015-JH-1903 R1 General Instruments

&!ji&L

(4 ,A.$) u&Jl Lb2 5 s

KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specifics tion Number

0 75-JH-7903 General Instruments

0 KOC

Engineering Group Specjfica&n

I

I1

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

2 of 163

CONTENTS

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1.0

SCOPE

2.0

STANDARD SPECIFICATIONS

3.0

SERVICE CONDITIONS . . . . . . . . . . . . . . . . 3.1 External Conditions . . . . . . . . . . . . . . 3.2 Sulphide Stress Cracking Considerations

4.0

BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Explosive Hazard Protection Methods . . . . . . . . . . . . . . . . . . . . . . 4.3 Protection from the Environment . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Measurements and Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Connection Sizes and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Instrument Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 Limitations o n Selection and Approved Manufacturers List . . . . . . . . 4.9 Line Break Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 1 0 Use of Barrier Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 1 Shop Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 2 Painting and Protective Finishing . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 1 3 Packing, Marking and Documentation . . . . . . . . . . . . . . . . . . . . . . 4 . 1 4 Spare Parts and Maintenance Requirements . . . . . . . . . . . . . . . . .

8 8 8 9 9 9 10 11 12 12 13 13 14 14 15

5.0

CONTROLVALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Scope o f Control Valve Selection . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Valve Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Valve Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Trim Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Valve Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Actuator Selection and Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Actuator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Noise, Flashing and Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 1 Installation Notes. Bypass and Handwheel Philosophy . . . . . . . . . . . 5 . 1 2 Accessories and Ancillary Items . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 4 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15 16 16 19 21 23 26 30 32 33 35 38 43 45

6.0

RELIEF AND SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Scope of Relief Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Relief Applications and Selection . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Design. Materials and Construction . . . . . . . . . . . . . . . . . . . . . . . 6.6 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 46 46 47 50 52 55

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6 6 7 7 8

Engineering Group Specifcahn

Specification Number

01 ~ - J H - I ~ o ~

Rev

Date

Sheet

1

15-9-94

3 o f 163

Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 55 57

FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Scope of Flow Measurement Section . . . . . . . . . . . . . . . . . . . . . . 7.3 Flow Instrument Types and Selection . . . . . . . . . . . . . . . . . . . . . . 7.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 58 58 58 64 68 71 72

8.0

PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Scope o f Pressure Measurement Section . . . . . . . . . . . . . . . . . . . . 8.3 Pressure Instruments Type and Selection . . . . . . . . . . . . . . . . . . . 8.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 72 72 73 75 76 81 82 83

9.0

TEMPERATURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Applicable Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Scope of Temperature Measurement Section . . . . . . . . . . . . . . . . . 9.3 Temperature Instrument Types and Selection . . . . . . . . . . . . . . . . 9.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 83 83 83 85 86 91 91 92

10.0 LEVEL MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Scope of Level Measurement Section . . . . . . . . . . . . . . . . . . . . . . 1 0 . 3 Level Instrument Type and Selection . . . . . . . . . . . . . . . . . . . . . . 10.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 . 6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 . 7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 93 93 93 97 99 106 106 108

6.7 6.8 6.9 7.0

11.0 TANK 11.1 11.2 11.3 11.4 1 1.5

METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of Tank Metering Section . . . . . . . . . . . . . . . . . . . . . . . . Tank Metering Instruments Type and Selection . . . . . . . . . . . . . . Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

108 108 108 109 110 112

Engineering Gmup SpeMcabion

Specification Number 015-~~-1903

Rev

Date

Sheet

1

15-9-94

4 o f 163

1 1 . 6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112 113 115

12.0 LOCAL PNEUMATIC CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Scope of Local Controller Specification . . . . . . . . . . . . . . . . . . . . 12.2 Pneumatic Controller Types and Selection . . . . . . . . . . . . . . . . . . 1 2 . 3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 115 115 117 117 118 118 119

13.0 SPEED MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Scope of Speed Measurement Section . . . . . . . . . . . . . . . . . . . . 13.2 Speed Measurement Instruments Type and Selection . . . . . . . . . . 13.3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . 1 3 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

119 119 119 120 120 121 121 122

14.0 VIBRATION SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Scope of Vibration Sensing Section . . . . . . . . . . . . . . . . . . . . . . 1 4 . 2 Vibration Sensing Instruments Type and Selection . . . . . . . . . . . . 1 4 . 3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . 7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122 122 122 123 123 123 123 124

15.0 SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Scope of Solenoid Valve Section . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . 3 Solenoid Valves Types and Selection . . . . . . . . . . . . . . . . . . . . . 15.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 15.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 124 124 125 126 126 128 128 129

16.0 SIGNAL CONVERTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Scope of Signal Converter Section . . . . . . . . . . . . . . . . . . . . . . . 1 6 . 2 Signal Converters Type and Selection . . . . . . . . . . . . . . . . . . . . . 16.3 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

129 129 129 130 130 131 132 133

Engineering Group Specl%caLion

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

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17.0 POSITION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 Scope of Position Switches Section . . . . . . . . . . . . . . . . . . . . . . 17.2 Position Switches Type and Selection . . . . . . . . . . . . . . . . . . . . . 1 7 . 3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7 N a m e ~ l a t eData . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 133 133 134 134 134 135 135

18.0 FLAME DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . 1 Scope of Flame Detection System . . . . . . . . . . . . . . . . . . . . . . . 18.2 Flame Detection Types and Selection . . . . . . . . . . . . . . . . . . . . . 18.3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . 5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 135 135 137 137 138 138 139

19.0 MISCELLANEOUS INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2 Scope of Miscellaneous Instrument Section . . . . . . . . . . . . . . . . . 19.3 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . 4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 19.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139 139 139 140 140 140 141 141 142

20.0ANALYSERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 Scope of Analysers Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 . 3 Analyzer Types and Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 20.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 . 7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142 142 142 142 143 143 155 155 156

21.0 LOCAL PANELS AND GAUGE BOARDS . . . . . . . . . . . . . . . . . . . . . . . . 21.1 Scope of Local Panel and Gauge Board Selection . . . . . . . . . . . . . 21.2 Local Panels and Gauge Boards Type and Selection . . . . . . . . . . . 21.3 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

157 157 157 158 158 161 162 163

OKOC

Engineering Group Specificakm

Specification Number

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6 of 163

1.0 SCOPE

2.0

1.1

This specification details the design, manufacture, inspection, testing and supply of plant instrumentation for installation at the Facility in Kuwait.

1.2

The plant instrumentation shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.

1.3

The provisions of this specification shall apply t o all major and ancillary plant, proprietary equipment and "packaged units" unless otherwise agreed t o in writing by the Company.

STANDARD SPECIFICATIONS 2.1

Instruments, systems and equipment shall conform in design, materials and performance, except where otherwise specified, w i t h the current issue and amendments of the applicable codes and standards prevailing on the effective date of the Contract: 2.1.1

International Standards NACE MR0175

2.1.2

2.1.3

Material Requirements - Sulphide Stress Cracking Resistant Material for Oilfield Equipment

British Standards BS 5 3 4 5

Code of Practice for the Selection, Installation and Maintenance of Electrical Equipment for Use in Potentially Explosive Atmospheres

BS 5 4 9 0

Specification for Classification of Degrees of Protection provided by Enclosures

BS 5 5 0 1

Electrical Apparatus for Potentially Explosive Atmospheres (Also CENELEC Std En50.0140 2 0 and 0 2 9 )

Engineering Group Specifications All equipment and accessories covered by this specification shall comply with all relevant Engineering Group specifications o f which the following are specifically referenced in this specification: 0 1 5-AH-1001

Basic Design Criteria

0 1 5-AH-1 0 0 2

International Codes and Standards

Engineering Group Specjficatkm

Specification Number 01 5-JH-1903

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0 1 5-JH-1901

Instrument Engineering Basic Data

01 5-JH-1902

Instrument Design

01 5-JH-1905

Emergency Shutdown Panel

0 1 5-JH-I 907

Motor-Operated Valves

0 1 5-JH-1908

Instrument Installation

0 1 5-JH-1909

Instrumentation for Package Equipment

0 1 5-KH-1902

Spare Parts and Maintenance Requirements

01 5-NH-1104

PlantiEquiprnent Noise Control

01 5-PH-1901

Electrical Design, Installation and Testing

0 1 5-XH-1005

Shop and Field Painting

0 1 5-UH-1001

Packing, Marking and Documentation

A non-inclusive listing of applicable codes and standards shall be found in the Engineering Group Specification entitled "lnstrument Engineering Basic Data" (Number 01 5-JH-1901). Specifically applicable codes are found at the beginning of each section of this specification. Compliance w i t h this specification shall not relieve the Contractor of its responsibility t o supply equipment suited t o meet the specified service conditions and applicable regulations. Where conflicts exist between this specification and other Drawings, standards, codes and specifications, the most stringent shall be applied.

3.0

SERVICE CONDITIONS

3.1

External Conditions

3.1.1

The equipment shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces o f hydrogen sulphide.

3.1.2

Plant instrumentation shall in all respects be suitable for continuous operation in the service conditions stated in the Engineering Group Specification entitled "Basic Design Criteria" (Number 0 1 5-AH1001).

Engineering Group Sp&cation 3.2

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S u l ~ h i d eStress Crackina Considerations The f l o w sheet for materials selection guidance issued with the Contract documents shall indicate where the level o f H2S present in the process fluid can be above the partial pressure level indicated as critical within NACE MR0175. Where such conditions are indicated, the Contractor shall supply equipment using materials, manufacturing methods and testing within the NACE specification. The requirements shall apply t o all components that can come into contact with the process fluid, including remote mounted instruments and impulse lines. When any part of the plant falls within the requirement for materials t o be specified and fabricated in accordance with the NACE code, it is deemed that the H,S content in the general atmosphere over the whole plant precludes the use of brass and copper for pressure parts such as lnstrument air tube and fittings. In this case, stainless steel grade 3 1 6 tube and double-ferrule fittings shall be used throughout.

4.0

BASIC ENGINEERING INFORMATION Hazardous Area General information on allocation of hazardous area divisions and responsibilities are stated in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 0 1 5-JH-1901). Contractor shall be responsible for confirmation o f suitable selections of hazardous area and o f protective execution methods t o ensure the safety of the complete Facility. E x ~ l o s i v eHazard Protection Methods 4.2.1

All field instruments having electrical or electronic connections shall be suitable for installation in the defined hazardous area. The general methods of protection are as follows:

I Zone 0 Areas I Zone 1 Areas Ex'i'a

4.2.2

Ex'i' a or b Ex'd' Ex'e' (Junction boxes) Ex's'

Zone 2 Areas Ex'i'a or b Ex'd' Ex'e' (junction boxes) Ex's'

Alternative systems such as Ex'p' (pressurization) or Ex 's' (special certification) shall be subject t o written Company approval.

OKOC

Engineering Group Specificathion

Specification Number 01 ~ - J H - I ~ o ~

Rev

Date

Sheet

1

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9 01 163

The preferred priority for the protection methods are given in the Engineering Group Specification entitled "lnstrument Design" (Number 0 1 5-JH-1902). All e a. u i. ~ m e n t shall be certified for the a . ~, ~ r. o ~ r i aarea te classification, gas group and temperature class b y a recognized European testing authority t o BS 5 5 0 1 (CENELEC Standard En50.014-020 and 0391, or equivalent. Components of systems protected b y control room-mounted intrinsically safe (IS)isolators shall be certified individually and shall be checked by the Contractor as a system including the field instrument, the cable and the isolator. Field instruments protected by an IS isolator do not require a certificate provided that a documented statement from the Approved Manufacturer is included t o confirm that the instrument may be used as "simple apparatus" in an IS circuit in accordance w i t h BS 5345. Protection from the Environment 4.3.1

The minimum acceptable standard o f protection against water or dust ingress is t o BS 5 4 9 0 (IEC 529) degree of protection IP 65.

4.3.2

Electronic parts shall be environmentally sealed or designed t o operate without change of atmosphere (breathing).

4.3.3

Sun shields are required for all instruments for protection from the direct sun. Additional cooling may be required t o maintain the instrument below 70°C ( 165°F) or the maximum instrument design temperature, whichever is the lower. The Contractor is responsible for providing such cooling either within the instrument design or as a design feature included in the installation of the instrument.

Utilities The available utilities and their process conditions are detailed in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 0 1 5-JH-1901). Measurements and Scales The selected units for calculations and scales are listed in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 015-JH-1901).

OKOC 4.6

Engineering Group Sprnc~fbn

Specification Number

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1

Date

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10 of 163

Connection Sizes and Tvoe 4.6.1

Electrical All electrical entries shall be I S 0 metric threaded. The preferred size is M 2 0 x 1.5 mm.

4.6.2

Process Where connection details are given, it is not acceptable for an adaptor t o be provided t o meet this requirement, except by individual Company agreement. Process connections for impulse tubing shall be 112-in NPT female. Process pipeline connections for thermowells shall be: 1.

For pipelines 1-112-in. flanged, rated at 3 0 0 lbs.(minimum).

2.

For vessels 2-in.(minimum) Ibs.(minimum).

flanged,

rated

300

The flange rating shall increase t o match the pipelvessel rating as necessary. The connection size may be increased if thermowell stresslvortex-shedding calculations dictate. The gasket type and face finish shall match the line specification. Atmospheric pressure and cooling water applications may use NPT screwed thermowells. Pneumatic (instrument air) connections shall be 114-in. NPT unless air flow requirements dictate a larger size. lnstrument air tubing/connections supplied as part of the instrument items shall conform t o the "instrument air hook-up" details given in the Engineering Group Specification entitled "lnstrument Installation" (Number 0 1 5-JH-1908). Level instrument chambers shall be flanged, minimum rating 3 0 0 lbs. The flange rating shall be increased t o match the vessel rating as necessary. The gasket type and face finish shall match the line specification. Connections may be direct t o the vessel for each instrument, but stand pipes shall be used t o avoid unnecessary vessel penetrations when their use does not impede o n access, walkway clearance etc. Ranges of instruments shall not be compromised t o suit installation on stand pipes. Shutdown instruments shall have dedicated vessel nozzles.

Engineering Group Specificahn

4.7

Specification Number

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Date

Sheet

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1 1 of 163

e.

Control valves shall be flanged and faced according t o the piping line classification, w i t h a minimum rating of 300 lbs. For fully welded lines, individual proposals shall be submitted t o the Company for approval.

f.

Where possible, analysis instruments shall use connections as for other instruments. Exceptions shall be submitted t o the Company for approval.

g.

Where multiple shutdown instruments are installed for 2 out of 3 voting, each shall have a dedicated tapping into the process piping or vessel.

Instrument Identification All instrument items shall be permanently and clearly marked for the following categories: 4.7.1

Nameplate Each item shall be identified w i t h a permanently fastened stainless steel or rust-resistant material nameplate comprising: a.

Manufacturers name.

b.

Model number.

c.

Serial number Temperature and Pressure Rating Of Wetted Parts.

d. e.

* Voltage and Switch Rating Set Point, RangelCalibration and Other Relevant Data.

f. g.

Instrument Tag No. (Separate Tag Plate Preferred)

* 4.7.2

= where applicable)

Certification Plate (For Certified Items) Each certified instrument shall have a certification plate giving as a minimum: a.

Type of approval and mark of certifying body.

b.

Certifying authority name

c.

Licenselcertificate number and date.

Engineering Group Spec57icatbn

!1

d. 4.7.3

Specification Number

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01 5-JH-1903

1

Date

15-9~94

Sheet

12 of 163

Area classification, gas group, temperature rating

Tag Plate

I Each instrument having a tag number on the P&ID shall be provided w i t h a stainless steel tag plate with the full alphanumeric tag number hard metal stamped or deep engraved. The minimum dimensions shall be 4 0 m m x 25 m m x 1.5 m m ( 1 % in. x 1 in. x 1/16 in.) with a 2-mm (1110-in.) hole drilled in one corner. The tag shall be fastened t o the instrument with stainless steel wire of minimum I.O-mm (1120-in.) diameter. Note:

4.7.4

A tag plate integral with the Approved Manufacturer's nameplate is acceptable provided the tagging is large, clear and easily read in the final installed position.

Equipment and Site Number Tag Plate Each instrument shall be allocated b y the Company an Equipment Identification Number (EIN) and a Site Number (SN). The Contractor shall manufacture and fit tag plates bearing the allocated numbers t o each instrument. The minimum dimensions shall be as those above.

4.8

4.9

Limitations o n Selection and A ~ o r o v e dManufacturers List 4.8.1

All instruments and instrument items shall be of heavy duty industrial type and be suitable for use in the stated environment.

4.8.2

Tried and tested equipment shall be used. Equipment approaching obsolescence shall be avoided.

4.8.3

Aluminium and aluminium alloys are not permitted except w i t h Company approval. Where use o f such alloys cannot be avoided, they shall be of a type suitable for use w i t h electrical instruments situated in a hazardous area, and be fully protected against the environment.

4.8.4

Manufacturers shall be selected from the Approved Manufacturer's list. Where a suitable manufacturer is not included o n the list, full details of the proposed manufacturer and the instrument or system together w i t h reasons for its inclusion shall be submitted t o the Company for approval.

Line Break Detection Line break resistors are required for all contact-type field switches. These shall be fitted in the instrument head where this does not infringe on the certification. Where this is not possible, they may be installed at the nearest

Engineering Group Specjficatkw

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01 5-JH-1903

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available junction point t o the instrument. The type and value of the resistor shall be agreed t o w i t h the Distributed Control System (DCS) supplier. 4.10

Use o f Barrier Glands 4.10.1

Barrier glands shall be avoided whenever possible.

4.10.2

Barrier glands with epoxy putty filling shall be used where a failure within an instrument could allow a flammable process medium t o be at pressure within the terminal enclosure.

4.10.3

The Contractor shall as a preferred option try t o ensure that the instrument design is such that failure of the element or capsule shall not cause the above condition, thus avoiding the need for Barrier Glands.

4.1 1 Shoo lnsoection and Testing

The Contractor shall be responsible for all inspection and testing o f materials and equipment prior t o delivery. No equipment or materials shall be delivered until all applicable tests have been completed and all defects rectified and re-tested successfully. Documentary evidenceshall be available for Company review if requested. 4.1 1.1

Quality Assurance and Quality Control a.

All items are t o be designed, manufactured, inspected and tested under the control o f a documented QA/QC system. General and specific requirements are provided in the Contract.

b.

Special reference t o inspectionitest actions within the detailed sections of this specification are additional t o and shall not replace or reduce the OAiQC requirements provided for in the Contract.

c.

Approved Manufacturer specific data and model numbers shown o n data sheets approved b y the Company in no way relieve the Contractor o f its responsibility t o provide equipment t o satisfy the service conditions stated on the specifications and data sheets. It is the Contractor's responsibility t o notify the Company of any conflict w i t h model numbers, materials or designs specified.

d. The Company shall be permitted t o witness Approved Manufacturer's QAiQC systems operating on all instruments during design, fabrication, assembly and testing.

wing Group ;pea;fication

e.

Specification Number

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Sheet

14 of 163

The Contractor shall submit for Company approval minimum inspection requirements summaries for each item prior to purchase of the equipment.

4.1 1.2 Shop Testing Company reserves the right t o witness testing or t o request additional testing according t o its requirements. Such witnessing shall include all control valves, relief valves, composite systems, control systems etc. The detailed requirement shall be noted by the Company o n the Contractor's submitted Quality (Test and Inspection) Plan. 4.12

Paintinq and Protective Finishinq All items shall be fully protected against the environmental conditions, the effects of the process fluids, normal wear and the handling normally expected during installation, erection and commissioning. Where an item cannot be rendered suitable for the conditions by selection of material, a paint finish shall be applied in accordance w i t h the Engineering Group Specification entitled "Shop and Field Painting" (Number 01 5-XH-1005). Where the Engineering Group Specification calls for Approved Manufacturers standard, an epoxy paint finish t o a recognized offshore standard shall be the minimum method o f protection used. Cadmium plating is not acceptable as a final finish. All Company-approved aluminium items shall be fully coated on all exposed surfaces. Mounting boards, brackets and small moving parts not suitable for painting shall be manufactured from stainless steel. Fasteners shall be stainless steel.

4.13

Packinq, Markinq and Documentation

4.13.1

General For all relevant requirements, refer t o the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 0 1 5-UH-1001).

Engineering Group spea'fication 4.13.2

Specification Number

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Date

01 5-JH-1903

1

15-9-94

Sheet

15 of 163

Packing for Shipment Immediate Packaging All items shall be packed in the Approved Manufacturer's standard packaging in such a w a y that unpacking will not be necessary until each item is required for erection. All necessary protection and desiccants shall be included. Equipment shall be capable of withstanding transport and storage without affecting subsequent satisfactory operation. Delivery Packaging Delivery packaging is covered by the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 01 5-UH-1001).

4.14

S ~ a r eParts and Maintenance Reauirements For all relevant requirements, refer t o the Engineering Group Specification entitled "Spare Parts and Maintenance Requirements" (Number 015-KH1902).

5.0

CONTROL VALVES

5.1

Applicable Standards ANSI 816.5

Steel Pipe Flanges and Flanged Fittings

ANSl B l 6 . 1 0

Face-to-Face and End-to-End Dimensions for Valves

ANSl B16.34

Valves

ANSl 81 6.37

Hydrostatic Testing of Control Valves

-

Flanged, Threaded and Weld Ended

ANSl B 16.104 Control Valve Seat Leakage API RP 550 Part 1

Manual on Installation of Refinery Instruments and Control Systems, Process Instrumentation and Control

BS 1655

Specification for Flanged Automatic Control Valves for the Process Industry

BS 5793 (IEC 534)

Industrial Process Control Valves

OKOC 5.2

Engineering Group Specjficahkm

Specification Number

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Date

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1

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Sheet

1 6 of 163

S c o ~ eof Control Valve Selection A "control valve" shall mean any valve which has a process control function o n the plant, normally denoted by having a tag number allocated on the P&ID. The following additional items also shall be considered in this section:

Actuated shutoff or emergency shutdown (ESD) valves shall be treated as control valves for the purpose of this specification, except where a topic discussed in the specification specifically states "control valve," and the context identifies that the topic is relevant t o modulating control valves only. Bypass valves shall be considered in the control valve analysis where the maximum or minimum f l o w allowable through the bypass could be critical for plant safety, or where noise or an unusual process consideration may apply. Electric motor-operated valves (MOVs) for modulating duty are covered by this section of this specification. Electric MOVs for onloff and ESD service are covered by the Engineering Group Specification entitled "Motor-Operated Valves" (Number 0 1 5-JH-1907). 5.3

Valve T v ~ e s 5.3.1

Standard Selection a.

Control valves for normal service shall generally be: Plug-type globe valves. Top and bottom guided (1-in. valves may be top guided only). Single seated or balanced trim w i t h flow-under plug. Flanged t o ANSI B16.5 w i t h face-to-face dimensions in accordance w i t h BS 1655lANSI B16.10. Pneumatically actuated, spring return diaphragm type. Fitted with pneumatic positioner. Positioners for valves w i t h actuators of 0.2 t o 1.0 barg ( 3 t o 1 5 psig) spring range shall be fitted w i t h positioner bypasses, except valves in split range service.

@ KOC

Engineering Group

Specification Number

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01 5-JH-1903

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17 of 1 6 3

Spe&icatiOn

b. Other trim and guidance types may be used if it can be shown that there are advantages in the particular service, e.g., cage guided, l o w dB trim, characterized ball etc. c.

5.3.2

Skirt-guided trim shall be avoided except for sizes 1-112 in. and less in l o w DP service.

Self-Acting Regulators Valves shall normally be controlled from an external signal from the DCS or ESD system or from a local controller. Self-acting regulators may be accepted for some services if i t can be shown that the failure characteristic will not lead t o dangerous process situations occurring. Where self-acting regulators are used, consideration shall be given t o the use of line-tapped signals in lieu of integral bleeds.

5.3.3

Valve Sizes a.

The minimum valve body size is 1 in., unless approved otherwise, in writing, b y the Company. If smaller sizes are approved, top guided only types may be used.

b.

Valves shall be selected from standard pipe line sizes: 1 in., 1-112 in., 2 in., 3 in., 4 in., 6 in., 8 in., 1 0 in., 12 in., 1 4 in., 1 6 in. etc.

5.3.4

c.

Unusual valve sizes, e.g., 1-114 in., 2-112 in., 5 in. etc. shall not be used.

d.

Valves in flashing service may, subject t o Company approval, have larger outlet size than inlet size.

Body Pressure Rating The minimum pressure rating for control valves shall be 3 0 0 lbs for sizes up t o and including 8-in. nominal bore (NB). Larger valves shall be line rated. Subject t o Company approval, shutoff valves of quarter-turn type may be accepted as split-body type and may be at line class rating (if the line is rated less than 3 0 0 lbs) in cases where the piping system specifies identical manual valves and advantages for spares stocking can be shown.

5.3.5

Screwed Valves Screwed-end valves for screwed piping classifications or welded-in valves for extreme service conditions may be allowed subject t o specific approval by the Company.

Engineering Group Specificab;on

Specification Number

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Date

01 5-JH-1903

1

15-9-94

Sheet

1 8 of 163

Tight Shutoff a.

Valves shall not be used for dual purposes (control and shutdown) when leakage cannot be tolerated. If necessary, an additional tight shutoff (TSO) valve shall be added for process interrupt service in cases where leakage would lead t o a shutdown. Valves used for control shall not be specified as TSO.

b.

Quarter-turn ball valves may be used for onioff service on clean process media. Valves for shutoff service on dirty media shall be specially selected for self cleaning properties, e.g., cutting or shearing action o n closing. Techniques such as seat flushing or purging shall be adopted as necessary t o ensure a correct seating of the trim.

Butterfly Valves Butterfly valves may be used o n high-capacity service where lowpressure losses are essential and the operating differential pressure is small. The minimum allowed body size is 2 in. wafer-type valves are acceptable provided alignment kits are part of the scope of supply. Ball Valves for Control Characterized ball valves of size 1-112 in. and upwards may be used where the available pressure drop precludes the use of a globe valve. If the valve design is o f flangeless body type, the valve shall be purchased with flange studs t o line class and an alignment kit. Rotary Plug Valves Low-void, self-flushing valves o f rotary-plug type may be used for particulate service where process conditions allow. Angle Valves Angle valves w i t h top-guided plug may be used w i t h Company approval. Three-Way Valves Three-way valves may be used for mixing or f l o w splitting service, and may be top guided only.

Engineering Group

Specification Number

Spc%?cd&n

5.3.12

01 5-JH-1903

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Soft Seats Globe valves for tight shutoff service in clean process fluids may be fitted w i t h soft seats for services up t o the soft insert allowable operating temperature. Lapped seats, Stellited as necessary, shall be used for higher process temperatures.

5.3.13

Failure Action The valve failure position indicated on the P&ID shall be achieved in the valvelactuator design. Fail locked systems shall have a defined drift position. If a drift position is not acceptable, doubleacting actuators with appropriate reservoir and trip systems shall be used, as for ESD valves, refer t o section 5.7 of this specification.

5.3.1 4

Special Applications Solutions for special applications or conditions not covered by this specification shall be submitted t o the Company for approval.

5.4

Valve Sizincl Reauirements Control of Design Data Valves shall be sized o n the basis of defined issues o f the process data sheets, P&ID, equipment and piping data. A document control system shall be maintained t o ensure that the valves are built t o a calculation based o n the final issue of data. Data sheets shall state the process data revision number, and calculations the data sheet revision number. Limiting Case The valve purchase data sheet shall specify the applicable upstream and downstream pressures (or pressure difference) for all cases given. Where the process conditions are such that varying combinations of different process fluids can be present, andlor the maximum or minimum flow can occur at varying pressure, sufficient calculations shall be performed t o ensure that the limiting case is selected as the design case. Calculation Required Valve sizing calculations shall be performed in accordance w i t h BS 5 7 9 3 (IEC 5 3 4 ) . Valve size calculations shall be produced at least for the minimum, design and over-design process conditions. Additional calculations, as necessary, shall be performed t o establish the correct trim form. Valve calculations shall also be

OKOC

Engineering Group SpedficdMn

Specification

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Rev

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Sheet

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20 of 163

performed for onioff valves (except full-bore ball valves) t o confirm adverse process conditions are not occurring. The differential pressure for a globe valve shall n o t be less than 0.7 bar (10 psi) at design flow. For DP less than 0 . 7 bar ( 1 0 psi), alternative valve types shall be selected. Overdesign Margin The valve trim shall be calculated so that the design f l o w is between 7 0 and 8 0 % of the fully open valve capacity, except that where an over-design figure is also t o be allowed for within the valve design, this shall occur at not greater than 90% of the valve capacity. Turndown The minimum flow shall be attainable within the turndown ratio of the selected valve/controller combination. The maximum turndown for standard valves shall not exceed 3 0 t o 1. For valves with CV less than 1, this shall reduce t o 1 0 t o 1. Special valves with high turndown characteristics may be offered t o the Company for approval t o suit special process conditions. Valve Stroke The stroke of the valve shall be within the band 1 0 % t o 9 0 % for all the above criteria. Effect o n Relief System The calculation shall show the f l o w at design and over-design pressure when the valve is fully open. The resulting over design on f l o w shall be confirmed against operating conditions and relief arrangements t o confirm plant safety. Where the flow through the valve is critical t o the sizing o f a relief or other safety system, the bypass valve (if fitted) shall also be fully specified w i t h an identical valve characteristic (CV) or maximum f l o w limit t o prevent maloperation under bypass control. Trim Capacity The selected valve shall be capable of accepting t w o trim changes up and d o w n from the finally calculated size t o allow for process design changes. This may be varied, subject t o Company agreement, when: a.

The calculated valve body is less than 1 in

Engineering Group specification

Specification Number

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01 5-JH-1903

1

15-9-94

Sheet 2 1 o i 163

b. The calculated valve body is t w o or more sizes below line size. A body one size smaller than the line shall be used with reduced trim. Leakage Rate The shutoff flow (leakage rate) shall be calculated at the shutoff design pressure, and the figure stated o n the calculation sheet and checked against operating conditions t o confirm plant safety, and t o confirm trip conditions will n o t arise during process interrupt. Additional TSO valves shall be added as necessary. Minimum Stop Where a minimum stop is specified (based o n flow), the appropriate valve opening shall be calculated. Back Flow Where back f l o w protection is required, the valve shall be checked t o confirm that the correct type of valve and adequate actuator force has been selected. Three-Way Valves For essential safety reasons, three-way valves shall be clearly identified as t o service, i.e., flow-splitting or flow-mixing or flowdiversion, and all operating combinations identified before making the calculation. Two-Phase Flow Suitable calculation methods shall be used for two-phase and flashing flow t o ensure the gas phase CV is properly considered.

