DGS IU 001 R0 Intrumentation and Control

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER: DGS-IU-001

Rev: 0 Date: March 2006

INSTRUMENTATION AND CONTROL

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TAKREER DESIGN GENERAL SPECIFICATION (DGS)


REVIEWED REV DATE DESCRIPTION BY

ENDORSED APPROVED

0 MAR 2006 Base Reference – Project 5601

DGS-IU-001




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TABLE OF CONTENTS

1.0 GENERAL...............................................................................................................................................5 1.1 INTRODUCTION .........................................................................................................................5 1.2 PURPOSE......................................................................................................................................5 1.3 DEFINITIONS ..............................................................................................................................5 1.4 EXCLUSIONS ..............................................................................................................................6

2.0 CODES AND STANDARDS ..................................................................................................................6 3.0 REFERENCE DOCUMENTS.................................................................................................................9

3.1 INSTRUMENTATION - GENERAL SPECIFICATIONS............................................................9 3.2 INSTRUMENTATION - EQUIPMENT SPECIFICATIONS .......................................................9 3.3 INSTRUMENTATION - SYSTEM SPECIFICATIONS ..............................................................9 3.4 INSTRUMENTATION - STANDARD DRAWINGS.................................................................10 3.5 ELECTRICAL - GENERAL SPECIFICATIONS....................................................................... 11 3.6 ELECTRICAL - EQUIPMENT SPECIFICATIONS .................................................................. 11 3.7 ELECTRICAL - STANDARD DRAWINGS.............................................................................. 11 3.8 PIPING - GENERAL SPECIFICATIONS .................................................................................. 11 3.9 PIPING - STANDARD DRAWINGS .........................................................................................12 3.10 PIPING - STANDARD PRACTICES .........................................................................................12 3.11 ARCHITECTURAL - GENERAL SPECIFICATIONS ..............................................................12 3.12 MECHANICAL - GENERAL SPECIFICATIONS.....................................................................12 3.13 STRUCTURAL - GENERAL SPECIFICATIONS .....................................................................12

4.0 DOCUMENT PRECEDENCE ..............................................................................................................12 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ..............................................................13 6.0 QUALITY ASSURANCE/QUALITY CONTROL ...............................................................................13 7.0 DOCUMENTATION .............................................................................................................................14 8.0 SUBCONTRACTORS/VENDORS.......................................................................................................14 9.0 HANDLING...........................................................................................................................................14 10.0 DESIGN.................................................................................................................................................15

10.1 DRAWINGS AND SPECIFICATIONS ......................................................................................15 10.2 INSTRUMENT SYMBOLS AND IDENTIFICATION..............................................................17

11.0 SYSTEM TECHNICAL REQUIREMENTS.........................................................................................18 11.1 GENERAL CONTROL PHILOSOPHY .....................................................................................18 11.2 CONTROL AND MONITORING SYSTEMS ...........................................................................21

12.0 FEED INSTRUMENT GENERAL REQUIREMENTS........................................................................23 12.1 CLIMATE....................................................................................................................................23 12.2 INSTRUMENT ENCLOSURE ...................................................................................................23 12.3 PAINTING...................................................................................................................................24 12.4 TROPICALIZATION..................................................................................................................24

13.0 HAZARDOUS AREA ...........................................................................................................................24 13.1 HAZARDOUS AREA CLASSIFICATION ................................................................................24 13.2 INSTRUMENTS SAFETY CLASSIFICATION ........................................................................24 13.3 TYPE TEST CERTIFICATE.......................................................................................................25 13.4 CERTIFIED AUTHORITIES......................................................................................................25

14.0 INSTRUMENT PASSIVE PROTECTION AGAINST FIRE ...............................................................26




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15.0 SELECTION OF INSTRUMENTS.......................................................................................................26

15.1 GENERAL...................................................................................................................................26 15.2 CHARTS AND SCALES ............................................................................................................27 15.3 RADIO FREQUENCY INTERFERENCE .................................................................................27 15.4 TRANSMITTERS AND LOCAL INDICATORS.......................................................................27 15.5 TRANSMITTER TEST/CONNECTION BOXES......................................................................28 15.6 FLANGE SURFACE FINISH.....................................................................................................28 15.7 RATING OF PRESSURE-CONTAINING PARTS.....................................................................28 15.8 SELECTION OF MATERIALS..................................................................................................28 15.9 FLOW MEASUREMENT...........................................................................................................31 15.10 LEVEL MEASUREMENT .........................................................................................................35 15.11 PRESSURE MEASUREMENT ..................................................................................................37 15.12 TEMPERATURE MEASUREMENT .........................................................................................39 15.13 ELECTRICAL PARAMETERS..................................................................................................44 15.14 SPEED INSTRUMENTS ............................................................................................................44 15.15 MACHINE MONITORS.............................................................................................................44 15.16 ON-LINE PROCESS STREAM ANALYZERS .........................................................................46 15.17 RECEIVER INSTRUMENTS.....................................................................................................46 15.18 CONTROL VALVES...................................................................................................................46 15.19 SAFETY AND RELIEF VALVES...............................................................................................51 15.20 MOVS..........................................................................................................................................54 15.21 ELECTRONIC AND ELECTRICAL CABLES .........................................................................54 15.22 CORROSION MONITORING ...................................................................................................56

16.0 INSTRUMENT CONTROL BUILDINGS AND ROOMS AND SISS.................................................57 16.1 GENERAL...................................................................................................................................57 16.2 LIGHTING ..................................................................................................................................57 16.3 FALSE FLOORS.........................................................................................................................57 16.4 FALSE CEILINGS ......................................................................................................................57 16.5 NOISE .........................................................................................................................................57 16.6 FIRE AND GAS DETECTION AND PROTECTION................................................................57 16.7 TELEPHONES, INTERCOMS, PUBLIC ADDRESS................................................................58

17.0 CABINETS AND LOCAL CONTROL PANELS .................................................................................58 17.1 INSTRUMENT IN LOCAL PANELS ........................................................................................58 17.2 MARSHALING CABINETS ......................................................................................................59

18.0 INSTRUMENT AIR SUPPLY...............................................................................................................59 19.0 ELECTRICAL POWER SUPPLIES AND EARTHING.......................................................................59

19.1 GENERAL...................................................................................................................................59 19.2 EARTHING.................................................................................................................................60

20.0 INSTRUMENT INSTALLATION.........................................................................................................61 20.1 GENERAL...................................................................................................................................61 20.2 INSTRUMENT INSTALLATION DETAILS.............................................................................61 20.3 PACKAGE EQUIPMENT INSTRUMENTATION ....................................................................62 20.4 INSTRUMENT MOUNTING.....................................................................................................62 20.5 INSTRUMENT PROTECTION..................................................................................................63 20.6 HAZARDOUS SERVICE ...........................................................................................................63 20.7 INSTRUMENT PROCESS CONNECTIONS ............................................................................64 20.8 INSTRUMENT PROCESS PIPING ...........................................................................................65 20.9 INSTRUMENT AIR PIPING ......................................................................................................66 20.10 SUNSHADES..............................................................................................................................67 20.11 PASSIVE CONDITIONED SHELTERS.....................................................................................68




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21.0 LABELING............................................................................................................................................68 22.0 INSTRUMENT RECEIVING, STORAGE AND INSTALLATION .....................................................68

22.1 GENERAL...................................................................................................................................68 23.0 PAINTING .............................................................................................................................................69 24.0 TRAINING ............................................................................................................................................69

24.1 DCS ...........................................................................................................................................69 24.2 ESD AND FIRE AND GAS SYSTEM .......................................................................................70 24.3 ANALYZERS..............................................................................................................................70 24.4 PACKAGE UNIT CONTROL SYSTEM....................................................................................70

APPENDIX 1 ...................................................................................................................................................71




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1.0 GENERAL

1.1 INTRODUCTION

This design specification along with specifications, practices, and standards referenced herein, provides the basis for engineering and design of the instrumentation required for monitoring and control to be provided for the Project.

This Project will include new refinery units as well as revamps and upgrades in existing units. In addition, this Project will interface with ongoing projects at the Ruwais Refinery.

1.2 PURPOSE

The purpose of this specification is to establish the minimum design requirements and standards for Process Instrumentation and Control Systems and will apply to the following tasks for the Project:

a. Basic Engineering or FEED b. Detailed Engineering c. Purchasing d. Construction e. Installation f. Commissioning g. Licensor Coordination

The CONTRACTOR’S scope of work will be defined by the EPC (Engineering, Procurement and Construction) packages generated by the ENGINEER. The packages will be developed to interface properly with the ongoing projects at the Ruwais and Umm Al Nar Facilities.

Deviations from the requirements of this specification shall not be allowed unless a specific and express waiver is given by the COMPANY in writing.

The objective of the COMPANY is to achieve a design strategy based on minimizing the Life Cycle Cost (cost of ownership) by utilizing the state-of-the-art in proven technology.

Standardization of Philosophy of Design, drawing format, material (instrumentation and installation material), shall be assured across-the-board for all units (main plant, licensed units, package units, etc.).

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

General Definitions:

CONCESSION REQUEST — A deviation requested by the SUBCONTRACTOR or VENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

SHALL — Indicates a mandatory requirement.




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SHOULD — The use of the word “should” indicates a strong recommendation to comply with the requirements of this document.

Specific Definitions:

AFR — Auxiliary Field Room. This term is obsolete. For this Project, the proper term is SIS (Satellite Instrument Shelter).

CUBCR — Combined Utility Buildings Control Room

DCR — The Dispatch Control Room at the Ruwais Facility (oil movements area).

GUP — The General Utilities Plant (an ongoing project at the Ruwais Facility).

ICS — Integrated Control System.

MCR — The existing Main Control Room at the Ruwais Facility.

PACS — Process Automation and Computerization System (an ongoing, multi-site TAKREER project which includes the Ruwais and Umm Al Nar Facilities).

PMCR — The Port Mooring Control Room at the Ruwais Facility (jetty area).

SIS — Satellite Instrument Shelter.

UCR — The Utility Control Room at the Ruwais Facility.

1.4 EXCLUSIONS

This section is not applicable to this Specification.

2.0 CODES AND STANDARDS

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

The following codes and standards shall, to the extent specified herein, form a part of this specification. The latest edition in force shall apply.

American Petroleum Institute (API)

API RP 520 Recommended Practice for the Design and Installation of Pressure Relieving Systems

API RP 521 Guide for Pressure Relief and Depressurizing Systems (for information purpose only)

API RP 526 Flanged Steel Safety Relief Valves (Sections 1 to 4)

API RP 527 Commercial Seat Tightness of Safety Relief Valves with Metal to Metal Seat

API RP 551 Process Measurement Instrumentation




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API RP 552

Transmission Systems

API RP 554 Process Instrumentation and Control

API RP 555 Process Analyzers

API STD 670 Vibration, Axial Position and Bearing Temperature Monitoring Systems

API RP 2000 Tank Venting

API MPMS 14.3.2 Installation of Straightening Vanes

American Society of Mechanical Engineers (ASME)

Sec. I Boiler and Pressure Vessel Code

Sec. VIII Boiler and Pressure Vessel Code

B16.5 Pipe Flanges and Flanged Fittings

B16.10 Face-to-Face and End-to-End Dimensions of Valves

B31.1 Power Piping

B31.3 Chemical Plant and Petroleum Refinery Piping

B46.1 Surface Texture

American Society for Testing and Materials (ASTM)

G93-88 Standard Practice for Cleaning Methods for Material and Equipment Used in Oxygen Enriched Environments

Deutsches Institut Fur Normung e.V. (DIN)

DIN 43760 Standard for Resistance Temperature Detectors (RTD’s)

Fluid Control Institute (FCI)

FCI 70-2 Standard for Control Valve Leakage

International Electrotechnical Commission (IEC)

IEC 60079-1 Construction and Verification Test of Flameproof Enclosure of Electric Apparatus

IEC 60079-0 Electrical Apparatus for Explosive Gas Atmosphere - General Requirements

IEC 60079-11 Construction and Test Intrinsically-Safe and Associated Apparatus

IEC 60079-14 Electrical Installation in Explosive Gas Atmosphere

IEC 60189-1 to 7 Low Frequency Cables and Wires with Insulation and PVC Sheath




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IEC 60227-1 to 5

Polyvinyl Chloride Insulated Cables, Rated Voltage Up to and Including 450/750 V

IEC 60245-1 to 4 Rubber Insulated Cables of Rated Voltage Up to and Including 450/750 V

IEC 60331 Fire Resisting Characteristics of Electric Cables

IEC 60332 Test on Electric Cables Under Fire Conditions

IEC 60529 Degrees for Protection Provided by Enclosures (IP Code)

IEC 60584-1 Reference Tables - Thermocouples

IEC 60584-2 Thermocouple - Tolerance

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 61000-4 Radiated Electromagnetic Field Requirements

International Organization for Standardization (ISO)

ISO No. 5167 Fluid Measurement with Orifice Plates

ISO No. 5168 Flow Measurement Calculation of Errors

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 9011 Quality Management Guidelines for Performance Improvement System

International Society for Measurement and Control (ISA)

ISA – 5.1 Instruments Symbols and Identification

ISA – 5.2 Binary Logic Diagrams

ISA – 5.3 Graphic Symbols for Distributed Control

ISA – 5.4 Instrument Loop Diagrams

ISA – 51.1 Process Instrumentation Terminology

Telecommunication

ETISALAT Requirements as per International Radio Consultative Committee (CCIR) N385-1 Line of Sight

CCITT International Consultative Committee for Telegrams and Telephone

IEEE International Electrical Electronic Engineers (USA)

National Association of Corrosion Engineers (NACE)

MR-01-75 Sour Service Piping Design and Materials




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3.0 REFERENCE DOCUMENTS

The following Project Specifications and Standards shall act as the guidelines for this Project.

During engineering, any conflicts with or exceptions to the Project Specifications and Standards shall be identified to the COMPANY in writing for clarification.

3.1 INSTRUMENTATION - GENERAL SPECIFICATIONS

DGS-IU-002 Instrument Installation Design

DGS-IU-003 Instrument Piping Systems Material Specification

DGS-IU-004 Instrument Storage and Calibration

DGS-IU-005 Instrument Piping - Field Pressure Testing

DGS-IU-007 Instruments Furnished with Packaged Units

DGS-IU-009 Instrumentation for Depressuring Systems

DGS-IU-010 Analyzer Shelters

DGS-IU-011 Packaged Analyzer Systems

DGS-IU-012 Pressure Relief Devices

3.2 INSTRUMENTATION - EQUIPMENT SPECIFICATIONS

DGS-IE-001 Flow Instruments

DGS-IE-002 dp Type Flow Elements and Meter Runs

DGS-IE-003 Control Valves

3.3 INSTRUMENTATION - SYSTEM SPECIFICATIONS

DGS-IS-001 Distributed Control System (DCS)

DGS-IS-002 Integrated Control System Vendor (ICV)

DGS-IS-003 Fire and Gas Detection System

DGS-IS-004 Emergency Shutdown System (ESD)

DGS-IS-005 Programmable Logic Controllers (PLC)

DGS-IS-008 Closed Circuit Television System (CCTV)

DGS-IS-009 Telephone Sets

DGS-IS-010 PA and Intercom System

DGS-IS-011 Machinery Condition Monitoring (MCM)




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DGS-IS-012

Security and Surveillance System

DGS-IS-014 Marshaling Cabinets

DGS-IS-015 System Cables

3.4 INSTRUMENTATION - STANDARD DRAWINGS

STD-IU-00001 Typical Arrangement for Fire Detection Tubing-Floating Roof Tanks

STD-IU-00002 Typical Arrangement for Fire Detection Tubing

STD-IU-00003 Void

STD-IU-00004 Analyzer Sample System (150# Service) to Analyzer House

STD-IU-00005 Analyzer Sample System with Steam Tracing (600# Service) to Analyzer House

STD-IU-00006 Analyzer Sample Return (600# Service) Sample to Analyzer House

STD-IU-00007 Analyzer Sample System (600# Service) Steam Traced to Analyzer House

STD-IU-00008 Analyzer Sample System (150# Service) with Pre-Cond. Sys. Analyzer House

STD-IU-00011 Instrument Nameplates

STD-IU-00012 Instrument Nameplates

STD-IU-00013 Purge Orifice Nipple

STD-IU-00014 Parallel Threaded Connections

STD-IU-00015 Mounting Plate (L-Shape)

