D 2x90

Gland 20S Gland 20 Gland 25

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

Gland 32 Gland 40 12 PAINTING

EExd/e cable gland E1X EExd/e cable gland E1X

RESHADAT RENOVATION AND DEVELOPMENT PROJECT

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