5.5

Trim Selection

5.5.1

Characterized Positioners Wherever possible, the trim characteristic shall be specified so as t o obtain a linear installed valve characteristic over the operating range. Characterized positioners are only accepted where the correct inherent trim types are not possible.

5.5.2

Selection of Characteristic The inherent trim characteristic (or characterization in the case of non-globe types) shall be carefully selected for each application t o provide the best control compromise. The following table (table 1)

Engineering Group Spedfication

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can be used t o assist the selection. The Contractor is responsible for ensuring that the final trim selection provides control within specification. Small Pressure Drops Systems shall be individually assessed when the pressure drop across the control valve is less than 25% of the total dynamic pressure loss at design f l o w rate. Standard cases I f detailed process analysis is not available, the trim shall be selected as linear where 50% or more of the dynamic system pressure drop a t design f l o w is across t h e valve, and equal percent for other applications. TABLE 1: SELECTION

Level 1

(

VALVE CHARACTERIS ICS

Equal Percentage

Linear

Quick Opening

If full load DP is less than

If pressure drop is constant.

When DP increases w i t h load at a rate greater than 2: 1

20% o f no-load DP.

Flow

I f no guide lines are available f l o w range changes less than 10:l but system rangeability above 20:1, i.e., desired f l o w rate relatively constant but valve DP varies widely due t o load changes. When valve is in bypass and controller does not have square root extractor.

For f l o w range greater than 10:1, except w h e n measuring element has no square root extractor and control valve is diverting f l o w from the measuring elements.

Pressure

For liquid service. For compressible fluids if downstream line is shorter than 30 m ( 100 ft.) if DP varies more than 5 : l . If process demand varies more than

Compressible fluids if downstream system capacity is large.

1

I

General

5.6

If operating conditions are unpredictable.

Where control can be obtained by on-off action. When maximum valve capacity must be obtained rapidly. When liquid temp. may be controlled by mixing liquid streams.

Valve Desian Reauirements Valve Positioning All control valves shall be supplied w i t h a positioner. Some process shutdown valves may require a positioner in unusual cases if the service demands precisely controlled rates of opening or closing, these shall be indicated o n the P&ID if required. For all services where 0 . 2 t o 1 . 0 barg ( 3 t o 1 5 psig) actuators are provided, or where any vibration is present, pneumatic positioners w i t h a separate signal convertor shall be used. Other services may use direct electro-pneumatic (EIP) positioners subject t o Company approval. Failure Action The action of valves o n failure o f the operating medium shall be determined b y process requirements w i t h regard t o safe operation and emergency shutdown and shall be noted on the P&ID. The failure action shall be the same for signal loss, air power loss and actuator failure. Field accessories shall be provided as necessary t o achieve the actions. High- and Low-Temperature Service Where the temperature of the controlled fluid exceeds 230" C (450" F), an extension neck or bonnet shall be used. The Approved valve Manufacturer's recommendations shall be followed for valves in cryogenic service. Bellows Seals For specified duties as agreed t o by the Company, e.g., toxic fluids or penetrating liquids, the valve stems shall be double bellows sealed w i t h the outer bellows gland sealed t o the stem. An appropriate system shall be fitted t o monitor t h e enclosed space t o detect inner bellows leakage. Where indicated o n the P&ID, purging

of the interspace and a purge f l o w alarm shall be used. Replacement of Trim The valve trim (plug and seat, ball and seat etc.) shall be removable. Access t o the trim for globe-type valves shall be from the top of the valve. If a bottom flange is fitted t o the body for access t o the seat, this shall not be drilled and tapped for drainage or pulling. Opening and Closing Times and Valve Response a.

All data sheets shall specify the maximum allowed opening and closing times based o n the process conditions and equipment being operated. Valves in compressor anti-surge control shall have a stroke time not exceeding 5 seconds.

b. The response time shall also be stated, based on the time for the valve t o complete its movement when the signal t o the positioner undergoes a 10% step change. Minimum and Maximum Stops Minimum stops shall not be used except w i t h Company approval. Minimum f l o w shall be achieved b y providing piping and valve bypasses w i t h an orifice restriction. Maximum stops shall only be fitted if valve over-design cannot be tolerated safely. In all cases the stops shall be based on the calculated stem position for given f l o w and pressure conditions. The stops shall as a minimum be double nut locked and shall be permanently secured, preferably by welding, after proving during commissioning. The stop mechanism shall be picked out in a contrasting colour t o the valve and actuator. Seat Leakage Valve data sheets shall state the seat leakage t o be tolerated. Generally, valves in depressurising, shutoff and emergency shutd o w n shall be specified class V and for process shutoff shall be specified t o class IV of ANSI 81 6.104. Bubble-tight valves shall be specified for shutdown of flammable fluids for supply t o end users such as the fuel supply t o a fired heater, and for all total ESD applications. Gland Packing a.

For normal service on clean fluids, a bolted bonnet w i t h gasket and retaining recess shall be fitted, packed with interlocking self-lubricating packing of the Teflon or Grafoil type. Lantern

Engineering Group Spea7ication

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ring and spring followers shall be used For highertemperatures, 2 0 5 t o 540°C ( 4 0 0 t o 100O0F), solid graphite packing shall be provided, with braided packing where solids may be deposited o n the stem. Finned bonnets, cooling rings and thermal isolation techniaues shall be used.

I

5.6.1 0

I

5.6.1 1

b.

For higher temperatures, 205 t o 540°C ( 4 0 0 t o 100O0F), solid graphite packing shall be provided, w i t h braided packing where solids may be deposited o n the stem. Finned bonnets, cooling rings and thermal isolation techniques shall be used as necessary.

c.

Packing for valves above 540°C (1000°F) shall be the subject of individual agreement w i t h the Company.

d.

Low-temperature service, minus 5 5 t o 0°C (minus 67 t o 32°F) shall use solid teflon V-rings w i t h an extended bonnet and thermal isolation suitable for the service.

e.

Packing shall be accessed through adequately sized bolted stuffing boxes.

f.

The Approved Manufacturer's installations instructions, e.g., bonnet over or under body, side-mounting restrictions etc. shall be strictly followed t o prevent damage occurring t o the packing.

g.

Other packing materials and methods may be offered for Company approval by submitting full details, accompanied by the Approved Manufacturer's statement of the advantages offered.

Gland Lubrication All glands shall be drilled and tapped for lubrication units even where packing is self-lubricated. Lubricators shall only be fitted as necessary. Un-used tappings shall be plugged. The plug material shall be compatible w i t h the bonnet material. Lubricators for highpressure valves (greater than 1 5 barg, i.e., 2 2 0 psig ) shall have an isolating valve fitted between the lubricator and the stuffing box. Direction of Flow The direction o f flow through the valve shall be clearly and indelibly marked on the body, preferably b y a cast on arrow or stamped plate.

__1

Engineering Group Sp&icat;on

5.7

Specification Number

Rev

Date

Sheet

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1

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2 6 of 163

Actuator Selection and Sizing 5.7.1

Selection The actuator shall be purchased together w i t h the valve as an integrated package. Where the actuator manufacturer is not on the Approved Manufacturer's list, the selection is subject t o Company approval. Actuators shall normally be pneumatic-diaphragm type for globe valves, plug valves and butterfly valves and pneumatic spring return piston actuators o f scotch yoke or geared type for onioff quarter-turn valves. Piston actuators of air or hydraulic type may be used with Company approval when it can be shown that long strokes, high forces, speeds etc. are essential. Motor-operated modulating valves, piston-operated pneumatic actuators, airloil systems or other special actuation methods may be used in special circumstances subject t o Company approval. For control valves the normal pneumatic actuator spring range shall be 0.2 t o 1 . 0 barg ( 3 t o 1 5 psig), t o enable positioner bypasses t o be fitted. If i t can be shown that a bypass is not necessary or undesirable, or if circumstances demand a higher force or a higher speed than is available from 1.0 barg (14.5 psig), an alternative spring rate may be used, subject t o approval by the Company. Under no circumstances shall the spring rate exceed 4 . 0 barg ( 6 0 psig). The actuator shall be able t o withstand a mechanical design air pressure of 11.3 barg ( 16 4 psig). Pneumatic piston actuators are t o be sized t o supply the full specified force at an air pressure no greater than 4 . 0 barg ( 6 0 psig).

5.7.2

Actuator Sizing Criteria, Control Valves a.

The actuator shall be able t o overcome a minimum of 1 2 5 % of the worst predictable process and mechanical forces within the valve, inclusive of fluid shutoff pressures, coking or solids, gland compression, stiction and friction and all other expected or possible forces. As a minimum, the process force shall be taken as the upstream process design pressure (or the piping mechanical design pressure if the actuator size resulting from this is economic) and an atmospheric downstream pressure. Where this calculation results in an uneconomic actuator, or

Specification Number

Engineering Group SpecMcatkm

01 ~ - J H - I ~ o ~

Rev

Date

1

15-9-94

Sheet

27 of 163'

one which is too large t o provide a n adequate speed of response, the overall solution shall be subject t o Company approval. b.

If back-flow protection is parr of the valve service, the actuator shall be capable of the necessary forces t o achieve the operation.

c.

Sizing criteria for actuators for three-way valves shall be chosen t o enable the valve t o operate against the worst maximum design differential pressure across a single port. All the operating scenario shall be reviewed t o confirm that the worst case has been foreseen.

d.

The selected actuator sizing criteria shall be clearly stated on the data sheet. For pneumatic actuators, full details of the minimum, maximum and spring design air pressures shall be noted.

e.

The actuator shall be sufficiently powerful that bench setting for achievement o f specified leakage rate is not required.

5.7.3 Actuator Sizing Criteria, Emergency Shutdown Valves a.

Calculation Requirements 1.

This section applies t o all valves controlled directly from the ESD logic, including vent valves and de-pressurizing valves.

2.

As shutdown valves spend long periods without cycling, particular care shall be taken t o ensure that the actuators deliver sufficient force t o fully openiclose the valves at the extremities of operation when called upon t o do so. Due regard shall be paid t o the possibility of sticking and gummy deposits o n valves which are stationary for long periods.

3. The torque 1 linear force delivered b y the actuator at the minimum air design pressure shall be at least double the calculated force for the most arduous of the following conditions or combination of conditions, and any other restrictions applicable in the particular application: a.

Breakaway force.

b.

Running force.

c.

Re-seat force.

Engineering Group

Spedficafibn

4.

b.

c.

Specification Number

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Sheet

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d.

Gland or packing forces.

e.

Coking, dirt, rust or gumming clearance forces, internal and external.

f.

Safety factors o n all the figures.

g.

Positive tolerances on all measured figures.

The design check shall ensure that the other mechanical components of the valve are specified with sufficient strength t o utilize the forces of the oversized actuator.

Actuator Selection 1.

Actuators shall normally be diaphragm type when globe valves have been specified for shutdown duty, and spring return piston actuators operating through a scotch yoke or gearbox for quarter-turn type. Where a pneumatically powered shutdown valve is in a service where the standard spring return system is n o t suitable due t o return force or closing speed restriction, a double-acting or spring-assisted system shall be used.

2.

The requirement and method of operating double-acting actuators shall be indicated on the P&ID, w i t h the speed Parameters stated.

Actuating Method

1.

Generally, the actuation method for ESD, vent and depressurizing valves shall be selected from t w o types: a.

Direct Pneumatic Type The actuator shall operate directly on air supplied from a dedicated reservoir.

b.

Indirect Hydraulic Type These valves shall be operated by an air-driven hydraulic package. The air shall be supplied from a dedicated reservoir.

2.

For both types, the air reservoir shall be supplied with sufficient reserve capacity t o enable three complete valve operation cycles. The reservoir shall be sized for 3-full strokes of the valve with a 50% safety factor. The reservoir may be dedicated t o a single valve, or t o a group

o f valves when the service of these valves is strictly related and controlled by the same ESD logic sequence, and the valves are positioned within a 5 - m pipe run from the reservoir. 3.

d.

The reservoir shall be charged at the normal Facility instrument air pressure. The supply t o the reservoir shall incorporate filters and check valves t o ensure that the air supply for the ESD valve is retained during loss o f general air pressure. The design pressure for reservoir sizing purposes shall be the same as the actuator sizing design pressure, which shall not exceed 4.0 barg (60 psig).

Trip Action The trip action shall be initiated in all cases by the deenergisation of a solenoid valve(s) powered from the Facility ESD system, for all situations including reset, ESD trip or controlled vent action and any air failure actuation resulting from the reservoir low-low pressure switch signal.

For the l o w air pressure alarm and safety actions, electronic pressure switches shall be fitted t o the reservoir t o detect when the air reservoir pressure is at 15% ( l o w alarm) and at 5 % (low-low trip) above the reservoir sizing pressure. The l o w pressure switch shall bring up DCS alarm t o warn of a possible problem o n the air supply, the low-low pressure switch signal passes t o the ESD system, which will institute the necessary action o n the logic svstem as follows: a.

Single-Acting (Spring Return) Actuators

Unless otherwise specified, the low-low pressure switch input will prevent further use of air toward the "plant unsafe" (run) condition but allow manual selection of a trip t o the "plant safe" condition. The valve will thus stay in the "Run" condition until the air pressure drops below the spring-return force, the spring will then drive the valve toward the "safe" position. b.

Double-Acting Actuators

Unless otherwise specified, the low-low signal shall cause a trip of the valve t o the safe position while there is still sufficient air t o ensure that the valve can be moved t o the safe position.

A t Company option, alternative strategies may be adopted. The Contractor shall submit full details of the philosophy, the hook-up and proposed field and control room-mounted instrument and operator interface for Company approval. The ESD logic shall not be self-resetting. The solenoid valve shall be of mechanically self-resetting type, but shall require electrical reset b y operation of a local pushbutton openlclose station interfacing w i t h the ESD system, operable when the logic has been enabled b y the control room operator. Details are provided in the Engineering Group Specification entitled "Emergency Shutdown Panel" (Number 0 1 5-JH-1095). Where an ESD valve is also used t o perform a process interrupt function, an additional solenoid valve shall be supplied. This shall be operated from the control logic and shall be so positioned and piped that the ESD function shall overrule the control function in the case of an ESD trip. 5.7.4

Actuators for Motor-Operated Valves (MOVs) MOV actuators fall into t w o service categories: a.

Direct motorlgearbox drives for direct application t o the valve stem in onloff application (no modulation) are covered by the Engineering Group Specification entitled "Motor-Operated Valves" (Number 0 1 5-JH-1907).

b.

Electric MOVs for modulating service: actuators in this category shall only be used when stipulated or authorized by the Company. The actuator, electrical control card and power control gear shall all be purchased as a fully integrated matched set. The actuators can be used in closed-loop service, or open loop w i t h valve position feed back b y precision potentiometer. The actuator shall be fitted w i t h torque and end of travel switches that shall override the control signals. The actuators must be certified for use within the hazardous area classification o f the Facilitv.

5.8

Actuator Construction 5.8.1

Diaphragm Actuators a.

The pneumatic diaphragm actuator shall be of totally enclosed spring-return type.

Engineering Group SpeaZication

Specification Number

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Sheet

01 5-JH-1903

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31 of 1 6 3

The actuator shall be direct or reverse acting according t o the required process failure action. Within this constraint, direct acting (spring up) actuators are preferred in the sandy environment due t o the avoidance o f a shaft seal and wiper. The spring shall be of linear characteristic over the stem travel range, and be corrosion resistant. A spring screw and locknut shall be readily placed for adjustment. The yoke shall be of cast steel or ductile iron, adequately painted or plated against the environment in accordance with the Engineering Group Specification entitled "Shop and Field Painting" (Number 0 1 5-XH-1005). A valve position indicator shall be fitted, synchronized and scaled t o match the actual valve stroke. The connection t o the valve stem shall be a threaded split clamp with clamping bolt. The diaphragm case construction.

shall be o f

bolted pressed steel

The diaphragm shall be of nylon reinforced neoprene or Buna N. the maximum allowable deviation from the rated effective area shall not exceed plus 1 5 % and minus 0 % through the entire travel.

5.8.2

Quarter-Turn, Piston- and Cylinder-Type Pneumatic Actuators a.

Only heavy industrial types shall be accepted. The actuator shall preferably be of steel w i t h a chrome-plated bore, or stainless steel. High-grade aluminium with a suitable coating system may be used, subject t o Company approval.

b.

The flow sheet for materials selection guidance issued with the Contract documents shall indicate where the level of H,S present in the process fluid can be above the partial pressure level indicated as critical within the NACE MR0175. When any part of the plant falls within the requirement for materials and fabrication t o be in accordance w i t h the NACE code, it is deemed that the H2S content of the general atmosphere over the whole Facility requires the use of solid stainless steel actuators, also in these circumstances, chrome plating is not permitted.

c.

The mechanism, shafts etc. shall be adequately protected against dust ingress. If bellows are used, the design shall protect against dust being drawn in due t o air change during operation. Exposed shafts shall be stainless steel. Tie rods and other exposed fastenings shall be stainless steel.

Engineering Group SpeiHcatEon

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1

5.8.3

d.

Ports shall be a minimum size 114-in. NPT. Smaller ports with adapters are not acceptable. Ports o f at least 114 in. of other thread forms shall be accepted provided they are fitted with permanent NPT thread form adapters. Exhaust ports shall be fitted with a silencerhand screen.

e.

A n external position indicator and inductive type certified limit switches (in a protective box) shall be fitted.

Hydraulic and Special-Purpose Actuators A detailed specification and analysis o f all proposed actuators shall be presented t o the Company for approval.

5.9

Noise. Flashinq and Cavitation 5.9.1

Noise a. The Company shall be informed of all cases where the predicted noise level o f a control valve or its bypass valve approaches t o within 3 Db o f the maximum permitted noise level of 8 5 dB A, or any lower figure stated in the Engineering Group Specification entitled "PlantiEquipment Noise Control" (Number 015-NH-1104). In all cases where it is necessary t o use special control valves, silencers or other devices, they shall be subject t o the prior approval of the Company.

b. Where the outlet pressure is less than half the inlet pressure in the design case, valve noise will probably occur at normal duty. noise-reducing trim shall be specified as standard for these valves. c.

Control valve noise shall wherever possible be stopped at the source. The preferred design priorities are: 1.

Re-appraisal of the process design or arrangement t o avoid the root noise cause.

2.

Selection of a suitable valve and t r i m type

3. Lo-dB plates downstream of the valve. 4.

Insulation of the valve and downstream piping.

5.

Geographical relocation of the equipment items and piping t o enable external screening t o be considered, or valves t o be away from personnel areas. This approach can only be used when the valve noise contribution does not cause the global plant noise t o exceed the Company stated limits.

5.9.2

Potential Flashing andlor Potential Cavitating Service a.

Valves shall be selected that are specially designed for these services. Valves of l o w recovery type, using frictional paths, multiple port cages, vortex f l o w or other methods of velocity and anti-cavitation control shall be specified.

b.

Potential blockage of the trim shall be carefully considered when selecting l o w recovery valves. Design appraisal shall be conducted t o confirm that any particulates or sludging present in the process will not block the passages. Normally, drillings less than 3-mm (118-in.) diameter shall be avoided.

5.10 Construction Requirements 5.10.1

Pressure E n v e l o ~ e The pressure envelope is defined as all parts of the valve which, if a failure occurred, would allow process fluids to be released t o the atmosphere. This includes the body, bonnet, flanges, plugs and seal plates and any other part retaining the pressure. The pressure-part materials shall be equal t o the line specification for piping class valves in the same service. The Approved valve Manufacturer shall, however, confirm that the material is fit for the service and the mechanical design criteria stated o n the data sheet. In the interests of standardization, a higher grade of material may be offered t o cover a number of services; however, the metallurgy shall be individually verified b y the Contractor as suitable for the applicable service conditions. Forged materials shall be used throughout except with Company approval for alternatives.

5.10.2

Valve Trim a.

The valve trim is that part of the valve which controls the flow o f fluids. This includes the valve seat and plug, ball etc., the stem, the cage and any other renewable parts separate from the body.

b.

The materials for the valve internals shall be selected for the individual service, w i t h a minimum requirement of 316 stainless steel. For special services, the Approved Manufacturer's recommendation shall be offered for approval b y the Company.

Engineering Group Sp&icaMn

Specification Number

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01 5-JH-1903

1

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15~9-94

Sheet

34

of

c.

The addition of stellite coatings (or solid stellite parts for small valves and special services) and special hardening treatments shall be performed as necessary.

d.

Chrome plating of trim parts is not permitted.

e.

Table 2 indicates the minimum selection requirements for various services:

TABLE 2: TRIM MATERIALS AND APPLICATION service.

valve

Valve size

P TI= General Throffling Services. including gases and vapours. neutral water.

Globe Valves

sizes fa 2 in. 3 in. o r larger

P Limit i n BarlPSIl 0 - 1 4 12001 0 - 7 11 W l

T e m p Limit

-c

Globe Valves

Tlirn M n t e l i a i r

PFI 3 0 0 16001 3 0 0 16001

hydrocarbon liquids, o f chemicals compatible w i t h t r i m mstsria1r smam General Same service as above e x c e p t application requires frequent a h m ~ o f f

A l l sizes 2 I". 3 in. o r larger

a s above except frequent h h u t ~ o f f

Guide Burhingr

-

A i l sizes

Seat Rings

Stem Guide Bushings

A l l sizes

Greater t h a n 2513501

All sizes

Greater t h a n 2513501

Plug

Seat Rings Stem Guide Bushings

-

3 1 6 Stainless Steel Stelllte Faced Seating Surfaces and Guide Ports - 3 1 6 Stainless Steel

-

A l l sizes

3 1 6 Stainless Steel Stellite Faced Core or 1 7 - 4 or Hardened.

3 1 6 Stainless Steel A l l surfaces Sfellite e x c e p t b e t w e e n D.P. piugs and b e t w e e n plugs and guide post tearing surfaces not required. 3 1 6 Stainless Steel

-

stei1ite Sheath Hard Chrome Finish Stainless Steel

Globe Valves or

Stellite Faced

Seailng Surfacer and Guide Pasts

Flashing Liquids

Chlorine and Fluorine Gases and Compounds

Hardened 4 4 0 C or 1 7 - 4 PH 4 4 0 C not used i n acidic boiler feed. 3 1 6 S t s i n i e r r Sfeei

Plug

All Sizes

General - Same service a s above except application requires frequent s h u t - o f f

- H a r d e n e d 4 4 0 C or 17-4PH

Stem

A l l sizes

A l l Sizes

3 1 6 Stainless Steel 3 1 6 S t a ~ n l e s rSteel 3 1 6 Stainless S i e e l

3 1 6 Stainless Steel Steliite Faced seating s u r f a c e s 3 1 6 Stainless Steel - Sfellife Faced seating S u r f a c e r - 3 1 6 Stainless Steel

Seet Rings

Globe Valves

-

Plug Seat Rings Stem Guide Bushings

mu9

Fleshing liquids

steam GeneralbSame Services

Stellite Faced Care.

A11 t r i m p a n s o f M o n e l

Spacer Type For all Services

163

Globe Valves with cage Trim

All Sires

100114401

or b o d y rating i f less

1 9 0 14001 Trim variation*

Plug Cage Stem

Hardened 1 7 - 4 PH 4 1 6 or 4 4 0 C Hardened 1 7 - 4 PH. - 3 1 6 Stainless Steel

10091 OOE 10821 *2 1

awes

1002 01 OZ 1-1 6 L 01 66UO!lSP Ueluuooa~

A~ol'aj

IAI 3. 1w!1 dual

p e l q IOU

az!~ anls,,

WPA

OBJ!nlOS

seawas

5.1 1.2

Control Valve Accessibility Control valves, whether electrically, pneumatically or hydraulically operated shall be installed so that they are readily accessible from grade or a fixed platform for ease of maintenance and hand operation. Control valves shall be installed so that the stem is truly vertical. Where this is not possible, valves can be installed in other orientations, provided that: 1.

The Approved valve Manufacturer approves the valve/actuator combination being installed in the alternative orientation especially w i t h respect t o the overhung weight of the actuator being carried by the yokelseal assembly and the effect caused t o the gland packing.

2.

Agreement of the Company is obtained.

Notwithstanding the above, actuators for butterfly valves shall always be installed with the actuator shaft vertical and easily accessible from grade or fixed platform. Clearance shall be provided above and below control valves so that the bottom flange and plug can be removed w i t h the valve body in the pipeline. Where this is not possible, subject t o agreement w i t h the Company, the valve body may be swung around a single flange bolt for maintenance work. In this case, there shall still be allowed sufficient access t o the valve to enable inspection of the valve trim without removing any flange bolting. 5.1 1.3

Bypass and Handwheel Philosophy a.

The Contract-specific P&ID shall s h o w all bypasses required for startup and for the maximum availability of the plant during breakdown, upset conditions and maintenance operations without affecting safety.

b.

In certain instances, full bypassing of a control valve, using block and bypass valves will n o t be possible. In these circumstances, a valve actuator override by use of a handwheel shall be indicated on the P&ID, enabling control t o be manually executed while maintenance of the control and actuating elements of the loop is conducted.

Engineering Group SpecYi7cation c.

d.

Specification Number 01 ~ - J H - I ~ o ~

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Date

Sheet

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When fitted, block and bypass systems shall as a minimum conform t o the following: 1.

Sizes shall not be smaller than API RP550, Part I, section 6, Table 6.1.

2.

Pipeline stresses shall not transfer t o the bypass line when the main valve is removed for maintenance.

3.

When the control valve is mounted in a pre-stressed line, the bypass shall be anchored or located separately t o the main line, with sufficient flexibility t o prevent stressing forces affecting the bypass line. The piping either side of the control valve shall have provision for safe location while the valve is out of line.

4.

Where blockvalves are provided, a valve or valves shall be fitted so that when the block valves are closed, pressure may be relieved and the control valve drained. Such drain and vent valves shall be of roddable type.

As a general guideline, though possibly overruled b y process considerations or safety considerations, Contract-specific or Company instructions, the following shall apply: 1.

Cases where block and bypass shall normally apply. (a) Where a valve controls a service common t o a number of users.

( b ) Where a valve is in continuous operation and there is not sufficient assurance of reliability over the anticipated period between plant overhauls, e.g., on corrosive or erosive service or where the temperature is below 0°C (32°F) or above 180°C (365°F). The shutdown cost of the appropriate sections of the plant de-commissioned due t o a failure shall be taken into account. ( c ) Where failure of the valve would necessitate continuous operator action t o maintain the process control, e.g., the fuel supply t o a fired heater.

( d ) In the case that block and bypasses are n o t initially specified, but the service is safe t o have them, the piping layout shall allow for the future addition of the facility.

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Engineering Gmup Specification

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38 of 1 6 3

( e l Where conditions (a), (b), or ( c ) are met and a handwheel is indicated on the P&ID, but the cost of a handwheel is greater than a block and bypass, then the block and by-pass shall be installed.

2. Cases where valve handwheel shall normally apply: (a) Where conditions are met where it would be safe t o provide a bypass, but a block and bypass system is not selected, a permanent side-mounted handwheel shall be fitted. (See also "Cases where block and bypass shall normally apply," 1 above).

3. Cases where a by-pass or handwheel shall not be fitted: (a) Bypasses shall not be fitted o n valves for process shutdown or ESD service.

I I

I I

I I I

(b) Bypasses shall not be fitted for hydrogen service (c) Bypasses shall not be provided on three-way valves. (d) Bypasses shall not be fitted around self-acting steam pressure regulators.

5.1 2 Accessories and Ancillary Items

5.1 2.1

Mounting a.

Where accessories are required w i t h the valve, they shall be purchased by the Contractor as a fully mounted and tested assembly. The mechanical installation arrangements for the valve shall be carefully reviewed before designing the accessory mounts t o ensure that the completed system is accessible for operation and for maintenance and bypassing arrangements in the installed position.

b.

As a general rule:

1.

Pneumatic or EIP positioner shall be fully mounted.

2.

Solenoid valves shall be fully mounted.

3. Limit switch sets, position transmitters, etc., shall be fully mounted.

4.

Handwheel sets shall be fully mounted (except for butterfly valves).

5.

Lock-up kits shall be fully mounted. -

N12-0056

Engineerhg Group Sp&cat.-6n

Specification Number

01 ~ - J H - I ~ o ~

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Date

Sheet

1

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39 of 163

6. Supply air sets and backup reservoir and fail-safe kits shall normally be tested with the valve but supplied loose for mounting adjacent t o the valve. In the case of large valves, the air set may be mounted on the valve.

7. All piping and fittings o n the valve and accessories shall be in accordance w i t h the Engineering Group Specification entitled "Instrument installation" (Number 0 1 5-JH-1908) and be of stainless steel or copperlbrass material in accordance with the H,S considerations. The size shall be 318-in.OD for power air and 114-in. OD for signals. T w i n ferrule stainless steel fittings shall be used when stainless piping is fitted. 5.1 2 . 2

Pneumatic Positioners a.

Pneumatic positioners shall be of the force or motion balanced type, suitable for 0.2 t o 1 .O barg ( 3 t o 15 psi) input signals. They shall be fitted w i t h 50-mm (2-in.) dial pressure gauges indicating the signal input pressure and the output pressure t o the valve actuator. The air connection size shall be 114 NPT.

b. The cases shall be resistant t o the environmental conditions and the bleed port protected from windblown dust and sand. c.

All mechanical linkages, fastenings etc. shall be suitable for operation in the sandy environment and shall be of stainless steel material.

d. The positioner shall be reversible in the field, and shall be fully adjustable for span. e.

The positioner shall be side mounted on globe valves, and be t o p mounted o n quarter-turn piston actuated valves.

f.

The output will normally be within the range 0 . 2 t o 1 . 0 barg ( 3 t o 15 psig). If a higher output range is required the maximum pressure shall be 4 . 0 barg ( 6 0 psig), b u t the positioner shall withstand 8 . 0 barg ( 12 0 psig) without mechanical damage.

g.

A pneumatic bypass shall be fitted t o all positioners for 0 . 2 t o 1.0 barg (3 t o 15 psig) actuators unless the application is inappropriate, and shall be defined o n the data sheet.

5.1 2.3

Electro-Pneumatic Positionel Subject t o Company agreement, valves o n control service where a pneumatic bypass is not appropriate, and where vibration and other undesirable service conditions are not present, electro-pneumatic positioners (EIP) may be used in place of the pneumatic positioner and associated signal convertor. The operating signal shall be 4 - 2 0 m A . The specification shall be the same as for the pneumatic positioner, w i t h only one 50m m (2-in.) gauge displaying the output t o the actuator only. The positioner shall be certified for use in the defined hazardous area, in accordance w i t h the Company-selected execution code.

5.1 2.4

5.1 2 . 5

Split Range Control a.