STD-IU-00016 Mounting Plate (Rectangular)

STD-IU-00017 Cubicle Panel for Compressor or Boiler Instruments

STD-IU-00018 Level Gauges (Reflex Type)

STD-IU-00019 Level Gauges (Transparent Type)

STD-IU-00020 Level Transmitters (Displacer Type)

STD-IU-00021 Flanged Thermowell

STD-IU-00022 Backup Flange for Flanged Thermowell

STD-IU-00023 Threaded Thermowell

STD-IU-00024 Thermocouple Assembly (Standard)

STD-IU-00025 Thermocouple Assembly (Furnace Tube Skin)




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STD-IU-00026

Thermocouple Assembly (Reactor Skin)

STD-IU-00027 Thermocouple Assembly (Reactor Multipoint)

STD-IU-00028 Symbology for Instrument Loop Drawings

STD-IU-00029 Symbology for Logic Diagrams

STD-IU-00030 Orifice Plates

STD-IU-00031 Instrument Installation Details

3.5 ELECTRICAL - GENERAL SPECIFICATIONS

DGS-EU-001 Electrical Design Guidelines

DGS-EU-002 Specification for Electrical Items on Packaged Equipment

DGS-EU-020 Field Commissioning of Electrical Installation and Equipment

3.6 ELECTRICAL - EQUIPMENT SPECIFICATIONS

DGS-EE-008 Static AC UPS System

DGS-EE-009 Direct Current UPS System

DGS-EE-011 Power, Control, and Earthing Cables

DGS-EE-012 Instrument and Thermocouple Cable

DGS-EE-014 Interposing Relay Panels

DGS-EE-023 Electrical Heat Tracing

3.7 ELECTRICAL - STANDARD DRAWINGS

STD-EU-00001 through 00003 Electrical Diagram Symbols

STD-EU-00004 Electric Standard Abbreviations

STD-EU-00071 Electric Heat Tracing Assemblies

STD-EU-00011 through 00013 Standard Earthing Installation Assemblies

3.8 PIPING - GENERAL SPECIFICATIONS

DGS-PU-001 General Piping - Process and Utility Design, Layout and Drawings

DGS-PU-003 Technical Specification for Piping Systems




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3.9 PIPING - STANDARD DRAWINGS

STD-PU-00003 Vessel Layout and Orientation - General

STD-PU-00004 Flange Tap Orientation, Clearances and Meter Runs

STD-PU-00010 Thermowell Detail Selection

STD-PU-00012 Instrument Symbols and Tagging

STD-PU-00014 Control Valve Manifold Arrangement and Layout Guide

STD-PU-00015 Control Valve Clearances

STD-PU-00016 Relief Valve Piping Location

STD-PU-00017 Level Instruments

3.10 PIPING - STANDARD PRACTICES

STD-PP-D-00001 through 00004 Symbology for P&IDs (Piping and Instrument Diagrams)

3.11 ARCHITECTURAL - GENERAL SPECIFICATIONS

DGS-AU-063 HVAC System

3.12 MECHANICAL - GENERAL SPECIFICATIONS

DGS-MU-002 Preservation and Export Packing

DGS-MD-002 Pressure Vessels - General

DGS-MF-002 Field Erected Welded Steel Storage Tanks

DGS-MU-009 Equipment Noise Control

DGS-MU-013 Criticality Rating System

DGS-MU-014 Minimum Shop Inspection and Certification Requirements

DGS-MX-001 Painting

TEC-MU-003 Equipment Data Forms Procedure

3.13 STRUCTURAL - GENERAL SPECIFICATIONS

DGS-CU-002 Structural Engineering Design Criteria

4.0 DOCUMENT PRECEDENCE

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




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The CONTRACTOR shall notify the COMPANY 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 precedence shall be obtained from the COMPANY in writing before proceeding with the design/ manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

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

6.0 QUALITY ASSURANCE/QUALITY CONTROL

CONTRACTOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design. Implementation of the system shall be in accordance with the CONTRACTOR’S Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval.

The VENDOR shall have in effect at all times, a QA/QC program which 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 that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.

VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design.

A copy of the VENDOR’S QA/QC program shall be submitted to the CONTRACTOR with its quotation for 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 certified, then only a copy of the VENDOR’S ISO 9001 certificate is required. In addition, if VENDOR’S facility is ISO certified, CONTRACTOR’S QA audit requirements will be waived in favor of ISO 9001 registrar audits, unless the 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 CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDOR’S activities.

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




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The COMPANY/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 CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR witness points.

The Criticality Rating (CR) System outlined in Project Specification DGS-MU-013 shall be used to develop the design checking levels and minimum requirements for shop inspection, testing and materials certification given in Project Specification DGS-MU-014.

7.0 DOCUMENTATION

The CONTRACTOR shall define the requirements for MANUFACTURER/ VENDOR drawings and documentation for CONTRACTOR’S authorization or information as listed in the individual Material Requisitions and Purchase Orders.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be constructed as permissions to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing.

Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

a. Official trade name of the VENDOR

b. VENDOR’S drawing number

c. Drawing title giving the description of contents whereby the drawing can be identified

d. A symbol or letter indicating the latest issue or revision

e. PO number and item tag numbers

f. TAKREER Logo.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term “Latest Revision” shall not be used.

8.0 SUBCONTRACTORS/VENDORS

This section is not applicable to this Specification.

9.0 HANDLING

CONTRACTOR shall ensure preparation for shipment shall be in accordance with the VENDOR’S 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.




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

Preparation for shipment and packing will be subject to inspection and rejection by COMPANY’S/CONTRACTOR’S 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.

All equipment and material shall be preserved and export packed in accordance with Project Preservation Specification, DGS-MU-002.

10.0 DESIGN

10.1 DRAWINGS AND SPECIFICATIONS

Requirement of Drawings and Documents for COMPANY review, comments and approval shall be as per Attachment 1.

10.1.1 Construction and Layout Drawings

Construction drawings will contain instrument locations for all tagged instruments that have signals to or from devices.

10.1.2 Plant Standard Details

Plant standard details will show installation details for electrical, pneumatics, process hook ups and mounting arrangement.

Each detail will contain a specific reference number and a material take-off listing for electrical, pneumatic, process, and mounting materials. The Instrument Index shall be used to generate tag listings for the details.

10.1.3 Loop Drawings

Loop drawings will be drawn for each loop in each instrument system for main plant and all package units, and for all instrument systems therein (DCS, ESD, Fire and Gas, SCADA, machinery monitor, etc.).

Each loop shall contain the following information:

a. a standard presentation of the loop b. I/O card locations (i.e. rack, file, slot) c. wiring terminations (with terminal numbers) between field instrumentation, I/O cards, panel

instruments and junction boxes, if applicable d. instrument cable numbers e. J. B. location and number f. failure position for (a) Control Signal and (b) Air Signal g. reference drawings




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Complex loops (e.g. boiler control loops) should be supported by narrative description.

10.1.4 Logic Diagram Drawings

Logic diagram drawings shall include binary operation function sequences, interlocks, interaction and interrupts using ISA standard symbology. Diagrams will flow from left to right where possible. The diagram should be supported by a narrative description of the function. This is mandatory for complex logics.

10.1.5 Console and Panel Drawings

Console and panel drawings will include front, back and interior panel layouts. Details will be part of the specification. Any interconnection wiring/cables will be indicated complete with its terminals.

10.1.6 DCS, PLC, and Computer Block Diagrams

These overviews will show how the system hardware is tied together with hi-ways, serial links and major instrument cables. There shall be a plant level simplified overview and detailed overviews which show smaller section of plant with actual amount of hardware estimated. This shall be based on the system in the market that require maximum space, power, heat load to result in conservative sizing of Satellite Instrument Shelters (SIS) and Control Rooms.

Also grounding for each of these systems will be shown in a separate drawing.

10.1.7 Instrument Index

The instrument index will be a complete listing of all tagged instruments and shall include as a minimum, the following:

a. tag number b. process description c. vendor and model number d. P.O. and requisition no. e. construction drawing f. P&ID g. loop drawing h. installation detail (impulse line, electrical hook-up, weather protection, pneumatic, air supply

and mounting details) i. location j. calibration range k. data sheet no. l. line no. and specifications m. calculation sheet n. criticality




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A sample Instrument Index shall be included in all EPC tenders to ensure homogeneity within the whole site complex.

10.1.8 Instrument Specifications

A specification sheet will be generated for each instrument. Items such as PIs, TIs, etc. will be combined on single specifications. Specification sheets shall contain as a minimum, the relevant process data, mechanical design and specification data, metallurgy, vendor name, model no., requisition no., P.O. no., notes, etc. In addition, the CONTRACTOR shall ensure the successful completion of the Equipment Data Forms per the Equipment Data Forms Procedure, TEC-MU-003. Instrument data sheets shall be ENGINEER’S standard and shall be in accordance with ISA standards, as specified by the COMPANY.

10.1.9 Instrument Calculation

A calculation will be made considering different cases/scenarios for each control valve, safety valve and flow device. These calculations will be included in the design books.

10.1.10 Integrated Control System I/O Schedule

An I/O schedule shall be made for the above system based on P&IDs, control and operating philosophy documents for main process plant, utilities, offsites and package units. This shall also reflect exchange of signals to MCC, HVAC and to any existing plant systems as applicable. The format shall be developed in consultation with the system vendor to convey the required data for database and display/logic configuration.

10.1.11 Instrument Location Plan Drawings (Layout Drawings)

A detailed scaled location plan drawing shall be made based on piping General Arrangement Drawing (GADs) to locate instrument tapping points, instrument mounting elevations, junction boxes, tray routings, etc. Separate drawings shall be made for each area for (a) air supply distribution and consumers (b) electrical instruments.

10.2 INSTRUMENT SYMBOLS AND IDENTIFICATION

10.2.1 The symbology for instrumentation shall be defined by Piping Standards STD-PP-D-00001 through 00004.

10.2.2 Each instrument loop will have its own alpha numeric number. Any duplicate item within a loop will have an alphabetic suffix following the number:

Process Area GUP Offsites

Flow 100 - 999 100-999 100-999

Level 100 - 999 100-999 100-999

Pressure 100 - 999 100-999 100-999

Pressure Gauge 100 - 999 100-999 100-999

Temperature 100 - 599 100-599 100-599

Temperature Gauge 600 - 999 600-999 600-999




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Process Area GUP Offsites

Miscellaneous 100 - 999 100-999 100-999

Relief and Safety Valves 100 - 999 100-999 100-999

Emergency Shutdown 100 - 999 100-999 100-999

Retrofit, expansion, or modifications in existing process units, utilities, or offsites shall use spare tag numbers available in those units. These tag numbers will be made available during the detailed engineer phase of the project.

10.2.3 Plant/area numbers, will be a three or four digit number preceding the loop number, e.g:

120 FALL 177 A

Area Number Functional Identification

Three digit Number

Alphabetic Suffix (e.g. split range valves)

10.2.4 Consistency with Existing Plant Numbering System

Although numbering system shall be as defined in Sections 10.2.2 and 10.2.3, the numbering system shall be modified in consultation with end user/operator to provide numbering system consistent with existing plant and avoid duplications. Specific blocks will be defined by end user/operator.

10.2.5 Package Units

Major vendors will be given block of tag numbers by the ENGINEER. For example, flow tags for package units will be numbered from 500 to 999 (or 5000 to 9999 if applicable) and individual block of 100 or 50 numbers (typical) within this 500 to 999 (or 5000 to 9999) will be assigned to each Package unit by ENGINEER. All tag numbers whether by ENGINEER or VENDOR will be referenced in an index supplied by ENGINEER and shall be subject to the COMPANY’S approval.

10.2.6 Numbering of Instruments

ENGINEER shall number all instruments, including those instruments in Licensors’ units, as per P&IDs.

10.2.7 Existing Expanded Area

ENGINEER will coordinate through a site survey for block of numbers in these areas, so no duplication occurs.

11.0 SYSTEM TECHNICAL REQUIREMENTS

11.1 GENERAL CONTROL PHILOSOPHY

In general, centralized plant control utilizing Integrated Control System (ICS) from a Main Control Room is required along with Satellite Instrument Shelters (SISs) located at convenient places in close proximity to the plant to house all instrument racks/panels, etc.




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Only hiways and few dedicated hardwired cables shall be run to Main Control Room. Otherwise all instrument cables shall be terminated in SISs. MCR shall have all operational control consoles and enable full start-up, monitoring and control and shutdown of the plant. SISs shall be normally unmanned.

The main intent of the Integrated Control System (ICS) is to eliminate all foreign platforms (hardware and software) as far as practically possible. Plant safety and reliability shall not be compromised. Use of foreign platforms shall be very carefully scrutinized and COMPANY approval shall be obtained.

Foreign devices (other instrument systems, microprocessor based systems, PC based systems and computer based systems) use shall be limited. Whenever Foreign Devices are used, they shall provide peer-to-peer communication with DCS system. All the Control and Monitoring Functions of the foreign device shall be performed from DCS Operator Control including engineering functions.

For foreign devices, ENGINEER shall ensure the data and features as available in Foreign Device Systems (work stations, their locations, printers) conveyed by gateways or serial interface to the plant DCS. ENGINEER shall maximize true integration by implementing other instrument sub-systems in DCS hardware/ software.

11.1.1 Unified Operator Interface

A single-window approach shall be implemented for the plant. For details, refer to DCS Project Specification, DGS-IS-001.

11.1.2 Package Unit Equipment

Refer to Project Specification DGS-IU-007. Control, monitoring, alarm, and shutdown information for all equipment packages shall be brought back to main control centers.

A new state of the art, computer based vibration monitoring system shall be used for all major rotating equipment. Refer to Project Specification DGS-IS-011.

11.1.3 Satellite Instrument Shelters (SIS)

In general, buildings shall be installed to house ICS I/O and processors and other devices that can be protected in these buildings in order to minimize field cabling length. The SISs and MCRs shall be sized to include 30% future use in floor space, power at all levels and HVAC.

11.1.4 Control Room and SISs

All these buildings shall be located in a safe (nonclassified) area. The buildings shall be constructed as per Structural Specification DGS-CU-002.

11.1.5 Process and Utilities

Main operational control will be out of the main control building. Required number of new SISs will be located in the main process and utility areas.




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11.1.6 Tank Farm and Off-Site Facilities

In general, main operational control will be out of the Dispatch Control Room using required number of SISs.

11.1.7 Interfacing with Existing Instruments

Interfacing existing instruments in general, shall be done through DCS by having peer-to-peer communication.

Interfacing with special type of instruments (as an example 4-wire transmitter) may be necessary. Such interfaces shall be through a current isolator for analog signals and a interposing relay for digital signals. CONTRACTOR shall provide required number of isolators and relays powered and connected.

11.1.8 System and Measuring Units

If a conflict occurs between the units listed below and units in other project specifications, the units listed below shall be used for instrumentation purposes.

The following engineering units shall be used. They generally will be in accordance with the international system (ISO)

Verification/approval should be obtained from the COMPANY in writing for variances or additions to the following:

UNITS OF MEASUREMENT

QUANTITY UNIT ABBREVIATION

Acceleration meter per sec per sec m/s2

Amount of Substance kilogram mole kg-mol or kmol

Area Square meter m2

Concentration parts per million ppm or wt%

Conductivity microSiemens per centimeter µS/cm

Density kilograms per cubic meter kg/m3

Electrical Current ampere A

Energy-Electrical kilowatt hour kWh

Flow - Process Liquid cubic meter per hour m3 /hr+

Flow - Gas and Vapor normal cubic meter per hour Nm3/hr*

Flow - BFW and Steam metric tons per hour t/hr

Force kilogram force kgf

Heat kilocalorie kCal

Length (Vessel Level) millimeter mm

Length (Storage Tank Level) meter m

Length kilometer km




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UNITS OF MEASUREMENT

QUANTITY UNIT ABBREVIATION

Level (General Applications) 1 percent 1%

Mass kilogram kg

Mass ton te or t

Molecular weight kilogram per kilogram mole MWT or MW

Power kilowatt kW

Pressure Gauge kilogram per square centimeter - gauge

kg/cm2g

Pressure Absolute kilogram per square centimeter - absolute

kg/cm2a

Pressure Differential (high) kilogram per square centimeter kg/cm2

Pressure Differential (low) millimeters of water column mmH2O

Production Capacity metric tons per year te/y or t/y

Speed - Linear meter per second m/s

Speed - Rotating revolutions per minute rpm

Temperature degree centigrade °C

Time hour hr or H or h

Vibration (velocity) millimeter per second mm/s

Vibration (displacement) micrometers µm

Viscosity - Dynamic centipoise cP

Volume Cubic meter m3

* Given at normal conditions (0°C and 1.0332 kg/cm2a + Given at operating conditions

For display of analog variables, a maximum of five total digits shall be used with a maximum of three decimal places. For custody transfer and totalized values, a maximum of nine total digits shall be used, with a maximum of three decimal places. Number of digits displayed shall not exceed the number of significant places inherent in the measurement system.