Unless an exception is approved b y the Company, split range control shall be accomplished b y using t w o outputs from the DCS system. Each output shall be scaled t o 0 - 1 0 0 % at the DCS. Each valve shall have an individual positioner scaled 0 . 2 t o 1 .O barg ( 3 t o 1 5 psig) or 4 - 2 0 mA, according t o type, for full valve travel.

b.

Pneumatic bypasses shall not be installed o n positioners for split range service.

Air Lock-Up Kits For valves having a fail locked requirement on air failure, and a defined drift direction, an air lock-up kit shall be provided, mounted and piped on the valve. The pneumatic snap action lock-up relay shall detect l o w pressure downstream of the air set and lock-in the air contained in the actuator. The system shall normally be self-resetting o n a differential basis. Careful design correlation shall be conducted for all the pressure levels chosen for the elements of the system as follows in ascending order: 1.

Setting of air regulator.

2.

Reset pressure.

3.

Lock-up pressure.

4.

Spring rate pressure

Engineethg Gmup SpedficaMn

c.

5.12.6

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

41 of 1 6 3

In the event that a "drift" action is not desirable, the valve shall employ a double acting actuator and positioner, and the lockup kit shall act o n both sides o f the actuator.

Fail Locked Action for OnIOff Valves Where a fail locked action is specified for onloff valves, the valve shall stay in its last position in all failure cases, including electrical and air pressure failure. The electrical failure action shall normally be accomplished by the provision of a double-acting actuator using separate solenoids for each travel direction and a neutral midposition. Single press or "inching" operation shall be appropriately actioned by the logic arrangement. The air failure action shall be accomplished by use o f a lock-up kit acting on both sides of the actuator. Alternative suitable systems may be offered t o the Company for approval.

5.1 2.7

Handwheels a.

Handwheels for globe, butterfly and three-way valves shall be side mounted, lockable and de-clutchable and linked in such a manner that the actuator can be removed when the handwheel is engaged.

b. The operational force required shall not exceed 2 3 kgs ( 5 0 lbs) at the rim.

5.12.8

c.

Quarter-turn valves using linear diaphragm or piston actuators may utilize handwheels as specified for globe valves, or alternative arrangements giving equal facilities. The handwheel may be detachable where permanent fitting is impractical or undesirable. A suitably designed parking place shall be assigned t o the removed unit.

d.

Low-powered electric actuators up t o 1 1 3 Newton Metre ( 1 0 0 0 inch pounds) torque may be hand-positioned directly through the gearbox shaft b y use of a wrench on a squareended shaft. Higher powered types require a handwheel geared d o w n t o a reasonable torque and a declutchable or withdrawable device t o prevent rotation when the motor is operating.

Solenoid Valves a.

Solenoid valves shall be direct acting, spring return and of robust design for heavy industrial use. The coil and spring power shall be selected t o provide ample operational force t o position the solenoid correctly under all applicable service conditions and air pressures up t o 11.3 barg ( 164 psig).

Engineering Gmup Sp&c8ti0n

Specification Number

Rev

01 5-JH-1903

1

Date

15~9-94

Sheet

42 of 163

The operating voltage shall be stated in the Engineering Group Specification entitled "Instrument Design" (Number 0 1 5-JH1902). The solenoid shall generally be factory mounted t o the valve, and where this is not possible shall be tested w i t h the valve, hooked up in a way that closely approximates the final installed situation. Solenoids for fast action ESD service shall be mounted as close t o the actuator port as possible, quick exhaust valves shall be added if necessary t o achieve the specified closing time. Solenoid valves shall not be installed in signal lines unless they are for control services, e.g., injection of a pre-set signal. Solenoid valves shall not be used directly in process lines without Company approval. Approval shall not be given in the case of shutdown applications. These services require the use of a valve w i t h limit switches installed t o prove valve status. For cases where a solenoid valve may be suitable (e.g., tightness testing systems in clean gases which are noncorrosive and non-gumming t o the valve or its seals). The Contractor shall submit full details for Company approval of the proposed application. Solenoids shall be certified for use in the applicable hazardous area. 5.1 2.9

Limit Switches a.

Where valve limit switches are required, they shall be of the inductive proximity type unless modified b y the Contract documents.

b.

They shall be supplied mounted in an enclosure sealed t o IP 65. The switch box, complete w i t h internally adjustable switch actuators shall be mounted o n the valve yoke and be driven by stainless steel linkages and shafts properly sealed for use in the sandy environment.

c.

The switches shall be terminated within the enclosure, which shall have overall hazardous area certification in accordance w i t h the applicable Contract-specified execution method.

5.12.1 0 Air Filter Regulator Sets a.

Each valve or individual instrument air user on the valve shall be fitted w i t h an air set. This shall consist of an air regulator

Engineering Group Specjficatim

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

43 of 163

w i t h suitable spring range, an integral filter and drain b o w l and a 50-mm (2-in.) output air gauge. b.

5.13

The airset shall generally be of downstream relieving type. Spring adjustment shall be by hexagon stainless steel screw and locknut. The port size shall be 114-in. NPT.

Performance Reauirements

5.13.1 Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum requirements directly related t o control valves and shall not in any way replace or reduce the general QAIQC requirements.

b. The inspection and test plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality o f the product:

A check of all materials of construction by crosscomparing the goods, the material test certificates and the data sheets and Drawings. A check o f the dimensions of the finished valves against the drawings supplied for the Contract and approved by the Company. A check of the completed valve and all accessories against the data sheet and specification requirements.

A check of the valve position and failure arrangements against the data sheet.

A check of the valve plug travel against the approved Drawings. A check that the valve packing and gasketting is in accordance w i t h the data sheets and s ~ e c i f i c a t i o n s . A check o n the valve nameplate data in accordance w i t h this specification and the data sheets and Drawings. Full testing of the valve in accordance w i t h this specification, the Approved Manufacturer's additional QA procedures and the approved test and inspection plan.

Specification Number

Rev

Date

Sheet

0 1 5-JH-1903

1

15-9-94

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" ~mup

, Specr%icatbn

9.

A check o n the valve and accessories painting and protection and general suitability for the environment.

10. A check o n the tagging being in accordance w i t h this specification and the data sheets. 5.1 3.2

Valve Testing a.

Non-destructive testing (NDT) frequencies, types and methods shall be specified by the Approved Manufacturer in accordance w i t h the Contract QAIQC specifications. All tests shall be listed in the inspection and test plan and submitted t o the Company for approval.

b. The following standard performance tests shall be performed: Valve hydrostatic pressure test, conducted according to ANSI B 16.34 and B 16.37. Seat leakage test for valves class IV and above, in conformity t o ANSI B1 6-104. Air and de-mineralized water shall be used as the respective phase fluids. Valves of lower sealing ratings shall only be checked t o confirm the actuator can operate against the design fluid pressure. Prove that the actuator will open against the design fluid pressure in the case of f l o w over plug and quarter-turn valves. Confirm valve speed of travel over the full stroke is in accordance w i t h the data sheet. Also check stroke linearity w i t h increasing and decreasing input signal. Perform hysteresis check. Sensitivity shall be based on a proven or observed valve movement when the signal is changed b y 0 . 0 2 barg ( 0 . 3 psig). The test shall be conducted in 2 0 % steps from 10% t o 90% of valve travel, i n b o t h directions. Perform response check. When the signal is changed by l o % , the valve shall start t o move without perceptible delay. Total signal response times in excess of 4 seconds for the 10% change are t o be submitted t o the Company for approval for the specific application. The test will not apply at the fully open and fully closed positions.

5.1 3.3

Actuator Testing a.

The actuator shall be tested in conjunction w i t h the valve.

@ KOC

Engineering Group Speo%mtbn

Specification Number

Rev

01 ~ ~ J H - 1 9 0 3

1

Date

15~9-94

Sheet

45 of 1 6 3

b. The diaphragm case shall be tested for leakages. The test shall be conducted at 3 barg (45 psig), or at the higher level at which the actuator is specified t o operate. The test shall be successful if n o leakage is detected over a 3-minute period around the diaphragm case bolts, periphery of the diaphragm and at the breathing side of the diaphragm. c.

I

5.1 3.4

For push-up actuators with packing at the shaft seal, the leakage test shall be additionally applied around the shaft at several positions of stroke.

Certification All the certification for each valve or group of valves shall be collated in a Valve Data Book which shall be available at final inspection. The book shall include as a minimum:

I

I I

I

a.

Completed test and inspection plan.

b.

Material certificates and component test certificates

c.

NDT certificates.

d. Weld procedures and qualifications.

I

e.

Pressure test certificate.

I

f.

Leakage test certificate.

g.

Valve and actuator performance test certificate. recorded figures t o be added during the test.

I

h. Hazardous area certificates.

I I I

N12-0056

i. 5.14

Actual

As-built Drawings as necessary.

N a r n e ~ l a t eData General information for production of the nameplate data is given in section 4.7 of this specification, Instrument Identification. Additionally, for valves, the following information is required: a.

Valve serial number.

b.

Valve model or catalogue number.

c.

Body material.

d.

Body rating and size.

6.0

e.

Trim material or specification number.

f.

Trim size.

g.

Trim CV rating.

h.

Trim characteristic.

I.

Stem travel in mm.

j.

Action "air t o close" or "air t o open."

RELIEF AND SAFETY VALVES 6.1

6.2

Applicable Standards ANSl B 1 6 . 5

Steel Pipe Flanges and Flanged Fittings

ANSl B 1.20.1

Pipe Threads

API RP 5 2 0

Sizing, Selection and Installation of Pressure Relieving Devices in Refineries

API RP 5 2 1

Guide for Pressure Relieving and Depressurising Systems

API Std 526

Flanged Steel Safety Relief Valves

API Std 527

Commercial Seat Tightness for Safety Relief Valves with Metal-to-Metal Seats

Scope of Relief Valve Section 6.2.1

Cases a.

This specification covers all systems o f pressure relief for the following relief cases: 1.

Maloperation Control failure resulting in excessive pressure build-up due t o malfunction in temperature or fluid control into or out of a vessel or protected system.

2.

Fire Case Overheating of a vessel or piping system due t o an external fire or source of heat.

Engineering Gmup SpeaZcabion 3.

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

47 of 163

Thermal Overload Liquid relief of pressure build up in a system that is blocked in due t o receiving heat input from the surrounding ambient conditions or from equipment in the line.

b . The most severe of the applicable cases shall be taken for design purposes. The cases shall not be additive. Relief Devices This specification covers mechanical devices such as relief and safety valves, thermal relief valves and bursting discs. Other devices may be necessary for special process conditions, e.g., Utype blow-out w e t legs. The use of any such device shall be approved by the Company before adoption. Redundancy a.

T w i n or multiple safety valve systems shall be supplied if required b y vessel codes, the P&ID or detailed analysis of the process system.

b.

All pressure relief valves o n critical service (excluding thermal relief) shall be supplied w i t h an installed spare equally sized relief valve.

Isolating Valves

6.3

a.

Where relief valves are 1 0 0 % spared, the inlet and outlet lines will be provided w i t h interlocked isolation valves t o ensure one valve is on-line w h e n the other is off-line. The interlocking isolation valves shall have the ability t o be padlocked t o prevent unauthorised operation. The off-line relief valve shall be able t o be removed for servicing.

b.

Isolation valves where fitted for other relief valves shall be fullbore roddable type and fitted w i t h a "locked open" facility.

Relief Aoolications and Selection

6.3.1

Normal Case a.

2-0056

The selected relief valve for the standard application shall be: 1.

Full lift, snap action w i t h enclosed spring.

2.

Flanged connections, minimum 3 0 0 LB rated on the inlet side.

3.

Bolted bonnet.

4.

Screwed cap.

5.

Full one-piece nozzle.

Liquid relief valves for service o n systems such as pump outlets, where snap-action valves are inadvisable, shall be proportional types. Liquid thermal relief valves (size 314-in.x I - i n . ) shall be of screwed construction (except when required for NACE service) w i t h semi-nozzle. Large relief valves (6-in. and above) may use inlet flanges rated at 1 5 0 LB when the process conditions allow. The relief valves shall be sized t o API RP 520, designed and constructed in accordance w i t h API RP 5 2 6 and be tested t o API RP 5 2 1 . They shall be furnished w i t h type approval testing conforming t o the vessel design code, and where the applicable vessel is supplied w i t h a code stamp, then relief valves shall also be code stamped. High Temperatures High-temperature valves shall use exposed springs. The Approved Manufacturer recommendations for the valve design and packing shall be followed. Back Pressure Applications a.

Valves of balanced bellows design shall be used for the following applications: 1.

Where the built-up back pressure due t o downstream piping, silencers and fittings exceeds 10% of the valve set Dressure.

2.

For a constant back-pressure application where the sum of the valve and piping accumulation and the constant back pressure would result in an over-pressure o f the vessel.

3.

Where an imposed back pressure is not constant and the variations can exceed 5 % of the valve set Dressure.

4.

Where savings in the downstream disposal piping can be made because of the increased allowable piping accumulation and back-pressure.

Specification Number

Engineedng Group Specificatbn

01 5 ~ J H ~ 1 9 0 3

Rev

Date

Sheet

1

15-9-94

49 of 163

Pilot-Operated Systems a.

Pilot-operated systems shall be considered for the following applications: Where automatic de-pressurisation is required in addition t o over-pressure protection. Where "valve simmer" could be a problem, t o enable short relieving periods w i t h small differentials and tight shutoff. Where set pressure is within 10% of operating pressure. Installations requiring the valve t o be tested when installed and under pressure. High-volume relief. Economic considerations for larger valves, 4-in.x 6-in. and above. Other applications which are difficult or impractical w i t h conventional relief valves.

b.

All pilot-operated systems shall be provided w i t h dual pilots arranged so that either pilot can be maintained and tested while the other is in service.

Bellows Seals Where the service requires absolute security o f the seal between the relief disc shaft and the bonnet, bellows seals shall be fitted. Applications include corrosive, hazardous and lethal substances which have special relief disposal conditions. R u ~ t u r eDiscs a.

Rupture discs as a sole protection for plant safety shall only be used w i t h Company approval.

b.

Rupture discs may be fitted upstream of a relief valve in corrosive or particulate service or where the valve operation could be affected adversely b y contact w i t h the process. The following considerations shall apply:

1.

Nozzle flushing, if required for particulate service, shall use fluids compatible w i t h the line fluids. The flushing system shall be independently protected against over-pressure.

2.

c.

Disc fracture detection shall be installed for each application. This shall be independent of the relief valve actuation. When IS techniques are being used, the method for non-conductive fluids is b y use of an electrical contact which breaks t o alarm at the DCS when a frangible element o n the downstream disc surface is broken as the disc ruptures. When non-IS systems are specified or the fluid is conductive, a bleed shall be installed o n the space between the disc and the relief valve. This shall be routed t o the relief system downstream of the relief valve. The bleed piping shall incorporate a restriction orifice sized at 3.00 m m ( ' I , in.) and an excess flow check valve as necessary. The bleed shall be monitored by a pressure gauge and pressure switch on the high pressure side of the restriction, t o detect and alarm t o the DCS any fracture of the disc.

All rupture discs shall be manufactured in batches using the same plate material. A t least three discs shall be pressure ruptured t o confirm the calibration. Each fitted disc shall be supplied with t w o spares from the same batch.

Sizina Reauirements 6.4.1

Control of Design Data Valves shall be sized on the basis of defined issues of the process data sheets, P&ID, equipment and piping data. A document control shall be maintained t o ensure that the valves are built t o the latest case evaluation and calculation, based on the final data. Data sheets shall state the process data revision number, and calculations the data sheet revision number.

6.4.2

Limiting Case a.

The valve data sheet shall specify the selected case, all applicable vessel and process conditions, the constant, variable and built-up downstream pressures and the allowable noise level.

b.

Silencing where necessary shall be purchased with the valve, and the back-pressure caused shall be included in the calculation.

c.

Where a number of process conditions and/or choices of applicable case exist, sufficient calculations shall be performed t o ensure that the limiting case and conditions are selected as the design case.

Engjneerfng Group Spedficatbn d.

6.4.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

5 1 of 1 6 3

Regardless of the accumulation value, the relief valve setting shall not be greater than the vessel design pressure.

Calculation Required a.

The calculation shall be conducted in accordance with API RP 520 or t o the code dictated b y the vessel design code and shall be submitted t o Company for approval before purchase.

b.

The calculation shall tabulate: 1.

Valve tag number.

2.

System and equipment protected.

3.

Cases applicable and the selected case.

4.

Relief loads for each of the applicable cases.

5.

Blowdown restrictions and calculated figure.

6.

Type of valve, e.g., proportional, balanced bellows etc

7.

Body and inlet and outlet flange sizes and ratings.

8. Pipelvessel line specification, line number and sizes. 9.

Back-pressure force at full relief.

10. Operating setting and the cold setting, both at the Approved Manufacturer's test facility and the Company and the Contractor's Site workshops. The calculations shall take into account the different ambient pressures and temperatures. 11. Valve capacity at relieving conditions. 6.4.4

Blowdown a.

The blowdown for spring operated valves shall be as follows: 1.

Valves of set pressure 7.0 barg ( 1 0 0 psig) and less: valve shall re-seat at not less than 0.14 barg ( 2 psig) below the set pressure, lower limit set b y process requirement (normally 5 % below set pressure).

2.

Valves of set pressure over 7 . 0 barg ( 1 0 0 psig): valve shall re-seat at not less than 2% or more than 7 % below the set pressure.

-

Engineering Group speaifcab;on b.

6.4.5

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

5 2 of 163

Pilot-operated valves shall conform t o the above criteria 01 have defined limits set according t o the process conditions.

Limits on Valve Selection The minimum size shall be I - i n . x 2-in. except for thermal relief valves (TSV). The area of discharge of flanged valves operating at set pressures over 1 9 barg ( 2 7 6 psig) shall be n o t less than four times the area of the nozzle. The area of discharge shall apply t o any point in the valve downstream of the nozzle, including the discharge flange opening. The selected orifice size shall exceed the calculated area only b y an amount as limited by standard orifices available. The valve shall be selected at such a size that a larger orifice may be fitted at a later date t o accommodate process changes. A n allowance of 1 0 % increase of f l o w shall be possible without increasing the overall accumulation. A minimum number of valves shall be used in multiple safety valve applications. Mixed orifice sizes are not acceptable.

6.5

Desiqn, Materials and Construction 6.5.1

Lifting Levers Lifting levers shall be installed only on air, nitrogen or low-pressure steam service or where dictated b y the vessel design code.

6.5.2

ShippingiTest Gags Gags shall be fitted t o all valves except thermal relief valves.

6.5.3

Code Requirements a.

The relief valves shall be designed and constructed within the applicable vessel design code.

b.

Where a code is not stipulated, the valves shall conform t o the ASME code for Section VIII, Div I.

c.

This requirement shall not apply t o thermal relief valves for pipingiequipment service only.

-

--

6.5.4

Connections Bodies shall be flanged (except thermal relief valves) t o ANSl B16.5, rated and faced in accordance with the vessellpiping specifications. The flanges shall be forged integrally w i t h the body. Welded-on flanges are not acceptable. Welded in safety valves are not allowed. Where valves shall be installed o n fully welded systems, the Contractor shall submit an alternative flange system, suitable for the process conditions, for Company approval. Screwed valves (314-in. x 1-in.) for thermal relief shall have threads formed in accordance w i t h ANSl €31.20.1.

6.5.5

Body and Flange Ratings and Material The normal materials shall be carbonsteel bodies w i t h stainless steel trim. The trim shall include: 1.

The nozzle.

2.

The disc and disc holder.

3.

The stem and guide.

4.

The blowdown ring, ring pin and bushing.

5.

All other parts contacting the inlet side process fluid.

The body may be cast or forged. The bonnet shall be of the same material as the body. All the trim components shall be renewable. The nozzle and disc shall be of forged material. All materials shall be upgraded as necessary t o suit the actual service rating. Valves of "lightweight" pattern are not permitted. The inlet side of all relief valves (flange, nozzle, disc and seat) shall be rated equal t o the pressure temperature rating of the inlet flange. The outlet side of all relief valves (flange, body, bonnet, packing etc.) shall be equal t o the pressure temperature rating of the piping class flange.

h. The body and flanges shall be of the same material as the applicable connecting pipework. This can be varied only under the following conditions:

1.

In the interests of providing a common body for a number o f applications, a single material may be specified provided that it can be shown t o be equal or superior t o the pipe class material in each of the applications.

2.

In order t o enable the body t o be rated equally t o the piping class flanges, the body may be o f a superior material.

Nozzle and Seat a.

Safety relief valves shall be of "full nozzle" design. Thermal relief valves may be of "semi-nozzle" design. Valves w i t h seat material integral w i t h the body are not acceptable.

b.

Nozzles shall have integral seats of sufficient proportions t o permit several lapping operations.

c.

Soft seats shall be fitted on air, water and nitrogen service up t o the soft seat allowable temperature. Hard-faced seats and disks shall be used on abrasive service and all steam valves.

Cold Setting The Contractor shall calculate the "cold setting" pressures based o n the "service setting" figures specified according t o the selected case. The "cold setting" shall also be noted o n the data sheets. Valve Springs a.

Valve springs shall be coated for corrosion resistance and be of materials suitable for the operating temperature t o enable the setting t o be held between bench tests. The material shall normally be an alloy steel for valves in services between minus 20" C (minus 68°F) t o 230" C ( + 4 4 6 ° F ) . Springs of other materials shall be selected according t o the process and surrounding conditions. Springs for valves in NACE service shall be of lnconel X 750.

+

b.

Safety /relief valves for set pressures o f 2 0 barg ( 2 9 0 psig) or less shall have springs suitable for a range of adjustment of plus or minus 1 0 % . Valves set at above 2 0 barg ( 2 9 0 psig) shall have spring ranges suitable for a range of adjustment of plus or minus 5 % of the set pressure.

Engineering Group Specificalion

6.5.9

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

159-94

5 5 of 163

Bellows Where the service requires bellows seals t o be fitted, the minimum material requirement is stainless steel.

6.5.10

In-Line Testing The stem shall be suitably extended and threaded t o allow the installation of in-line, on stream testing machinery.

Noise The noise emitted b y a single relief valve at maximum operation shall not exceed 105 dB A or any lower figure stated in the Engineering Group Specification entitled "Plant/Equipment Noise Control" (Number 0 1 5-NH1104). The Contractor shall state the predicted noise spectrum on the data sheets submitted for approval t o the Company. Installation Notes Each relief valve shall be installed, w i t h the spring vertical, in a position accessible for inspection and maintenance, but shall be clear o f walkways where relief noise could be a hazard t o operating personnel. The piping and supporting shall be designed t o withstand the valve back pressure forces at full relief. The valve shall not be used t o support the downstream piping (except abbreviated vent legs) or silencers. Vent legs shall be positioned so as not t o cause any hazard t o personnel or equipment while the valve is relieving. Vertical vent legs shall be provided w i t h a drain hole t o prevent water build-up in the leg. Heat tracing shall be fitted as necessary in sub-zero service conditions t o avoid icing in the discharge piping. For large relief valves, a permanent lifting facility shall be installed for servicing and removal of the valve. Performance Reauirements 6.8.1

Quality Control (QC) a.

OC shall be as detailed in the Contract. This section states the minimum additional requirements related t o relief valves only and shall not in any way replace or reduce the general OAIOC requirements.

b. The inspection and test plan shall include the following checks in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check o f all materials of construction b y crosscomparing the goods, the material test certificates and the data sheets and Drawings.

2. A check of the dimensions of the finished valves against the Drawings supplied for the Contract and approved by the Company.

3. A check of the completed valve and all accessories against the data sheet and specification requirements. 4.

A check o n the valve nameplate data in accordance with this specification and the data sheets and Drawings.

5.

Full testing of the valve in accordance with this specification, the Approved Manufacturer's additional QAIQC procedures and the approved test and inspection plan.

6.

A check o n the valve and accessories painting and protection and general suitability for the environment.

7.

A check on the tagging being in accordance with this specification and the data sheets.

Casting Quality Castings shall be true t o form and free from shrinkage defects, strains, scales, lumps, sand holes, or other defects. Testing a.

The nozzle and body shall be hydrostatically tested before assembly at 1.5 times the respective ratings of the inlet and outlet flanges.

b. The valve shall be calibrated b y popping pneumatically at the cold differential test pressure calculated for the conditions prevailing at the testing workshop. c.

The valve shall be pressure tested as an assembly at no greater than 1.5 times the rating of the outlet flange, but this figure shall be reduced if there is a design restriction o n back pressure on the outlet side of the nozzle.

@ KOC

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spea%ication d.

6.8.4

The valve shall be tested for leakage across the seat by a procedure in accordance with API RP-527. Tests to "commercial" standard are acceptable for non-hazardous service. Valves for hydrocarbons and corrosive substances shall be bubble tight.

Documentation All the certification for each valve or group of valves shall be collated in a Valve Data Book which shall be available at final inspection. The book shall include as a minimum:

6.9

a.

Completed test and inspection plan.

b.

Material certificates and component certificates.

c.

NDT certificates.

d.

Weld procedures and qualifications.

e.

Pressure test certificates.

f.

Leakage test certificates.

g.

Relief set pressure certificate.

h.

As-built Drawings as necessary.

Nameolate Data General information for production of the nameplate data is given in section 4.7 of this specification, Instrument Identification. Additionally, for relief valves, the following information is required:

.

a.

Body material

b.

Trim material.

c.

Rating of inlet and outlet flange (nozzle and body).

d.

Nozzle size or number.

e.

Set pressure.

f.

Cold set pressure.

9.

Spring number and spring range.

@ KOC 7.0

Engineering Group SpWcation

Specification Number

Rev

01 5-JH-1903

1

Sheet

Date

58 of 163

15~9~94

FLOW MEASUREMENT A ~ o l i c a b l eStandards API RP550 Manual o n Installation of Refinery Instruments and Control Part 1 Systems, Process Instrumentation and Control ISA RP3.2

Flanged-Mounted, Measurement

Sharp-Edged

Orifice

Plates

for

Flow

I S 0 51 6 7

Measurement of Fluid Flow b y Means of Orifice Plates, Nozzles and Venturi Tubes Inserted in Circular Cross-Section Conduits Running Full

S c o ~ eo f Flow Measurement Section This section covers the requirements for the measurement of f l o w variables in the Facility for local indication, local control, remote control, remote signalling or transmission. Flow Instrument Tvpes and Selection 7.3.1

Accuracy Requirement Evaluation Flow measurement equipment shall be classified depending on the purpose o f its application. 1.

Fiscal or commercial use.

2.

Plant mass balance, long-term storage and reporting computer or calculated set-point control.

3.

Feedback control and operator information.

Fiscal or commercial applications shall be indicated o n the P&ID and require the use of highly accurate instruments such as turbine and positive displacement type and special provisions for checking and verifying the measurements. Each fiscal application shall be the subject of individual proposal, evaluation and Company approval and is not covered b y this specification except in a general sense. Instruments for mass balance calculations and long-term storage and reporting computer input are t o be specified with no relaxation on any of the design factors affecting accuracy. These include the physical restraints such as straight lengths and other tappings etc., but also cover requirements for density and temperature corrections and other physical variables.

Engineering Group

Specification Number 01 5-JH~1903

SpecjfiCdtEon

d.

7.3.2

Rev 1

Date

15~9~94

Sheet 5 9 of 163

Instruments used on feedback control are required t o give a repeatable and correctly characterized signal throughout the range, o f sufficient accuracy t o control the plant and provide a proper level of equipment performance information t o the operator. Certain relaxations on the accuracy conditions can be submitted for Company review and comment.

Instrument Type For all applications other than fiscal, the standard selection of instrument wherever process conditions allow shall be the square-edged, concentric-orifice plate w i t h flange taps and a differential pressure transmitter. Corner taps and other entrance forms shall be used to overcome high viscosity, l o w DP, high Reynolds numbers etc. within the calculation requirements of I S 0 5 1 6 7 . Pipe taps shall be used where back-flushed chemical seals are required, for services such as viscous, corrosive or particulate service. Conical entrance or quarter-circle orifice plates shall be used t o measure high-velocity liquids or slurries. Segmental or eccentric-orifice plates shall be used on liquids containing large amounts of solids. Critical f l o w orifices w i t h upstream pressure gauge shall be used t o measure stripping steam flow. The upstream pressure must be greater than twice the downstream pressure throughout the range. The pressure gauge shall be scaled in flow units. Fabricated metering runs shall be used for line sizes 2 in. and below. Sizes smaller than 2 in. shall only be used if it can be shown that swaging up t o 2 in, is not viable. Vent and drain holes shall not be used on orifice plates fitted into metering runs. Where l o w pressure loss is essential, venturi or f l o w tube (Dall) type meters shall be used. Where no appreciable pressure loss can be tolerated, pitot and annubar tubes shall be used o n clean service only. These shall be o f the retractable under pressure type unless the line can be isolated without local or complete shutdown. These instruments shall not be used on lines subject t o scraping.

Engineering Group spea;ficBt&n

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

60 of 163

For small rates of flow such as samples for analysers, variable area meters shall be used. For purging flow, variable area meters with a constant f l o w regulator and a low-flow alarm shall be used. Sight glasses shall only be used at atmospheric pressure, on oil and water flows t o machinery, where the lack of a f l o w will cause an alarm from another measurement before any injurious result could arise. Totalizing shall be performed in the DCS or long-term storage and reporting computer systems. Should the Company specifically require local totalizing instruments, these shall be positive displacement, w i t h or without local temperature compensation according t o the process conditions. Except where the Company has specified a particular type of instrument, a written application for each unusual case shall be made t o the Company justifying the selection of such other devices as: 1.

Vortex flow.

2.

Turbine meters.

3.

Electromagnetic flowmeters

4.

Ultrasonic flowmeters.

5.

Positive displacement flowmeters.

6.

Target-type flowmeters.

7.

Thermal-type flowmeters.

8.

Coriolis-type mass flowmeters.

9.

Insertion meters (of any type).

Flow elements which may endanger downstream equipment due t o possible loss of mechanical components upon failure shall not be offered, e.g., insertion turbine meter in a comDressor inlet. Integral orifice instruments shall be avoided unless this type is specifically identified on the P&ID as the Company requirement.

OKOC

Engineering Group

Specification Number

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Date

Sheet

01 5-JH-1903

1

15-9-94

61 of 163

specjfication 7.3.3

7.3.4

Local lndication of Flow a.

Local f l o w indication for gases, liquids and steam shall be by use o f an orifice plate, a pneumatic or electronic differential pressure transmitter and a receiving pressure gauge or series connected electronic indicator. When the electronic transmitter also serves a DCS indicator or is part of a control loop, a retransmitted signal from the DCS shall be used instead of a series connection in the field.

b.

Variable area, positive displacement and other instrument types may be used within the limitations stated in the preceding sections.

Flow Measurement for Remote Control or lndication a.

Remote transmission shall be b y use o f an orifice plate and an electronic differential Dressure transmitter.

b. All transmitters shall have an integral signal indicator with a scale characteristic the same as the output.

7.3.5

c.

Turbine meters shall be considered where high accuracy or high turndown is required, subject t o Company approval.

d.

Other instrument selections may be made within the limitations stated above.

Alarms and Trips Alarms Intermediate and pre-alarms shall be generated in the DCS from the transmitter signal that is used for control and indication. Magnetic or proximity switches o n variable area ( V A ) meters shall only be used on non-hazardous service and require Company approval. In-line f l o w switches shall not be used except where specifically required or approved by the Company. Trips For applications where the detection of high-high or low-low trip is required for general or local shutdown, a separate transmitter is required, with a high integrity control room mounted trip amplifier t o provide the switching action. High and l o w trip may be generated from the same transmitter provided it is in range.

c.

7.3.6

In the case of orifice meters, the same orifice plate and flange set shall be used for all transmitters, but each instrument shall have its o w n isolation valve.

Local Flow Control a.

Where local f l o w control is specified, generally an orifice plate and pneumatic differential pressure transmitter w i t h local receiver controller shall be used. Other forms of DP primary element may be used within the limitations stated in this specification.

b. V A meters fitted w i t h constant flow regulators may only be used for fixed rate flows such as flushing and purging. A f l o w alarm shall alwavs be fitted.

7.4

Sizina and Ranclincl Reauirements 7.4.1

Differential Pressure Instruments Orifice plates used o n differential pressure f l o w measurement installations shall be sized t o I S 0 5167. Computer input and output data is required for Company review. Sizes below 50 m m (2in.) not covered by I S 0 5167 shall be calculated in accordance with the Approved Manufacturer's proven system. Corner taps are required on small lines. Meter maximum used in f l o w calculations shall be taken as

20% above maximum design f l o w rate. For feedback control, flow rate turndown for an orifice plate fitted w i t h a single conventional electronic transmitter shall not be greater than 3:l. The transmitter span shall be selected so that the turndown is within the capsule range Smart transmitters may be used t o the limits (normally 6:l). Approved Manufacturer's recommended turndown, but not greater than 10:l.Range increases b y change of orifice plate shall only be allowed when specifically requested b y the Company, and only when seniorljunior type fittings are used. For flow rates up t o (but not exceeding) 10:l t w o conventional (i.e., non-smart) transmitters may be used. The first transmitter shall be ranged t o approximately 35% of range (to the nearest sensible unit) and the second shall be ranged 100%. Transfer shall be bumpless. For mass balance and long-term storage and reporting computer purposes, due regard shall be paid t o the ranging

Specification Number

Engineering Group SpecNcdtion

01 5-JH-1903

Rev

Sheet

Date

1

15~9~94

6 3 of 163

of the primary element as well as the transmitter capability before choosing overall acceptable ranges within the accuracy required. f.

Mass f l o w measurement shall be based o n differential pressure or volumetric measurement supplemented b y other measurement corrections (e.g., pressure and temperature). Temperature, pressure or density correction shall be used as specifiedlagreed t o with the Company.

g.

Where a transmitter is in a low-low or high-high detection service only, i t may be ranged at 5 0 % of the range of the control transmitter.

h.

Corrections shall not normally be applied t o trip instruments unless they are essential for safe detection of the out-of-limit condition.

i.

Differential pressure transmitters shall be ranged for a full scale differential of 2 5 0 mbar ( 1 0 0 ins WGI where ever possible. Alternative ranges may be selected from the table below: 5 0 mbar 1 0 0 mbar

1

1 ( 2 0 ins WG) 1 (40 ins WG) I

5 0 0 mbar

1

( 2 0 0 ins WG)

I

j.

Other ranges may be used subject t o Company approval

k.

The following rules shall be followed: 1.

The minimum orifice size shall be 8 m m (113 in.), ( 3 m m (118 in.) for restriction orifices) unless approved otherwise b y the Company.

2.

The calculated d/D ratio (Beta ratio) for square-edged orifice plates shall be within the range 0.4 t o 0 . 7 0 for n e w equipment. For plant modification or exceptional cases, both subject t o approval b y the Company, ratios between 0 . 2 5 and 0.75 are acceptable. If the initially calculated beta ratio exceeds 0 . 7 for a 5 0 0 mbar ( 2 0 0 ins WG) DP transmitter range, the line shall be swaged up for the metering length as necessary.

3.

The beta ratio for conical entrance plates shall not exceed 0.3, and for quarter circle shall not exceed 0 . 6 .

Engineering Gmup Sp&icatbn 7.4.2

Specification Number

01 ~ - J H - I ~ o ~

Rev

1

Date

15-9~94

Sheet

64 of 163

VA Meters V A meters shall be sized w i t h sufficient capacity t o absorb line fluctuations such as opening of manual valves etc. Internal spring buffers and other protection as necessary shall be fitted t o prevent damage t o the operating element.

7.4.3

Turbine, Positive Displacement (PD) and Other Specific Types of Meter Turbine and PD meters shall be sized according t o the Approved Manufacturer's recommendations and ranges shall be dependant o n flow rates and service conditions.

7.5

Construction Reauirements 7.5.1

General All flowmeters shall have a positive means of identifying the direction o f flow.

7.5.2

Orifice Plates a.

Orifice plates shall be manufactured in accordance with the dimensions and tolerances given in ISA RP 3.2, "FlangeMounted Sharp-Edged Orifice Plates for Flow Measurement" or API RP 550, Part I.

b. The standard orifice plate material shall be 3 1 6 stainless steel. This selection shall be varied when process conditions require an alternative material. Brackish water may require monel; high-velocity steam service may require specially selected materials w i t h Stellite overlay. 7.5.3

Flanges and Metering Runs a.

Orifice plates shall be installed in straight lengths of process pipework in accordance with I S 0 5167. The half length alternatives given in section 1 . I may be submitted for approval b y the Company for use w i t h instruments used only in feedback control or operator aid services. Any other variations are subject t o approval by the Company.

b.

In general, orifice plates shall be installed between orifice flanges rated at 3 0 0 lbs minimum and bored t o the pipe size used in service and in the calculation. Pipe connections shall be weld neck. Process tappings shall be 112-in. NPT. Unused tappings shall be plugged for the correct pressure rating with a compatible material.

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Engineering Group Sp&caihn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

65 of 163

The flange material, facing and type of gasket shall be as the line s~ecification. Where RTJ gaskets are specified, flange or corner taps shall not be used. Alternatives such as pipe taps ( D and D l 2 or 2.5D and 8D), orifice carriers or alternative instruments shall be considered. For difficult cases, fabricated spool inserts w i t h integrally machined orifice may be offered for approval by the Company. Where it is necessary t o change orifice plates without major plant disruption, retractable plate adaptors or carriers may be used. Fabricated metering sections ( 5 0 m m ( 2 in.) and below) shall normally be supplied complete w i t h all fittings including flange bolting, isolation valves and orifice plate w i t h gaskets. All items shall be t o line specification except where it has been agreed t o use a higher specification, e.g., 31 6 stainless steel, for standardization. The metallurgy o f the weld t o the main pipework shall be checked before such material is accepted. The length of the metering run shall be in accordance, as a minimum, with the dimensions given in I S 0 5 1 6 7 (pro-rata against dimensions for larger pipes) over which the roundness and dimensional accuracy o f the piping shall be ensured. 7.5.4

Differential Pressure Transmitters a.

Electronic transmitters shall be o f the strain gauge, piezo resistive or capacitive type. Other elements may be used provided that accuracy, stability and reliability criteria meet operational requirements.

b.

Differential pressure transmitters shall have a minimum 1 0 0 bar ( 1 4 5 0 psi) rated stainless steel body. All wetted parts shall be 316 stainless steel as minimum w i t h superior alternative materials t o suit service conditions.

c.

Transmitters shall be capable of withstanding over-range pressure on either side of the capsule at least equal t o the body rating.

d. Transmitters shall be installed w i t h a local output indicator. This may be an integral part o f the transmitter body, provided it can be clearly read in the finally installed position. Otherwise, it shall be a loop-powered or re-transmitted output of the measured signal.

0 KOC

Engineering Gmup Specificahion

e.

7.5.5

Specification Number

Rev

01 5-JH-1903

1

Date

15-9~94

Sheet

6 6 of 163

f.

If the output is used t o assist the local operation of a control valve with handwheel or valved bypass, a local indicator scaled in physical units shall be visible from the control valve. Process connections shall be 112-in. NPT female.

g.

Electrical entry shall be M 2 0 x 1.5 ISO.

h.

Pneumatic transmitters shall have a 50-mm (2-in.) gauge fitted showing the output, w i t h a square root scale. Air connections shall be 114 in. NPT.

i.

Electronic transmitters shall be suitable for two-wire 4 - 2 0 mA, nominal 24-VDC transmission and be of "smart" type.

j.

Pneumatic transmitters shall be o f the force balance type and have an output between 0 . 2 and 1 . 0 barg (3 t o 15 psig), w i t h a 1.4 barg ( 2 0 psig) air supply.

k.

Mounting shall be b y means of 2-in. pipe clamp, or by direct mounting from the process manifold.

Turbine Meters and PD Meters The use of turbine meters or PD meters measurement shall be approved b y the Company.

for

any

Turbine meters shall be supplied w i t h stainless steel bodies and wetted parts as a minimum. The body rating shall be suitable for the service conditions. The connection flanges shall be ANSI 3 0 0 lb minimum. PD meter bodies may be of forged steel when the service conditions permit, and the flange rating may be t o line specification for l o w pressure duties. Pulse outputs from transmitting PD and turbine meters shall be integrated via the main control room interface or DCS digital t o analogue input cards, performance details of which should be specified b y the Approved Manufacturer. Where transmission distances exceed the limits of the selfpowered instrument, head-mounted pre-amplifiers shall be provided. Automatic flow limiting devices shall be installed where process conditions could cause meters t o operate above the maximum f l o w rate specified b y the Approved meter Manufacturer. Alternatively, a high-flow alarm may be supplied subject t o the agreement o f the Company.

Engineering Group

Spedfication

7.5.6

Specification Number

Rev

01 5-JH-1903

1

Date

15~s-94

Sheet

67 o f 163

g.

Where fluid properties can have an adverse effect on meter mechanical performance, turbine meters w i t h tungsten carbide or similar bearings are required. I n adverse fluid conditions including fluids w i t h poor lubricating qualities, in particular LPG products, consideration shall be given t o force fed lubrication.

h.

Dual-head turbine meter systems shall be provided w i t h discrepancy alarms. In the case o f fiscal metering, the t w o turbine meter outputs shall be run in separate cables.

i.

The connection between the moving and indicating parts shall be by glandless magnetic coupling.

j.

Conversion of the volume measurement t o mass f l o w by correction for temperature or density shall be a DCS function. Field automatic temperature compensation is subject t o Company approval. Instruments in such service shall have an additional dial for uncompensated flow. Ranges of temperature elements for automatic temperature compensators for heated oil PD metering installations shall be such as t o cater for all temperatures which can be expected under operational and static conditions. The effects o f line and tank heating variations shall be taken into account.

V A Flowmeters V A meters o f the tapered tube and float type shall be used where appropriate. V A meters shall have a metal metering tube as standard. The connection t o the piping system shall be ANSl flanged, 3 0 0 Ib minimum. The tube and flanges shall be 3 1 6 stainless steel as a minimum, facings and gaskets etc. shall be in accordance w i t h the piping class. The connection between the moving and indicating parts shall be b y glandless magnetic coupling. Glass tube meters o f mechanically protected type used on tubes up t o 2 0 - m m (314-in.) diameter hazardous services, w i t h temperatures up t o 130" C on fluids always above freezing, and may be flanged 1 5 0 LB or have NPT screwed connections.

may be in non(266"F), t o ANSl

The tube and float shall be renewable without recalibration being required.

e.

7.5.7

Filtering requirements shall be supplied, similar t o PD meter philosophy.

Diaphragm Seals The tappings for all instruments used for handling viscous or corrosive fluids or slurries shall be sealed. Seals may be the liquid type employing seal pots or the chemical type (diaphragm seal) utilizing a diaphragm w i t h silicon oil (or other fluid) between the diaphragm and the pressure element of the instrument. Diaphragm seals are the preferred method for these applications within the temperature limitations for this type o f seal. The transmitters shall be supplied with the capillary tubes fitted and tested as a unit. The l o w and high pressure transmitter chambers shall be of equal volume when these seals are fitted. The seals may need t o be used in conjunction w i t h a flushing system in some circumstances, e.g., some slurries. The flushing fluid shall be compatible w i t h the process fluid and be supplied via a constant flow regulator and low-flow alarm. Connecting capillary tubing shall be 3 m m (118 in.) stainless w i t h spiral-wound stainless steel armour.

7.5.8

Other Flow Meters Design and construction of other types of f l o w meters shall be t o the Approved Manufacturer's standard, provided that the materials and pressure design is suitable for the applicable service conditions. Welded in equipment is subject t o individual Company approval.

Installation Notes 7.6.1

Differential Pressure Installations a.

Piping isolation block valves shall be supplied for all differential pressure installations. Transmitters may share isolation valves (e.g., in the case of high turndown applications where t w o transmitters are used) but instruments o n shutdown service shall have individual locked oDen block valves.

b.

A five-valve manifold shall be provided for all differential pressure transmitters.

Engineering Group Sp&icBtion

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

6 9 of 163

Three-valve process manifolds may be used on low-pressure installations. The manifold shall be mounted o n the instrument support, the transmitter shall be supported from the manifold. lnstruments on shutdown service shall have their manifold valve handles removed. lnstruments o n toxic, high-pressure or flammable service shall have their manifold vents and drains piped t o a closed header. Process line tappings shall be fitted w i t h line class isolating valves of roddable type. lnstruments shall be close coupled whenever possible. The use of condensate pots and vent chambers shall be minimised b y use of respective elevations of the tappings and the instrument, t o provide self-draining for dry gases and self-ventinglwet leg filling for liquids and condensates. Tappings for immiscible fluids shall be horizontal t o minimise separation. Horizontal metering runs are preferred for liquid flow, and are mandatory for eccentric orifices. Vertical runs may be used w i t h downward f l o w for steam and condensates, and upward f l o w for liquids close t o their boiling (vaporization) point. M i n i m u m straight metering lengths upstream and downstream of the orifice plate or other primary element shall be selected from the relevant tables in I S 0 5167. The sections of the pipe in which the orifices are mounted shall be cylindrical, smooth and free from splatters, burns and scale. Mill finish internally is satisfactory within the above conditions. The welded joint between the pipe and orifice flange shall be square, concentric, free from undercut and all excessive metal projection shall be removed by grinding after the flanges are installed. For accurate determination of the operating conditions at the location of the f l o w measurement, a test thermowell shall be provided, unless there is a temperature tapping already fitted for another purpose. For gas or steam service, a pressure tapping shall also be fitted. The tappings shall be outside the required straight run.

Engineering Group

Sp&cation 7.6.2

Specification Number

Rev

Date

Sheet

015-JH-1903

1

15-9-94

7 0 of 163

PD and Turbine Meters a.

If servicing of the instrument is required without shutting d o w n the line, block and bypass valves are required. These shall be in accordance w i t h the line specification i.e., dual with bleed o n hazardous services. If the line is t o be shut d o w n for service, at least one isolating valve of the block and bleed type shall be provided in each meter path.

b.

Strainers shall be installed upstream of metering installations. The mesh of the strainer shall be selected t o cause minimal pressure drop and shall be that recommended by the Approved meter Manufacturer.

c.

A n indicating device (e.g., differential pressure instrument) shall be installed across the strainers t o measure any increase in differential pressure caused by imminent blockage, and shall be arranged t o activate a remote high differential alarm at the DCS.

d. Turbine and PD meters shall be mounted in lines that are always full of the fluid t o be measured e.

7.6.3

Airlvapour separators shall be provided where there is a possibility of entrained gases in the fluids routed t o the metering system. These devices shall be combined with the filters where possible. The vapours must be routed t o a safe disposal system or returned t o a lower pressure system. Small quantities can be vented b y manual means, large quantities require a fully automatic separation system (outside the scope of this specification).

V A Meters a.

Fluids which may contain solids shall be adequately filtered upstream of the V A meters.

b. V A meters shall be installed truly vertical and be located w i t h sufficient clearance t o permit tube and float removal without removing the meter body from the line. c.

I f the flow must not be interrupted during plant operations, line size block and bypass valves shall be provided. The meter shall normally be fitted in the bypass leg t o avoid line stresses being imposed on the meter.

Engineering Group Sp&iicab;on

7.7

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 1 of 163

Performance Reauirements 7.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o flow instruments only and shall not in any w a y replace or reduce the general QAIQC requirements.

b. The Inspection and Test Plan shall include the following checks in addition t o those found necessary by the Approved Manufacturer t o ensure the quality of the product: A check o f all materials of construction by crosscomparing the goods, the material test certificates and the data sheets and Drawings. A check o f the dimensions of the finished instruments against the drawings supplied for the Contract and approved b y the Company. A check of the completed instruments and all accessories against the data sheet and specification requirements. A check o n the nameplate data in accordance with this specification and the data sheets and Drawings. Full testing of the instrument in accordance this specification, the Approved Manufacturer's additional QAIQC procedures and the approved Test and Inspection Plan. A check o n the instrument and accessories painting and protection and general suitability for the environment. A check on the tagging in accordance this specification and the data sheets. 7.7.2

Testing a.

Forged items or items which are formed b y welding into a pressure enclosure shall be hydrostatically tested at 1.5 times the rating of the flanges.

b.

Transmitter instruments shall be factory calibrated t o the range noted o n the data sheets.

Engineerhg Group SpecHmtbn 7.7.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 2 of 163

Documentation All the certification for each instrument or group of instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum:

7.8

a.

Completed Test and Inspection Plan.

b.

Material certificates and component certificates.

c.

NDT certificates.

d.

Weld procedures and qualifications.

e.

Pressure test certificates.

f.

Calibration certificates.

g.

As-built Drawings as necessary.

N a r n e ~ l a t eData General information for production of the nameplate data is given in section 4.7 of this specification, lnstrument Identification. Additionally, for orifice plates, the following information is required t o be stamped o n the projecting tag of the orifice plate: On The Upstream Face: a. lnstrument tag number. b. Line rating. c. Plate material and thickness. d. Plate bore size and pipe internal diameter (ID). f. Process fluid and temperature.

8.0

PRESSURE MEASUREMENT 8.1

A ~ o l i c a b l eStandards BS 1780

8.2

Specification Gauges

for

Bourdon Tube

Pressure and

Vacuum

S c o ~ eof Pressure Measurement Section This section covers the measurement of all process pressure variables in

@ KOC

Engineerhg Group Sp&cation

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 3 of 163

the plant, for the purposes of local indication, local control, remote signalling or transmission.

8.3

Pressure Instruments T v ~ e and Selection 8.3.1

Local lndication o f Pressure or Differential Pressure a.

b.

I

I

I

8.3.2

Local indicators shall be installed for monitoring purposes wherever there is a pressure change of the process caused b y the action of a control element of the system. They shall also be installed for the following purposes: 1.

Where a vessel code requires a gauge t o be fitted

2.

Where a filter or other piece o f equipment is subject t o change of pressure drop o n a "life" or "maintenance period" basis.

3.

Wherever there is a transmitter or s w i t c h detecting a pressure variable.

4.

A t positions o n the plant where the process designer deems that pressure monitoring is desirable.

Local indicators shall be of the following types: 1.

1 5 0 - m m (6-in.) dial-size field mounted absolute, gauge or differential pressure gauges.

2.

100-rnm (4-in.) board mounted gauges.

3.

Strip-type draught gauges

Pressure Measurement For Remote Control or lndication a.

Electronic transmitters shall be used in all cases where a continuous transmission of a pressure measurement is required in the control room for use in a control loop, or for indication or data acquisition.

b.

Transmitters shall be installed w i t h a local output indicator. This may be an integral part o f the transmitter body, provided it can be clearly read in the finally installed position. Otherwise, it shall be a loop powered or re-transmitted output of the measured signal.

c.

If the output is used t o assist the local operation of a control valve w i t h handwheel or valved bypass, a local indicator scaled in physical units shall be visible from the control valve.

-

@ KOC

Engineering Gmup specjfication d.

8.3.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 4 of 163

If a transmitter is o n shutdown service, the measurement shall be duplicated by a locally mounted direct reading pressure gauge, having its o w n process tapping. Local output indicators are not acceptable for this duplicate measurement.

Alarms and Trips a.

Alarms 1.

Intermediate alarms and pre-alarms shall be generated in the DCS from a transmitter signal that is also used for control and/or indication.

2.

Pressure gauges with a switch contact may be used only for alarms o n non-hazardous service such as HVAC. The application of such switches is subject t o approval b y the Company. Where used, these switches shall be of a type that maintains the signal for the whole range respectively above or below the set-point (not momentary); otherwise the Contractor shall provide latchldelatch logic.

b. Trips For applications where the detection of high-high and/or lowl o w pressure is used for general or local shutdown, a dedicated process pressure switch is required. 8.3.4

8.3.5

Local Pneumatic Pressure Control a.

Where local pressure control is specified, a pneumatic pressure transmitter shall be used, feeding into a local receiving controller.

b.

For suitable services approved b y the Company, the pressure element may be incorporated as an integral part of a local controller. The design of the instrument shall be t o the Approved Manufacturer's standard practice. The local controller shall be in accordance t o section 1 2 . 2 . 2 of this specification.

Viscous, Corrosive or Particulate Service Special methods for prevention of nozzle blockage shall be adopted, such as diaphragm seals andlor flushing systems, t o ensure the integrity and availability of instruments installed in adverse process conditions.

@ KOC 8.4

Engineering Group Speoi7mhn

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet 7 5 of 163

Sizina and Ranainq Reauirernents The pressure applied t o the instrument shall be corrected t o allow for static pressure heads from tall vessels etc. Instruments for vacuum ~ r o t e c t i o nof full vacuum.

service

shall

have

under-range

Pressure Gauges Pressure gauges shall be ranged so that the normal pressure shall be in the middle third of the w a n . For large turndown requirements, the normal pressure can be read at a maximum of 7 5 % of scale provided that the maximum pressure is not above 9 0 % of scale. Additional gauges shall be added as necessary t o ensure that the process range is adequately covered. Ranges shall be selected from the standard list in BS 1780, Part 2. The gauge shall be able t o withstand, without affect on the zero or calibration range, the safety relief pressure of the system in which it is installed. If this cannot be accomplished within the design over-range of the instrument (which shall not be less than 1 . 4 x range for standard gauges), other provisions such as over-range protection shall be installed. Pressure Transmitters (Electronic and Pneumatic) a.

Where possible, pressure transmitters shall use the same range selection as pressure gauges. However, the range of a transmitter shall always be within the range of the local gauge used t o monitor its output.

b.

The normal pressure shall not be read at greater than 7 5 % o f the transmitter calibrated range for instruments reading steady pressure. For fluctuating service, the normal pressure shall be not more than 60% o f the range. Suppressed ranges can be used for control loops or large ranged indications t o improve accuracy and clarity of the readout.

c.

The calibrated range of the between 6 0 % and 8 0 % circumstances shall the Approved Manufacturer's turndown rating.

transmitter shall preferably utilize of the capsule span. Under no unit be calibrated outside the recommendations for span and

Engineering Group Spec17icabion

8.4.5

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 6 of 1 6 3

Pressure Switches The pressure switch span shall be selected t o cover the requirements of : 1.

The required range.

2.

The switch reset hysteresis.

3.

Be within the range of the monitoring pressure gauge.

The proof pressure shall be within the system relief pressure. "Gauge minders" are not permitted o n shutdown instruments. Particular attention shall be paid t o ensure that the switch reset can occur without completely venting lines, stopping pumps etc.

8.5

Desian and Construction Instruments measuring absolute pressure shall have compensation for barometric pressure changes.

8.5.1

Pressure Gauges a.

Casing and Dial Gauges o f 150-mm (6-in.) diameter shall be standard. 100-mm (4-in.) gauges shall only be used for panelmounted applications where a number of gauges are installed together. Draught gauges of strip type shall be mounted on a local panel w i t h illumination or may employ a quadrant edgewise illuminator. The connection shall be at the bottom and shall be 112in. NPT male for process gauges and 114-in. NPT male for receiver gauges. Diaphragm sealed gauges shall use the Approved Manufacturer's standard connection (normally 1-in. flange t o line pipe rating). Gauges shall be moisture and dust resistant w i t h n o change of atmosphere. Dials shall be white w i t h black numerals. Gauges shall be fitted with shatterproof safety glass.

@ KOC

Engineering Group Sp&icab;on

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

7 7 of 163

The casing shall be of Phenolic material or 3 1 6 stainless steel. Circular gauges below 2 5 barg ( 3 6 3 psig) scaling shall have a safety blow-out disc in the back. Gauges for higher pressures shall have a solid front and blow-out rear. Gauges for services above 4 0 barg ( 5 8 0 psig) shall be the full safety pattern type. The gauge shall be filled w i t h glycerine as standard, gauges in vibration or pulsation duty shall be fitted w i t h gauge snubbers (pulsation dampers) t o the same material specification as the element. The dial shall be marked as follows: (a) Unit title. (b) Manufacturers full name. ( c ) Manufacturers full model number.

(d) Element material spec. and grade. (e) Other key details, e.g., "To NACE MR01075" etc. b. Measuring Element and Movement For general use, the gauge shall use a bourdon tube measuring element. The accuracy shall be 1 % or better. The movement shall be either rotary geared stainless steel or cam and roller type. There shall be an external zeroing device. Slack diaphragm elements can be used for l o w pressure applications (less than 0 . 8 barg, i.e., 1 2 psig). Bellows or diaphragm elements shall differential pressure gauges.

be used for

Dual element gauges shall only be used when the differential pressure exceeds 10% o f the available static Dressure. The element material for process gauges shall be 3 1 6 stainless steel as a standard, and t o a superior specification when the service demands.

Engineer@ Grvup Speaiccafion 6.

8.5.2

8.5.3

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

7 8 of 1 6 3

Receiver gauges shall have bronze extra-wide bourdon tubes w i t h brass socket and tip.

Electronic Transmitters a.

Electronic transmitters shall be of the strain gauge, piezoresistive or capacitance type. Other elements may be used provided that accuracy, stability and reliability criteria meet operational requirements.

b.

For low-pressure ranges, minus 1 barg t o plus 2 barg (minus 1 5 t o + 3 0 psig), differential pressure instruments shall be used for gauge pressure service, w i t h the low-pressure connection open t o the atmosphere or connected t o a reference zero.

c.

Electronic transmitters shall be of the two-wire type, operating at a nominal 2 4 VDC. They shall be certified for the hazardous area in accordance w i t h the execution code noted in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 0 1 5-JH-I 9 0 1 ) .

d.

Electronic transmitters of the "smart" type shall be used.

e.

Transmitters shall have a minimum 1 0 0 barg ( 1 4 5 0 psig) rated stainless steel body. All wetted parts shall be 31 6 stainless steel as a minimum, with the specification increased as necessary for the service.

f.

Transmitters shall be capable of withstanding over range pressure on either side of the capsule at least equal t o the body rating.

g.

Connections shall be 112-in. NPT female

h.

Electrical entry shall be M 2 0 x 1.5 I S 0

i.

Mounting shall be by bolting t o the mounted manifold wherever possible, and shall be from the manifold in cases where the vent and drains are piped or a protection box is supplied.

Pressure and Differential Pressure Switches a.

Pressure switches shall be of a design where the sensing element is remote from the switch housing. The movement of the element shall be translated into a snap action on the switch, with a fixed or adjustable differential.

@ KOC

Engineem Group SpMcBtrion

Specification Number

Rev

015-JH-1903

1

Date

15~9-94

Sheet

7 9 of 163

Switches shall be hermetically sealed single-pole double t h r o w (SPDT). The switch contacts shall be selected according t o the service conditions and certification stated in the Contract requirements. Generally, this shall be: 1.

For Ex'd' apparatus connected directly t o a PLC or relay system, contacts shall be minimum I amp rated for 1 1 0 VAC.

2.

For IS systems using "simple apparatus," contacts shall be gold plated and suitable for l o w signal levels.

The set-point shall be adjustable over the whole range, with an internally calibrated scale. The process wetted parts of the system shall be of 3 1 6 stainless steel material as a minimum, with the specification increased in accordance with the process requirements. To avoid the need t o provide barrier glands for electrical entries, pressure switches shall be of a type which provide positive protection against process fluids entering the electrical housing in the event of element failure, i.e., by means of a solid barrier and a vent. Process connection shall be 112-in. NPT female. Electrical connection shall be M 2 0 x 1.5 ISO. Mounting arrangements Manufacturer's standard. 8.5.4

shall

be

the

Approved

Pneumatic Pressure Transmitters a.

Pneumatic transmitters nozzle and flapper type.

shall be o f the motion-balanced

b.

The output will be from 0.2 t o I.O barg (3 t o 1 5 psig), with a 1 . 4 barg ( 2 0 psig) supply air pressure.

c.

A n output signal gauge shall be supplied.

d.

Process connection size shall be 112-in. NPT female. Signal and air supply connections shall be 114-in. NPT female.

e.

Mounting will be by 2-in. pipe clamp.

Diaphragm Seals All instruments used for handling viscous or corrosive fluids shall be sealed. Seals may be the liquid type employing seal pots or the chemical sealed type (diaphragm seal) utilizing a diaphragm and a silicon oil (or other suitable fluid) filling t o transmit the pressure signal. Diaphragm seals are the preferred method within the constraints of temperature limitation for the filling fluid. The instruments shall be purchased w i t h the seals and capillary tubes fitted and tested as a unit. For instruments used o n differential pressure service, the low-and high-pressure chambers shall be o f equal volume when chemical seals are fitted. Capillary tubing shall be stainless steel 3 - m m (118-in.) ID protected b y spiral-wound stainless steel armour sheathing. Flushing Systems a.

Flushing can be constant b y use of a constant f l o w regulator and low-flow alarm, or intermittent b y manual pump. Valve connections shall be provided o n a spool between the line class valve and the seal where flushing is t o be performed.

b. The flushing liquid shall be compatible w i t h the process fluid. High-Temperature Service Process instruments connected t o high-temperature systems shall be installed w i t h provision t o maintain the instrument temperature below 70" C (158'F) during normal duty, venting and bleeding etc. A condensate seal, scroll, extended capillary or proprietary cooling extension shall be fitted. Low-Temperature Service Pressure instruments connected t o crude oil, w e t gas or water service in sub-zero conditions shall have winterisation provisions. Pulsating Service a.