11.1.8.1 Field instrument indicators shall be scaled in Engineering Units.

11.2 CONTROL AND MONITORING SYSTEMS

The following control and monitoring systems will be provided in the main control rooms and SISs as decided during above study done by ENGINEER (10.1):

• Process Control System

• Fire and Gas Systems




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• Hardwired Push Buttons for Deluge/Halon/Inergen Release and Main/Zone ESD are for major system failures. Push buttons will be wired into the final channel output and to an ESD input. Each push button action, including those for manual actuation of deluge valves, shall be logged into the ESD/DCS sequence of events/alarm system.

• Shutdown Systems (ESD)

• Manual initiators for trip systems shall be according to the provisions of TUV AK6.

11.2.1 Fire and Gas System

The Fire and Gas system shall be state-of-the-art Fire and Gas systems and be part of ICS as per Project Specification DGS-IS-003 and duly approved by the COMPANY.

11.2.2 Shutdown and Alarm Systems

Alarm Systems

Alarm systems shall warn operators of an abnormal condition. Alarms shall be located in the DCS systems.

These alarms if not addressed and/or if the process does not react positively will shutdown equipment, control valves, etc.

11.2.3 Shutdown Systems

Shutdown system shall be state-of-the-art ESD systems implemented as a part of ICS. However, in specific cases, Triple Modular Redundant (TMR) with a voting system may be required. Shutdown systems shall be stand-alone type located in SISs and have dedicated primary devices. Information (alarms, start/stop of motors, valve open/close) and manual activation (override, resets, test push buttons) will be available in the DCS control stations through data bus communications. Manual actuation of ESD will be through hard wired push buttons and located as a part of the DCS control. First out and sequence of event (SOE) ability for major critical equipment items and for integrated equipment items/units where related trip may occur in rapid succession. This requirement includes package units.

The ESD systems shall have the facility to test repair/calibrate primary elements without activating the executive shutdown action. ESD valves shall be generally be implemented in such a manner to allow for on line testing without shutting down the process. In some cases bypass capability may be provided. Software jogging may also be evaluated for certain application. The ESD systems shall be as per Specification DGS-IS-004.

11.2.4 Analyzers

All analyzers will be evaluated on application, installation, sampling system requirements, maintainability, and return on investment. See Project Specification DGS-IU-011 for reference.

Analyzers shall be mounted in pressurized and air-conditioned shelters and shall be prepackaged with analyzers and accessories. See Project Specification DGS-IU-010 and DGS-IU-011. A study shall be made by ENGINEER on the number of shelters, location, etc., for COMPANY review and approval.




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ENGINEER shall be aware that the COMPANY intends to use advanced analyzer applications in selected offsites areas. ENGINEER shall be informed as to what the applications are during detailed engineering. Typically, installation of these advanced analyzers will be simpler than the conventional analyzers they would replace.

12.0 FEED INSTRUMENT GENERAL REQUIREMENTS

12.1 CLIMATE

All equipment mounted externally shall be able to operate in extreme weather conditions of temperature, precipitation, humidity, and salt-laden atmosphere.

Maximum Temperature (Shade) 58°C

Maximum Temperature (Solar) 87°C

Minimum Temperature 5°C

Maximum 24 Hr. Solar Temperature Differential 40°C

Maximum Relative Humidity at 43°C 95%

Barometric Pressure 760 mm Hg.

Control and rack rooms will be air-conditioned to 25-30°C and pressurized and with air locks. Refer to Project HVAC Specification DGS-CU-063.

All instrumentation, whether inside or outside, will be designed for maximum shade conditions at 58°C. Instruments located in direct sun areas shall be designed either for maximum solar conditions or shall be covered by a suitable sunshade.

For shade details of pressure and differential pressure transmitters, see Project Specification DGS-IU-002.

Where instruments require shades which are not available as standard equipment or require specially made supports/brackets such as for displacer level instruments, tank gauges, etc., these shall be shown on detailed construction drawings, and a decision shall be taken whether these can form part of the installation activities or whether they should be requisitioned for prefabrication.

In the field, only gauges, transmitters, switches, positioners, transducers are permitted. All other instruments shall be in adjacent functionally related SISs. Local panels near package equipment shall have only gauges, push buttons, lamps, etc. and all other relevant information shall be located in adjacent functionally relevant SISs.

Discrepancy between above information and other project design documents should be highlighted by ENGINEER/CONTRACTOR to COMPANY for decision.

12.2 INSTRUMENT ENCLOSURE

Instrument enclosure’s “degree of protection” shall be in accordance with IEC 60529. The minimum degree of protection for junction boxes, electronic instruments, coils (solenoid valves), pneumatic instruments shall be IP 65. NOTE: Attachment of identification plates installed on instrument enclosures, etc. shall not adversely affect the degree of

protection.




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12.3 PAINTING

Finish of plant-mounted instruments shall follow Project Painting Specification DGS-MX-001. Color codes for field instrument, cabinets, panels, junction boxes, etc. shall follow each plant specification.

Instruments and the following items shall be protected against paint used on equipment and process units:

a. Glass fronts

b. Moving parts, i.e. control valve stems and positioners

c. Vents and drains

d. Name plates

e. Tube fittings and cable glands

f. Isolation and vent valves

12.4 TROPICALIZATION

Instruments will be tropicalized for humidity and fungus.

Particular consideration shall be taken on all printed circuit boards, even those located in control rooms shall be varnished and electrostatically protected.

CONTRACTOR shall take into account when electronic equipment is unpacked, that it is stored, temporary or permanent, in air conditioned environment.

13.0 HAZARDOUS AREA

13.1 HAZARDOUS AREA CLASSIFICATION

Refer to the area classification drawings for details of hazardous and safe areas.

13.2 INSTRUMENTS SAFETY CLASSIFICATION

The following protection means the electrical apparatus shall be considered for installation within hazardous areas:

a. Intrinsic safety “i”

b. Flameproof enclosures “d”

c. Pressurized enclosures “p”

d. Increased safety “e”

Use of Pressurized enclosures shall be kept to an absolute minimum.

Inside Zone O, electrical instruments shall not be installed.




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Inside Zone 1 and 2, the choices of protection within process and utility units shall be as follows:

INSTRUMENTS AND ACCESSORIES ZONE 1 ZONE 2 Switches i i Transmitters i i Positioners i i Temperature sensors i i Level gauge illuminators d e Junction boxes e e Cable glands d d Solenoid valves d d Local cabinets d or p d or p Fire and gas detectors i or d* i or d* RTU (if not in safe area) e or i e or i

*Type “d” may be used in case of Type “i” nonavailability. Type “d” is to be generally applied for all instrumentation within hazardous area at the oil movements offsites area.

Analyzer shelters shall preferably be installed in safe area. If installed in hazardous area, then shelters must be pressurized by taking air from safe area.

For offsite areas, analyzer shelters are not required where analyzer housings are rated for the environment. If analyzer systems can be procured that meet the electrical hazard rating of an area with no reduction in operability or maintainability as well as reducing capital costs, then such applications shall be recommended for COMPANY approval.

In certain areas defined by the COMPANY, “i” ratings are not allowed, “d” ratings only are acceptable.

13.3 TYPE TEST CERTIFICATE

Each electrical instrument or system to be installed in hazardous area shall be built according to IEC recommendations and corresponding national translations and publications.

The local regulations shall have precedence if they are more stringent than the international corresponding code. For each concerned type of instrument or instrument system, the CONTRACTOR shall obtain from the VENDORS (and before purchasing stage) a copy of the certificate of conformity to the standards delivered by a certified national authority.

13.4 CERTIFIED AUTHORITIES

• LCIE and CERCHAR in France • TUV (Technisher Uberwachungs-Verein) • PTB in Germany • CSA in Canada • UL in USA • BASEEFA in UK




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14.0 INSTRUMENT PASSIVE PROTECTION AGAINST FIRE

The following cables shall be fire resistant and meet IEC 60331:

a. Cables to fire pumps

b. Cables to remote fire fighting equipment

c. Fire detection circuits

d. Cables for ESD systems

e. Cables for safety evacuation lighting

f. Public address systems

g. Critical Control loops/valves required for shutting down the unit. Cables for MOVs on critical application or with large inventory of hydrocarbon (e.g. tanks, etc.)

h. Critical signals to monitor important process parameters

All other signal and control cables will be flame retardant and meet IEC-60332.

Accessories for ESD valves and actuators, and remote operated on/off valves will be protected from fire by installation inside protective local boxes. The boxes shall be rated for 30 minute fire ring without increasing internal temperature above the max. allowable limit for the actuator and accessories. The box design shall be provided with suitable access for operation of integral push buttons or to view local readouts/ status.

15.0 SELECTION OF INSTRUMENTS

15.1 GENERAL

The makes and types of instruments shall be in accordance with the COMPANY’S ‘List of Selected Instrument Equipment’.

In general, the process instrumentation, control system, safeguarding system, fire and gas system, ESD system etc. shall be based on distributed networked control instrumentation located in air conditioned pressurized rack and control rooms, and will be used in conjunction with electronic transmitters and I/P converters. Basic process control, start-up, monitoring and shutdown for main process, utility, off-site areas including the package units in these areas shall be done from DCS through the Unified Operator Interface concept. Critical loops should be defined carefully and redundancy up to field equipment shall be considered for high safety and reliability. For further details, refer to Project Specification DGS-IS-001.

All instrument material and components coming in contact with sour gas (as decided by piping material class), shall be certified per NACE MR 01-75 (latest edition).

Unless otherwise specified, the instrument ranges shall be selected such that the normal value will be between 50 and 75% of scale range taking into account the specified minimum and maximum values. Additional instruments may become necessary for normal minimum and maximum values. In these cases, a single scale and auto-ranging facility shall be provided in the DCS. For trip functions, the instrument range shall be selected such that the process trip value will be between 25 and 75% of transmitter/switch output range.




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Dedicated instruments shall be used for instruments in trip service and ESD service with individual sensor, tapping point, cabling and power supply systems.

15.1.1 In general, only transmitters shall be used for all types of logic. Switches shall only be used with COMPANY agreement.

15.2 CHARTS AND SCALES

Variable Chart Scale

Temperature 0-100 Linear Direct Reading

Pressure 0-100 Linear Direct Reading

Flow (Differential) Direct Reading Direct Reading

Flow (Linearized) Direct Reading Direct Reading

Level 0-100 Linear 0-100 Linear

Analyzer 0-100 Linear Direct Reading

Signal to Valves 0-100% 0-100%

15.3 RADIO FREQUENCY INTERFERENCE

Unless otherwise specified by the COMPANY, with reference IEC 61000-4, for portable radio transmitters/receivers which have an electromagnetic field strength of 10 mV in the frequency range between 20 to 1.000 MHz, the total effect of the radio frequency interference shall be equal to or less than +/-0.1% of the output span with the instrument enclosure (cover) in place, and equal to or less than +/-0.5% of the output span with the instrument enclosure (cover) removed.

15.4 TRANSMITTERS AND LOCAL INDICATORS

All transmitters shall be provided with permanent local integral indicators. If a transmitter output indicator is required, then additional indicators shall be installed in such a way that it can be read from the relevant control valve(s). All transmitters shall be Smart type, configurable as either analogue mode (4-20 mA output) or digital mode. This device shall be a two-wire, 4-20 mA, 24 VDC loop-powered unit, powered from the DCS section of the plant ICS. The device shall provide self diagnostics. The device shall also provide digital communication with the DCS through field proven communications protocol (HART or equivalent). This digital communication shall be easily upgradable to utilize the future international fieldbus standard once that standard is proven. Strong preference is given to systems that allow calibration, configuration and on-line diagnostics to take place in the DCS, e.g. an integrated system not a stand-alone platform. COMPANY will inform VENDOR as to the supplier of the DCS prior to any bid activity.

The standard pneumatic signal shall be 0.2 - 1.0 kg/cm2g.

For pneumatic transmitters, the local indicator shall have a nominal diameter of 150 mm.

Unless otherwise specified by the COMPANY, for electronic transmitters, the local external indicator shall be a moving coil meter with nominal diameter of 150 mm (approximately), depending on the selected make and type.

All local indicators shall have a scale calibration in accordance with Section 15.2.




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15.5 TRANSMITTER TEST/CONNECTION BOXES

Unless otherwise specified by the COMPANY, and if the transmitters are not already equipped with a socket plug for hand held calibrator, all SMART transmitters should have a connector box with plugs and sockets for connecting the instrument and for inserting calibration equipment in the signal circuit . The test connection box shall be as specified on Standard Drawing STD-IU-00031.

A smaller interface box, without the test facility, for terminating the field cable and connecting the instrument with a short flexible cable may be applied with approval of the company.

Notes: 1. In view of the long delivery time of these boxes, they should be ordered at an early stage, preferably with all boxes required for the project on one requisition.

2. The connector box shall not be used for connection of permanent local indicator.

15.6 FLANGE SURFACE FINISH

Where gaskets are required at the interface between equipment forming part of instrument engineering and equipment forming part of mechanical engineering, the following applies:

a. For high vacuum services (i.e. at absolute pressures of 20 mbar or lower) the instrument facing shall be flat and have a ‘super smooth’ finish with an average roughness of 1.6 micro meter (62.5 micro inches).

NOTE: The required O-ring groove shall be specified by piping engineering.

b. For all other services, the instrument facing shall follow the requirements as defined in the pipe class specifications. See Project Specification DGS-PU-003.

For details of surface finish, see ASME B46.1.

15.7 RATING OF PRESSURE-CONTAINING PARTS

For instruments which are subjected to operating conditions, the rating of pressure-containing parts shall be in accordance with the piping class, except that for carbon steel apparatus, in which case the rating shall not be less than ANSI Class 300.

15.8 SELECTION OF MATERIALS

15.8.1 General

All wetted parts of transmitters, pressure gauges, etc. including ancillary equipment shall be AISI 316L type stainless steel, unless other materials are required for the specified fluid/process conditions.

For material selection of control valves, see Project Specification, DGS-IE-003. For further guidance on the selection of materials, see Project Specifications DGS-PU-003 and DGS-IU-003.

Special attention shall be paid to the materials for instruments on low temperature service.




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The basis of material selection for instruments shall be per the Material Selection Diagrams. In all cases, material selection requires the approval of the COMPANY.

In all cases, choice of materials for each specific instrument shall be subject to review by the COMPANY.

15.8.2 On-Line Instrument

For the measuring elements in the instruments, the selected materials shall ensure a good measurement and be corrosion resistant. These requirements are satisfied by the materials specified in the following sections of this publication, related standard drawings and standard forms.

With reference to the selection of materials for “on-line” instruments, the service and/or type of plant is classified as follows:

a. general refinery service

b. special plants such as hydrogen fluoride alkylation plants

c. special services (utilities) with reducing acids such as hydrochloric and sulfuric acid

d. chemical plants

For instrument impulse line material, refer to Project Specification DGS-IU-003.

a. General refinery service:

• This covers hydrocarbons with sulfur components/naphthenic acids, water with ammonia and hydrogen chloride etc. It also includes sour services. For on-line instruments, all wetted parts excluding the diaphragm of pressure transmitters, differential pressure transmitters and diaphragm seals and pressure gauges on sour service shall be of AISI 316L type stainless steel. The measuring element diaphragm material shall be one of the following materials:

• Stainless Steel 316L

• A cobalt base alloy containing chromium (Cr) and molybdenum (Mo), such as Elgilloy (trade name) with the following composition, Cr = 20, Ni = 15, Fe = 15, Mo = 7, Co = 42. The manufacturer shall guarantee that weld decay is not expected by restricting the carbon content.

• Hastelloy and Monel for H2S concentrated service.