Instruments connected t o equipment and services in pulsating service shall be protected b y pressure snubbers of an approved adjustable type. The material for the snubbers shall be the same as that selected for the instrument wetted parts.

Engineering Group Spea'fcathn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

8 1 of 163

b. The use of partially closed valves is not permitted. 8.5.10

Range Protection a.

Pressure instruments shall generally be pressure rated up t o the setting of the system relief valve, or other maximum pressure that can arise under fault conditions. Where this would prevent the instrument being suitably ranged for its process function, the correct range shall be selected and over-range protection shall be provided.

b. Over-range protection is not shutdown pressure switches. c.

8.6

permitted

on

emergency

The protectors, or "gauge minders," shall be adjustable ( w i t h lock-nut) and shall be of a material equal t o that selected for the instrument wetted parts.

Installation Notes A piping block valve may be shared by a transmitter and local gauge, but a shutdown instrument shall have an individual locked open line class block valve. Where an instrument is mounted at a distance exceeding 2.5 m ( 8 ft.) from the primary block valve, an additional block valve shall be installed adjacent t o the instrument. The block valve and connecting piping shall be line class. Each direct pressure instrument shall have an individual t w o valve manifold. A five-valve manifold shall be used for DP application. Low-pressure DP may use a three-valve manifold. Shutdown manifolds shall be labelled as such and valve handles removed. Manifold vents and drains shall be piped t o a safe place or disposal system except for instruments in non-hazardous service such as low-pressure non-toxic and non-flammable fluids. Pressure instruments shall be installed in orientations in accordance with the Approved Manufacturer's instructions and shall not be mounted directly o n machinery. Gauges up t o 150-mm (6-in.) diameter may be supported direct from the process pipe work in suitable cases. Pulsation and gauge minders when required shall be mounted as close t o the instrument as possible.

8.7

8.6.8

Pressure instruments o n LPG or high-pressure steam service shall be fitted w i t h a restriction orifice of 1.44-mm (1116-in.) diameter downstream of the piping class block valve t o prevent excess flow in the event of a fracture o f the measuring element.

8.6.9

The transmitter air signal output piping from pneumatic transmitters shall incorporate a tee w i t h valve and plug for connection o f a calibration gauge.

Performance Reauirernents 8.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o pressure instruments only and shall not in any w a y replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality o f the product: A check of the instrument and all accessories in accordance with this specification and the data sheets and Drawings. Full works calibration and issue o f test and calibration certificate. A check on the nameplate data in accordance with this specification and the data sheets and Drawings.

A check o n the painting and protection and general suitability for the environment. A check o n the tagging in accordance w i t h specification and the data sheets. 8.7.2

this

Documentation The following data shall be available at final inspection: a.

Completed test and inspection plan.

b.

Material certificates and NACE certificates where required by the Contract.

c.

Instrument test and calibration certificate.

d.

Hazardous area certificates.

8.8

Nameolate Data General information for production of the nameplate data is given in section 4 . 7 of this specification.

9.0

TEMPERATURE MEASUREMENT 9.1

9.2

A ~ ~ l i c a b Codes le BS 1 8 4 3

Colour Code Thermocouples

for

Twin

Compensating

Cable

BS 1 9 0 4

Specification for Industrial Platinum Thermometer Sensors

BS 4 9 3 7

International Thermocouple Reference Tables

for

S c o ~ eof Tern~eratureMeasurement Section This section covers the requirements for the measurement of temperature variables in the plant for local indication, local control, remote control, remote signalling and transmission.

9.3

Temoerature Instrument Tvoes and Selection 9.3.1

9.3.2

Local Indication of Temperature a.

Local indication of temperature shall generally be by bimetallic, gas-or liquid-filled dial thermometers.

b.

Mercury in steel thermometers for local indication, recording or control is not permitted.

c.

Bi-metallic thermometers shall only be used where errors in indication in excess of 1 % of span are acceptable.

d.

Local temperature indication o n cryogenic service shall utilize a galvanometer-type indicator in conjunction w i t h a pad-type thermocouple. These indicators shall be direct reading in "C, w i t h "F equivalents.

Temperature Measurement for Remote Control or Indication a.

Thermocouples or resistance thermometer detectors with local millivolt or resistance t o current converters are the chosen method of temperature measurement and signal transmission for centralized control, multi-point indication and recording.

b. The choice between resistance thermometers and thermocouples shall be made, taking the following points

Engineering Group Spedficatbn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

84 of 163

into consideration:

1. Where accuracy of measurement greater than that obtainable w i t h a thermocouple is required, a resistance thermometer shall be used. 2.

c.

d.

Resistance thermometers shall not be used where high frequency vibration is present, e.g., in high-velocity steam or gas streams, or at temperatures greater than 750°C ( 1380°F).

Resistance Temperature Detectors (RTDs) shall be used in the following specific applications: 1.

Temperature compensation in f l o w measurement.

2.

Remote indication of temperature span less than 5 0 "C (122°F) or where the span of temperature t o be measured includes 0" C (32°F).

3.

Where a temperature measurement is t o be used t o prove a plant's performance (mass balance).

Thermocouples and RTDs shall be provided w i t h field mounted 4 - 2 0 mA, two-wire "smart" transmitters certified for the electrical area classification.

Wherever possible, a local temperature indicator shall be fitted at the same process position as the transmitting element. Alarms and Trips a.

Alarms 1.

Intermediate alarms and trips shall be generated in the DCS software from the transmitter signal that is also used for control and indication.

2.

Dial thermometers with integral switches shall not be used as field-mounted temperature switches.

For applications where the detection of high-high or low-low temperature trips are required for general or local shutdown, dedicated temperature-measuring points w i t h dedicated transmitters and trip amplifiers shall be specified. High-high and low-low trip may be generated from the same transmitter (and trip amplifier) provided it is in range.

Engineering Group specjfi~ahn c.

9.3.4

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

85 of 163

Thermocouples or resistance thermometers used in conjunction w i t h interlocks or ESD systems shall not be connected t o any other instrument.

Local Temperature Control Where local temperature control is required, thermal liquid or gas-filled type indicating transmitters shall be used, with the pneumatic output feeding a receiving controller. Details of pneumatic controllers are given in a section 12.2.5 of this specification. Combined transmitterlcontrollers of the liquid-or gas-filled type may be offered for Company approval for simple services such as tank heating up t o 300" C (572°F) range. Pneumatic instruments shall have an output o f 0.2-1.0 barg ( 3 t o 1 5 psig) w i t h a supply pressure of 1 . 4 barg ( 2 0 psig). A n output gauge shall be provided. The transmitter element shall be a bulb type, 12-mm (112in.) diameter preferred, with a bendable neck and armoured PVC-sheathed capillary connection t o the transmitter. The normal ranges shall be 5 O ( l 2 2 ) , l O O ( 2 l 2 ) and 2 0 0 ( 3 9 2 ) "C ( O F ) . When local temperature transmitters are fitted, a check dial thermometer shall be fitted in the same process position.

9.4

Sizinq and Ranqina Requirements 9.4.1

The use of RTDs shall be limited t o the range : -200" C t o + 7 5 0 "C (-328°F t o + 1380°F).

9.4.2

Thermocouples shall be ranged according t o the temperature limitations of the couple materials or limitations imposed by the specific application and are as follows:

Engineering Gmup

Specification Number

Rev

01 5-JH-1903

1

Spec&ahn

1

1

T ,v. ~ e

Material

15-9~94

Sheet

86 of 163

I Nominal Temperature (

Range "C (" F).

I

I

l B l

Date

Platinum - 3 0 % Rhodium /Platinum - 6 % Rhodium

0 to 1820 (32 to 3300)

E

Nick - Chromium /Copper - Nickel

-270 to 1000 (-450 t o 1 8 3 0 )

J

IronICopper - Nickel

-210 to 760 (-340 to 1400)

K

Nickel - Chronium /Nickel - Aluminium

-270 to 1372 ( - 4 5 0 t o 2500)

Platinum - 1 3 % Rhodium /Platinum

1

-50 to 1768 ( - 6 0 t o 32201

S

Platinum - 1 0 % Rhodium /Platinum

-50 to 1768 -(60 to 3220)

T

CopperICopper - Nickel

-270 to 440 (-450 to 750)

Type J and K thermocouples are the preferred types; other types may be used for specific applications subject t o Company approval. Local indicators (dial thermometers) shall have the following preferred standard ranges:

The range of any temperature measuring instrument shall be the Approved Manufacturer's shortest standard span appropriate t o the application.

9.5

Construction Recluirements 9.5.1

Temperature Gauges a.

Gauges or dial thermometers shall be bi-metallic, gas-or liquid-filled type w i t h a 150-mm ( 6 -in.) dial calibrated in "C and "F equivalent. A n extension capillary shall be specified t o facilitate ease o f reading; where a capillary extension is used, the capillary tube shall be supported along its length.

9.5.2

9.5.3

b.

Capillaries shall covered.

be stainless

steel

armoured and

PVC

c.

Bi-metallic dial thermometers shall be hermetically sealed, every angle, 9.5-mm (318-in.) stem, with external pointer adjustment.

d.

The connection of the head t o the well shall be by 112-in. NPT adjustable union.

Resistance Temperature Detectors (RTDs) a.

RTD elements shall comply w i t h BS 1 9 0 4 and shall be Platinum type PT 100, i.e., 1 0 0 ohms @ 0°C. and Fundamental Interval (FI) o f 38.5 ohms. They shall be of the grade of accuracy appropriate t o the application.

b.

RTDs shall be connected t o measuring instruments by either a three- or four-wire system. Three wire systems are preferred for normal process measurement applications.

c.

All applications shall use duplex element RTDs even if only one signal is required.

Thermocouoles a. Thermocouples shall comply w i t h BS 4 9 3 7 . b. Thermocouples shall be mineral insulated spring-loaded type, sheathed t o 6-mm (114-in.) diameter w i t h the hot junction insulated from or bonded t o the sheath. Larger diameter sheaths may be used for special applications. c.

Thermocouple sheaths shall be constructed from seamless tube material of minimum 1 - m m (3164-in.) wall thickness selected t o suit temperatures and specific conditions. (See section 9 . 4 for details.)

d. The minimum sheathing material grade is 3 1 6 stainless steel. lncolloy shall be used for all services above 1000" C ( 1832°F) e.

Thermocouples for use above 1 2 0 0 " C (2192°F) may be constructed from bare wire w i t h ceramic insulators for applications where the element may be prone t o binding in the well.

f.

All applications shall use duplex thermocouple elements, even if only one signal is required.

0 KOC

Engineering Grvup SpeiMcabion

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

8 8 of 163

Thermocouple head terminals shall be marked w i t h positive and negative symbols. When the thermocouple has wired terminations, these should preferably be colour coded t o BS 1843. Alternatively, they shall be sleeved and identified as positive and negative. On cryogenic process pipework, pad-type thermocouples shall be used wherever possible. Thermowells shall only be used where absolutely necessary for accuracy or sensitivity. Skin thermocouples shall be specified in certain special e.g., furnace tube skin temperature applications, measurement; the hot junction shall be permanently secured t o the tube or pipe. The protection tube or pad shall be shaped t o match, and welded t o the furnace tube or pipe. External insulation shall be fitted over the protection tube where it is e x ~ o s e dt o the burner flame. Care shall be taken in the selection of the protection tube material and pad t o ensure the correct metallurgy of the weld t o the parent pipe. Terminal Head Thermocouples and RTDs shall be o f the duplex type, i.e., t w o elements mounted in the same thermowell or sheath with all connections taken t o a head-mounted terminal block. The elements shall be connected d o w n t o an intermediate junction box mounted adjacent t o the transmitter and containing sufficient terminals t o connect both elements. For thermocouples, the cable shall be the correct-extension type and the terminals shall be manufactured from the correctextension material. One element shall be connected from the intermediate junction box t o the field mounted transmitterlconverter. For thermocouples, the correct extension cable shall be used. The second element shall terminate at the intermediate junction box terminals, enabling the element t o be changed over at the junction box in case of failure of the first element. Head-mounted terminal enclosures and the intermediate box shall be weatherproof t o IP65 as a minimum and certified for the electrical area classification. When t w o or more thermocouples or resistance detectors are located in the same thermowell, they shall be individually and permanently identified regarding function, e.g.,

Engineering Gmup SpeiHcaLkm

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

89 o f 163

temperature-indicating indicator (TI). e.

9.5.5

controller

(TIC)

or

temperature

The head shall be connected t o the well b y a galvanised extension complete w i t h a union coupling. The connection thread in the well shall be 112-in. NPT.

Temperature Switches a.

Temperature switches may only be used in specific circumstances w i t h specific Company approval such as "package vendor" equipment of standard design, or where indicated o n the approved P&IDs.

b. Temperature switches shall be SPDT, weatherproof t o IP65 minimum and must be certified for the electrical area classification. Switches can be of the liquid-filled type with stainless steel bulb, capillary and armour and shall include union connection. Alternatively, switches may be of the bimetallic type. Temperature setting and differential adjustment shall be external t o the switch housing. Indicating-type switches are preferred. c. 9.5.6

Electrical entry size shall be 20 mm, threaded t o I S 0 1.5.

Temperature Transmitters a.

Electro-motive force (EMF) or resistance t o current converters shall be used for all remote transmission of temperature signals.

b.

Converters shall be field mounted at the nearest accessible point adjacent t o the measuring point, and be of "smart" type. Converters shall be weatherproof t o IP 6 5 as a minimum and shall be certified for the electrical area classification.

c.

Dial thermometers shall be provided as a "check gauge" for temperature measuring points where indicated on the P&IDs.

d.

Transmitters shall be specified suitable for the installed thermocouples and the installed three- or four-wire RTD configurations and shall have upscale burnout in the event of loss o f input from either RTDs or TICS. They shall incorporate linearisation circuits in accordance w i t h the connected element. Outputs linear t o input signal are not acceptable. Linearisation in the auxiliary room interface cabinet or the DCS 110 is acceptable as an alternative.

-

OKOC

Engineering Group SpecMcation e.

9.5.7

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

90 of 163

Electrical entry shall be 20 m m (314 in.) 1.5 ISO.

Thermowells a.

Thermowells shall be specified for all temperature detecting elements, with the exception of detectors on skin point and cryogenic service, and shall enable the element t o be removed during plant operations.

b.

40-mm (1.5-in.) flanged thermowells shall be used for all normal duties o n pipework and 5 0 m m ( 2 in.) for vessels, unless otherwise stated. Thermowells shall be solid drilled and tapered, the flange shall be attached b y fillet welding for 3 0 0 lbs rated flanges and full-penetration welding for higher ratings.

c.

Flange ratings shall be 3 0 0 lbs. minimum or a higher rating t o suit the relevant vessel or piping specification. The flangeface type and finish shall be in accordance with the relevant piping specification.

d.

Thermowell material shall be 3 1 6 stainless steel minimum or alternative materials t o suit process conditions.

e.

Screwed thermowells, size 314-in. NPT, shall only be used on cooling water or atmospheric vessel applications.

f.

The ID of thermowells for duplex thermocouples and resistance thermorneters shall be t o suit 6 m m (114 in.) elements. Larger diameter elements may be used for special applications.

g. The surface of the well shall be smooth and free from burrs and notches. The transition at diameter changes and connection t o the flange shall be a smooth radius t o minimise stress amplification.

h.

Where thermowells are installed in gas or vapour lines or in lines subjected t o high-liquid velocities, combined stress and vibration calculations shall be carried out t o a proven method.

i.

All thermowells shall be manufactured of certified materials and shall be pressure tested. Welding shall be conducted in accordance with ASME IX.

j.

Proprietary thermowells supplied w i t h instruments shall meet the requirements of this specification.

Specification Number

Engineering Group SpMcation 9.6

1

Date

15~9~94

Sheet

91 of 163

Installation Notes 9.6.1

9.6.2

9.6.3 9.7

01 5 . ~ ~ ~ 1 9 0 3

Rev

Thermowells shall not be installed in line sizes less than 1 0 0 m m (4 in). In smaller lines where temperature measurement is required, the line shall be swaged up t o 1 0 0 m m (4 in) or, for 3in. lines and above, the thermowell shall be mounted in an elbow. Temperature instruments, i.e., dial thermometers, transmitters etc shall be installed such that they are readable and accessible from ladders and platforms. All wells shall be installed in positions such that the element and head can be withdrawn without removing other equipment.

Performance Reauirements 9.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o temperature instruments only and shall not in any w a y replace or reduce the general QAIQC requirements.

b.

The inspection and test plan shall include the following checks in addition t o those found necessary by the Approved Manufacturer t o ensure the quality of the product: A check of all materials of construction by crosscomparing the goods, the material test certificates and the data sheets and Drawings. A check of the dimensions of the finished instruments against the Drawings supplied for the Contract and approved b y the Company. A check o f the completed instruments and all accessories against the data sheet and specification requirements. A check o n the nameplate data in accordance with this specification and the data sheets and Drawings. Full testing of the instrument in accordance this specification, Approved Manufacturer's additional QAIQC procedures and the approved test and inspection plan. A check on the instrument and accessories painting and protection and general suitability for the environment.

7. A check o n the tagging in accordance this specification and the data sheets. Testing a.

Forged items or items which are formed b y welding into a pressure enclosure shall be hydrostatically tested at 1.5 times the rating of the flanges, or 1.5 times the line rating, whichever is higher.

b. Transmitter instruments shall be factory calibrated t o the range noted on the data sheets. Documentation All the certification for each instrument or group of instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum:

9.8

a.

Completed Test and Inspection Plan.

b.

Material certificates thermowells.

c.

NDT certificates (minimum dye penetrant test of all welds).

d.

Weld procedures and qualifications.

e.

Pressure test certificates.

f.

Calibration certificates.

and

component

certificates

for

Nameolate Data General information for production of the nameplate data is given in section 4.7 of this specification, lnstrument Identification. Additionally, for thermowells, the following information is required t o be stamped on the flange rim or lagging extension: a.

Instrument tag number.

b

Temperature Range.

c.

Flange rating and size.

d.

Test pressure.

e.

Material

, SpeMcatr;on f.

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

93 of 163

Bore (element) size.

10.0 LEVEL MEASUREMENT 10.1 Aoolicable Standards

BS 3 4 6 3

Specification for Pressure Vessels

Observation

and

Gauge

Glasses

for

10.2 Scooe of Level Measurement Section This section details the measurement of all process level variables on the plant, for the purposes of local indication or remote signalling or transmission. 10.3 Level Instrument Tvoe and Selection 10.3.1

General a.

Level instruments shall be selected t o provide the required accuracy and integrity w i t h the emphasis o n simplicity of installation and maintenance.

b.

Level instruments shall be placed in chambers external t o the vessel and not mounted internally except w i t h the approval of the Company.

c.

Level instruments shall be mounted o n stand pipes (bridles) t o avoid excessive numbers of individual vessel nozzles, provided that: 1.

Construction requirements o f the pipinglvessel fabrication code can be met without compromising the required ranges.

2.

Access for operational readings and maintenance is not impaired.

3.

Walkway clear space is not impeded.

d.

Where a safety trip function is required, a separate instrument shall be supplied. Shutdown instruments shall not share connections or standpipes w i t h control instruments.

e.

I f level instrument requirements are included in the fabrication code for the vessel, these shall be followed during the selection and the specification o f level instruments.

Engineen'ng Gmup SpeiHCdtion

f.

10.3.2

Specification Number

Rev

Date

Sheet

0 1 5-JH-1903

1

15-9-94

94 of 163

Some liquids which in their service condition may be of suitable consistency for float or displacer measurement methods may form coagulants when exposed t o reduced temperatures in external chambers. In these cases, methods shall be considered t o prevent this formation, e.g., by trace heating, or an alternative instrument system selection.

Local Gauges All vessels, columns and tanks which have level instruments such as transmitters, controllers or switches shall be provided w i t h local visual liquid gauges. Other vessels shall have gauges when observation of level is important t o operation or safety. The gauge shall cover the complete operating range of any other level instrument installed o n the same vessel section. For local indication o f level, direct vision gauges of transparent or reflex type shall be applied, unless process conditions, physical dimensions or required accuracy mean that other types of instruments offer technical or commercial advantages without loss o f performance or integrity. Glass tube gauges shall not be used. Gauges for caustic service shall have protective sleeving or mica shielding. Reflex gauges shall be used o n all clean services except liquid level interface. Transparent gauges shall be used on acid, caustics, dirty fluids, coloured liquids and liquid interface where the interface is visually discernible. For high-pressure, high-temperature, toxic or hazardous duties the use of magnetic follower gauges shall be considered. DP type, self-acting mechanical level indicators (Yarway type) may be used for the back-up gauge o n steam drum applications. For large vessels and tanks, a number of overlapping gauges shall be used. The overlap of the visible length shall not be less than 2 5 m m ( 1 in.). For total ranges exceeding 2.2 m (7ft.) on atmospheric or low-pressure systems, DP measurement and transmission t o a local gauge, or the requirements indicated in section 11, Tank Metering, of this specification shall be considered.

Engineering Group Specir7cdthn

10.3.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

95 of 163

i.

For cold services, glass-type gauges can be obscured by frost or condensation. "Non-frosting" gauges shall be specified. For applications where heating o f level gauges is required, the heating element(s) shall be external. Where other conditions are favourable, a float-operated magnetic coupled level indicator shall be considered for those applications which would otherwise require a heated gauge.

j.

Local level indicators for open storage tanks shall be float type w i t h internal guides and w i t h a gauge board. Approval shall be obtained from the Company for all internally mounted installations.

Level Transmitters Displacer-type instruments are preferred for transmitted measurement of level when the range does not exceed 1.5 m ( 5 f t 0 in.), or 2.5 m (8 f t 0 in.) for static vessels and separators. Lengths up t o 3 m ( 1 0 f t 0 in.) can be offered for Company approval in special cases when the vessel has no agitation. Internally mounted displacers may be accepted, subject t o Company approval, for simple applications such as for noncorrosive atmospheric service and for storage tanks. Any such proposal shall cover positive means of retaining, retrieving and guiding the displacer. DP transmitters shall be used for longer spans and where the liquid is viscous, corrosive or particulate or where flashing, agitation or vibration may occur. DP transmitters may be used for non-critical applications such as water and fuel tanks when the span is greater than 1 . 5 m ( 5 f t 0 in). When materials are liable t o separate, solidify or deposit in impulse lines the connections shall be purged andlor, if the temperature permits, diaphragm seals shall be used. Differential systems shall use a w e t reference leg except in dry gas service when a dry or gas purged reference leg shall be used. Mechanical ball float level transmitterlcontrollers shall not be used on process vessels. Bubble-type systems may be used on atmospheric and constant l o w pressure tanks of the blanketed type where the accuracy is not of prime importance.

Engineering Group SpMcatbn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

96 of 163

h. Other types of measurement, e.g., capacitance or ultrasonic may be offered t o the Company for approval. The use o f radioactive instruments shall only be considered after consultation w i t h the Company. 10.3.4

lnterface Service The upper connection of all interface installations shall always be submerged in the less dense liquid. Additional connections t o the vessel may be installed as necessary t o drain back separated fluids. The additional connections shall be o f an equal size and standard as the main connections. All proposed systems for interface measurement are subject t o Company approval. Gauging shall be b y through-vision gauge glasses where practical. Float-type instruments with magnetic followers may be used for suitable services. lnterface transmitters shall normally be o f displacer type. Where the specific gravity difference is 0 . 1 or less, capacitance-type instruments shall be considered.

10.3.5

Alarms and Trips a.

Alarms Intermediate alarms and pre-alarms shall be generated in the DCS from a transmitter signal that is also used for control and/or indication. The use of magnetic switches mounted outside float-type level gauges t o generate alarms shall only be used o n non-hazardous service and with Company approval.

b. Trips For applications where the detection of high-high and/or lowl o w level is used for general or local shutdown, dedicated instruments shall be used and they shall be direct-mounted process switches. Float-type switches shall normally be used. Displacer operated switches shall only be used where the exact switching point cannot be determined at the design stage. c.

If for mechanical reasons and if agreed t o b y the Company, level switches have t o be internally installed, they shall only be o n vessels which can be emptied and depressurised during plant operation.

Engineering Group Spea%icathn

10.3.6

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

9 7 of 163

d.

Where appreciable changes in liquid density occur across the plant operating range, including startup conditions, calculations shall be performed, for Company approval, t o confirm that the measurement system chosen for the application is not rendered unsafe at any condition.

e.

Corrections shall only be made t o transmitted signals used for shutdown purposes when it can be shown that failure of the correction signal in either direction cannot reduce the shutdown integrity.

Tank Metering Where accurate assessment of tank contents on a mass basis are required t o be measured, the equipment is covered in section 1 1 . 0 of this specification.

10.3.7

Local Level Control a.

Where local level control is specified, a pneumatic transmitter (displacer or differential pressure as appropriate) shall be used, feeding into a receiver controller.

b.

Combined transmitterlcontroller systems may be offered for Company approval when the service conditions are suitable.

c.

The local controller shall be in accordance w i t h section 12.2.4 of this specification.

10.4 Sizina and Ranains Reauirements

10.4.1

Range Criteria a.

The calculation of level instrument range depends o n the physical dimensions of the installation. The operating levels in the vessels can depend o n complex process calculations, particularly when exposed surface areas are important, or when dip tubes, overflow separation or similar vessel internals are fitted. The selection of ranges should be determined in association w i t h the Contractor's process engineers t o achieve the required monitoring and control while retaining a practical and economic installation.

b. The design of the system shall take into account the avoidance wherever possible of trapped fluids when an instrument is isolated and drained. This problem is more common on small vessels. Changes of the preferred nozzle locations are acceptable when there are improvements t o the self-drainage or valve drainage systems.

Engineering Group Specl7caiion 10.4.2

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

98 of 163

Level Coordination Sketches Prior t o level connections being finalized on any vessel, tank etc., detailed level coordination sketches shall be submitted t o Company for review. These shall detail all pertinent factors, dimensionally related t o the tangent line or inside-shell of the vessel, such as: Key dimensions o f vessels. Instrument type and rating. Connection centres type and rating. Span or visible length. Calibrated range. Elevation for DP instruments. Process level at normal, alarm and ESD levels. Reference t o codes (e.g., steam drums) where applicable.

10.4.3

10.4.4

Visible Range a.

The visible length or display of the level gauge shall exceed the range of the transmitter b y the greater of 5 % or 5 0 m m ( 2 in.) on both l o w and high level. The normal, alarm and trip levels and the transmitter 0 % and 1 0 0 % points shall be marked on the gauge body.

b.

The range of the transmitter shall place normal level at the 5 0 % position unless modified by process restraints, shall extend beyond the highest and lowest levels by the greater of 5% of the range or 5 0 m m (2 in.), and shall encompass any trip switches b y the same margin. If alarms are generated b y the control transmitter, they shall be sufficiently separated from the trip levels t o enable operator intervention t o prevent a trip following an alarm. Such a separation shall be the greater of 1 0 % o f the instrument range or 5 0 m m ( 2 in.), or a calculated figure based o n the rate o f change of level caused b y flow in or out of the vessel, t o give the operator several minutes t o act.

Code Requirements Where the vessel is designed t o special codes, e.g.,team drums, and the code requirements conflict w i t h the general

2-0056

Engineetfng Group Spe&cBtion

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

99 of 163

considerations stated, the code requirements shall be complied with. DP Instruments For DP applications, zero elevation/suppression calculations shall be performed for each case. Where vessel level measurement is severely modified b y temperature (density) changes, correction shall be applied. Where the upper vapour density can vary greatly because o f temperaturelpressure range, correction shall be applied. The DP transmitter specification shall be attached t o the calculation and submitted t o the Company for approval. Direct Action For transmitted signals (control or shutdown), an increase in level shall give an increase in measurement unless otherwise agreed t o with the Company for safe operation. Interface Service For liquid-liquid interface service, special attention shall be given t o the displacer or float diameter t o enable satisfactory sensitivity, especially when the difference in densities is small. Standard Manufacture Centre-to-centre dimensions, ranges and visible lengths of all level instruments shall be t o the Approved Manufacturer's standards. Specially designed instruments shall be used only in exceptional instances with Company approval.

10.5 Construction Reauirernents 10.5.1

Connection Type, Size and Rating a.

Connections t o the vessel shall be in accordance with the vessel specification for size (2-in. nozzles shall be used as a minimum), flange rating ( 3 0 0 lb shall be used as a minimurn) and flange facinglgasket type.

b. The connection t o the instrument shall be (refer t o table below) 2-in. NB or I - i n . NB via a reducing nozzle or reducing spool, 3 0 0 lb (minimum rating) and a line class isolating valve.

Engineering Group SpecHmtbn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

100 of 163

The instrument connections and positions are as follows: INST. TYPE

I Gauae Glass

INST. CONNECTION

CONN. POSN. I

I side-side

I

I

1 in.-300 lb min.

Magnetic Gauge

side-side

1 in.-300 lb min.

Displacement Tx

side-bottom

2 in.-300 lb min.

Level Switch

side-bottom

1 in.-300 lb min.

DP TX

mnfr. std.

112 in.-NPT (5-valve manifold)

1

I

Special connections and other sizes and types shall be subject t o approval b y Company. All instruments shall be fitted w i t h full bore roddable 112 in. drain and vent valves. These shall be plugged for standard services and piped t o a safe location for hazardous services. Piped system disposal arrangements shall include a safe visual means of checking that effluent f l o w has stopped, e.g., tun dish or sight f l o w tube. 10.5.2

Stand Pipes (Vessel Bridles) a.

Where stand pipes are used they shall be constructed using the same fittings, materials, codes, production techniques and inspection procedures as the vessel trim. They shall be 4-in. NB but may be 2 in. or 3 in. w i t h Company approval. They shall be connected t o the vessel b y isolating valves t o line specification (minimum 3 0 0 lb rated) and be adequately supported. Each instrument shall be individually served by full-bore type roddable isolating valves of 1-in. NB 3 0 0 lb minimum rating (2-in. NB for displacement transmitters). The stand pipe isolating valves shall be capable of being locked in the open position.

b. All stand pipes shall be fitted w i t h full bore roddable 314-in. drain valves and 1-in. vent valves. These shall be plugged for standard services and piped t o a safe location for hazardous services. Piped system disposal arrangements shall include a safe visual means of checking that effluent f l o w has stopped, e.g., tun dish or sight f l o w tube. c.

The stand pipe shall be insulated t o at least the same standard as the vessel. Since the temperature of the fluid in the stand pipe will vary from the bulk fluid temperature, calculations shall be performed t o ensure that:

Engineering Group Spedfic~fhn

10.5.3

Specification Number

01 5-JH-1903

Rev

Date

Sheet

1

15-9-94

101 of 163

1.