• Instruments on H2S / sour service shall be certified suitable for NACE MR-01-75

Pressure gauges on sour services shall be of Monel 400.

b. Hydrogen Fluoride (HF) Alkylation Plant Service:

For on-line instruments all wetted parts excluding the diaphragm of pressure transmitters, differential pressure transmitters and diaphragm seals shall be of Monel 400. The measuring element diaphragm material shall be Hastelloy C 276. It should be noted that only a small section of the plant will be classified in HF service. For the other sections of the plant for which the concentration of HF is sufficiently low, AISI Type 316L Stainless Steel should be selected; see general refinery service.




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c. Special Services (Utilities)

In utilities services (demineralization plant) strong reducing acids such as hydrochloric and sulfuric acid are often used. For on-line instruments all wetted parts excluding the diaphragm of pressure transmitters, differential pressure transmitters and diaphragm seals shall be Hastelloy B-2 or Hastelloy C-276. The measuring element diaphragm material shall be tantalum (Ta).

d. Chemical Plants:

The material selection for pressure transmitters, differential pressure transmitters, pressure gauges, manifolds and impulse lines, etc. is in general related to the material of the equipment and piping. No guidance can be given because of the large variations in products handled. As a general rule, AISI 316L will be suitable for stainless steel and carbon steel equipment and piping. In the case of special stainless steel with increased Mo content, Incoloy 825 and/or Hastelloy C-276 are applied for the equipment and/or piping, the selected material for pressure transmitters and differential pressure transmitters and manifolds, etc. should be Hastelloy C-276. In all cases, advice from the material specialist shall be sought.

15.8.3 In-Line Instruments

In addition to the above, the pressure-containing parts of the instruments shall be compatible with the operating conditions. For “in-line” instruments subject to operating pressure, temperature, erosion and corrosion, e.g. orifice plates or positive displacement meters, the selection of materials should be in accordance with the piping class, unless Section 15.8.2 is overruling. In cases where special materials shall be used, this shall be clearly marked on the respective items.

15.8.4 Surrounding Atmosphere

Corrosion from the surrounding atmosphere. Special attention shall be paid to instruments and ancillary equipment which will be used in, for example, marine (jetty) services and/or installed in coastal and offshore environmental conditions.

15.8.5 Oxygen Service

The following special requirements for instrumentation on oxygen service overrule, where applicable, other specifications:

a. All instrument parts in contact with oxygen shall be AISI 316L type stainless steel, and have smooth surfaces.

b. Gasket material shall be PTFE for pressures up to 40 kg/cm2g.

c. Filling fluids for capsules and diaphragm seals shall not present a hazard if diaphragm should fail and shall be selected accordingly. A suitable liquid is Fluorolube. The special liquid shall be indicated on the outside of the capsule, e.g., by etching.

d. The instruments shall be very carefully degreased, cleaned and dried by the MANUFACTURER before dispatch, and also on site immediately before installation. The MANUFACTURER shall certify and tag the instruments ‘suitable for oxygen service’. For cleanliness and inspection methods, see ASTM G93-88.




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NOTES:

1. All instruments in contact with oxygen shall be ordered separately from other materials.

2. Sealed packaging shall be specified to keep the instruments clean during transport and storage.

15.8.6 Chlorine Service

The following special requirements of instrumentation on chlorine service overrule, where applicable, other specification:

a. Filling fluids for capsules and diaphragm seals shall not present a hazard if the diaphragm should fail and shall be selected accordingly. A suitable liquid is ‘Fluorolube’. The Special fluid shall be indicated on the outside of the capsule, e.g. by etching.

15.8.7 Diaphragm Seals

Diaphragm Seal shall normally be integral with the instrument. The application of diaphragm seals with capillary extensions shall be kept to an absolute minimum.

Special attention shall be paid to diaphragm seals on low differential pressure and pressure applications.

Applications of diaphragm seals with capillary extensions require the written approval of the COMPANY.

When a diaphragm seal is required, the largest practical size should be applied. Special coating materials may be considered where these will improve the corrosion resistance of the diaphragm. The type of coating material requires the written approval of the COMPANY.

The capillary tubing material shall be of AISI type 316 type stainless steel and be shielded by flexible stainless steel tubing with a neoprene or PVC cover, according to MANUFACTURER’S standard.

The length of capillary tubing shall suit the application, but the length should be at least 1.0 meter. For differential pressure applications the capillary tubings shall be of the same length.

The maximum allowable operating temperature for liquid-filled diaphragms shall be observed.

The above requirement shall be taken into account when selecting and specifying the instrument.

15.9 FLOW MEASUREMENT

For flow measurement several types of instruments can be used - differential pressure devices, area meters, positive displacement meters, sonic meters, vortex meters, turbine meters, magnetic meters, coriolis, etc.




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15.9.1 General

In general D/P type flow measurement will be preferred for safety and control/monitoring applications having one or more of the following features:

a. Line size from 2 inches up to 24 inches.

b. Reynolds number at minimum flow of 20,000 or more.

For this type, flow measurement accuracies are reliable over a 3-1 rangeability. For 10-1 rangeability use rotameters, area meters, turbine meters, vortex shedding meters, and positive displacement meters. For lines under 2 inches and other special applications, use integral orifice meters, target meters, corner tap calibrated runs, rotameters, turbine meters, positive displacement meters and meters for mass flow. For viscous fluids, use quadrant edge orifices, target meters, area meters, and positive displacement meters. For dirty fluids, suspended solids, and slurries, use eccentric orifices, segmental orifices, venturis, magnetic meters, and rotameters. For corrosive fluids, use magnetic meters and rotameters. For low differential pressure loss, use venturis, pitots, proprietary averaging pitot tubes, and vortex shedding meters. For compressor suction line, only Venturi tubes shall be used.

For material balance and sales meters, flow shall be compensated. Custody transfer meters shall have their own meter prover.

15.9.2 Differential Pressure Transmitters

Standard signal for electronic transmitters shall be as per Section 15.4. For pneumatic transmitters, 0.2 - 1 kg/cm2g signal range shall be used.

a. Electronic differential pressure instruments shall be strain gauge, or capacitance type diffused silicon or semi-conductor type.

b. Temperature compensation and time constant to be per Rosemount Model 3051 or better for differential pressure flow measurement.

c. Pneumatic differential pressure instruments shall be blind force balance type.

d. Bellows type with integral bellows and 150 mm dial can be used for local indication. (Barton type meter).

All direct connected flow meters will have measuring system over range protection equal to measured chamber pressure rating.

The use of Mercury and Liquid Filling type instruments shall require approval from COMPANY.

15.9.3 Orifice Plates

In general, orifice plates shall be the primary measuring device for differential pressure instruments.

Measuring elements shall be designed as recommended by ISO 5167 and 5168 standards.




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Orifice plates shall be ANSI 316 unless otherwise specified and mounted between flange tap type orifice flanges complete with jack screw.

Each plate shall have tab which projects beyond flanges.

The word UPSTREAM, bore diameter, tag. No., line size and pressure rating will be permanently marked on upstream side. The item number and plate material will be permanently marked on downstream side.

For custody meter orifice flanges and other applications with large rangeability (e.g., well flow etc.) retractable type orifice flanges shall be provided.

For further information, see Project Specification DGS-IE-002.

15.9.4 Orifice Calculations

The ratio of the orifice diameter to inside pipe diameter or beta ratio is between 0.20 and 0.75. Meter differentials of 500, 1250, 2500, 5000 mm H2O shall be used. 2500 mm is preferred, calculated per ISO 5167. Calculations shall be for flange type orifice meter.

15.9.5 Lines 2” and Under

Use of meter runs and integral orifices is allowed if plugging is not a problem.

15.9.6 Straightening Vanes

Use of straightening flanges shall be avoided. If used, they shall be flange type, 316 SS, or vane type and meet API MPMS 14.3.2 or as per piping specification if piping specification is more stringent.

15.9.7 Flow Integration

Continuous flow integration may be accomplished by locally mounted integrators or integrators mounted in control building. If a computer is used, integration should be done within the computer. Integration may be done within the DCS system. For custody transfer applications, special care shall be given to guarantee the security and integrity of the flow calculation parameters within the DCS (memory, etc.).

15.9.8 Displacement Meters

Displacement meters may be used for batch operations, or high accuracy totalizing when rate of flow is not required. A removable strainer shall be installed ahead of each meter.

For further information, refer to Project Specification DGS-IE-001.

15.9.9 Turbine Meters

Turbine meters may be used on clean liquid streams where high accuracy or greater flow range-ability is required.




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Applications include accounting streams and in-line blending. For accounting applications, suitable meter provers shall be provided.

A strainer is required ahead of each meter along with differential pressure transmitter across strainer giving an alarm in DCS/Flow computer. Dual pick-up and transmitters shall be provided.


15.9.10 Magnetic Meters

Magnetic meters may be used for conductive liquids such as potable water, sea water, and severe liquid services such as slurries, some corrosive fluids and gravity flow.


15.9.11 Rotameters

If the stream can not be properly measured with an orifice in a 2-inch line, with integral orifice d/p cell, or with corner tap meter runs, area type meters may be used for flow measurements. Also, use area meters: (1) where a suitable orifice installation cannot be used; (2) for highly viscous or highly corrosive materials; (3) for fluids containing solids in suspension; or (4) when rangeability greater than three to one is required. Glass tube meters with light metal protective cases are used for air and water unless the temperature or pressure exceeds the meter rating. Meters on other services will be armored type, either metal tube, or glass tube within a pressure sealed enclosure. Indicating scales are graduated 0 to 100 and a scale factor is used.

Area meter transmitters of the deflection type and may be used. Local indication is by a deflection pointer and scale or a receiver gauge in the transmitter case. Electronic transmitters shall be used for interfacing with DCS.


15.9.12 Vortex Meters

Vortex meters may be used for the following application:

a. Reynolds number higher than 20,000 (best performance for RE > 100,000).

b. Flow rates which will not go beyond 115 to 120% of the design value (to prevent damage to shedding bar).


15.9.13 Coriolis Meters

Coriolis type mass flowmeters shall generally be preferred for critical applications requiring highly accurate and reliable measurements of mass flow and/or density. The mass flow reading shall be insensitive to changes in temperature, pressure, flow profile and fluid viscosity. The mass flow reading shall also be unaffected by the presence of small volumes of air or gas in the flowing stream.




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The transmitter shall be of the “smart” type with modular microprocessor based electronics suitable for installation in the ambient conditions described in Sections 12.0 and 13.0 of this specification. The transmitter shall have two analog 4-20 mA outputs configurable for flow rate, density, or temperature.


15.10 LEVEL MEASUREMENT

15.10.1 General

For most applications above 1219 mm (48 inches) or where the temperature of the process fluid is below 0oC, use differential pressure transmitters. For heavy viscous liquids these type instruments will be purged or have seals. External cage displacement type will be used only on clean liquids. Use float and tape on tanks at or near atmospheric pressure. Gauge glasses will be used for all vessels except those with float and tape, or cryogenic temperatures, or extremely viscous liquids. For level pre-alarms, level switches can be used. However, for level shutdown/trip alarms, level transmitters shall be used.

For most applications, the differential type level transmitters may be mounted on a bridle along with the level gauge glasses. Level switches for noncritical alarms and noncritical interlocks may also be bridle mounted, along with the differential level transmitters and level gauge glasses. For more critical applications, level switches may be directly connected to the vessel. Where SIL Level 3 ESD systems are required, the signal source level transmitters for shutdown shall be mounted on separate vessel nozzles.

For liquid-liquid interface service (e.g. water boots on vessels), displacer type transmitters and transparent type level glasses, each directly connected to the vessel shall normally be used. The use of bridles in liquid-liquid interface shall be minimized, but may be considered where multiple level devices are required, and the temperature differences between the vessel contents and the bridle contents will not cause measurement error.

15.10.2 Gauge Glasses

Flat glass reflex type gage glasses are used for local level indication. There are four exceptions. In these cases, transparent type with integral illuminators suitable for hazardous area classification shall be used:

a. Interface

b. Very high viscosity fluids

c. Acid or caustic

d. Steam and condensate above 20 kg/cm2g

All of these require through-vision or transparent gauge glasses and illuminators. For caustic and some acid services, protective shields are used. For steam and condensate above 20 kg/cm2g, Mica shields are used. Frost shields shall be used when operating temperature is below 0°C.

Gauge glasses will cover complete operating ranges of transmitters and alarm switches.




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Gauge glass center to center distance for each gauge shall not be more than 1540 mm. For level coverage beyond 1540 mm, multiple level gauges shall be used with a minimum overlap of 50 mm in visibility.

Gauge glass to be assembled with gauge cocks to meet vessel/stand pipe center to center distance and visibility requirements. Only one size of gauge glass shall be used as a standard whenever possible.

All reflex and transparent gauge glasses have ½-inch female NPT end connections. Gauge glass valves are angle pattern offset type with internal ball check and removable seats. The valves have union tank connections, ¾ inch x ½ inch NPT male or 2 inch flanged. Valves connect to gauge glasses with ½ inch Schedule 80 nipples. Vent and drain connections are plugged with barstock plugs. While, gauge glasses in general shall be of top and bottom connection, sometimes side/side connections may be required. Vents and drains of level instrument shall be connected to a suitable header.

The use of local magnetic level indicators in specific cases shall be explored.

The readable range of a level gauge shall cover the required operating range and the entire range of other level instruments on the same process equipment.

15.10.3 Storage Tank Level Measurement

Local level indication for large tanks or spheres is by ENRAF 854, 873, SAAB REX or latest provided with the latest microprocessor based Tank Level Management System using 2-wire serial link (hiway based). It shall be possible to link temperature and density measurements into this system. Tank level indicators shall be provided with stilling well, isolation valve, and calibration chamber as per VENDOR’S recommendation.

At least 3 temperature points and a density measurement shall be provided per tank.

15.10.4 Float and Displacement

Displacement type will be used for clean liquid applications up to 1219 mm (48 inches). External displacer cages, segregated from vessels by block valves shall be used. External displacer cages will be supplied with 2 inch minimum flange side and bottom connections and rotatable heads. 4 inch top mounted displacers shall be used where side and bottom type is unsuitable and shall have a stilling well of the diameter as the vessel nozzle. The chambers shall have isolation as well as vents and drain valves.

Displacement type instruments will be used up to 1219 mm and where the operating temperature is above 0°C. For temperatures lower than 0°C, even for measurements up to 1219 mm, a DP transmitter shall be selected to minimize the effect of liquid boiling and to obtain a stable measurement. For high temperature, compensation due to density changes shall be calculated to obtain the true level.

For interface, special consideration will be given to displacer diameter to ensure sensitivity. Ultrasonic type instruments may also be considered.

Electrical switch contacts shall be sealed snap acting micro-switch (single pole, double throw 24 VDC. Mercury bottle type switches shall not be used. Liquid level switches shall be used for alarms, interlocks, and not for ESD systems. Transmitters shall be used for ESD systems.




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For high temperature (higher than 200°C) as well as low temperature (lower than 0°C), insulation extension or torque tube extension shall be applied.

15.10.5 Differential Pressure Transmitters

Differential type will be used on all applications requiring wide ranges (above 1219 mm). Diaphragm type level transmitters are acceptable.

Remote seals may be used where plugging exists.

DP transmitters shall have zero elevation and suppression kit. For Level transmitter signal range, refer to Section 15.4. DP transmitters shall be strain gauge or capacitance type.

DP Transmitters shall not be used in high pressure service where the difference between vapor density and liquid density at operating conditions are too small to achieve reliable measurement. For ratings higher than ANSI 600 lbs., the calibration calculation shall account for vapor density at operating conditions. Use of displacers shall be considered if the calculation results in a calibrated span of less 1219 mm H2O.

To obtain in such cases satisfactory indication of the actual level under all operating conditions, consideration should be given to correcting the level transmitter output by a computing device using the output of the pressure transmitter or other suitable means.

15.10.6 Capacitance

Capacitance probes or electrodes can be used for alarm, or on-off level control when the fluids’ dielectric constants vary enough to determine the interface. They also may be used for solids and slurries.

15.10.7 Nuclear

Nuclear absorption is required to conform to government requirements. They are used where sensor cannot contact the process fluid.

15.11 PRESSURE MEASUREMENT

For pressure three principal types of primary elements shall be used: bourdon tubes, bellows and diaphragms.

Helices and spirals are a modification of bourdon tubes. Other types, such as strain gauges and piezoelectric elements may be used.

15.11.1 General

Pressure instruments fall into three groups, transmitters, direct reading instruments and pressure switches.

Electronic pressure instruments shall be solid state strain gauge or capacitance type.

Pneumatic pressure instruments shall be blind force balance.




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Use C type bourdon tubes, spiral or helical elements for all pressure applications with range spans 0-1 kg/cm2 and larger.

Provide clean out diaphragm type chemical protectors for pressure instruments where measured material will clog or corrode the measuring element.

All pressure gauges and pressure switches shall be provided with over range protectors (ORP) when the maximum operating pressure is beyond the over range pressure for a particular range.

Use bellows for ranges minus 1 kg/cm2 to 1 kg/cm2 and for absolute pressures.

Use diaphragms for ranges between atmospheric pressure and 0.3 kg/cm2. Pressures can be measured with D/P cells where necessary.

Use D/P cells with one side open to atmosphere for low pressures and vacuum ranges at or near atmospheric pressure.

15.11.2 Pressure Transmitters

All electronic pressure transmitters shall be Smart Type. Refer to Section 15.4.

0.2 to 1.0 kg/cm2 shall be applied for pneumatic transmitters.

Range and range spans shall be adjustable. Select ranges listed in Section 15.11.4 where possible.

15.11.3 Local Pneumatic Indicating Controllers

Standard signal shall be 0.2 to 1.0 kg/cm2, with spiral or helical elements, motion balance controller and weatherproof case.

15.11.4 Pressure Gauges

Gauges shall be entirely made of stainless steel and shall have 100 mm diameter white dials, back blowout protection and seals where application requires them. Where excessive vibration is probable, liquid filled dampening devices shall be used. Snubbers shall be provided for pulsating/oscillating services. Over range protectors shall be provided where the design pressure of vessel/system exceeds the maximum over range pressure.

Ranges shall be:

0-1, 2, 3, 4, 6, 10, 16, 25, 40, 60, 100, 160, 250, 400, 600, 1000 kg/cm2 gauge.

Minus 1 kg/cm2 to 1, 2, 3, 4, 6 kg/cm2.

15.11.5 Pressure Switches

Direct mounted pressure switches shall be used only for fire detection circuits and in Package units. For main plant applications, pressure transmitter with alarm card or receiver switch shall be used.

Switches shall have internally accessible adjustments for set point.




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Pressure switches shall have fixed differential.

Adjusters shall be provided with scales. Contacts shall be single pole double throw, except where double pole double throw snap acting are available and suitable.

Cases shall meet electrical classification of the area where located.

15.12 TEMPERATURE MEASUREMENT

15.12.1 General

Temperature measurements mainly will be made by Thermocouple, Resistance Element, or Bimetallic Thermometer.

All electronic temperature transmitters shall be Smart Type, conforming to the requirements of Section 15.4.

Dial thermometer check points will be used for all local temperature controllers.

Separate thermocouple or RTD check indication points will be used for control room controllers.

RTD’s shall be applied for temperatures up to 500°C except special applications like Reactors which shall be based on Thermocouples. New technologies such as IR thermocouples and high range RTD may be explored by Engineer.

For control applications, use thermocouple or RTD 4-20 mA DC transmitters mounted within 3 m of element heads with direct connection to DCS (multiplexer not required).

For indication loops only use thermocouple or RTD direct. Use of multiplexer system is not acceptable.

Normally, use bimetallic, every angle dial thermometer for local indication.

Minimum use should be made of filled bulbs. This shall be limited to noncritical services, such as lube oil and auxiliary systems in package units.

Calibration for resistance bulbs will be to DIN 43760 Class A.

Thermocouple burnout must produce safe controller and/or indicator action or failure.

Use local pneumatic or electronic controllers for simple control such as tank heaters, on-off control.

15.12.2 Thermocouples

For the arrangement of thermocouple mounted in thermowells, see Standard Drawings STD-IU-00021 through 00024; for surface mounting, see Standard Drawing STD-IU-00026.

Unless otherwise specified by the COMPANY, the cable entry shall be M 20 / 1.5.

The thermocouples shall be of the mineral-insulated metal sheathed type with measuring junction free from earth (minimum insulation 10 Mohm @ 100 VDC).




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Thermocouple tolerance class shall be in accordance with IEC 60584-2.

The thermocouple shall be:

a. type K tolerance class 1 for temperatures from -20°C to 1000°C

b. type T tolerance class 3 for temperatures below -20°C

c. type B tolerance class 2 for temperatures above 1000°C

Thermocouple tolerances shall be in accordance with IEC 60584-2. NOTES:

1. For thermocouple type letter designations refer to IEC 60584-1.

2. Special attention shall be paid to preventing the introduction of cold junctions at the interconnections of thermocouple compensation cables, where dedicated thermocouple terminals shall be used.

The use of duplex couples shall be avoided except where special thermowell constructions are required or where process conditions demand exotic materials for vessels, pipe and/or thermowell. The use of one duplex thermocouple for control service and the other for the initiation of safeguarding systems is not allowed.

Where type K thermocouples operate on temperatures services above 800°C and hydrogen diffusion to the thermocouple material may be expected, magnesium-oxide insulated thermocouples with inconel protective sheeting should be used, or a titanium getter wire shall be specified in addition to the normal execution.

Thermocouples for measuring skin temperature of furnace tubes shall be in accordance with Standard Drawing STD-IU-00025.

In each furnace two additional type B thermocouples shall be installed close to two of the type K skin couples for checking purposes. These type B thermocouples shall be connected to an accessible junction box for termination to portable instrument. NOTE: For monitoring furnace tubes at very high temperatures, such as in hydrocracking furnaces, consideration may be

given to the use of optical pyrometers, provided these are then only used for trend indication.

With regard to deterioration (drift) of type K thermocouples at very high temperatures, such as in hydrocracking furnaces, consideration should be given to the use of type B thermocouples, provided these are then only used for furnace coil balancing.

All thermocouples used for furnace coil balancing shall be from the same batch and be calibrated/certified for the specified operating temperature. In addition to the standard identification, the thermocouples shall be provided with batch and certificate number.

For Reaction Furnace applications in Sulfur plants, pyrometers shall be used. In order to properly calibrate the pyrometers, a Type R thermocouple with a double walled ceramic thermowell with a 50% length metallic sleeve and a continuous inert gas (N2) purge shall be provided.




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Where multiple thermocouple assemblies are required, e.g. for measuring temperature at several levels in a reactor, they shall be assembled from mineral-insulated thermocouple elements of appropriate lengths, in a flexible metal sheath or bound together with a metal wire or mesh to form a composite flexible assembly per Standard Drawing STD-IU-00027. NOTE: Where specified the elements with wells may be delivered in one assembly.

The outside diameter of the individual thermocouple assemblies shall be adequate for mechanical strength, but sufficiently small to allow the complete assembly to be coiled to a radius of 0.75 meters for shipping and for flexibility during installation.

The thermocouples shall be supplied complete with flexible insulated tails of thermocouple material. These shall end in a junction box containing a thermal block suitable for connecting the flexible tails to thermocouple signal cables having solid conductors of 1.2 mm diameter. The mechanical mounting of this junction box shall be appropriate for the type of thermowell being used.

15.12.3 Resistance Thermometers

For the arrangement of resistance thermometer assemblies mounted in thermowells, see Standard Drawing STD-IU-00021 through 00024; for surface mounting see Standard Drawing STD-IU-00026.

Unless otherwise specified by the COMPANY the cable entry shall be M 20 x 1.5.

The resistance thermometer elements shall normally be of the platinum type 100 ohm at 0°C tolerance Class A.

Resistance thermometer tolerances shall be in accordance with IEC 751. NOTE: For relation between resistance and temperature refer to IEC 751.

The resistance thermometer elements used for average temperature measurements in storage tanks may be made of other materials, e.g. nickel or copper, the characteristic shall then be in accordance with the MANUFACTURER’S standard.

15.12.4 Instruments for Thermocouple and Resistance Thermometers

Instruments connected to thermocouples shall have automatic compensation for temperature variations at the reference junction.

Hardwired indicating or recording instruments shall be of the electronic self-balancing or analogue-to-digital conversion type. Direct operating-moving coil type instruments shall not be used.

Instruments forming part of safeguarding systems or temperature control systems shall have a thermocouple burn-out feature, driving the instrument in the direction which will cause a change to the operationally safest value.

Instruments connected to resistance thermometers shall have a 3-wire system (usually for bridge-balancing circuits) or 4-wire system (typically for constant current circuits).




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15.12.5 Bimetallic Dial Thermometers

Bimetal thermometers shall be heavy duty weatherproof, 150 mm diameter, rotatable head, 316 SS material complete with thermowell. Bimetal thermometers shall be used for local indication of temperature from - 30°C to + 400°C.

15.12.6 Thermowells

15.12.6.1 General

Thermowells are provided for four general purposes:

a. Thermocouple or Resistance Bulb Assemblies

b. Dial Thermometers

c. Filled Bulbs

d. Test Wells

Thermowells shall be purchased with instruments. All wells shall have the insertion length stamped in a location visible after installation.

15.12.6.2 Standard Construction

Construction shall be drilled solid barstock. If welded thermowells are used in hydrogen service they shall have full penetration welds to prevent hydrogen (migration) pocketing.

15.12.6.3 Interchangeability

Where practical thermocouples, RTD’s and filled bulbs are to be interchangeable, and any of these can be inserted into a test well.

15.12.6.4 Connections

Thermowell process connection shall normally be 1-1/2 inch flanged for piping and 2” for tanks and vessels. All thermowells shall have a ½ inch NPT female connection for measuring element. Thermowells in nonprocess, low pressure service (e.g. cooling water) may be 1” NPT. Thermowells in heater flue gas service shall be 1-1/2” NPT.

15.12.6.5 Materials

The well and flange material is Type 316 stainless steel unless the application requires a higher alloy. If welded construction is used, the well and flange material shall be 316L SS.

15.12.6.6 Well Length

Thermowell lengths are based on vessel or pipe size. For line sizes less than 4”, the line shall be expanded to 4” for installing the thermowell.




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For well lengths and diameter and thermometer stems, see ‘U’ dimension, Table 1. Filled bulb systems are treated as special items.

Thermowell “U” Dimensions

TABLE 1

PIPE SIZE/PROCESS U LENGTH (MM)

4” 230

6” 255

8” and above 305

Equip. 455 (typical)

NOTES:

a. Nonstandard items, such as special thermocouple assemblies, are not covered by the above table.

b. Dimensions for flanged wells are based on a nozzle projection of 150 mm from outside of pipe or vessel to face of flange, for all pipe sizes. If projection length is different than 150 mm, “U” dimensions should be suitably modified.

c. This design of Thermowell is applicable up to and including ANSI 600 lbs. For 900 lbs and higher ratings, manufacturer standard shall apply subject to review by the ENGINEER.

15.12.7 Well Limitations

Calculations for flow induced vibration will be made for all wells where velocity is above 6 meters per second.

15.12.7.1 Test Wells

Use standard thermowells. Each well to have ½ inch 316 SS plug and chain connected to well.

15.12.7.2 Column Thermowells

Normally install column thermowells in the liquid unless noted otherwise on the P&ID. The preferred location for thermowells in columns is in the downcomer from the tray on which the temperature is desired. The thermowell locations should be about three to six inches above the tray on which the downcomer feeds. This places the thermowell in the liquid at a point where there is good mixing. If it is impossible to locate the well in the downcomer, then locate the well in the liquid immediately ahead of the downcomer weir on the tray on which the temperature is desired.

Orientation is to be such that thermowells, thermocouples, etc., are accessible from a ladder or platform.




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15.13 ELECTRICAL PARAMETERS

Where measurement of electrical parameters, such as AC current, voltage, power consumption, or temperatures in electrical equipment, such as transformers or motors, are required in the control room, signal converters should normally be installed in the electrical switchgear for providing:

a. a potential free on/off signal for alarm annunciation or safeguarding functions and status indication.

b. a 4 to 20 mA DC signal measured variables (I, V).

These converters shall be capable of preventing damage to the main plant instrumentation in case of an insulation failure in the electrical equipment.

15.14 SPEED INSTRUMENTS

Speed-measuring instruments are usually supplied as part of rotating equipment, see Project Specification DGS-IU-007 and Machinery Condition Monitoring Specification DGS-IS-011.

On large rotating equipment, the speed measurement should have a separate channel in the machine monitoring system.

15.15 MACHINE MONITORS

15.15.1 General

For monitoring the vibration and shaft position of large rotating equipment, the probes and oscillator-demodulators form part of instrument engineering but are usually supplied with the equipment, see Project Specification DGS-IU-007 and Machinery Condition Monitoring Specification DGS-IS-011. The make and type of these items shall therefore be agreed upon between instrument engineering and mechanical engineering at an early stage of the project.

The following statements are based on the usual situation where each measured value (axial shaft position or radial vibration) will have independent probes and oscillator/demodulators, hereafter called ‘channels’.

15.15.2 The Monitors

Where permanent machine monitoring is required, the monitors shall:

a. be in accordance with API Std 670 (Unless otherwise stated below);

b. preferably be suitable for an electricity supply of 24 VDC, floating;

c. be suitable for mounting in standard 483 mm (19 in.) racks;

d. be installed in system cabinet(s) for machine safeguarding in SISs; and

e. include all functions for machine monitoring as required by mechanical engineering.




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15.15.3 Monitoring Functions

Where axial shaft position is monitored, this will normally be used for alarm annunciation and for machine safeguarding.

These monitors shall then be of the dual-channel input type with a selector switch enabling a shutdown initiation by either channel alone or by both channels together when reaching the set point(s), i.e. a ‘dual voting’ monitor. NOTE: During normal operation, the selector switch shall be in the dual-voting position where both channels are required

for initiating a shutdown. Should one channel become inoperative, the remaining healthy channel shall be selected for the shutdown.

The monitors shall not have a shutdown override switch (shutdown bypass). NOTE: This deviates from API Std 670. Where a shutdown override is required, this shall be incorporated in the

(downstream) binary logic safeguarding system.

Where radial vibration is monitored, the monitors may be of the single channel or dual channel type: for bearings, the monitor shall select the highest signal for the shutdown function, if required.

The phase-reference transducer channel, if present does not need a permanent monitor, this signal shall be available on a test socket for orbit analysis, etc. by mechanical engineering.

15.15.4 Monitor Display

The display should be microprocessor based and consist of:

a. alarm annunciation (visible and audible) for:

• circuit fault monitoring for each system

• a pre-alarm (alert) and trip alarm (danger) for both shaft position channels per casing

• a common pre-alarm (alert) and a common trip alarm (danger) for all vibration channels per casing

• gap voltage and alarm and trip limits

b. indicators for each monitored channel, as called for on the P&IDs.

Each monitor shall be provide with potential free contacts for external alarms and a 4 to 20 mA auxiliary output for remote monitoring.

The monitoring system shall have a serial interface based on the Project ICS Specification DGS-IS-002 to convey individual channel data (among value and alarm status) to the DCS or Computers. In addition, it shall have a port for connecting to an off-line vibration analysis system for Dynamic and Transient data.

When indicated in the P&ID, the display on the local panel (near the rotating equipment) should comprise:

a. pre-alarms (alert) and trip alarms (danger) as specified above for the main panel.

b. indicators for each shaft position and radial vibration channel, as called for on the P&IDs.




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15.15.5 Typical Arrangement

A typical arrangement for a machine monitoring system comprising all facilities mentioned above is shown in Project Specification DGS-IS-011.

For each individual case a decision shall be made which of these facilities are required, and the necessary instrumentation shall be arranged by instrument engineering. NOTE: Machine monitoring systems as with driver control signals for variable speed drivers (VSD) are considered as an

integral part of the VSD system and therefore will not conform to Project Specification DGS-IS-011.

15.16 ON-LINE PROCESS STREAM ANALYZERS

In principle, the make and types of on-line process stream analyzers shall be in accordance with the ‘List of Selected Instrument Equipment’ as prepared by the COMPANY in an early stage of the project. When more detailed information on the intended application is available, the CONTRACTOR shall check whether other makes or types would be more suitable and, if so, shall propose these for written agreement by the COMPANY.

The requisitions shall contain all data necessary for ensuring a rational purchasing procedure and particular attention shall be paid to operating conditions - including composition - of the sample as presented to the analyzer. See also Project Specifications DGS-IU-010 and DGS-IU-011.

Especially in cases where the releases of flammable substances may occur in analyzer enclosure, detailed attention shall be paid to providing an adequate type of protection for use in explosive gas atmosphere. Analyzers including sample handling, shelters, disposal, etc. shall be in line with the Standards referred to in Section 2.0.