Mechanical integrity is not affected b y differential expansion between the nozzle centres. The weight of the stand pipe and all the attached instruments shall also be taken into account.

2.

Fluid density changes do not cause measurement errors outside acceptable limits for the application.

Materials and Fabrication All instrument wetted pressure parts shall be constructed using materials equal t o the vessel design specifications, w i t h welding, heat treatment, NDT, certification and hydrotesting all conducted t o the same standard as the vessel. NACE, impact testing and any other special Project or service requirements shall be noted o n the data sheets and shall be supplied. Operating parts o f the instruments shall be constructed of materials suitable for the service w i t h a minimum requirement o f 3 1 6 stainless steel. If the float of float-type instruments cannot be pressure tested at the vessel test pressure, this shall be clearly labelled on the outside of the instrument. Where the measured liquid contains particles or material which would accumulate in the chamber or connecting piping, the nozzle(s) shall be purged w i t h a compatible fluid. The fluid shall be monitored b y a constant f l o w regulator and alarm.

1 0 . 5 . 4 Visual Gauges (Glass and Magnetic Coupled Types) a.

General Requirements 1.

All fittings and valves for gauges shall be of steel unless the service requires different materials.

2.

All gauges shall be stamped w i t h the maximum working pressure and temperature.

3.

Gauges o n vaporising service shall be manufactured with oversized chambers.

4.

Expansion and contraction of gauges used o n hot or cold liquids shall be compensated w i t h piping expansion loops supplied with the instruments.

Engineering Gmup s~ecjfi~atkm

b.

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

102 of 1 6 3

5.

In addition t o the line class valve, all gauges shall be supplied w i t h shutoff valves o n the top and bottom connections and 112-in. full-bore roddable-type drain and vent valves. Shutoff valves shall be 112-in. NPT nipple connected of the handwheel-operated quick action offset screw-down type, w i t h bolted bonnets and safety velocity ball checks.

6.

For special services using exotic materials, the shutoff valve may be replaced w i t h a 112-in. line class valve or omitted completely subject t o Company approval.

Glass Type Gauges Glass tube gauges shall not be used. Gauges on coded vessels shall be code stamped. All gauges shall have approval b y Lloyds or an equal body. Gauges shall comply generally w i t h the requirements of BS 3463. Gauges for caustic service shall be fitted w i t h caustic resistant inserts. Gauges for cold service shall have frost protection. Double-plate and reflex gauges shall have forged steel columns and toughened Borosilicate glass. Allowance shall be made t o take up expansion without undue stress on the instrument or nozzles. Transparent gauges shall be backlit w i t h an illuminator suitably certified for the hazardous area. A foot switch shall be supplied, connected t o the electrical system in such a w a y that the light remains on for an adjustable period after depression of the switch. The specification of the electrical items shall be in accordance with the Engineering Group Specification entitled "Electrical Design, Installation and Testing" (Number 0 1 5-PH1901). Extended gauge glasses shall not be o f more than four sections long.

c.

Magnetic Coupled Gauges 1.

T w o types are acceptable:

@ KOC

Engineering Group SpeaiCicBtbn

2.

10.5.5

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

103 of 163

a.

Parallel-tube types having a density balanced float in a parallel chamber magnetically coupled t o the float in the process fluid.

b.

Magnetic-indicator types where magnetised flaps or balls w i t h contrasting paint colour on each side roll over as the float magnet passes them.

The chamber material shall be 31 6 stainless steel unless the service demands a higher specification.

Displacer Instruments a.

The top and bottom of the chamber shall be full-sized flanged t o enable withdrawal of the displacer and cleaning.

b. The head shall be rotatable on the flanges t o enable orientation. c.

The required handing shall be noted o n the data sheet

d.

Electronic transmitters shall have an output of 4 - 2 0 mA for a 24-VDC supply and be certified in accordance with the hazardous area and execution code stated in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 0 1 5-JH-1901). A n output indicator shall be provided.

e.

Pneumatic instruments shall have an output o f 0 . 2 - 1 . 0 barg ( 3 t o 1 5 psig) with a supply pressure o f 1 . 4 barg ( 2 0 psig). An output gauge shall be provided.

f.

Displacer instruments shall be glandless.

g.

Standard materials are:

h.

1.

Displacer: 3 1 6 stainless steel.

2.

Torque tube: Inconel.

Internal displacers may be used where an external arrangement is not possible (e.g., sumps). In this case, facilities shall be provided t o allow testing and routine maintenance. All such displacers shall be shielded and guided, and a means shall be provided t o retain and recover dislodged displacers. The mounting flange for top-mounted instruments is 4 in. unless a larger size is required.

10.5.6

i.

Instruments for high- or low-temperature service conditions shall employ finned torque tube extensions as necessary t o maintain the temperature between the operational limits.

j.

Displacer chambers connected t o hydrocarbon vessels employing steam as a stripping medium shall be provided w i t h a gas purge of the vapour connection.

DP Instruments DP measurements shall normally employ a filled reference leg connected above the vessel liquid phase, w i t h a reversed transmitter output. Filling of the leg shall be b y condensation method where possible. Where filling of the legs b y gravity feed from sloping impulse piping cannot be guaranteed, constant head chambers shall be installed. Where it is difficult t o maintain a filled reference leg, e.g., in vacuum systems, a dry or purged leg shall be used. A dry leg is defined as a service where the vessel is always below the temperature at which the contained liquids would evaporate at ambient pressure. Purged legs are liquid filled at startup and maintained b y the purging system. The purge fluid may be liquid, gas or steam. The leg shall be initially filled w i t h the purge fluid for liquid purge, and w i t h water for the steam-purged system. Gas-purged legs shall be filled w i t h a suitable non-vaporising liquid. Connections shall be provided t o fill the legs at startup. Where materials are liable t o separate, solidify or deposit in impulse lines, the lines shall be purged or direct-mounting, liquid-filled diaphragm systems shall be used o n the 2-in. vessel connection. Where deposition is serious, purging of the nozzle can be used in addition t o the diaphragm seal. All materials used shall be suitable for the service conditions. Extended diaphragm systems passing into the nozzle, flush with the vessel wall may be used with 4-in. or 6-in. vessel nozzle sizes. Extended diaphragms shall not be used on vessels requiring periodic mechanical cleaning. Transmitters for closed vessels shall have range suppression or elevation facilities as required. Range suppression shall take account of the differences in density of the leg fillings, including the gas phase for high-pressure applications.

Engineering Group Speaicicafion

10.5.7

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

105 of 163

i.

Electronic transmitters shall provide a 4 - 2 0 mA signal using a 24-VDC supply, and be certified in accordance with the hazardous area and execution code stated in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 015-JH-1901). A n output indicator shall be fitted.

j.

Pneumatic transmitters shall provide a 0.2-1.0 barg ( 3 t o 15 psig) signal w i t h a 1 . 4 barg ( 2 0 psig) supply and be fitted w i t h an output gauge.

Level Switches Direct-acting level switches shall be external-float type with magnetically operated (glandless) transmission of float movement t o the switching element. The coupling shall be shielded against accumulation o f magnetic particles and provide high integrity partitioning between process and electronics. The float shall be of 3 1 6 stainless steel as a minimum and shall withstand the vessel test pressure. Applications where the float is suitable for the service but cannot safely withstand the test pressure shall be referred t o the Company for approval. Integral float stops shall be provided t o limit the angle of float travel, and shall be fitted as close t o the float as possible. Floats shall be restrained in cages (or alternative) t o restrain the float from blocking nozzles in the event of becoming detached. Oversize floats shall be fitted in housings with oversized flanges so that the instrument can be fittedlwithdrawn with the float in position (applicable for vessel-mounted switches where these have been allowed by the Company). Switches shall be environmentally sealed. Contacts shall be SPDT and shall be rated at 1 amp at 2 4 VDC for Ex'd' certified equipment and shall be gold plated for IS (simple apparatus) applications. They shall be certified for the hazardous area noted in the Contract documents. Where the process conditions are such that the float will be subjected t o turbulence, provision shall be made by shielding, guiding or other means t o eliminate the effects of turbulence on the float shaft and bearing assembly.

Engineering Group Speo5cation

Specification Number

Rev

Date

Sheet

0 1 5-JH-1903

1

15-9-94

106 of 163

10.6 Installation Notes

Access for Maintenance Each level instrument shall be capable o f individual removal without shutting downldraining the vessel. As well as ensuring that adequate isolation valves are located in accessible positions, installations shall be checked t o confirm that sufficient headroom and removal space is allowed for the removal of the instruments, and for internals such as displacers without removal of the instruments. Access for Operation Gauges shall wherever possible be readable throughout their range from grade or from a single platform. If other levels have t o be accessed t o read the gauge, the stairway must be immediately accessible. Gauges t o be read from fixed ladders require Company approval. Mounting of Chambers Chambers shall be mounted truly vertical. Vents and Drains The complete installation o f instruments, chambers, connecting legs, impulse tubing etc. shall be completely drainable at a full shutdown. Installations which involve connecting legs below the vessel base are subject to Company approval, but where these are approved, shall have additional lockedlclosed drain valves t o drain the leg. Vent and drain piping for coagulating or condensing service o n corrosives or hydrocarbons require preheating or other precautions t o ensure that materials are not left in the line after use. Steam purging may be considered if steam is available. Flow t o the drain shall be visible in a safe commensurate with the materials being handled.

manner

Low-point traps on drain and vent piping are not acceptable.

10.7 Performance Reauirernents 10.7.1 Quality Control (QC) a. 2-0056

QC shall be as detailed in the Contract. This section states

Engineering Group Sp&ca&n

Specification Number 01 ~ - J H - I ~ o ~

Rev

Date

1

15-9-94

Sheet 107 of 163

the minimum additional requirements related t o level instruments only and shall not in any w a y replace or reduce the general QAIOC requirements. b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality o f the product: A check o f all materials o f construction b y crosscomparing the goods, the material test certificates and the data sheets and Drawings. A check of the dimensions o f the finished instruments against the Drawings supplied for the Contract and approved b y the Company. A check of the instrument and all accessories in accordance with this specification and the data sheets and Drawings.

Full testing of the instrument in accordance this specification, Approved Manufacturer's additional QAIQC procedures and the approved Test and Inspection Plan. A check o n the nameplate data in accordance w i t h this specification and the data sheets and Drawings. A check o n the painting and protection and general suitability for the environment. A check on the tagging in accordance w i t h specification and the data sheets.

this

1 0 . 7 . 2 Testing a.

The pressure enclosures shall be hydrostatically tested before assembly at 1.5 times the rating of the flanges.

b. The instrument shall be calibrated w i t h a fluid having the same properties as the process fluid. c.

The Instrument shall be pressure tested as an assembly at no greater than 1.5 times the rating of the flanges, but this figure shall be reduced if there is a design restriction on pressure o n any component. If such restrictions exist, this fact shall be clearly marked o n the instrument in English and Arabic languages.

Engineering Gmup SpMication

10.7.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

108 of 1 6 3

Documentation All the certification for each instrument or group of instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum: a.

Completed test and inspection plan.

b.

Material certificates and component certificates.

c.

NDT certificates.

d. Weld procedures and qualifications.

10.8

e.

Pressure test certificates.

f.

Test and calibration certificates.

g.

Hazardous area certificates.

h.

As-built Drawings as necessary.

N a m e ~ l a t eData 10.8.1

General information for production o f the nameplate data is given in section 4.7 o f this specification.

10.8.2

For level instruments the following additional information is required: a.

Body material

.

b. lnternals material.

.

c.

Rating of inlet and outlet flange

d.

Test pressure of complete instrument.

11.0 TANK METERING 1 1. I

A o ~ l i c a b l eStandards API

Manual of Petroleum Measurement Standards Gauging

-

Chapter 3 - Tank

11.2 S c o ~ eof Tank Meterina Section 11.2.1

This section details process measurements on tank and storage vessels where the selection criteria for instruments stated in the

Engineering Group Sp&catiiOn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

109 of 163

"level instruments " section of this specification cannot generally be applied due t o span restrictions. 11.2.2

This specification applies t o storage tanks only. For process vessels o n which conventional process level variables are required t o be measured, for the purposes o f local indication or remote signal transmission, the requirements are covered by section 10.0 of this specification, Level Measurement.

11.3 Tank Metering Instruments Tyoe and Selection

11.3.1

Use of Conventional Instruments Where conventional instruments are applied t o tank level measurements, e.g., level switches, direct DP measurement, displacer instruments, etc., the requirements of section 1 0 . 0 of this specification shall be followed. Dedicated level switches shall be used for the high and l o w trip detection. They shall be displacer type for low-level detection and float type for high level.

11.3.2

Measurement of Large Spans The method of measuring the full span of the tank shall be indicated on the P&ID issued for the Project, or if not indicated shall be agreed t o w i t h the Company during design definition. The selection shall be from the following instrument types: Inferred level measurement, using DP measurement by a DP transmitter. The local readout can be a direct reflection of the calibration o f the transmitter, or a re-transmitted signal from the DCS (including any specified corrections applied). Float-operated mechanically linked indicator w i t h position transmitter. Servo-motor-operated float or displacer-type surface-seeking systems. These shall be specified w i t h rnicro-processorbased calculation modules. Radar-type tank level gauges. Servo-motor operated surface-seeking capacitive tank level gauges. Sonic and ultrasonic tank level gauges Inductive tank level gauges.

h.

Resistive tank gauges.

i.

Various systems available such as by use of radio frequency signals and others in development.

1 1 . 3 . 3 Tank Gauging Systems

1 1.3.4

a.

Where measurement of level is combined with other variables (such as density measurements, temperature correction and extrapolated vessel volumes) t o enable the vessel contents t o be calculated, the system shall be deemed t o be a tank gauging system. All tank gauging systems shall have a local level indicator ( w i t h alarm points marked) and remote transmission of the level, contents evaluation data, and alarm sensing. Tank gauging systems shall comply w i t h the requirements o f the API manual of Petroleum Measurement Standards, Chapter 3, Tank Gauging. Where statements in that specification are preceded w i t h the adjective "should," this shall be read as "shall."

b.

Unless otherwise specified b y the Company, tank gauging applications on the Facility shall utilize a standard Approved Manufacturer's DP level measurement, w i t h separate transmission of the tank temperature and other variables. The DCS system shall calculate and display the tank level, liquid density and temperature and compute and display the mass and volume of the contents.

Pre-Alarm Switching The tank metering measurement shall be used t o derive the alarm high and l o w levels and t o start and stop pumps and other control devices. Separate devices shall b e used for the high-high and low-low trip point detection.

11.3.5

Shutdown Switching Shutdown inputs t o the ESD system shall be derived from dedicated high-high and low-low switches installed in external chambers o n the side of the tank.

11.4 Sizina and Ranclina Reauirements

1 1.4.1

Requirements Applicable t o All Systems a.

The calibrated range of the tank level measurement instrument shall cover the full range of tank levels, including alarm and trip points.

Engineering Group Specificab;on

Specification Number

Rev

01 5-JH-1903

1

Date

15~9-94

Sheet 1 1 1 of 1 6 3

For DP-based systems o n tanks w i t h liquid interface control, the calibrated range shall commence above the highest interface level. Level coordination sketches showing all pertinent information shall be produced b y the Contractor for all applications. These shall be approved b y the Company and verified by the Approved Manufacturer before order placement. Scales shall be as follows unless requested otherwise by the Company: 1.

Local and remote level indication: 0-100%.

2.

Liquid volume: cubic metres (m3)

3.

Mass: kilogram (kg).

4.

Density: kilogram per cubic metre (kg/m3)

Facilities shall be installed o n the tank adjacent t o the gauging system t o enable manual gauging b y dip rod. The complete system shall be field calibrated in accordance with all recommendations in the API code previously noted. Requirements for Hydrostatic Tank Gauging System The hydrostatic tank gauging (HTG) system shall be ranged in accordance w i t h the API Manual of Petroleum Measurement, Chapter 3. Temperature Measurement The temperature measurement shall be b y use o f an RTD. The RTD shall be mounted in a thermowell mounted adjacent t o the lower transmitter tapping and penetrating at least 1 m into the process fluid. The readout shall be ranged t o cover from zero t o the maximum possible process temperature, allowing for any increase due t o ambient effects. OilIWater Interface Measurement The oillwater interface detection shall be b y use of an externally mounted displacement transmitter, a capacitance probe, or by another Company-approved method. The range of the instrument shall cover all possible movement o f the interface level, up t o and including the upper process fluid outlet level.

Specification Number I

01 5-JH~1903

Soecjficaan

11.5

Rev

Date

1

15-9-94

Sheet

l 1 2 o f 163

Construction Reauirements 11.5.1

Requirements for All Systems The instruments used in tank metering systems shall be selected t o provide the required accuracy and integrity with emphasis o n simplicity o f installation, operation and maintenance. Where the instrument items forming parts of the system are of the types described in the other sections of this specification (pressure measurement, temperature measurement etc.,), the requirements of those sections shall be followed. The systems proposed shall be fully proven and the compatibility w i t h the selected DCS system shall be ensured, both for the required process parameter updates and for system diagnostic and integrity checks. Where field power supplies are required or servo motors are used, they shall be operable at the UPS power supplies available, 24-VDC or 110-VAC 5 0 Hz. Exceptions require Company approval. The system shall be capable of field calibration without shutd o w n or isolation o f equipment. Special equipment for calibration shall be part of the package. When the service requires special considerations such as the use of diaphragm seals etc., the approach shall be as specified in section 1 0 . 0 of this specification. The minimum material requirement for transmitter bodies and all wetted parts shall be 3 1 6 stainless steel. The material shall be upgraded t o suit the process conditions and any specified requirements such as corrosion resistance t o the NACE code etc. All field items shall be certified for use in the hazardous area and weatherproof t o IP65 minimum.

11.6

Installation Notes 11.6.1

All internally mounted devices such as floats and displacers shall be installed in stilling wells and shall be removable without draining the tank. Retention and retrieval devices shall be installed in case of detachment of the float or displacer.

11.6.2

The minimum flange size o n the tanks shall be 2-in. 3001b rated. Larger flanges and higher ratings shall be installed as necessary

Enginesting Group SpmCBtbn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

1 1 3 o f 163

for the process conditions and equipment loads. Flange finish and gaskets shall be in accordance w i t h the tank specification. 11.6.3

The system shall be installed in accordance with the requirements o f the Engineering Group Specification entitled "Instrument Installation" (Number 0 1 5-JH-I 9 0 8 ) and any applicable special notes contained in the "Level Measurement " section 1 0 . 0 of this specification. All instruments shall be provided with isolation valves t o enable removal for maintenance without tank drainage.

1 1 . 6 . 4 The measurement sensors shall be placed clear of all incoming and outgoing process f l o w penetrations, mixers or distributors and any possible eddy currents in the fluid etc. 11.6.5

11.7

The Contractor shall provide at each tank a junction box with a telephone jack connection for a portable telephone handset. These shall connect into the control room telephone exchange system.

Performance Reauirements 1 1.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o tank gauging systems only and shall not in any w a y replace or reduce the general QAIQC requirements.

b.

The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality o f the product: 1.

A check of all materials o f construction by crosscomparing the goods, the material test certificates and the data sheets and Drawings.

2.

A check o f the dimensions o f the finished instruments against the Drawings supplied for the Contract and approved by the Company.

3.

A check of the instrument and all accessories in accordance with this specification and the data sheets and Drawings.

4.

Full testing of the instrument in accordance this specification, Approved Manufacturer's additional QAIQC procedures and the approved test and inspection plan.

Engineehg Group Specjfica&n

11.7.2

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

1 1 4 o f 163

5.

A check on the nameplate data in accordance w i t h this specification and the data sheets and Drawings.

6.

A check o n the painting and protection and general suitability for the environment.

7.

A check o n the tagging in accordance with specification and the data sheets.

this

Testing a.

The pressure enclosures shall be hydrostatically tested before assembly at 1.5 times the rating of the flanges.

b. The instrument shall be calibrated w i t h a fluid having the same properties as the process fluid. c.

11.7.3

The instrument shall be pressure tested as an assembly at no greater than 1.5 times the rating of the flanges, but this figure shall be reduced if there is a design restriction on pressure on any component. If such restrictions exist, this fact shall be clearly marked o n the instrument in the English and Arabic languages.

Documentation All the certification for each instrument or group of instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum: a.

Completed Test and Inspection Plan.

b.

Material certificates and component certificates

c.

NDT certificates.

d.

Weld procedures and qualifications.

e.

Pressure test certificates.

f.

Test and calibration certificates.

g.

Hazardous area certificates.

h.

As-built Drawings as necessary.

11.8.1

General information for production of the nameplate data is given in section 4.7 of this specification.

11.8.2

For level instruments the following additional information is required:

.

a.

Body material

b.

lnternals material.

c.

Rating of connecting flanges

d.

Test pressure of complete instrument.

12.0 LOCAL PNEUMATIC CONTROLLERS 12.1

Scooe of Local Controller S ~ e c i f i c a t i o n This specification details the requirements for pneumatic controllers used for direct control of process variables o n the Facility.

12.2

Pneumatic Controller T v ~ e sand Selection 1 2.2.1

General Local controllers shall normally be o f the pneumatic receiver type. They shall be capable of controlling a process variable via a valve or other final element, by providing a 0 . 2 t o 1.0 barg (3 t o 1 5 psig) output lor some other range as determined by the requirement of the final element). The output shall be related t o the comparison between the received process variable measurement 1 a signal of 0 . 2 t o 1 . 0 barg ( 3 t o 1 5 psig), usually from a local transmitter) and the controller set point. The set point may be applied locally at the instrument, or when required b y the P&ID by use of an autoiremote switch, as a 0 . 2 t o 1 . 0 barg 13 t o 1 5 psig) signal from a remote source.

12.2.2

Local Pressure Controllers a.

Pressure controllers shall be specified as follows: 1.

T w o term, proportional and integral.

2.

Proportional band 0 t o 2 5 0 % for gas, 0 t o 5 0 0 % for liquid control.

Engineering Group

01 5~JH-1903

spec&atbn

b.

12.2.3

Date

1

15-9-94

1 1 6 o f 163

3.

External auto-manual station w i t h bumpless transfer facility.

4.

Reset wind-up prevention.

Combined transmitter/controller systems may be offered for Company approval when the service conditions are suitable for standard capsules.

Flow controllers shall be soecified as follows: 1.

T w o term, proportional and integral.

2.

Proportional band 0 t o 500%.

3.

External auto-manual station w i t h bumpless transfer facility.

4.

Reset wind-up prevention.

Local Level Controllers a.

b.

12.2.5

Sheet

Rev

Local Flow Controllers a.

12.2.4

Specification Number

Level controllers shall be specified as follows: 1.

T w o term, proportional normally used).

and

integral

2.

Proportional band 0-100%.

3.

External auto-manual station with facility.

4.

Reset wind-up prevention.

(integral

bumpless transfer

Combined transmitter/controller systems may be offered for Company approval when the service such as tank heating upto 300" C (572" F) range.

Local Temperature Controllers a.

not

Temperature controllers shall be specified as follows: 1. Three term, proportional, integral and derivative.

2.

Proportional band 0 t o 2 5 0 %

Engineering Group

Specification Number

Spmmtion

b.

01 5-JH-1903

Rev

Date

1

15-9-94

Sheet

117of 163

3.

External auto-manual station w i t h bumpless transfer facility.

4.

Reset wind-up prevention

Combined transmitter/controllers of the liquid or gas filled type may be offered for Company approval for simple services such as tank heating up t o 300°C (572°F) range.

12.3 Sizina and Ranaina Reauirements 12.3.1 The calibrated range of the controller shall be the same as the range selected for the associated transmitter. The span shall be selected so that the range accounts for at least 5 0 % of the span. 12.3.2

The scale shall be graduated t o the same characteristic as the transmitter output unless external signal conditioners are indicated on the P&ID .

12.4 Desian and Construction

12.4.1

General Local controllers shall be o f large case design with lockable front. They shall be mounted o n a 2-in. instrument stand or rear flange mounted. The movement shall be of nozzle and flapper motion or force- balance type, integral air supply and output gauges shall be fitted. Indicating scales shall be white w i t h black numerals. Units and multiplying factors shall be marked. Auto-manual switch shall be external. Set-point adjustment may be external or internal according t o the application. Auto-manual switch may be substituted for remotelbalancelautolmanual when indicated o n the P&ID. An indicator shall be provided for the remote signal. The wetted parts shall be 3 1 6 stainless steel (preferred) or bronze. The signal output shall be 0 . 2 t o 1.0 barg ( 3 t o 15 psig). The action shall be reversible. The supply air pressure shall be 1 . 4 barg ( 2 0 psigl. Air connections shall be 114-in. NPT

Engineering Gmup

Specification Number

Rev

Date

015-JH-1903

1

15-9-94

spmmiion

Sheet

1 1 8 0 1 163

h. The controller shall indicate set point, measurement and output. 12.4.2

Combined Pressure TransmitterIControllers Combined systems for direct pressure control shall only be used when the range is suitable for the Approved Manufacturer's standard capsule. The capsule shall be direct mounted in the controller. All wetted parts shall be stainless steel 3 1 6 as a minimum. All other features are as "controllers."

12.4.3

Temperature Controllers (See Section 12.2.5) a.

Filled system temperature controllers shall be capillary type with AlSl 3 1 6 stainless steel bulb, capillary and capillary armour which shall be PVC coated.

b.

Preferred capillary lengths are 3 m ( 1 0 ft.) and 1 0 m ( 3 0 ft.).

c.

Capillary tubing shall be supported throughout its entire length.

d.

Thermowells shall be used for all temperature detecting elements and shall be constructed from 3 0 4 stainless steel, minimum w i t h other materials t o suit process requirements.

e.

The thermowells shall follow the same requirements as those specified in section 9.0 o f this specification. 2-in. flanges may be used if necessary.

12.5 Installation Notes 12.5.1

The instruments shall be installed in accessible positions, between 1.2 and 1.6 m (4 and 5'1, ft.1 above grade or a fixed olatform.

11.5.2

Sun shields shall be provided.

12.6 Performance Reauirements

12.6.1

Quality Control (QCI a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o pressure instruments only and shall not in any w a y replace or reduce the general QAIQC requirements.

Specification Number

Engineering Gmup Sp&mtbn

Rev

Date

1

15-9-94

01 5 - ~ ~ ~ 1 9 0 3

Sheet

119 of 163

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check of the instrument and all accessories in accordance with this specification and the data sheets and Drawings.

2.

Full works calibration and issue of test and calibration certificate.

3. A check o n the nameplate data in accordance with this specification and the data sheets and Drawings.

12.6.2

4.

A check on the painting and protection and general suitability for the environment.

5.

A check on the tagging in accordance with specification and the data sheets.

this

Documentation The following data shall be available at final inspection:

12.7

a.

Completed test and inspection plan.

b.

Material certificates and NACE certificates where required by Contract documents

c.

Instrument test and calibration certificate.

Nameolate Data General information for production of the nameplate data is given in section 4.7 of this specification. Information for tagging of the thermowell is given in section 9.0 of this specification.

13.0 SPEED MEASUREMENT 13.1 Scooe of Soeed Measurement Section This section details the measurement of shaft rotational speed of equipment t o be installed at the Facility in Kuwait. 13.2 Soeed Measurement Instruments Tyoe and Selection 13.2.1

Standard System Rotational speed for indication at normal levels of accuracy shall be measured b y a field-mounted proximity sensor or magnetic

Engjneering Gmup

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Specjficatbn

Sheet

1 2 0 o f 163

pick-up, arranged t o detect the presence o f one or more indicators o n the rotating shaft. A control room-mounted integrator, scaled in accordance with the number of indicators, shall transmit the rotational speed as a 4 - 2 0 ma signal scaled in RPM t o the DCS, ESD or interlock system. Display and alarm outputs shall be developed in these downstream systems. 13.2.2

Alternative Systems Other types of system may be offered for Company approval if the system offers an equal standard of integrity and reliability.

13.2.3

Integration w i t h Monitoring Systems Where rotational speed measurement is specified as part of an overall equipment monitoring system, the Contractor shall ensure that the selected system is compatible w i t h the equipment installation and signal monitoring requirements.

1 3 . 2 . 4 Speed Control Where rotational speed is detected in order t o apply a feedback speed control t o the rotating equipment, the speed measurement system shall be selected t o operate in conjunction with the speed control device t o give the required level o f accuracy. 13.2.5

Vibrating Reeds Vibrating reed sensors shall not be used

13.3

Sizina and Ranaina Reauirernents 13.3.1

The display scale shall be calculated so that the maximum predicted running speed is between 6 0 % and 8 0 % of full scale.

13.3.2

The number of indicators o n the rotating part shall be selected as a maximum consistent with the repeat rating o f the field detector and the control room amplifier and integrator.

13.4 Construction Reauirements

13.4.1

Speed sensors are t o be of robust construction suitable for service o n the specific type of rotating equipment, taking into account vibration, temperature, lubricants etc.

13.4.2

Duplicate sensors, or systems as necessary, shall be supplied, allowing one unit t o be serviced while the other is on-line.

Engineering Group Speh7cation

13.5

13.6

Specification Number

Rev

01 5-JH-1903

1

Date

15~9-94

Sheet

121 of 163

13.4.3

The sensor casing shall be stainless steel. Local brackets shall be stainless steel.

13.4.4

Connecting leads shall be fully protected, as short as possible and terminated in an approved certified enclosure.

13.4.5

The sensors shall be immune from radio frequency interference.

Installation Notes 13.5.1

Detectors shall be installed in accessible positions w i t h sufficient protection t o enable freedom from damage during operation and maintenance.

13.5.2

They shall not be placed where debris from ruptured couplings, shear pins etc. can be expected t o impinge.

13.5.3

The units shall be factory installed and tested in conjunction with the equipment performance tests and connected t o the specified amplifierlintegrator.

Performance Reauirements 13.6.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o speed measurement instruments only and shall n o t in any way replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality o f the product: 1.

A check of the instrument and all accessories in accordance w i t h this specification and the data sheets and Drawings.

2.

Full works calibration and issue o f test and calibration certificate.

3.

A check o n the nameplate data in accordance with this specification and the data sheets and Drawings.

4.

A check o n the painting and protection and general suitability for the environment.

5.

A check o n the tagging in accordance specification and the data sheets.

with

this

Engineering Gmup

Specification Number

SpeCHcdb;on

13.6.2

0 1 5-JH-1903

Rev

Date

Sheet

1

15-9-94

1 2 2 o f 163

Documentation The following data shall be available at final inspection:

13.7

a.

Completed Test and Inspection Plan.

b.

Instrument test and calibration certificate.

c.