15.17 RECEIVER INSTRUMENTS

Project will minimize the use of recorders. Trend recording shall be available in the DCS system. However, discrete recorders shall be provided for certain critical applications.

Recorders will be incorporated into the DCS console architecture.

15.18 CONTROL VALVES

15.18.1 General

In general, globe body pattern is selected to fulfill most of the control valve requirements. Globe bodies are available with top and bottom guided trim or with cage guided trim. Top and bottom guided plugs are available in single or double seated configurations. Cage guided trim is available for balanced or unbalanced operation and is the type selected for most general applications. Valve trim is selected on the basis of operating conditions, service, control range, and low noise generating potential. Special angle patterns with customized trim are used in liquid service to prevent cavitation and in steam service to prevent excessive noise when there is a high differential pressure to downstream pressure ratio. Rotary valves are used to achieve higher capacities and used for slurries and salting service to reduce effects of erosion in the valve body.

Control valve body connections will be flanged, integrally cast, with the exception of butterfly valves which may be lugged.




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In general, butterfly valves are used where the available pressure drop is low or when greater capacities are needed.

Valve actuator selection is based on the force required to move the plug and provide proper shutoff. The manufacturer must provide an actuator that will throttle the valve at the maximum pressure drop specified and perform within the performance requirements below. The preferred actuator is the spring diaphragm type, but based on the application and design, balanced diaphragm, balanced piston, piloted piston, or piston and spring may be used.

The performance requirements are as follows:

a. Valve Leakage - For normal service not over 0.5 percent of maximum capacity, FCI Class II. For tight shutoff not over 0.01 percent of maximum capacity, FCI Class IV. For bubble tight shutoff or some degree below 0.01 percent, the valve will be specified bubble-tight, FCI Class V.

b. Actuator Range - Where possible, all valves operating at service conditions shall travel over their full range with an actuator loading pressure of 0.2 to 1.0 kg/cm2g.

For additional information, refer to Project Specification DGS-IE-003.

15.18.2 Sizing and Noise

Control valves shall be sized for minimum wide open capacity of 110 percent of maximum flow. The selected valve should normally be 60 to 80 percent open at normal flow. The selected valve shall be no less than 10 percent open at minimum flow, or within the MANUFACTURER’S minimum throttling Cv recommendation.

Butterfly valves shall be sized for a maximum flow at 60 degrees angular opening, except for a characterized vane valve (such as the “Fishtail”) which may be sized at 90 degrees angular opening. Three-way valves shall be sized to pass maximum flow through either port with minimum available pressure drop through the same port.

Valve noise in general must be 85 dBA or less measured at a distance of 1 meter from the valve for any flow condition. The treatment to obtain this rating shall be obtained by methods a. through d. If method a. cannot achieve 85 dBA, the other methods shall be considered:

a. Use special valve trim (DRAG type or equal)

b. Add a diffuser or silencer

c. Add acoustic insulation

d. Use heavier wall pipe

Where noise attenuation is achieved by using valves or diffusers with small flow passages, strainers will be used to avoid plugging these passages.

See Project Specification DGS-MU-008 for further information.




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15.18.3 Design

The valve body and trim material will be at least equal to the materials for hand valves in the same service shown in the piping line classification. See Project Specification DGS-PU-003. Trim material for control valves with globe bodies shall be 316 stainless steel for general applications. Normally, control valves shall be flanged, except valves such as butterfly.

The minimum body size for steel and alloy body valves is 1 inch. When valves smaller than these minimums are required, use a reduced size inner valve. For general process services, valves 1 inch and larger, shall be provided with process flanges. Valves in highly corrosive service will be flanged for all sizes. The body pressure-temperature rating shall accord with the line classification. Flanged globe valve face-to-face dimensions shall accord with ANSI B16.10.

Minimum body rating shall be Class 300, except for butterfly valves where 150 lbs. rating is acceptable. Only 1 inch, 1 1/2 inch, 2 inch, 3 inch, 4 inch, 6 inch, 8 inch, 10 inch, 12 inch, and higher sizes shall be used.

15.18.4 Inner Valve

Control valves for most applications will use an equal percentage characteristic. Conventional three-way valves will use a linear inner valve. Use linear valves for ratio applications unless a high variable pressure drop condition exists. Use quick opening types for pressure regulators, bypass control, and some applications with linear measurements. Special inner valve types will be used to handle slurries or other erosive streams.

Use special coatings and hardened alloys for inner valves when the pressure drop is high across the valve seats, or when the temperature is extremely high or low, or when the process fluid is highly corrosive or erosive. Control valve trim shall be stainless steel as a minimum. Hardened stainless steel or stellited facings shall be furnished for valve plugs, seat rings, guide posts, and bushings for pressure drop, which exceed 10 kg/cm2, or for fluids which contain solid particles, and all steam applications.

15.18.5 Actuators

Pneumatic actuators include spring-loaded diaphragms, springless diaphragms, and cylinder actuators. Actuators for electronic control systems are the pneumatic type using electropneumatic transducers. Actuators will generally be sized to stroke the valve when the maximum pressure drop is equal to:

a. The normal inlet pressure assuming zero down stream pressure.

b. The pump shutoff pressure at normal suction pressure.

c. Relieving set pressure plus normal pump differential pressure if a pumped system.

d. Relieving set pressure of a column or vessel that needs to be blocked in against a relieving condition.




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15.18.6 Packing

Bolted type packing box for globe body valves would be used and MANUFACTURER’S standard packing for the service conditions shown on the data sheets. For body temperatures above 200ºC or temperature below 0ºC, use extended bonnets. Use Teflon packing for general applications. Use conventional packing with grease seal and lubricator assembly, only where service conditions prohibit the plastic type. Bellows-sealed packing boxes are used for special applications involving toxic or hazardous fluids.

15.18.7 Hand Control Valves

Hand control valves are high lift type with back seats, characterized plug, fine threads, and stem position indicator. They will be sized in the same way as automatic control valves.

15.18.8 Self Actuated Valves

Use self-actuated valves (with internal sensing) for simple quick acting single time constant processes. These valves are limited to the force that the measurement fluid can produce on mechanical or pressure operators. Pilots shall be used for self-actuated valves for tank blanketing, FISHER or equivalent “Christmas tree” arrangement (series-parallel) regulators shall be used.

15.18.9 Elctropneumatic Positioners.

Smart type Valve Positioners shall be used, except where local pneumatic contol is required.

Pneumatic valve positioners for diaphragm actuators will generally have bypass switches and three pressure gauges. On split-range applications and piston actuators positioner bypass switches shall be omitted

Smart Electropneumatic positioners shall be used except for high vibration service. For high vibration service, use a separately mounted I/P transducer and a valve mounted pneumatic positioner. I/P transducers shall work in any orientation.

15.18.10 Diaphragm Pressure Gauges

Where a valve positioner or valve mounted pilot is not provided, each diaphragm valve will have pressure gauge to indicate diaphragm loading pressure. The gage is 2 inch, 0-2 kg/cm2g, with a ¼ inch bottom connection.

15.18.11 Handwheels

Valves 6 inch and above shall be provided with a handwheel, when indicated on the P&IDs. The handwheel shall not add friction to the valve actuator. Handwheels for butterfly valves are shaft mounted instead of yoke mounted. In all cases one operator must be able to transfer the valve from pneumatic to manual. Valves shall have labels to indicate transfer steps. When control valve has no bypass, handwheels shall be provided regardless of size.

15.18.12 Filter Regulators

Filter regulators shall be corrosion resistant with 316 SS pressure indicator and over pressure protection. Automatic water drains shall be used.




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15.18.13 Solenoid Valves

Solenoid valves shall be 316 SS with resilient seat for tight shutoff.

Consideration shall be given to air port size where high air capacity is required.

Minimum solenoid temperature ratings shall be ambient temperature (58ºC in shade) and metal temperature (87ºC solar).

Vents shall have a ‘U’ tube or bugscreen to avoid blockage.

15.18.14 Position Switches and Transmitters

Position switches shall be inductive proximity type and shall be provided for all on-off control valves in ESD services with monitoring in DCS. Critical control valves shall be provided with position transmitter and indicator in DCS. Position switches for other valves shall be provided only if indicated on the P&IDs.

Where a valve has limit switches, the valve shall be motorised.

15.18.15 Bypass Manifolds

Complete block and bypass manifolds shall be used in applications stated below. The bypass valve can be a globe or a gate valve, but in either case the valve must have good solid design so the plug or gate does not vibrate or move while in a fixed throttle position. Bypass valves are usually globe valves in sizes up to and including 4-inch.

Bypass valves and handwheels will be based on the following conditions:

a. Use a control valve without a manifold when the service is intermittent or can be closed off without shutting down the process. Also, there must be block valves in the line, plus drains so the control valve can be removed.

b. Use control valves with handwheels for large valves where block and bypass valves are expensive. The line must have the capability to be blocked-in and drained in case the control valve must be removed. A handwheel only protects against a faulty operator. It will not act as a bypass if the trim fails.

c. Use on systems that are extremely corrosive.

d. Bypass valves shall have Cv values equal to or greater than control valve Cv. Use globe valves for 4 inches and smaller, use ball valves in plugging service. Use gate valves one size smaller than the control valve for services requiring a capacity in excess of the capability of a 4 inch globe. Selection of bypass valves shall take into account their impact on the relief system.

15.18.16 On/Off Valves and Actuator

15.18.16.1 General

Valves shall generally be ball type and comply with piping specifications.




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15.18.16.2 Actuators

The following actuators shall be selected:

a. Quarter turn rotating actuators, single acting, piston type, spring return.

b. Quarter turn, double acting piston type.

c. Electric actuators, with inching facility, position indication etc. in a two-wire system.

d. Hydraulic for isolation valves, and require approval of the COMPANY.

Auxiliary fluid shall be instrument air/gas.

Reservoir shall be designed as per ASME Section 8 Division 1 with ASME ‘U’ stamp.

15.18.17 Accessories

Where applicable, valves will have the following accessories:

a. Limit switches

b. Solenoid valves

c. Reservoirs

d. Air pressure regulators

e. Filters

f. Check valves

g. Restriction orifices

h. Reset push button

i. Reservoir low pressure switch

j. Manual actuation test switch

k. Hand wheels

Where practical, accessories will be installed in weatherproof fiberglass or SS boxes to IP65 rating.

15.19 SAFETY AND RELIEF VALVES

15.19.1 General

Conventional relief valves will be used in services where there is no back pressure, or where the back pressure is constant. Balanced relief valves will be used where the back pressure may exceed 10 percent of the relieving pressure or is not a constant value, so as not to affect the set pressure of the valve, and shall also be used on hazardous, corrosive and toxic services. Safety valves for boilers and steam drums will conform to the power boiler code.




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Relief valves are different in design than safety valves, hence, they do not have as accurate a blow down and reseating characteristic. Relief valves will generally be set at 10 percent above operating pressures to prevent simmering and sealing problems.

Relief valves or safety valves will not be used as a pressure control. This does not apply to hydraulic type pressure regulators used in lube oil or other hydraulic systems. Rupture discs will be used for corrosive service alone, slurry flow and extremely viscous fluids. Where possible, use of rupture discs alone will be avoided as once they pop, the unit must be shut down. Reverse buckling insert type rupture discs will be used for services where rupture discs are subject to vacuum as well as pressure. Where no vacuum conditions or cyclic pressure applications exists, use conventional type discs. Always set them as high above the operating pressure as possible.

Pilot operated relief valves can be used on clean gas in pulsating service, or when the set point is less than 10 percent above the operating pressure.

Safety valves, relief valves, and rupture discs will be selected in accordance with governing Codes and Regulations. If the area in which the plant is located has no local codes or regulations, the ASME Power Boiler Code and the ASME Unfired Pressure Vessel Code are used as applicable.

Relief valves will be applied in accordance with the following:

Pressure Vessels ASME Section VIII

Power Boilers ASME Section I

Steam Generators ASME Section I

Tank Venting API RP-2000

Commercial Seat Tightness of Safety API RP-527

Relief Valves with Metal to Metal Seats

For additional requirements, refer to Project Specification DGS-IU-012.

15.19.2 Sizing Requirements

15.19.2.1 Valve Sizing

Each valve will be sized to relieve the maximum vapor or liquid load to protect the process system. Process relief loads due to blocked in conditions, reflux failure, cooling water failure, or runaway reactions, shall be obtained form the process material balance flow diagram, adjusted for set pressure conditions. Sizing calculations shall clearly state the basis. Relief loads due to fire, use API RP-520, latest revision, for the heat inputs. Rupture discs shall be sized on the same basis.

Relieving pressure or popping pressure shall be at or under the protected equipment design pressure, or maximum working pressure. Set pressure is the difference between relieving pressure and constant back pressure for conventional valves corrected for temperature. For balanced valves, relieving pressure, and set pressure are the same, corrected for temperature.

Allowable accumulation is per ASME Code.




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For safety valves, the back pressure must be atmospheric. For conventional relief valves, the variation is superimposed back pressure cannot exceed 10 percent of the set pressure. For balanced valves, the variable back pressure cannot exceed 50 percent of the set pressure. Stagger the set pressures when two or more relief valves are used.

15.19.2.2 Valve Body

Valve bodies shall be minimum cast steel with integrally cast flanges for all services except low pressure air and water. Parts contacting the process fluid are determined by line classification. Minimum inlet connections for flanged valves are 1-inch. All steel valves with inlet flange size 2-inch or smaller, shall be 150# minimum. Use 3/4-inch x 1-inch screwed valves for thermal relief.

15.19.2.3 Nozzle Disc and Spring

All flanged valves shall have full nozzles with one piece disc construction. Screwed valves shall have insert type nozzles with MANUFACTURER’S standard disc. The disc is a piston type held against process pressure by a spring. Disc, nozzle, guide, and ring are manufacturer’s standard stainless steel except where the line classification dictates a better material. Spring material is carbon steel up to 230ºC and tungsten steel for higher temperatures. The spring is adjustable for popping pressures within Code allowances above and below initial set pressure.

15.19.3 Accessories

15.19.3.1 Bonnet and Cap

Bolted pressure tight bonnets for all conventional valves except where the code requires open bonnets shall be used. Balanced valves shall have vented bonnets. Bonnet and cap material is carbon steel, unless process fluid entering bonnet on balanced safety valves requires alloy construction. The cap and bonnet will be provided with lugs for wire seal after setting the valve.

15.19.3.2 Lifting Levers

Lifting levers are provided on all safety valves used on steam, air service, and water above 60ºC.

15.19.3.3 Rupture Discs

Rupture discs shall be used:

a. Where relief loads caused by unexpected sources cannot be handled fast enough by relief valves.

b. On the inlet side of a relief valve to protect the valve if the process fluid is extremely corrosive, or polymerizes, or to insure against valve leakage of hazardous and toxic fluids.

15.19.3.4 Gags

Gags are not to be used.




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15.20 MOVS

In general, two wire MOV system shall be applied for all projects. However, if the MOVs in a project are very few (typically less than 30) then conventional wiring can be used. In all cases, the actuator shall be the intelligent/smart type with integral actuator enabling setting/configuration of the actuator without having to open the actuator. As a minimum, MOVs of either type shall be interfaced to the DCS to provide valve open/stop/close commands and open/close indication from DCS. MOVs in general shall be used as isolation valves. If used as ESD valves, then the command signals corresponding to ESD action (open, close or both) shall be hardwired and not dependent on the 2-wire system alone.

15.21 ELECTRONIC AND ELECTRICAL CABLES

15.21.1 General

All cables shall be water, oil and sunlight resistant, gas/vapor tight.

Flame retardant cables shall be used for instrument signals and comply with IEC 60332.

Fire resistant cables used for safety systems (Reference Section 14.0) and shall comply with IEC 60331.

Cables installed within instrument rack and control rooms shall be unarmored.

All buried cables from field will be lead-sheathed and armored to withstand the highly corrosive nature of the soil and to provide mechanical protection.

15.21.2 Cable Requirements

Flame retardant armored cables shall be overall shielded and individual shielded as specified.

Fire resistant armored cables shall be overall shielded and individual as specified.