Hazardous area certificates.

Nameolate Data General information for production of the nameplate data is given in section 4.7 o f this specification.

14.0 VIBRATION SENSING 14.1 S c o ~ eo f Vibration Sensins Section This section covers the measurement o f shaft vibration sensing of equipment t o be installed at the Facility in Kuwait. 14.2 Vibration Sensinq Instruments T v ~ e and Selection Standard System Degrees of vibration shall be measured b y field-mounted eddy current transducers or piezo-electric accelerometers mounted at the detection points o n the X and Y axis of the rotating shaft. A control room-mounted integrator, scaled in accordance w i t h the limiting conditions applicable t o the specific equipment shall transmit the vibration measurement as a 4-20 m A signal t o the DCS, ESD or interlock system. Adjustable contact alarm outputs shall also be available. Alternative Systems Other types of system may be offered for Company approval if the system offers an equal standard of integrity and reliability. Integration w i t h Monitoring Systems Where vibration measurement is specified as part of an overall equipment monitoring system. The Contractor shall ensure that the selected system is compatible with the equipment installation and signal monitoring requirements.

Engineering Group SpecY?7ica&n

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

123 of 163

14.3 Sizinq and Ranqinq Requirements

The display scale shall be calculated so that the maximum predicted running vibration is between 6 0 % and 8 0 % of full scale. 14.4 Construction Reauirernents

Vibration sensors shall be of robust construction suitable for service o n the specific type of rotating equipment, taking into account temperature, lubricants etc. Duplicate sensors, or complete systems as necessary, shall be supplied, allowing one unit t o be serviced while the other is online. The sensor casing and extension shall be stainless steel. Local brackets shall be stainless steel. Connecting leads shall be fully protected, as short as possible and terminated in an approved certified enclosure. The sensors shall be immune from radio frequency interference 14.5

Installation Notes 14.5.1

Detectors shall be installed in accessible positions with sufficient protection t o enable freedom from damage during operation and maintenance.

14.5.2

The sensors shall be positioned so that electromagnetic fields close t o the equipment do not affect the reading.

14.5.3

They shall not be placed where debris from ruptured couplings, shear pins etc. can be expected t o impinge.

1 4 . 5 . 4 The units shall be factory installed and tested in conjunction w i t h the equipment performance tests and connected t o the specified amplifierlintegrator. 14.6

Performance Reauirernents 14.6.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o vibrationsensing instruments only and shall not in any w a y replace or reduce the general QAIQC requirements.

@ KOC

Specification Number

Engineering Gmup Specr%ic~hn

01 5-JH-1903

I I

Rev

1

1 1

Date

15-9~94

I 1

Sheet

124 of 163

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check of the instrument and all accessories in accordance w i t h this specification and the data sheets and Drawings.

2.

Full works calibration and issue of test and calibration certificate.

3. A check o n the nameplate data in accordance w i t h this specification and the data sheets and Drawings.

14.6.2

4.

A check on the painting and protection and general suitability for the environment.

5.

A check o n the tagging in accordance specification and the data sheets.

with

this

Documentation The following data shall be available at final inspection:

a . Completed Test and Inspection Plan. b,

Instrument test and calibration certificate.

c.

Hazardous area certificates.

General information for production o f the nameplate data is given in section 4.7 of this s~ecification. 15.0 SOLENOID VALVES 15.1

A p ~ l i c a b l eStandards

BS 2 7 5 7

15.2

Method for Determining the Electrical Insulation

Thermal

Classification

of

S c o ~ eo f Solenoid Valve Section This section details the requirements fm the application of solenoid valves in the plant when used as part of the process control or shutdown system.

I

Engineering Group Specjfication

I

Specification Number

Rev

Date

0 1 5-JH-1903

1

15-9-94

Sheet

125 of 163

1 5 . 3 Solenoid Valves T v ~ e sand Selection

I

15.3.1

I

15.3.2

I

15.3.3

I

1 5 . 3 . 4 Reset of Solenoid Valves

Valve Type Solenoid valves shall be the direct-acting type. Pilot-operated valves are not a c c e ~ t a b l e . Application of Solenoid Valves Solenoid valves shall normally be used in the air or hydraulic power line acting as the actuating device operated b y the DCS, ESD or other control system t o cause full opening or closing of pneumatically or hydraulically powered valves. Solenoid Valves in Process Lines Solenoid valves shall not be used directly in process lines for ESD service. Any other use of solenoid valves in process lines requires Company approval. For cases where a solenoid valve may be suitable (e.g., tightness testing or sample injection systems using clean gases which are non-corrosive and nongumming t o the valve or its seals), the Contractor shall submit full details for Company approval o f the proposed application.

a.

Automatically re-setting solenoid valves shall be used for all applications except where "manual reset" is indicated on the P&ID.

b. Data sheets shall clearly state whether the reset function shall also action an override when the solenoid is not energised, i.e., reset and override. Tamper-proof reset shall be specified in all cases where an override for test purposes cannot be tolerated for safety reasons. Where not specified, tamper-proof valves shall be supplied.

I

15.3.5

Solenoid Valves Fitted t o Control Valves When a solenoid valve is fitted t o a control valve with positioner, the solenoid valve shall be fitted in the line between the positioner and the actuator. The solenoid valve shall not be in the signal line except where the purpose is t o inject a preset pneumatic signal.

15.3.6

Number of Ports Three-port solenoid valves shall be used for single-acting springreturn actuators, five-port valves shall be used for double-acting actuators.

Engineering Group Specricicadion 15.3.7

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

126 of 163

Solenoid Valves for Venting Service For venting both sides o f a double-acting actuator (e.g., t o enable manual override), t w o three-port valves shall be used.

15.4

Sizina and Ranaina Reauirements 15.4.1

Sizing for Speed of Operation The minimum solenoid valve size used shall have 114-in. NPT connections and a 6-mm (114-in.) orifice. The Contractor shall not assume that this is adequate t o achieve the required speed of operation without verification o f each case taking into account the completed installation o f actuated valvelconnecting tubelsolenoid valvelexhaust arrangement.

15.4.2

Sizing for Process Service In cases where the Company has approved the use o f a solenoid valve for direct process duty, each application shall be sized against the operating conditions.

15.5

Construction Reauirements 15.5.1

General Solenoid valves shall be direct-acting, spring-return type and shall be robustly constructed for heavy industrial use. The coil and spring shall be selected t o provide ample operational power t o position the valve stem correctly under all conceivable service conditions. An external earth stud shall be provided.

15.5.2

Design Rating The design pressures requirements):

shall

be

as

follows

(minimum

Operating

Mechanical

Pneumatic Service

8.5 barg ( 1 2 5 psig)

1 2 . 0 barg ( 1 7 5 psig)

Hydraulic Service

(to be according t o individual requirements but not less than the blocked-in pump head)

Processes Service

(to be according t o service requirements but not less than 1.5 x process design figure)

Engineering Group SpMcation 15.5.3

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

127 of 163

Coil Rating Coils shall be rated for continuous operation when connected t o the electrical supply stated in the Engineering Group Specification entitled "Instrument Engineering Basic Data" (Number 0 1 5-JH-1901). The temperature must not rise t o more than 70°C ( 158"F), (or the coil service rating if lower) when used at the ambient conditions prevalent at the Facility and with the sun shielding and heat dissipationicooling arrangements provided by the Contractor.

15.5.4

Coil Insulation Coil insulation shall be Class A t o BS 2 7 5 7 (minimum), and a surge suppression device shall be fitted within the terminal enclosure.

15.5.5

Terminations Integral terminals shall be provided for the termination of cabling. Flying leads extending from the coil enclosure are not acceotable.

15.5.6

Electrical Entry The electrical entry shall be I S 0 metric threaded t o M 2 0 x 1.5 mm.

15.5.7

Body Materials a.

Pneumatic solenoid valves shall be constructed of brass or stainless steel body, stainless steel trim and cast iron enclosure. Aluminium enclosures are acceptable only if fully epoxy painted.

b. All solenoid valves shall be stainless steel in cases where H2S is present in any part of the process in sufficient quantity t o warrant the need for materials t o be selected and manufactured in accordance w i t h the NACE code MR0175. This is t o enable the valve bodies t o resist the H2S that will be present in the atmosphere. c.

For process service, the body and trim material shall be suitable for the process fluid and design conditions, with 3 1 6 stainless steel as a minimum requirement.

d. The selection of seal material shall be t o the Approved Manufacturer's recommendation for the service and environmental conditions.

Engineering Group

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

spmca&n 15.5.8

Sheet

128 of 163

Lever Reset Operators Mechanical reset and test or tamper-proof reset shall be operable b y lever from a convenient position accessed from grade or a permanent platform. Pushbutton resets requiring high mechanical forces are not acceptable.

15.6 Installation Notes Supporting Solenoid valves shall be supported from the body or brackets. Supporting by the pneumatic pipework is not accepted. The valve spindle shall be vertical. Short P i ~ e w o r k The valve shall be mounted as close as possible t o the port that it controls. Exhaust Screen Each exhaust port shall incorporate a silencerisand screen, placed so that it shall not be affected b y windblown dirt or sand. Exhaust ports shall not be commoned. Unused ports shall be screened or plugged. The use of silencers and sand screens shall not detract from the attainment o f stipulated valve closure speeds when in ESD service.

15.7

Performance Reauirements 15.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o solenoid valves only and shall n o t in any w a y replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check of all materials of construction b y crosscomparing the goods and the data sheets and Drawings.

2.

A check o f the dimensions o f the finished solenoid valves against the Drawings supplied for the Contract and approved by the Company.

OKOC

Engineering Group SpMCdtion

15.7.2

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet 129 of 163

3.

A check of the instrument and all accessories in accordance w i t h this specification and the data sheets and Drawings.

4.

A check on the nameplate data in accordance w i t h this specification and the data sheets and Drawings.

5.

A check on the painting and protection and general suitability for the environment.

6.

A check o n the tagging in accordance w i t h specification and the data sheets.

this

Testing The solenoid valves shall be tested during manufacture in accordance with Approved Manufacturer's quality control system.

15.7.3

Documentation All the certification for each instrument or group o f instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum: a.

Completed test and inspection plan.

b.

Certificate of works test and conformitv.

c.

Hazardous area certificates.

General information for production of the nameplate data is given in section 4.7 of this specification. 16.0 SIGNAL CONVERTORS 16.1 S c o ~ eof Siqnal Converter Section This section details the requirements of signal convertors for use in signal transduction and manipulation of pneumatic and electronic signals used in instrument control loops. 16.2 Siqnal Converters Type and Selection 16.2.1

Current t o Pneumatic Conversion WP) Conversion of a control room 4 - 2 0 m A control signal t o a 0.2 t o

Engineering Group SpeaZcahn

Specification Number

01 ~ ~ J H - I ~ o ~

Rev

Date

1

15-9-94

Sheet

1 3 0 o f 163

1.0 barg ( 3 t o 1 5 psig) pneumatic signal shall normally be b y use of a 2-wire loop powered IIP convertor. For control valve service in non-vibrating applications, and if approved b y the Company, EIP positioners (where the signal conversion is an integral part of the valve positioner) may be used. 16.2.2

Pneumatic t o Current Convertors (P/I) Conversion of a field pneumatic signal for transmission t o the control room as an electronic signal shall be b y use of a 2-wire loop powered PI1 convertor.

16.2.3

Miscellaneous Convertors and Conditioners Field-mounted devices shall be used where depicted o n the P&ID for signal processing such as square root extraction, high and l o w selection, multiplying and delay services.

16.3

Sizina Reauirements The pneumatic output flow rate from convertors shall be checked against the maximum air requirement o f the user. Pneumatic relays and boosters shall be used as necessary t o ensure an adequate supply o f air. Current t o pressure (IIP) and pressure t o current (Pil) convertors shall be field adjustable and ranged so that 4 - 2 0 m A corresponds t o 0 . 2 t o 1.0 barg ( 3 t o 1 5 psig), unless required otherwise by the service. Split ranges shall be accomplished b y using t w o outputs from the DCS, each scaled at 0 - 1 0 0 %. In this case, each valve will have an individual l i p convertor scaled 0 . 2 t o 1 .O barg ( 3 t o 15 psig). Where split range control using one electronic output is required eg. 0.2 t o 0 . 6 barg ( 3 t o 9 psig) and 0 . 6 t o 1 . 0 barg (9 t o 15 psig) signals t o each valve respectively, one IIP convertor shall be used and the split ranging shall be carried out at the positioners. Other ranges may be specified w i t h the agreement of the Company.

16.4

Construction Reauirements 16.4.1

IIP Convertors

Engineering Group Specification

Specification Number

01 ~ - J H - I ~ o ~

Rev

Date

Sheet

1

15-9-94

131 of 163

4 - 2 0 m A 2 4 VDC.

ln~ut Output

1

0.2 t o 1 . 0 barg ( 3 - 1 5 psig). I

Air Supply

1

1.4 barg ( 2 0 psig)

I Electrical Connections 1 2 0 m m x Body Material

I Mountina Painting

1.5 I S 0

1

Zinc die cast

I 50-mrn (2-in.) voke

I EPOXY

1

The units shall be weatherproof t o IP 6 5 minimum and certified for the electrical area classification. P/I Converters Input

0.2 t o 1 .O barg (3-15 psig).

Output

4-20 m A 2 4 VDC

Air Supply

1.4 barg ( 2 0 psig)

Electrical Connections

2 0 m m x 1.5 I S 0

Body Material

Zinc die cast

Mountina

5 0 m m (2-in.) voke

I Painting

1 Epoxy

I

The units shall be weatherproof t o IP 65 minimum and certified for the electrical area classification. 16.5

Installation Notes 16.5.1

I/P convertors used w i t h final control elements such as control valves, shall be mounted away from the valve o n 50-mm (2-in.) pipe t o avoid possible malfunction of the unit caused by vibration.

16.5.2

All convertors shall be piped up using materials in accordance w i t h the Engineering Group Specification entitled "Instrument Installation" (Number 0 1 5-JH-1908).

16.5.3

Convertors shall be mounted vertically, supported from brackets and not by the pipework. A 50-mm ( 2-in.) diameter gauge shall be supplied w i t h all l/P convertors t o indicate the output.

1 6 . 5 . 4 Discrete pneumatic components used for field signal conditioning and manipulation shall be assembled o n a chassis mounted in a

Engineering Group Sp&cdhn

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

15-9-94

1 3 2 of 163

protective box, or mounted o n a substantial plate and a cover provided. 16.5.5

Sun shielding is required for all convertors.

16.6 Performance Reauirements 16.6.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o signal convertors only and shall not in any w a y replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: A check of the dimensions o f the finished items against the Drawings supplied for the Contract and approved by the Company. A check o f the equipment and all accessories in accordance with this specification and the data sheets and Drawings. Functional testing of instruments in accordance w i t h this specification, Approved Manufacturer's additional QAIQC procedures and the approved test and inspection plan.

A check on the nameplate data in accordance with this specification and the data sheets and Drawings. A check o n the painting and protection and general suitability for the environment. A check on the tagging in accordance s ~ e c i f i c a t i o nand the data sheets.

with

this

1 6 . 6 . 2 Testing Instruments shall be function tested and calibrated. 16.6.3

Documentation All the certification for each instrument or group of instruments shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum:

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a.

Completed Test and Inspection Plan

b.

Hazardous area certificates

16.7 Namedate Data General information for production of the nameplate data is given in the section 4.7 o f this specification.

17.0 POSITION SWITCHES 17.1 Scooe of Position Switches Section 17.1.I This section details the design and application o f all switches installed t o detect the limit or intermediate position of valve stems, dampers, safety devices or other items requiring an electrical transmission of a fixed position. This specification shali be applicable t o switches o n all equipment and packages t o be installed at the Facility in Kuwait.

17.1.2 This section does not detail position transmitters used for continuous feedback of the position of a moving part.

17.2 Position Switches Tvoe and Selection 17.2.1 Switches

shall be of the inductive proximity type, communicating with an IS amplifier mounted in the main control block auxiliary room. The amplifier shall give volt-free contact outputs t o the DCS and ESD equipment as necessary.

17.2.2 Conventional contact-type mechanical action limit switches shall only be used in specific applications when approved by the Company. When used, they shall be in mechanical fail-safe mode, i.e., the spring action shall push the follower toward the actuation point (inverse cam or hole etc.), so that a stuck switch cannot be interpreted as a safe position. Such switches shall use environmentally sealed switch contacts o f noble metal suitable for low-energy signals.

17.2.3 Proximity switches shall be purchased as sets ready mounted and terminated in a sealed enclosure containing the switch adjustment and actuation system. The only exposed part shall be the actuation shaft emerging from a sealing gland at the rear of the box. This shall be driven b y the moving part which is t o be position detected.

17.2.4 External

proximity switches may be used when space restrictions preclude the use of enclosed type, with approval from the Company, and provided that they can be located in a

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position safe from the possibility of mechanical damage during operation and maintenance activities. Such switches shall be of flying lead type, terminated in an IP 65 enclosure adjacent t o the switch. The length of the flying lead shall be minimised, and shall be protected throughout its length.

17.3

17.2.5

The actuation element shall be an unambiguous part of or addition t o the moving part of the valve etc., chosen t o be free o f accidental corruption by tools etc.

17.2.6

The adjustment facilities shall be locked after setting b y drilling and pinning.

Svstem Reauirements The switch system consists of the field proximity device and the control room amplifier. These items shall be selected w i t h matching characteristics in regard t o the performance and the IS certification requirements. The amplifying devices shall be of rack or de-mountable rail-mounted type and shall be installed in the standard interface cabinets in the control block auxiliary room.

17.4

17.5

Construction Reauirements 17.4.1

The switches shall be the Approved Manufacturer's standard units, certified for use in an IS circuit. They shall be mounted in boxes sealed t o a minimum standard IP65 constructed of reinforced polyester, stainless steel or cast iron. Terminals within the box shall be blue for IS circuits. Electrical entries shall be size M 2 0 1.5 ISO.

17.4.2

All external linkages, brackets, mountings etc. shall be stainless steel w i t h stainless steel fasteners.

Installation Notes 17.5.1

All equipment shall be positioned w i t h due regard t o access for maintenance. Wherever possible, the switches shall be mounted away from any vibrating equipment, the coupling system being designed t o suppress transmission o f harmful vibrations.

1 7 . 5 . 2 Where individual externally mounted proximity switches have been allowed, the actuating element is preferably a ferrous or magnetic part fastened securely t o a stainless steel moving part. Where this is not possible, the extension o f the actuating part shall be sufficient t o ensure that accidental actuation of the switch is not possible under all conditions, including movements caused b y wear etc.

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Performance Requirements 17.6.1

Quality Control (QC) a.

Quality Control shall be as detailed in the Contract. This section states the minimum additional requirements related t o position switches only and shall not in any way replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product:

17.6.2

1.

A check o f the switch and all accessories in accordance with this specification and the data sheets and Drawings.

2.

A check o n the nameplate data in accordance with this specification and the data sheets and Drawings.

3.

A check o n the tagging in accordance specification and the data sheets.

with

this

Documentation The following data shall be available at final inspection:

17.7

a.

Completed Test and Inspection Plan.

b.

Hazardous area certificates.

N a m e ~ l a t eData General information for production o f the nameplate data is given in section 4.7 of this s ~ e c i f i c a t i o n .

18.0 FLAME DETECTION 18.1

S c o ~ eof Flame Detection Svstem This section covers the design and application of flame detection devices used for verifying the presence of flame at the burner or pilot of fired equipment installed at the Facility in Kuwait.

18.2

Flame Detection T v ~ e sand Selection 18.2.1

Main Burner Flame Detection a.

Ultraviolet (UV) detectors of the self-checking type shall be

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used for gas flames.

18.2.2

18.2.3

b.

Combined element detectors, (UV with flicker or infrared) shall be used for all oil or dual fuel systems.

c.

In cases where the fuel is of a type where the detection signal o f the systems noted may be of insufficient strength t o guarantee detection under all firing loads and load combinations, additional detectors or alternative types shall be subject t o Company approval.

d.

lonisation flame rod detectors shall not be used for main flame detection.

Pilot Flame Detection a.

lonisation detectors of the flame rod type shall be used for pilot detection.

b.

A n earth electrode shall be installed t o earth the flame in case o f liftoff. This can be omitted if the design ensures that flame liftoff cannot occur under any conditions.

Intermittent Pilot Service Where the pilot is discontinued after the establishment of main flame, the pilot flame rod may be omitted. A single UV-type detector may be indicated on the P&ID. When this system is used, the detector shall be so positioned that it views the pilot and main flames at the same setting. The logic system must prove the pilot burner valve is closed, and stays closed, after the main flame establishment period before accepting the main flame signal.

18.2.4

Multiple Detector Systems a.

Where particular requirements for either increased integrity (voting 2 from 2 or 3 from 3 ) or increased availability (voting 1 from 2 or 2 from 3 ) multiple detectors are indicated on the P&ID, w i t h details of the vote required.

b. These requirements shall not be confused w i t h the voting systems used in cases where multiple detectors are selected b y Contractor in applications where adequate flame signal strength is not available at one detector sighting.

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SpecjficaliJn 18.3 Svstern Reauirements Scope

Flame detection equipment shall comprise a flame detection sensor and a flame detector amplifieriswitch unit. Self-checking Flame viewers shall be of the automatic self-checking type having the rotating shutter interlocked w i t h the output t o produce a continuous signal of the true flame state. Discrimination a.

The flame sensor shall be mounted o n the burner front or other suitable location where it is able t o v i e w the intended flame, whilst discriminating from other flames as necessary.

b.

It is a requirement that where a continuous pilot is used, the main flame viewer shall not see the pilot flame.

c.

A main burner viewer shall n o t see the flame of any other burner or pilot.

d.

A pilot viewer may see its associated main flame but no other.

Flame Amplifier a.

The flame amplifier shall be mounted in the interface rack in the main control block auxiliary room. The use o f systems that require field amplification or relay stations shall require Company approval.

b.

The amplifier relay shall have t w o noble metal changeover output contacts, one normally open and one normally closed.

c.

The amplifier shall have signal output terminals suitable for the connection of a flame strength indicator, or for permanent or future connection t o the DCS input system for display.

18.4 Construction Reauirements 18.4.1

Enclosure a.

The flame detector sensor shall be o f rugged, weatherproof construction and have a flange or substantial threaded union

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mounting t o the tapping nozzle. b. The enclosure shall be certified for use in the hazardous area surrounding the heater location. Systems requiring continuous air purge for certification purposes are not permitted. 18.4.2

Mounting a.

Viewer-type sensors shall be mounted o n adjustable, lockable swivel joints t o effect accurate alignment. This requirement can be waived if the Company is satisfied that the burnerlviewer arrangement is of completely standard proven design where the fixed alignment is ensured.

b. There shall be a coolinglpurging air connection o n the nozzle. Air shall only be connected if stipulated b y the Company. 18.4.3

Redundant Viewers If redundant viewing-type sensors are used, the tapping nozzle shall have a full-bore isolation valve incorporated t o enable isolation of the tapping when the detector is removed for cleaning.

18.5

18.6

Installation Notes 18.5.1

All detectors shall be installed w i t h sufficient cable slack t o enable full withdrawal without disconnection.

18.5.2

Nozzle lengths shall be sufficient t o carry the viewer head clear of the burner hot zone. Heat insulators shall be fitted as necessary t o ensure the instrument does not rise above the lower of its design temperature or 70" C ( 158°F).

Performance Reauirernents 18.6.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o flame detectors only and shall not in any w a y replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check of the instrument and all accessories in accordance with this specification and the data sheets

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and Drawings. 2.

Full works calibration and issue of test and calibration certificate.

3. A check o n the nameplate data in accordance w i t h this specification and the data sheets and Drawings.

18.6.2

4.

A check o n the painting and protection and general suitability for the environment.

5.

A check on the tagging in accordance with s ~ e c i f i c a t i o nand the data sheets.

this

Documentation The following data shall be available at final inspection: a.

Completed test and inspection plan.

b.

Instrument test and calibration certificate.

c.

Hazardous area certificates.

18.7 Namedate Data General information for production of the nameplate data is given in section 4.7 of this specification. 19.0 MISCELLANEOUS INSTRUMENTS 19.1 A ~ ~ l i c a b Standards le BS 5 5 0 1

Electrical Apparatus for Potentially Explosive Atmospheres

19.2 S c o ~ eof Miscellaneous Instrument Section 19.2.1

This section covers the requirements for miscellaneous instruments t o be used on equipment t o be installed at the Facility in Kuwait.

19.2.2

Miscellaneous instruments are defined as: a.

Field items which are identified by a tag number on the P&ID, but are of a type not specifically covered b y the other sections within this specification (refer t o the Contents page, page 2).

b.

Items provided by a Contractor as a standard part of a packaged or proprietary piece of equipment which can

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reasonably be described as an instrument or control item. This shall apply even if the item does not appear on the P&ID and has not been allocated a tag number. 19.3 Selection 19.3.1

lnstruments classified as "Miscellaneous" under the above description may only be supplied if alternative instruments selected from the other sections of this specification will not adequately perform the required function.

19.3.2

Miscellaneous instruments shall be selected in accordance with parameters set in this specification for similar types, with respect t o power supplies and signal levels, hazardous area protection methods, finishing, weatherproofing and all pertinent requirements. All miscellaneous instruments require Company approval before selection. lnstruments not complying with the general parameters shall be rejected.

19.4 Sizinq and Ranqinq Requirements The display scale shall be calculated so that the maximum predicted operating point is between 60% and 80% of full scale. 19.5 Construction Requirements

All miscellaneous instruments shall be o f robust construction suitable for service in the stated environment and particular service conditions. They shall be of the same standard and quality as is required in this specification for similar items. Items containing electrical parts shall be certified as suitable for the hazardous area by a recognized European testing authority and be in accordance with BS 5501. Any coils, contacts etc. shall be environment free encapsulated type. Contacts shall be noble metal. Environmental protection shall be provided standard IP 65 minimum.

t o the required

Stainless steel is the preferred material o f construction. Other materials may be used if suitable for the service, and must be adequately protected t o withstand the environmental conditions, an epoxy paint finish or hot dip galvanising are acceptable systems. Cadmium plating is not accepted as a final finish. Transparent parts shall be of shatterproof glass, mechanically protected where possible.

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19.5.7

Electrical items shall have integral terminals. Flying leads are not acceptable.

19.5.8

Electrical entries shall be M 2 0 x 1.5 ISO.

19.5.9

Pneumatic connections shall be 114-in. NPT.

19.5.10 Process connections shall be 3 0 0 lb flanged (minimum) or 112-in. NPT for line-mounted and impulse-connected items respectively. 19.5.1 1 Sensors shall be immune from radio frequency interference. Installation Notes Installation shall be carried out in accordance with the Engineering Group Specification entitled "Instrument Installation" (Number 015-JH-1908) as related t o similar instruments described in this specification and the particular requirements of the specific instrument. Performance Reauirernents 19.7.1

Quality Control (QC) a.

QC shall be as is detailed in the Contract. This section states the m i n i m u m additional requirements related t o miscellaneous instruments only and shall not in any way replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items in addition t o those found necessary b y the Approved Manufacturer t o ensure the quality of the product: 1.

A check of the instrument and all accessories in accordance with this specification and the data sheets and Drawings.

2.

Full works calibration and issue of test and calibration certificate.

3.

A check o n the nameplate data in accordance with this specification and the data sheets and Drawings.

4.

A check on the painting and protection and general suitability for the environment.

5.

A check o n the tagging in accordance with specification and the data sheets.

this

6.

19.7.2

Additional checks commensurate w i t h the type of instrument related t o similar instruments in this specification, e.g., welding, NDT etc.

Documentation The following data shall be available at final inspection: a.

Completed Test and Inspection Plan.

b.

Instrument test and calibration certificate.

c.

Hazardous area certificates.

d.

Other documents commensurate w i t h the type of instrument related t o similar instruments in this specification.

19.8 Nameplate Data General information for production of the nameplate data is given in section 4.7 of this specification. 20.0 ANALYSERS 20.1 Applicable Standards API 5 5 0 Part 2

Manual o n installation o f Refinery lnstruments and Control Systems, Process Stream Analysers

20.2 Scope of Analvsers Section This section details the requirements for lnstruments and systems t o be used for the analysis of process fluids and effluent at the Facility in Kuwait. 20.3 Analvzer T v ~ e sand Selection 20.3.1

Analyzer types shall be selected for their specific applications for process requirements. Where the type has not been specified by the Company, the Contractor shall propose a suitable system for approval.

20.3.2

Analysers shall be installed in a ventilated analyzer house except where the Company agrees that a particular instrument shall be fitted in the field or in a field shelter. Exceptions t o this are analysers w i t h an intrinsic fast loop requirement such as for the analysis of oxygen content of furnace flue gases, power of hydrogen (pH) analysers for alkalinitylacidity of liquids, density and conductivity analysers. These types of analysers shall be located close to the sample point.

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20.4

20.3.3

For analysers o n critical duties, e.g, on safety systems, consideration shall be given t o redundancy techniques. Detailed proposals shall be submitted t o the Company for approval in all cases where an analyzer output is vital t o a safety function.

20.3.4

Analysers shall be used on single streams unless multi-stream applications are approved by the Company.

Sizina and Ranaina Reauirements The range selected shall cover the full scale of variation possible o n the variable subjected t o analysis. The normal operating point shall preferably be at the midpoint of the scale. Indicating and control functions shall be carried out b y the plant DCS. Wherever possible, serial data links (e.g., RS 4 2 2 etc.) shall be used t o transmit analytical data t o the DCS; isolated 42 0 m A signals shall also be made available.

Where a separate safe area interface module is an essential part o f the system, this shall be in the unmanned auxiliary room in the control block. All necessary outputs displayed o n the interface unit must be presented as repeats t o the DCS. For ease of maintenance, analysers shall have also have local indicators wherever practicable. Local panel display facilities shall be provided where the individual indication is not visible at the analyzer. For instruments requiring field operator attention, e.g., those in the analyzer house, test displays, alarms etc. shall be located in a readily accessible position for maintenance. Purge alarms shall be readily visible t o the operator. Analysers o n closed loop control through the DCS shall operate through a cascade loop. The range o f set-point adjustment of the slave controller shall be restricted within preset high and l o w limits. Alarms shall be actuated (after a brief time delay) t o warn the DCS operator if the output from the analyzer attempts t o exceed these limits. 20.5

construction Reauirements 20.5.1

General a.

All analysers shall be microprocessor based and be provided with self-diagnostic and calibration functions.

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Analysers shall be suitable for the specified environmental exposure. All parts exposed t o the process shall be suitable for the pressure and temperature and resistant t o the specified fluid, and will be constructed of stainless steel grade 316 as a minimum. Alternative materials such as Monel, Hastelloy or lnconel shall be supplied where necessary. All components exposed t o process fluid o n sour service shall comply with the requirements of NACE MR0175. Analysers shall be certified for use in hazardous areas classified Zone 1, as a minimum. Non-certified analysers may be installed in certain services when the analyzer is t o be mounted in a safe area, or an analyzer house made safe b y purging, gas detection and electrical supply isolation procedures. Such applications are subject t o Company approval and shall only be allowed when the composition or amount of the sample inside the analyzer is insufficient t o produce an explosive or ignitable mixture in the event of component failure or leakage. Analyzer power supplies shall be 2 4 VDC or 1 1 0 V +/l o % , 5 0 HZ + / - 2 % . Sensitivity shall be +/- 112% of span, with reproducibility + / - 1 % or better. Analyzer outputs shall be 4 - 2 0 m A wherever possible and shall be linear over the specified range. Alarm or other digital outputs shall be by volt-free contact, on segregated terminals suitable for IS circuits. Analysers requiring manual restart after a power failure shall be protected from shutdown b y a power failure of 4 seconds or less. Routine maintenance shall be possible without disturbing the operation or location of the analyzer, and shall not be more frequent than once every 7 days. Analysis times shall be as short as possible, and in all control applications including alarm and protective systems, the permissible analysis times shall be agreed t o by the Company.

1

Engineeting Group SpecHcation 20.5.2

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Sampling Systems Sampling systems shall comprise all equipment necessary t o provide the analyzer with a continuous sample representative o f the process stream t o be measured. The sample shall be retained within temperature and pressure conditions specified for the analyzer. The delay time between the sample being withdrawn from the process and being made available t o the analyzer shall be as short as possible and shall not exceed five minutes for monitoring applications and three minutes for control applications. Shorter periods shall be provided according to the process requirement. Samples shall be drawn from a point in the process where stream conditions are such that the minimum of sample conditioning is necessary. This requirement is subject t o acceptable process, sampling and analysis lag. For direct process connected analysers, fast sample loops shall be provided. Where process conditions do not favour self-powering, the sample shall preferably be driven by a sample pump located close t o the sample takeoff point. Pumps shall not be placed inside analyzer housings unless this is demanded b y control considerations or other sampling difficulties. Circulating loops may be used, returning the sample t o a lower pressure point in the same process system. These may be used in the bypasses t o pumps, across vessels and other process elements. Samples shall not be taken across orifice plates used for f l o w measurement. Samples may be taken across control valves provided the sample flow is too small t o affect the control application, and the pressure drop across the valve is always sufficient t o ensure an adequate sample f l o w rate. Restriction devices shall not be placed in the line t o cause a pressure drop for circulating sample takeoff. The return points of circulating and bypass samples shall be selected so that the pressure is at least 2 bar (30 psi) above the vapour pressure of the sample. Secondary fast loops, where a relatively large volume fast loop or circulating loop f l o w bypasses an analyzer and the analyzer sample is supplied b y a fast loop from this bypass, shall be used t o maintain transport velocity and reduce time lag. This method shall be used for field-mounted analysers

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only and care shall be taken t o ensure that the final sample line volume is small in relation t o analyzer sample consumption. Secondary fast loops shall only be used in the following cases: 1.

Sample conditioning equipment causes time lags

2.

To reduce the amount o f sample entering the analyzer house.

The takeoff for a secondary fast loop shall be a restriction in the primary fast loop, adjustable so that the DP can be selected t o give optimum performance. Unless a fast loop is provided, process samples shall be drawn b y probes constructed t o API RP 550, Part 2, Figures 14-2 and 14-3. For lines below 100-mm (4-in.) diameter, the length of the stub connection shall be increased so that the probe insertion is not greater than one quarter of the line diameter. Circulating loop materials, i.e., tubing from sample point t o main filter and from filter t o return point, shall be the same as the line or vessel from where the sample is drawn. The filter shall also be c o m ~ a t i b l ew i t h the line class. Analyzer loop materials, i.e., tubing and major components between the main filter and the analyzer, shall be minimum stainless steel grade 3 1 6, unless the application necessitates alternative superior materials. Sample isolating valves shall be provided near t o the analyzer, outside any housing and accessible from grade or platform. Each sample isolating valve and the ends o f each sample line shall be clearly labelled with the stream identity and analyzer tag number. Sample lines shall have drains and vents as necessary. Permanent facilities shall be provided for sample lines and analyzer flushing when sample viscosity is greater than 5 0 0 centistokes at 50°C (122"F), and other cases as may be specified in the Contract. Double block and bleed isolation shall be provided if leakage o f the flushing medium would significantly affect the measured property o f the sample.

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Sample f l o w rate through each loop, bypass and analyzer shall be indicated locally. Sample pressure (and temperature if required) at the analyzer inlet shall also be indicated locally. Liquified gas samples shall be completely vaporized immediately adjacent t o the process line sample probe, with samples being kept above their d e w point. Flue gas and other vapour samples containing a large proportion of steam or other components which need t o be condensed and removed before analysis shall be given special consideration. Lines shall not be heated or lagged (except for personnel protection) and shall be continuously sloped downwards from the process connection t o the condensate removal point. Precautions shall be taken t o prevent damage t o the analyzer and sampling components because of abnormal plant conditions, e.g., reverse flow or if there is a danger of cross contamination of process streams.

Safeguards shall be provided t o protect analysers and sampling components from high pressure, temperature or vacuum conditions resulting from malfunction of the sampling system. Relief valves and automatic shutoff systems shall be considered t o protect those components installed in a system which has a limited pressure rating, e.g., sample conditioning vessels or glass-containing components. Where shutoff is used, an automatic vent shall be used t o prevent damage due t o pressure/vacuum in a blocked in system. Relief valves and vents shall be connected t o a vent or drainage system as required. A takeoff point shall be provided o n each sample stream to enable a sample check t o be made on the analyzer. This point shall be close t o the analyzer, shall be easily accessible and arranged so that drawing off a sample does not impair analyzer operation.

y.

Facilities shall be provided for introducing test samples into the analysers. Gaseous test samples, or volatile, toxic or otherwise dangerous liquid samples shall be stored outside the housing. Introduction o f a test sample shall not cause a hazard.

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Provisions for introducing a test sample shall include containers fitted with relief valves, pressure gauges, and pressurisation facilities.

aa. Solenoid valves shall not be used directly in sample lines, and shall only be applied for switching instrument air or nitrogen t o pneumatically operated valves. ab. All hazardous samples or test gases shall be automatically disconnected by operation of these valves when a gas emergency arises in the analyzer house. 20.5.3

20.5.4

20.5.5

Flow Rates t o Analvsers a.

The total amount of flammable fluids flowing t o the analyzer shall be limited by an excess f l o w valve which shall be of the self-closing type t o prevent exceeding the limits mentioned below.

b.

Maximum f l o w rate of flammable gases shall not exceed 2 0 normal litreslhour.

c.

Liquid flow rate shall not exceed the maximum required, as specified by the Approved Manufacturer of the analyzer concerned.

d.

Flow rates exceeding the above limits require the approval of the Company.

Sample Disposal Systems a.

Samples shall be returned back into the process stream wherever possible.

b.

Hydrocarbon gases or vapours which cannot be returned t o the process shall be discharged t o a flare system or an atmospheric vent at a safe height which shall be independent o f any process vent; due regard shall be given t o the vent's influence o n the surrounding electrical area classification.

c.

Hydrocarbon liquids which cannot be returned t o the process shall be discharged into a plant hydrocarbon recovery system or hydrocarbon liquid drain pit.

Sample Conditioning a.

The removal of entrainments in liauids shall be as follows:

-

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Entrained gases shall be separated b y passing the sample through an expansion pot w i t h a l o w level liquid takeoff. Liquid entrainments (i.e., oil in water) shall be coalesced and separated by specific gravity differences. The sample point shall be carefully chosen t o eliminate as much as possible solid entrainment. Further entrainment shall be eliminated using cyclone filters, coalescing of liquid droplets or by filtration o f solids. Chemical means and drying shall be used t o remove gases or water vapour which are either not required or could affect the accuracy o f the analyzer. These methods shall include : (a) Liquid or solid chemicals. (b) Desiccants (silica gel etc.). (c) Molecular sieves,

(d) Caustic pellets. (e) Concentrated sulphuric acid The treating medium shall in no w a y affect or influence the critical properties of the fluid stream t o be analysed.

20.5.6

Field Mounting o f Analysers a.

Field mounting of analysers shall only be considered under the following conditions: 1.

When the cost o f an analyzer house is disproportionate t o the advantages gained. If this is the case, the requirements of the analyzer shall be re-evaluated.

2.

The location of the analyzer away from the tapping would result in an unacceptable time lag.

3. The construction and installation of the analyzer is such that repair and routine maintenance can only be safely effected in the workshops. b.

When the analyzer is t o be field mounted, the construction and mounting shall be fully suitable for the environmental conditions and be fully protected against rain, sandstorms

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and possible vibration from neighbouring equipment. The black body temperature under the direct sun exceeds 8 0 " C (176" F). Sun shielding shall be provided so that the instrument does not rise above the lower of the instrument design temperature or 7 0 " C (158°F). Field-mounted analysers shall be installed individually or in groups close t o their sample points and protected by simple shelters and sun shields. Where an analyzer sample contains a possible source o f toxic vapours, the analyzer shall be located in a separate freely ventilated shelter. Shelters shall be weatherproof and constructed of either metal sheet on a steel frame or flame-retardant glass fibre. Each shelter shall be fitted w i t h the following: Electric lighting. Windows Concrete base sloped w i t h a fall of 1 in 3 0 t o a drain located at least 2 m (6 ft.) from the shelter. Exit points at both ends sized for the removal of all equipment. Doors, where fitted, shall be outward opening and provided w i t h windows. The lower edge o f all shelter walls shall be at least 1 8 in. aboveground w i t h ventilation provided along the uppermost part o f the shelter roof t o ensure free circulation of air within the building. T w o or more analysers may be housed in a single shelter. This arrangement is subject t o the restrictions for allowable transport time, taking into account the distance t o sample taps. Analysers or shelters shall not be located under pipe racks, air coolers or other items o f process equipment. All power supplies t o analysers shall have a field-mounted isolating switch. The analyzer, power supply isolating switch, sample takeoff and return points and sampling system components shall be readily accessible from grade or fixed platforms. Approximate sizes and locations o f all analysers 1 shelters shall be shown o n the plot plan when this is submitted for approval.

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Sheet

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20.5.7 Analvsers in Hazardous Areas Wherever possible, analysers shall be selected having all components certified for use in the hazardous area. Where this is not possible, and with Company approval, the analyzer can be mounted in a purged analyzer house and be connected t o a safety system such that all power t o the analyzer is cut o f f in the event of a failure o f the purge system or a gas emergency. Where an analyzer house is not provided, or the instrument is in a service that requires continuous operation, the use o f an individually purged and pressurized enclosure shall be offered for Company approval. The purge control unit shall be certified, b y a recognized European Testing Authority, and the complete enclosure and its fitted analyzer and components supplied as a system by the purge unit Approved Manufacturer. Analysers which handle flammable products within nonexplosion-proof housings shall n o t only be pressurized but shall also be purged b y a continuous f l o w of dilution air t o prevent the buildup of explosive concentrations in the event of a seal failure. If inert gas is used, pressurisation only is required if i t is at a higher pressure than the sample. Depending o n the area classification, the following purge systems shall be considered. In all cases, the purge systems shall be those of a specialist proprietary Approved Manufacturer and shall be supplied complete with interlocking system, timers, alarms etc. and be fully certified for the electrical area classification, and be approved b y the Company before detailed design commences. 1.

Overpressure only - shall be 5-25-mm W G ('/,-I in. WG) with at least ten volume changes per hour.

2.

Overpressure with alarm.

3.

Overpressure with interlock.

4.

Overpressure with l o w f l o w rate interlock.

The f l o w rate shall be related t o the maximum f l o w rate of the sample system t o cover the possibility of seal failure. A purge flow rate o f four times the maximum sample flow rate shall be regarded as a safe figure. This figure may be reduced depending o n the concentration of the flammable gas necessary t o remain below the lower explosive limit.

Engineering Gmup Sp&catlon

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The purge medium shall in general be dry instrument air. Nitrogen shall be used when the lower explosive limit is difficult t o reach or the location is remote and there is no instrument air supply. Purge systems shall be interlocked w i t h all analyzer power points so that on failure of the purge, the power points are switched off. Purge systems shall be alarmed for l o w pressures in all cases. High-purge pressure alarm and low-pressure shutdown shall be considered per installation. In the event of a shutdown of the analyzer system due t o purge failure, the system shall be interlocked such that the analysers cannot be switched on until at least five volume changes have taken place. 20.5.8

Analyzer House A n analyzer house shall be provided where i t is feasible t o install several analysers in one location, and where sampling stream lag time is n o t a major consideration or can be accommodated. The type o f analyzer house required shall be indicated in the Contract documents: a.

Masonry Construction The analyzer house shall be of solidly constructed design able t o withstand blast forces from inside or outside. Internal blast relief provisions shall be included in the design. The house shall be equipped with self-closing doors w i t h closure alarm switches. The analyzer house shall be fitted w i t h a dual ( 1 0 0 % redundant) air purging /cooling system t o maintain the temperature between 1 5 and 30°C ( 5 9 and 86"F), lighting at 2 5 0 lux minimum, Ex'd' power sockets and power distribution and all facilities and safety equipment normal for an operator w o r k area. Sinks and sluices shall be provided. The house shall be fitted w i t h fire and flammable gas detectors connected t o the plant-wide system. The space allocation shall be at least l - m (3-ft.) wall space and 2.5 m3 (88 ft3) volume for each analyzer, with 3 0 % spare allocation for future expansion.

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15-9-94

Sheet

153 of 163

Wherever possible, an analyzer house shall be located in a non-hazardous area or if this is not feasible, at worst in a Zone 2 area. Construction Drawings and materials specifications for the analyzer house shall be approved b y the Company. The Drawings shall show the locations of analysers, sample conditioning systems, laboratory sample points, calibration sample containers, gas cylinders and drains. Note : The sample lines and the sample conditioning

system will probably create a Zone 2 area around the analyzer house. All test sample bottles and conditioning equipment wherever possible shall be mounted in racks outside the analyzer house in a covered, vented gallery. All hazardous sample and test lines into the building shall have an automatic and a manual isolation valve outside the building. The location of the analyzer house shall be as close as practicable t o the sample takeoff points of the relevant analysers, in order t o minimise sample transport time lag and cooling of the sample t o l o w ambient temperature. The location shall also be free from spillage of water and process liquids. The analyzer house shall be ventilated w i t h air t o keep out flammable and toxic gases, and any leakage of flammable gases andlor vapours that may occur inside the house shall be diluted t o a safe level. The f l o w o f air shall be sufficient to: (a). Dilute escaping vapours resulting from the failure of any sample line t o less than 2 0 % of the LEL. (b). Maintain the pressure inside the analyzer house at 0 . 2 5 mbarg (1110-in.WG) above that of the outside atmosphere, t o prevent ingress of that atmosphere. 11. The ventilation system shall be capable of at least 1 2 volume changes per hour t o ensure adequate dilution of the internal atmosphere.

12. The required air flow rate shall be calculated for each analyzer house based o n the above conditions and shall be submitted t o the Company for approval.

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13. Air intake t o the ventilation system shall be taken through a stack provided w i t h a rain hood and, wherever necessary, a sand filter.

14. The air shall be drawn from a non-hazardous area, and the intake duct and diameter should be sized so as t o limit the air velocity inside the ducting t o a maximum of 8 misecond ( 2 6 ftisecond). 1 5 . Gas detectors shall be provided within the ventilation ducts t o detect the presence o f any airborne flammable gases. 16. Should the analyzer house ventilation system fail or be shut d o w n due t o gas detected in the inlet duct, protective measures shall be taken against the potentially hazardous atmosphere caused by possible leakages both inside and outside the house. All analysers which cannot be switched o f f in such circumstances shall be engineered for operation in a Zone 1 environment.

17. Upon failure of the ventilation system or failure of a door t o close within a preset time, an audible and visual alarm shall be initiated in the analyzer building and in the control room.

18. When flammable gas is detected in the ventilation air inlet ducts, the ventilation system shall be switched off and isolated. 19. When flammable gas is detected inside the analyzer house but not at the inlet, the ventilation system shall be left running, but all non-certified equipment shall be switched off and isolated. 20. After a failure of the ventilation system, non-explosion proof equipment can only be switched o n when: (a). The gas detected in the house is below 2 0 % of the L.E.L ( b ) . The ventilation system has been running for a sufficient length of time for at least five air volume changes.

Specification Number

Engineering Group

Date

1

15-9-94

O I ~ - J H - ~ ~ O ~

SpMcation b.

Rev

Sheet

1 5 5 of 163

Steel Framed Building with Cladding Enclosed analyzer houses constructed of steel framing having insulated metal cladding shall incorporate all features of the masonry-built houses, including provisions for air-conditioning, purging, pressurisation gas detection.

c.

and the the and

Glass-Reinforced Polyester (GRP) Construction Enclosed analyzer houses of GRP or similar lightweight materials may be used for a limited number of analysers. The houses shall be installed o n a tiled concrete base and shall include all the features o f the masonry analyzer house including the provisions for air conditioning, purging, pressurisation and gas detection. The construction shall not be rated as blast resistant. Windows may be installed as for the ventilated field analyzer shelters. Sinks and sluices may be omitted if not required for the installed analysers. A sloping floor piped t o an external drain shall be installed. The analysers shall be installed o n floor-mounted frames and shall not be supported from the analyzer house walls. A sun shield shall be installed t o protect the GRP from direct exposure t o the sun.

20.6

Installation Notes Analysers and related equipment shall be installed in accordance with the Engineering Group Specification entitled "Instrument Installation" (Number 0 1 5-JH-1908), as modified for the special requirements o f process analysis equipment.

20.7

Performance Reauirernents 20.7.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o analysis instruments only and shall not in any w a y replace or reduce the general QA/OC requirements.

Specification Number

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01 5 ~ J H ~ 1 9 0 3

b. The test and inspection plan shall include the following items in addition t o those found necessary by the Approved Manufacturer t o ensure the quality of the product: 1.

A check of the instrument and all accessories in accordance w i t h this specification and the data sheets and Drawings.

2.

Full works calibration and issue of test and calibration certificate.

3. A check on the nameplate data in accordance with this specification and the data sheets and Drawings.

20.7.2

4.

A check o n the painting and protection and general suitability for the environment.

5.

A check o n the tagging in accordance s ~ e c i f i c a t i o nand the data sheets.

6.

Additional checks commensurate w i t h the type of instrument related t o similar instruments in this specification, e.g., welding, NDT etc.

with

this

Documentation The following data shall be available at final inspection:

20.8

a.

Completed test and inspection plan.

b.

Instrument test and calibration certificate.

c.

Hazardous area certificates.

d.

Other documents commensurate w i t h the type o f instrument related t o similar instruments in this specification.

Namedate Data 20.8.1

General information for production of the nameplate data is given in section 4.7 of this specification.

20.8.2

In addition, the analyzer systems as a whole shall be fitted with clear, dual-language labels at all isolation valves, test points, indicators, test panels, flammable gas detector test points etc. Labels outside shall be stainless steel. Inside the analyzer house, laminate or similar labels, white w i t h black legends shall be used, provided adequate allowance is made for differential expansion between the label and panel materials t o prevent cracking in service.

-

Engineering Group Speaiccation

Specification Number

Rev

Date

Sheet

01 5-JH-1903

1

159-94

157 of 163

21.0 LOCAL PANELS AND GAUGE BOARDS 21.1

S c o ~ eof Local Panel and Gauae Board Selection This section covers the design and application of all local panels and gauge boards used for assisting field operational control.

21.2

Local Panels and Gauae Boards T v ~ e and Selection 21.2.1

Centralized Control Control and monitoring shall wherever possible be via the control room DCS and its operator. The use o f local panels shall be minimised within the constraints of safe, economical control of the Facility.

21.2.2

Local Panels Where an equipment package requires t o be startedistopped in the field andlor t o have important operating statusldata relayed t o the field from the ESDIDCS systems, a local panel shall be installed adjacent t o the equipment, readily accessible from grade or a fixed platform. Such panels shall not contain logic or any components other than terminals, lamps and pushbuttons.

21.2.3

Special Panels By agreement with the Company, special-purpose local panels can be supplied. Examples are: a.

Where the field repeat and control interface is complex, a field hardened VDU operator station may be supplied, with a redundant data link t o the main DCS system. The station shall in all respects comply w i t h the requirements for the hazardous area certification and ingress protection, and be mounted in a room maintained under environmental conditions suitable for the equipment contained.

b. Where a standard piece of equipment o f proven design and performance is proposed, subject t o Company approval, discrete electronic components may be contained within the certified enclosure. Such equipment shall only be accepted when its use is intermittent and maintenance can be conducted without plant shutdown. 21.2.4

Gauge Boards Where a number of gauges are in related service, they shall be collected together o n a clearly labelled gauge board t o assist the easy, unambiguous reading of the process variables.

Engineering Group Speai7cab;on

21.2.5

Specification Number

Rev

Date

01 5-JH-1903

1

15-9-94

Sheet

1 5 8 of 1 6 3

Field Enclosures Where conditions dictate that the amplifier or transducer for a particular piece o f equipment requires t o be field mounted close t o the tapping points, the Approved Manufacturer shall provide a local enclosure. It is the Contractor's responsibility t o specify the equipment directly suitable for the environment and hazardous area, or t o provide such additional protection as is necessary.

21.2.6

Miscellaneous Panels Panels and boards shall also be provided t o assist in clarifying plant areas for maintenance purposes, e.g., sample points collected together, gas injection points for detector testing, solenoid valve reset groupings for related services in tight locations etc.

21.3

Sizina Reauirements 21.3.1

Layout for Operator Access Local panels shall be the minimum size commensurate with clear and adequate spacing of the instruments and associated bilingual labelling (English and Arabic). Instruments t o be viewed b y the operator shall be between 1.4 and 1 . 6 m (4'1, and 5'1, ft.) from grade or a fixed platform. Pushbuttons shall be between 1 . 0 and 1.5 m ( 3 and 5 ft.) from the same levels.

21.3.2

21.4

Terminations a.

Items requiring termination, maintenance etc. such as solenoid valves shall be not less than 3 0 0 m m ( 12 in.) and not more than 1.8 m ( 6 ft.) above the standing surface.

b.

Terminal boxes shall be placed w i t h the bottom entry gland at least 3 0 0 m m ( 1 2 in.) above the platform level, or a sufficient distance above grade t o manipulate lead-sheathed multicore cables.

Construction Reauirements 21.4.1

General a.

Local panels shall be constructed as free-standing, pre-wired assemblies. They shall consist of one or more certified junction boxes with certified lamps and pushbuttons installed in the front face. They shall be complete w i t h certified junction box for connection of main plant cabling. The lamps and pushbuttons shall be labelled externally w i t h full tag number and service, in English and Arabic and internally with

@ KOC

Engineering Group SpeMcafhn

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Date

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tag number only. For Zone 1 or 2 use, the junction boxes shall be Ex'e', the pushbuttons Ex'i' and the lamps Ex'd' or Ex's'. b. The junction boxes shall conform t o the details given in the Engineering Group Specification entitled "Instrument Installation" (Number 01 5-JH-1908). c.

Panels having a large number of lamps/buttons may use a fabricated carcase w i t h the junction boxes mounted inside and connected by flying lead t o certified lamplpushbutton units o n the front face. The hazardous area within the enclosure shall be rated one zone higher than the surrounding area, unless adequate ventilation can be ensured.

Gauge Boards Gauge boards shall be constructed as free standing. The front facing shall be 5-mm (3116-in.) plate, suitably plated or painted for the service conditions. The gauges and isolating valves shall be pre-assembled and piped t o bulkhead or termination fittings. The method of mounting gauges shall not infringe upon the blow-out integrity. The gauges shall be labelled w i t h full tag number and the service, in English and Arabic. All installation materials, including tray work, shall be as specified in the Engineering Group Specification entitled "Instrument Installation" (Number 01 5-JH-19081. Field Enclosures Local transducerlamplifying stations will normally be supplied as certified weatherproof enclosures b y the Approved Manufacturer and installed by the Contractor onto a panel constructed similar t o a gauge board. Where the equipment is n o t t o protection standard IP65 or better, a secondary enclosure may be provided; however, since the hazardous area classification will increase t o the next zone, the Contractor shall ensure that the equipment certification is suitable. Other techniques, such as purged and pressurized panels, may be adopted subject t o Company approval. Framework The supporting framework shall be provided w i t h drilled base feet of ample proportions t o support the weight and wind forces, without causing trip points o n the grade or platform area where the panel or board is installed. Lifting points shall be provided as necessary. Where removable lifting points are provided, blanking bolts and washers shall be fitted after installation. The

Engineering Group SpetMcathn

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Sheet

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framework shall be manufactured of robust angles and sections welded together, galvanised after manufacture and after drilling of all holes. 21.4.5

Visibility and Sun Screens Measures shall be adopted t o ensure that the panel lamps, indicators etc. can be easily read under any expected light conditions. In most external locations, side enclosures and overhead deflectors will be required in addition t o mounting the panels in advantageous positions. Care shall be taken t o ensure that the use o f such enclosing does not increase the hazardous area classification above the rating of the equipment.

21.4.6

Lamp Test All panels having lamps shall also include a lamp test pushbutton which shall communicate w i t h the logic system and thus activate all unlit lamps when depressed.

21.4.7

Fabrication and Finishing a.

Fabricated cubicles, side panels etc. shall be of minimum 2m m (313241-1.) plate with folded edges and welded construction. They shall be painted in accordance w i t h the Engineering Group Specification entitled "Shop and Field Painting" (Number 0 1 5-XH-1005). Ventilated panels shall have high level louvres w i t h mesh screens. Opening doors shall be supplied w i t h robust stainless steel hinges and T-key door fastening system. Door locks shall be fitted only where agreed t o as specifically required b y the Company.

b. All entries shall be from the bottom, preferably direct into the junction boxes via an open bottom so that free ventilation is possible. For grade-mounted panels, a closed bottom is required t o prevent ingress o f wind blown materials. In this case, the cable shall enter the panel via a cable stopper gland (without stripping of the cable sheath) mounted in the base gland plate and then be terminated in the junction box. In these cases, an adequate ventilation system is required t o prevent an increase in the hazardous area classification. 21.4.8

Local Indicators Local electronic indicators shall be digital IS type when the clarity of the reading can be ensured under the sunlight conditions. Indicating dial type may be used subject t o Company approval.

Engineering Gmup spedfi~atbn 21.4.9

Specification Number 0 1 5-JH-1903

Rev

Date

1

15-9-94

Sheet 1 6 1 of 163

Terminations Terminations, wiring etc. within the junction boxes shall be in accordance w i t h the Engineering Group Specification entitled "Instrument Installation" (Number 0 1 5-JH-1908), including glanding, numbering, earthing etc. The minimum cable core size shall be 1.5 mm2.

21.4.1 0 Earthing All panels/cubicles shall have a fully wired earthing system connecting all metal components via greenlyellow earth conductors (of minimum 6 mm2) back t o one main plant earth boss, with 10-mm (318-in.) brass earth stud, 3 0 - m m (13116-in.) projection and t w o brass nuts and washers. 21.4.1 1 Sunshield All panels and gauge boards require an overhead sun shield of such proportions and materials that the temperature of the panel does not rise above 70°C ( 158°F) due t o direct sun effects or reradiation. 11.5 Installation Notes

Visibility Control panels shall be installed in the truly vertical position. They shall be installed in the best position t o make use of ambient light while minimising the effect of glare, and shall be adequately lit for night use b y general or specific illuminators. The panel instruments, lights and annunciators shall be clearly visible t o the operator under all possible lighting conditions. The Contractor shall make whatever provisions are necessary t o achieve this condition t o Company satisfaction. Choice of Location Panels shall be mounted as far as possible from sources of harmful matter and vibration. Access The space in front of the panel shall be an unobstructed passageway of at least 1 5 0 0 m m (5 ft.) A minimum distance of 1 0 0 0 m m (3'1, ft.) shall be provided for rear access when required. All visual instruments shall be within the range 1.4 t o 1.6 m (4'1, t o 5'1, ft.) and operator accessible instruments 1.0 m t o 1.5 m ( 3 t o 5 f t . ) from the standing platform level.

Engineering Group

Specification Number

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specmation 21.6 Performance Reauirements 21.6.1

Quality Control (QC) a.

QC shall be as detailed in the Contract. This section states the minimum additional requirements related t o local panels and gauge boards only and shall not in any w a y replace or reduce the general QAIOC requirements.

b.

The test and inspection plan shall include the following items in addition t o those found necessary by the Approved Manufacturer t o ensure the quality of the product: A check of the dimensions o f the finished items against the Drawings supplied for the Contract and approved by the Company. A check o f the panellcubicle and all accessories in accordance with this specification and the data sheets and Drawings. Full point-to-point, functional and earth resistance testing of the panellcubicle in accordance this specification, the Approved Manufacturer's additional QA/QC procedures and the approved test and inspection plan. A check on the nameplate data in accordance with this specification and the data sheets and Drawings. A check o n the painting and protection and general suitability for the environment. A check o n the tagging in accordance w i t h specification and the data sheets.

21.6.2

this

Testing a.

LampiPushbutton panels shall be tested b y applying simulated signals and loads at the junction box terminals.

b.

Gauge boards shall be tested w i t h instrument quality air up t o the rating of the instrument or the air line, whichever is lower. A soap and water or bubble chamber test shall confirm the tightness of the joints.

c.

Cubicles containing the Approved Manufacturer's amplifying equipment shall be tested in simulated conditions with the sensor and receiving equipment connected.

Engineering Group Speaiccation 21.6.3

Specification Number

Rev

Date

Sheet

01 5-JH-1903

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163 01 163

Documentation All the certification for each cubiclelpanel shall be collated in a Data Book which shall be available at final inspection. The book shall include as a minimum:

21.7

a.

Completed test and inspection plan.

b.

Weld procedures for structural welds.

c.

Leak test certificates.

d.

Hazardous area certificates.

e.

As-built Drawings as necessary.

N a m e ~ l a t eData

21.7.1

General information for production o f the nameplate data is given in section 4.7 of this specification.

21.7.2

The proposed title for "Service" of panel front instruments shall be submitted t o the Company for approval.

21.7.3

Front-of-panel labels shall be engraved and infilled stainless steel. The labels shall be fastened with stainless steel screws. Adhesive jointing paste shall be used o n the rear of the label so that moisture cannot penetrate behind and cause rust marks at the screw holes.