Cables shall be overall shielded with drain wire for the following cases:

a. Signals cables (4-20 mA)

b. mV or resistance signals

Cables shall be twisted pair shielded and overall shielded with drain wirefor following cases:

a. Gas detector signals (if not 4-20 mA)

b. Fire detector signals (if not 4-20 mA)

c. Frequency signals (flowmeters for example)

d. Vibration signals (if not 4-20 mA)

e. All other MCM low voltage signals




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Cables shall be overall shielded with drain wire for following cases:

a. Use for 24 VDC

b. Telephone

Cables shall be without any shielding for Solenoid Valves.

15.21.3 Instrument Signal Cables

The main consideration to be taken into account shall be:

a. Conductors size and number

b. Conductors insulation

c. Protection against salty water and hydrocarbons (probable leakage from hydrocarbon sewer systems)

d. Mechanical protection

e. Protection against potentially high temperature

f. Protection against fire

g. Protection from signal interferences

Cable construction shall be according to IEC recommendation.

For instrument and thermocouple cable see DGS-EE-012.

15.21.4 Cables for Electrical Power Supply of Instruments

Refer to Project Specification DGS-EU-001 and DGS-EE-011.

15.21.5 Cable Installation

Electronic and signal wiring shall be separated from power wiring and electrical equipment to minimize noise interference.

The following standard table shall apply:

a. 125 V 10A 300 mm

b. 250 V 50A 450 mm

c. 440 V 200A 600 mm

For U/G cable installation refer to Project Specification DGS-EU-001.




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Installation Above Ground:

Installation shall generally use hot dipped galvanized and painted trays. However the tray material shall be selected by the Electrical Engineering Department.

Cable trays dimensions shall be adequate to accommodate 30% spare cable.

Cable brackets for attachment to cable trays, cable ties and other accessories shall be as per Electrical Specification DGS-EU-001.

Only one cable layer will be permitted on cable trays.

Cable in conduits shall not be used.

15.21.6 Junction Boxes

Junction Boxes shall be of high impact resistant, UV resistant Polycarbonate material. Junction boxes located in the units shall be distributed in order to place them as near as possible to the center of their associated instruments. The degree of protection shall be at least IP 65 using closed cell neoprene gaskets with detachable lids and stainless steel captive screws.

They will be built in accordance with safety requirements and will be fitted with cable glands (bottom mounted). Cable glands shall be brass, double compression type with PVC protective shrouds.

Junction boxes will be fitted with an extension earth terminal.

15.21.7 Cable Termination and Local Instruments

For each conductor, 60 to 80 mm slack shall be left at the instrument or in the terminal wireways.

The connection of instrument in the process unit is made with a “drip loop” in the cable of 20 to 30 cm.

15.21.8 Earthing of Local Instruments

Shields shall be earthed at one point only. This point is located in the instrument room.

Cable glands shall never be used for earthing purposes.

15.21.9 Fiber Optic Cable

Fiber optic cables shall be installed strictly per the VENDOR’S guidelines under VENDOR’S supervision. Minimum of 100% spare fibers shall be left in each multi- fibre cable.

15.22 CORROSION MONITORING

Corrosion probes shown on the P&ID’s instrumented with transmitters and DCS indicators shall be Rohrback Corrosometer Probes, Model Series 3500. The elements shall be 20 mils thick (T20), carbon steel (K03005). The probes shall be sized for full insertion into the pipe through a 1-1/2 inch flanged nozzle. In line classes lower than ANSI 600 lbs., the probes shall be provided with isolation valves and packing glands for removal on-the-run. For line classes ANSI 600 lbs. and higher, fixed probes without packing glands shall be used.




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The probe shall be wired to a Rohrback 4020LT series analog transmitter, which shall be wired as an input to the DCS. The analog reading from the probe shall be displayed by the DCS. The DCS shall also be programmed to trend the reading versus time and integrate it to calculate metal loss.

16.0 INSTRUMENT CONTROL BUILDINGS AND ROOMS AND SISS

See Project Specification DGS-CU-002 for design guidelines.

16.1 GENERAL

Control buildings and Satellite Instrument Shelters (SISs) shall be located in nonhazardous areas, and shall be blast resistant.

All control, rack and computer rooms will be pressurized and have entry airlocks. This applies to Main Control Building as well as SISs.

Control rooms shall be designed on a third-party ergonomic study results and approved by COMPANY.

16.2 LIGHTING

Incandescent adjustable intensity lighting shall be used for operator CRT consoles. Care will be taken to protect CRT operators from glare.

Other technical rooms shall have fluorescent lighting.

16.3 FALSE FLOORS

Control, rack and computer rooms will have raised floors (minimum 60 cm).

16.4 FALSE CEILINGS

Fire-resistant, soundproof false ceilings worked in conjunction with room lighting shall be installed.

Fire-resistant, soundproof false ceilings worked in conjunction with room lighting shall be installed.

16.5 NOISE

Noise will be taken into account and shall meet COMPANY’S requirements per Project Specification DGS-MU-009.

16.6 FIRE AND GAS DETECTION AND PROTECTION

See Project Specification DGS-IS-003 for reference.

All plant buildings, control building and SISs shall be provided with the necessary fire gas detection and protection.

Fire and Gas Detection and Protection system will be in accordance with ENGINEER’S specification duly approved by COMPANY and should be integrated with running Fire and Gas system. However, implementation of MONTREAL protocol concerning use of zone-friendly materials shall take precedence against any other specification or standard.




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16.7 TELEPHONES, INTERCOMS, PUBLIC ADDRESS

Telephone, intercom and public address systems communications will be taken into account when specifying buildings and control rooms based on Project Specifications DGS-IS-009 and DGS-IS-010.

17.0 CABINETS AND LOCAL CONTROL PANELS

See STD-IU-00017 for design guidelines.

Local panels shall be numbered by the equipment code LP, preceded by the four digit unit number and followed by the number(s) of the relevant equipment to which the local panel is assigned, for example 0211-LP-F-2001 is the local panel for furnace 0211-F-2001.

Where the size of the cubicle in accordance with Standard Drawing STD-IU-00017 would be out of proportion to the requirements, smaller cubicles or open panels with weather protective covers should be considered; subject to approval by the COMPANY.

The paint procedure for local panels shall be as per MANUFACTURER’S standard. Colors shall be as per Project Painting Specification DGS-MX-001. All panels located outdoor near equipments shall be made of 316 SS. Where the local panel or cubicle require openings for ventilation these openings shall be provided with screens to prevent the ingress of vermin/insects. For these openings, the minimum degree of protection shall be IP 20.

Cubicle panels in accordance with Standard Drawing STD-IU-00017, shall be supplied with a bottom plinth and base plate and additionally provided with a fan and fresh air inlet. The fresh air inlet shall be protected with dust/water screens.

Cubicle panels shall have both internal and external illumination; open panels shall have external front illumination only, fluorescent type lamps shall be applied. The fluorescent lighting shall be suitable for the area ambient conditions and classification.

Cubicles shall be provided with early warning fire/smoke detectors strategically located for optimum early sensitivity based on a study by ENGINEER.

Whenever possible, instruments shall be mounted at eye level, but not lower than 750 mm from the base. Instruments requiring operator’s action (switches, etc.) shall not be higher than 1750 mm.

Unless otherwise specified, the use of black PVC tubing with color markers inside cubicle panels is acceptable. The material used within the local panel shall be suitable for the area in which the local panel is to be installed.

Local panels shall be located well away from steam outlets, wet areas, and other undesirable locations.

17.1 INSTRUMENT IN LOCAL PANELS

Where plant instruments are grouped on local panels e.g. for operator convenience, the indicating instruments should normally be as specified in and in addition be suitable for flush mounting.

These indicators shall be connected to transmitters at the measuring point. NOTE: In cases where the transmitter forms part of a trip system, the associated receiving gauges should either be

provided with an isolator or warning plates stating:




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WARNING

INSTRUMENT FORMS PART OF THE TRIP SYSTEM

Direct process connections between process fluids and enclosed instrument panels is not permitted. Wherever necessary, transmitters shall be applied.

When local panels are installed in the open, provisions for weather-proof instruments should be applied accordingly.

17.2 MARSHALING CABINETS

Refer to Project Specification DGS-IS-014 for the requirements for Marshaling Cabinets.

18.0 INSTRUMENT AIR SUPPLY

Instrument air shall be dry, clean (dust free) and oil free, and shall be provided by dry type compressors. Compressors should provide 7 kg/cm2g minimum at the furthest consumption point from compressors.

Instruments shall use Instrument air at following conditions:

a. Normal pressure 7.5 kg/cm2g

b. Minimum pressure 3.5 kg/cm2g

c. Design pressure 10 kg/cm2g

d. Water dew point -20°C at 7.5 kg/cm2g

Instrument air receiver shall be sized for 30 minutes operation at maximum demand rate and pressure when all compressors are lost.

19.0 ELECTRICAL POWER SUPPLIES AND EARTHING

19.1 GENERAL NOTE: Voltage levels given are to be verified by ENGINEER with end-user/ operator.

Electrical supplies for instruments and systems shall comply with the following:

Instrument power distribution system for 24 V DC and 240 VAC shall be designed so that a minimum of two separate power feeders (one normal and one emergency supply) from MCC’s shall be extended to each central control building and SISs.

These feeders shall be tied into an instrument distribution panel. Also, UPS systems with batteries and battery chargers shall be supplied for:

a. DCS, ESD, F & G

b. Other instrument systems critical for the Process operation and safety.

c. Devices, which if tripped would have an adverse effect on process and affect an orderly shutdown.

d. Radio for SCADA System and plant Radio System, Paging System.




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Batteries with UPS shall be in two banks one for Telecom, Radio, Paging and Fire Gas Systems and shall be sized for 12 Hrs after loss of power. The other battery bank supplying DCS, ESD, etc., shall be sized for 30 minutes duration after loss of power.

24 V DC current shall be used for the supply of the following systems: DC wiring shall be of the two wire, type (+ and -). However, considering long cable distances in plants, 110V DC or 48 V DC may be studied by ENGINEER for COMPANY approval.

a. Alarms and shutdown systems

b. Telemetry and telecommunication systems

The ESD System in any case shall be on 24 VDC for inputs, logic and outputs.

240 V 50 Hz A.C. shall be used for:

a. Electronic instrumentation

b. Fire and gas system

c. Control room Video Display Unit and printers

d. Specific local instruments and systems as tank gauging equipment, automatic samplers, etc.

e. Video copier

The Instrument systems shall work satisfactorily with the following general characteristic:

a. Voltage 240 VAC +/- 10%

b. Frequency 50 Hz +/- 2%

c. Harmonic Contents: 5% nominal

d. Voltage dip of 20% nominal VAC for less than 10 msec

All UPS (AC and DC) equipments shall be monitored by the DCS through a serial link. Also status of main feeder fuses/MCB’s shall be monitored by the DCS.

For further information, refer to Specifications DGS-EE-008 and DGS-EE-009.

19.2 EARTHING

All electrical devices shall be earthed to protect personnel and equipment against electrical discharges.

Several earthing circuits shall be provided as follows:

a. Primary earth: this is the circuit ensuring safety in the alternating current distribution network; all cable armor, instrument housing and electrical equipment support must be connected to the primary earth ground by means of a suitable cable, busbar or earth conductor.

b. Electronic earth: this is the reference point for all electronic signals.




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All commons (in the case of a DC supply with a polarity to earth), all the earth references of Zener barriers, all instrument cable shields shall be connected to this earth via the electronic earth circuit. Shields shall be earthed only at one point.

a. For conventional instrument systems, this single earthing point shall be in the control or rack rooms.

b. For digital instrument distributed control systems, this single earthing point shall be in the decentralizing technical room.

c. The measured resistance between the “electronic earth” and the “true earth” must be minimal per Project Specification DGS-EU-001.

d. The electronic earth circuitry shall be a dedicated and isolated from the primary earth in order to avoid electronic noise and provided with high frequency chokes.

e. When a computer is used, the computer vendor may request a further isolated earth for the computer.

See standard drawings STD-ED-00011 through 00013 for further information.

20.0 INSTRUMENT INSTALLATION

See Project Specification DGS-PU-001, DGS-IU-002 and DGS-IU-003. Instrument Installation Details shall be in compliance with STD-IU-00031.

20.1 GENERAL

The following is not within scope of this specification:

a. Installation of panel-mounted instruments. Instrument panels are usually shop fabricated and shipped to the job site completely piped and wired. Occasionally, small local boards will be needed that will require a special installation detail.

b. Process piping for in-line instruments (rotameters, relief valves, etc.) and for level displacers, level switches and level gages all of which are detailed by Piping.

c. Installation of primary flow elements and primary block valves.

20.2 INSTRUMENT INSTALLATION DETAILS

The complete installation of a particular instrument will require from one to four detail drawings (typical). These details will cover instrument process piping, air piping, electrical connection and mounting. The applicable detail drawings for each instrument will be shown on the Instrument Index.

a. The installation details will show the approximate configuration of the piping and the instrument location relative to the process connections. The exact placement of the instrument and routing of piping shall be determined in the field. However, the location of the instrument with respect to the process connection shall be as shown on the instrument location plan drawing.




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b. Each detail has a list of instruments covered by the detail and the material required for one installation.

c. Instrument process piping details are described as “close-coupled”, “semi-remote”, or “remote”.

d. The close-coupled instrument shall be supported by the primary valve and the primary valve is readily accessible.

e. The semi-remote instrument is mounted from 1 to 2 meters from the primary valve and the primary valve is readily accessible.

f. The remote instrument is mounted more than 2 meters from the primary valve.

g. All applicable details for each installation shall be examined by ENGINEER before work on mounting or piping is started. This is particularly important when sealing or purging is shown on the detail, and when heat tracing or special insulation is indicated.

h. Sufficient clearance shall be provided for removal of the instrument cover or the instrument enclosure and for access to external adjustments.

20.3 PACKAGE EQUIPMENT INSTRUMENTATION

Instruments supplied by package vendor but installed by CONTRACTOR will be covered by ENGINEER’S details.

Package instrument specifications, installation drawings, manuals, parts lists, etc., shall be in accordance with Project Specification DGS-IU-007.

Packaged equipment shall be designed so that sufficient area is available for instrument access.

20.4 INSTRUMENT MOUNTING

The location of field instruments shall be selected so that they all accessible from grade, walkways, platforms or fixed ladders. Length of impulse line shall be kept to absolute minimum. The use of portable ladders or access platforms shall be restricted as per table below.

Instrument Access and Visibility Table

Allowable access depends on instrument type and will be as indicated hereafter:

Accessibility From Grade Platform Permanent Ladder

Portable Ladder

Root Valves Thermowells Line Mtd. Flow Trans.

Level Gauges Temp. Gauges

*

All Other Instruments




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* For dial thermometers, limited accessibility is acceptable only when the instrument mounted directly on the process connection can be read from an accessible location. The distance between grade or platform level and the instrument shall be a maximum of 0.5 m horizontally and/or 2m vertically.

Portable ladder access can be used for instruments located not more than 4m vertically above grade level only when permanent accessibility is not feasible or would obstruct a passage-way. The whole stanchion assembly shall be galvanized and painted as per the Painting Specification DGS-MX-001.

20.5 INSTRUMENT PROTECTION

Instruments require protection from: fluids which are corrosive or too hot, fluids containing solids which may settle in the line or instrument, viscous liquid which will harden at ambient temperature, cryogenic service, and pressure pulsation’s which could damage the instrument mechanism and result in inaccurate measurements.

Protection shall be accomplished by various methods:

a. Purge to prevent solids or viscous liquids from entering the instrument process piping.

b. Install a siphon for close-coupled pressure gauges and a condensate seal leg for other instruments in steam and hot condensable vapor service.

c. Provide a heated enclosure for instruments as required.

d. Heat traced and insulate to prevent fluids from becoming too viscous. Use of diaphragm seal type instrument is preferred.

e. Install a pulsation dampened upstream of all pressure instruments in the discharge line of reciprocating pumps and in the sanction and discharge lines or reciprocating compressors/pumps.

f. Provide a diaphragm seal to prevent process fluids which are extremely corrosive or which contain solids from plugging-up the instrument.

g. The use of high grade materials.

h. The use of strainers for services containing solids.

i. Painting and/or coating as per Painting Specifications DGS-MX-001.

j. Sunshades shall be provided for all electronic field mounted instruments.

20.6 HAZARDOUS SERVICE

Instrument drain connections in sour/lethal services shall be piped to the nearest process sewer, area drain, or other applicable drain point. Hazardous services include acids, caustic, toxic fluids, and blow downs for fluids with operating temperatures of 260°C or greater.

Instrument vent connections in a sour/lethal service shall be piped to the nearest process vent.

Process instrument piping in hazardous service shall conform to Piping Specification DGS-PU-001. Instrument body, and wetted parts, tube fittings shall conform to Piping Specifications DGS-PU-003.




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20.7 INSTRUMENT PROCESS CONNECTIONS

Instrument Device

Connection On Equipment

Instrument Connection

Vent and Drain

Pressure Vessel

Piping Storage Tank

Press. Gauge 2” RF Flg ½” NPT 2” RF Flg ½” ½” Press. Switch / Press Trans

2” RF Flg ½” NPT 2” RF Flg ½” ½”

DPT 2” RF Flg ½” NPT 2” RF Flg ½” ½” Level Displ.. 2” RF Flg 2” RF Flg 2” RF Flg (Note 3) ¾” Level Switch 2” RF Flg 2” RF Flg 2” RF Flg (Note 3) ¾” Gauge Glass 2” RF Flg 2” RF Flg 2” RF Flg ¾” (Note 5) ½” DPT 2” RF Flg 2” RF Flg 2” RF Flg ½” ¾” Thermowell 2” RF Flg 1½” RF Flg 2” RF Flg To Suit INSTLN Local Indicator 2” RF Flg 1½” RF Flg 2” RF Flg To Suit INSTLN Thermocouple 2” RF Flg 1½” RF Flg 2” RF Flg To Suit INSTLN RTD 2” RF Flg 1½” RF Flg 2” RF Flg To Suit INSTLN Filled Bulb 2” RF Flg 1½” RF Flg 2” RF Flg To Suit INSTLN In-Line Ind. Line size Rotameter Line size Line size

(Note 4)

Annubar 3” RF Flg Vendor Analyzer 2” RF Flg 2” RF Flg 2” RF Flg Vendor

Where listed above, NPT connections may be used where permitted by Piping Specification DGS-PU-003, where piping supplies a flange, a lap joint style tubing adapter or flanged style gauge mount shall be used.

NOTES:

1. 1” NPT thermowells can be used on low pressure, non process service (e.g. cooling water)

Process flange connections 150 LB minimum rating.

Instrument impulse tubing shall be 10 mm O.D., 1.5 mm minimum wall thickness, 316 SS.

Instrument pneumatic signal air supply tubing minimum size 6 mm O.D., 1 mm minimum wall thickness, 316 SS.

2. Vessel and tank connections are 2” minimum per DGS-MD-002 and DGS-MF-002.

3. An external chamber with 4” RF top flange, 2” RF side flange, and 3/4” RF vent and drain flanges shall be provided.

4. Confirm sizing with meter capacity and measurement requirements.

5. Gauge valve process connection is ¾” MNPT. Gauge glass chamber connection is ½” FNPT. Flanged gauge valves shall be used where required per vessel trim class.




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20.8 INSTRUMENT PROCESS PIPING

20.8.1 Materials

Process piping material shall be based on 317L SS tubing and double compression 316 SS fittings for connections between primary block value and instrument.

Where the materials mentioned above are not suitable for service then the piping specification material will prevail.

See Project Specification DGS-IU-003.

20.8.2 Installation

Instrument piping shall be arranged to avoid measurement error caused by condensate build-up in gas service, air/vapor entrapment in liquid service, or overheating of the instrument in hot fluid service.

a. Consideration shall be given to readability, accessibility, ease of maintenance, and to avoid obstructing accessories.

b. Close-coupled pressure gauges shall have their line taps on top of a horizontal line when feasible. If it is more convenient for design, accessibility, or readability to be on a vertical line or on the side of a horizontal line, tap will be orientated to avoid having the gauge extend into narrow walkways.

c. Indicating instruments shall be installed to be readable from their associated manual control device and for operating convenience.

d. A line class primary block valve shall be provided at each process connection.

e. Remote mounted instruments that are not accessible to the primary block valve shall have an additional shut off valve and a bleed valve at the instrument.

f. The instrument process piping shall slope up or down toward the instrument at least 2.5 cm per 30 cm.

g. All instrument piping shall be self-supporting when the instrument is removed for maintenance. Use tube unions only where necessary on long runs.

h. Differential pressure instrument leads shall be run together as much as possible.

i. Mount instruments in liquid service below the line tap. On horizontal lines, orient the taps preferably on the horizontal centerline or alternatively 45 degrees down the horizontal centerline.

j. Mount instruments in steam service below the line tap. On horizontal lines, orient the taps preferably on the horizontal centerline or alternatively 45 degrees up the horizontal centerline. Condensate pots shall be provided for all steam installations.




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k. Selected process services shall have “TEE” branch connections, each with primary block valve for future instrument installation. The future connection shall be plugged.

l. For sour and lethal service, instrument drain valves and vent valves shall be connected to closed drain and vent systems.

m. Mount instruments in gas or cold service above the line tap. On horizontal lines, orient the taps preferably on the horizontal centerline or alternatively 45 degrees up the horizontal centerline. If the instrument must be located below the line taps, install valved drain pots.

20.9 INSTRUMENT AIR PIPING

20.9.1 Materials

317L SS tubing and 316 SS fittings will be used for local pneumatic loops, between control valves and I/P transducers and after pressure regulators on air supply to instruments.

Air supply headers and subheaders materials will be as per piping specifications.

For further information, refer to Project Specification DGS-IU-003.

20.9.2 Tubing Installation

Use tube unions only where necessary on long runs. Continuous runs will be the preferred.

Tubing shall be adequately supported and protected by several methods:

a. in SS raceway or angle

b. clipped to protective structural members

c. individual tube 80 cm long can be installed without support

20.9.3 Air Supply Piping Installation

Main instrument air headers will be shown on piping drawings. Subheaders will be shown on instrument location plans and installation details. Instrument air supply lines shall be connected to instruments with 1/2” ball type valves.

a. Minimum size of subheader shall be 3/4”.

b. Air supply to an individual instrument shall be routed directly from air header to shutoff valve at the air-set of the instrument.

c. Air Supply line shall be 3/4” for 5 instruments and 2 spares.

d. Air supply line shall be 1” for 12 instrument and 4 spares.

e. Air supply test points for pneumatic supply to test equipment shall be provided for each group of instruments.

f. Drain valves will be installed at low points.




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g. No quick disconnects will be used.

h. Spare take-offs will have valves with plugs (15% spare valves).

i. Each tap on the air header should be numbered to show the instrument, control valve, I/P transducer, etc. connected to it.

20.9.4 Air Sets

A corrosion resistant air-regulator and filter shall be installed for each instrument which has a pneumatic output signal, such as a transmitter, I/P transducer, controller, positioner, and relay. The air-set has a filter regulator with auto drain, integral dripwell, 50 mm gauge and draincock. The air-set is usually supplied with the instrument when it can be factory installed.

20.9.5 Loading Gauges

Where there is no other indication of the loading pressure on a pneumatic operator a 50 mm 316 SS loading gauge shall be installed.

20.9.6 Process Piping Pressure Tests

Instrument process piping up to block valve shall be tested with piping on equipment to which it is connected.

• For remote installations, testing of the lead line from the first block valve up to the secondary block valve at the instrument can be done simultaneously, provided the instrument is blocked off from the source of pressure and vented to atmosphere.

• For close-coupled installations the connection on the downstream side of the first block valves is broken, and the balance of the instrument piping is tested separately during instrument checkout and calibration.


20.9.7 Instrument Air Piping Pressure Test

Instrument air subheader piping and pneumatic signal tubing shall be pressure leak tested with dry air. Check by a visual (Soap or other suitable clear test fluid) and audible inspection with the main header at normal operating pressure and with the air-sets set for 1.5 or 2 kg/cm2g outlet pressure.

Testing of the main instrument air header is not within the scope of this specification. All subheader block valves shall be tightly closed during the pressure test of the main header.


20.10 SUNSHADES

Sunshades to protect all electronic instruments in the field shall be provided. The selection and maintaining of the sunshade shall provide adequate coverage and at the same time permit maintenance and removal of instruments without having to remove the sunshades.




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20.11 PASSIVE CONDITIONED SHELTERS

Passive Conditioned Shelters (PSC) shall be used for desert location like wellheads, along the pipeline route etc. These shall be made of aluminum skin mounted on concrete foundations and shall be designed to produce at least 15°C lower than the prevailing ambient temperature. PSCs shall be supplied complete with solar panel, regulator and batteries. Minimum size is 3m x 2m.

21.0 LABELING

The following devices shall be labeled:

a. instruments

b. wiring and cables (as a minimum, instrument tag number shall be provided)

c. local panels

d. cubicle and junction boxes

e. terminals

f. consoles

All instruments are received with MANUFACTURER’S installation instructions, and these should be carefully read and followed. Always note if the instrument package or body has special warning tags or marks.

All nameplates shall be manufactured with materials giving long service within an aggressive environment.

Nameplates will be attached with stainless steel screws.

Stick on nameplates shall not be used. Screwed nameplates shall be preferred to riveted ones.

22.0 INSTRUMENT RECEIVING, STORAGE AND INSTALLATION

22.1 GENERAL

Field instruments are designed for continuous operations in an outside atmosphere within certain ambient condition limits for each type of manufacturer. However, before they are operating, many instruments are damaged during storage, installation, and while waiting for start-up. This damage is caused by moisture, heat, corrosion, dirt, dust, fungus, manhandling, and aging. When an instrument is installed and operating within its design conditions, it generally requires only minimum maintenance.

Generally, as a rule for the instrument, it is best to receive, install, check, and start operation in as short a time as possible. However, there are limits to this. So during storage and installation, they require adequate protection. Additional protection is required during longtime storage. Longtime storage is considered as six months or more.

All instruments are received with MANUFACTURER’S installation instructions, and these should be carefully read and followed. Always note if the instrument package or body has special warning tags or marks.




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After the instruments are installed, power them whenever possible. This helps perform a burning-in and delays the components’ aging process. If the installed instrument components cannot withstand the ambient conditions, the protection boxes, or houses, should be heated or traced to protect them. Always check for special instructions on electronic instruments that are in an unpowered state with ambient temperatures less than 0°C or more than 65°C.

Complete instruments and parts have to be store in dust-free area at controlled temperature environment. Sensitive parts such as a cards, PCBs and chips are to be covered in anti-static sheets.

Specification DGS-IU-004 will cover proper handling methods for the following different types:

a. Transmitters and local control instruments, either electronic or pneumatic

b. Instrument cases of electronic components, relays, or switches

c. Local control boards

d. Main control boards and racks

e. Pressure, temperature, and flow switches

f. Dial thermometers, pressure gauges, and gauge glasses

g. Control valves, relief valves, solenoid valves, displacement level instruments, and float switches

h. Analyzers

i. DCS equipment, computer and peripherals

j. Miscellaneous items

See Project Specifications DGS-IU-004 and DGS-MU-002 for further information.

23.0 PAINTING

All instruments, panels and instruments accessories, ducts, etc. shall be painted in accordance with Painting Specification DGS-MX-001.

24.0 TRAINING

Minimum training requirements shall be provided for major instrument systems. CONTRACTOR shall recommend training necessary for systems not listed. The duration and number of persons given below are guidelines and are to be finalized during PROJECT execution:

24.1 DCS

a. Engineering and Configuration Courses - two to four weeks at VENDOR’S factory for five persons.

b. Maintenance Course - one week each for four sessions with five persons each in Abu Dhabi.

c. Operator, Shift-in-charge, Supervisor, etc. - three days for each session covering eight persons in each session for 64 persons in Abu Dhabi.




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24.2 ESD AND FIRE AND GAS SYSTEM

a. Same as in DCS, except two weeks, location - Abu Dhabi

b. Same as in DCS, except two sessions

24.3 ANALYZERS

a. Same as DCS

b. Same as DCS, except two sessions

24.4 PACKAGE UNIT CONTROL SYSTEM

a. Same as DCS, except one week, one session of five persons.

Same as DCS, except three days for each session of six persons covering total 12 persons

INSTRUMENTATION AND CONTROL DGS- IU-001 REV: 0 Date: March 2006 Page 71 of 72

COMPANY DOCUMENTATION REQUIREMENTS TO BE ISSUED TO COMPANY BY CONTRACTOR

APPENDIX 1

SR

DOCUMENT DESCRIPTION

TYPE DOC. CLASS

DISTRIBUTION SCHEDULE RESPONSE PERIODS

NO. L: LETTER T:TRANSM.

For Review & Approval

Approved for Construction

Handover Doc.* (No. of working days)

1 - Fire and Safety Engineering

- Fire protection Philosophy L/1 3 3 5 10

- Equipment and Facilities Spacing Criteria L/1 3 3 5 10

- Gas and Fire Detection System L/1 3 3 5

- Design Calculations Optimization L/3 3 10

- Equipment Specifications L/1 3 3 5 10

- Data Sheets T/2 2 5 10

- Operation and Control Schemes L/2 3 3 5 10

- Logic Diagram, Cause and Effect Matrix L/2 3 3 5 10

- Interconnection and Termination Drawings T/3 2 5 10

- Equipment Location Drawings L/2 2 3 5 3

- Vendor Data and Drawings T/3 -- 5 10

Doc. Class: Class 1: For Approval by COMPANY Class 2: For Review and Comments Class 3: For information

INSTRUMENTATION AND CONTROL DGS- IU-001 REV: 0 Date: March 2006 Page 72 of 72

COMPANY DOCUMENTATION REQUIREMENTS TO BE ISSUED TO COMPANY BY CONTRACTOR

APPENDIX 1 TYPE DOC. CLASS DISTRIBUTION SCHEDULE RESPONSE PERIODS

SR NO. DOCUMENT DESCRIPTION L: LETTER T:TRANSM.

For Review & Approval

Approved for Construction

Handover Doc.* (No. of working days)

1 - Instrumentation and Control System Engineering - Update Definition of Operating and Control philosophy L/1 3 3 5 10 - Definition of Emergency Shutdown System and Study L/1 3 3 5 10 - General Specification for Instrumentation/Control T/1 3 3 5 10 - General Specification for Package Unit T/1 3 3 5 10 - Specification for Instrument and Instrument System T/1 3 3 5 10 - Hardware Configuration Diagrams T/2 4 3 5 10 - APC Strategies (if awarded) T/1 3 3 5 15 - M.I.S. Specifications (if awarded) T/2 3 3 5 15 - Plant Computer Specifications (if awarded) T/1 3 3 5 15 - Flow element, Safety/Control Valve Sizing Calcs T/3 3 -- 5 -- - Instrument Index T/3 3 -- 5 -- - Instrument Data Sheets T/2 3 3 5 10 - Material/Purchase Requisition T/1 3 3 5 10 - Control Room Layouts L/1 4 3 5 10 - Control Panel Layouts L/1 4 3 5 10 - Loop Diagrams and Schematics T/3 4 3 5 -- - Mimic Sketches T/1 4 3 5 15 - Formats for Report of Log, Alarm Trip, etc. T/1 3 3 5 15 - Safety and Shutdown Logic Diagrams, CBE diagrams T/2 4 3 5 15 - Main Cable Route and Trenches T/3 4 -- 5 -- - Instrument Location Plans T/3 4 -- 5 -- - Interconnection and Termination Drawings T/3 4 -- 5 -- - Instrument Cable Schedule T/3 4 -- 5 -- - Installation Drawings and Details T/3 4 3 5 -- - Construction/Installation Specifications T/2 3 3 5 10 - MTO for Erection Material T/3 4 -- 5 -- 2 Communications and Surveillance Engineering - Communications and Surveillance Narrative Specs T/1 3 3 5 10 - Hardware Configuration Diagrams T/2 4 3 5 10 - Material/Purchase Requisition T/1 3 3 5 10 - Wiring List T/3 3 -- 5 -- - Equipment Location and Installation Plans L/3 4 -- 5 -- - Interconnection Diagrams T/3 4 -- 5 -- - Formats for Reports of Alarm Log Trip, etc. T/1 3 3 5 15 - Mimic Sketches T/1 3 3 5 15 - Construction/Installation Specifications T/2 3 3 5 10 - Design Calculations T/3 3 -- 5 --

NOTE: This table is the General Requirements. For specific requirements for each job, refer to contract agreement.

DGS IU 001 R0 Intrumentation and Control

Documents

control page

piping standard drawings

electrical standard

piping standard practices

document precedence

reference documents

base reference project

table of contents