Download I-ET-6000.67-0000-800-PDY-001=E...
TECHNICAL SPECIFICATION CLIENT: JOB:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET
AB-PQF / COMPERJ
1 of 8
COMPLEXO PETROQUÍMICO DO RIO DE JANEIRO
AREA:
GENERAL
TITLE:
COMPER/EE/EAI
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
REVISION INDEX REV
DESCRIPTION AND/OR AFFECTED SHEETS
0 A
ORIGINAL. INCLUDED REQUEREMENTS FOR BOILER, CEMS AND FILDBUS FUNDATION RISK MANAGEMENT.
B C D E
REVISED WHERE INDICATED. REVISED WHERE INDICATED REVISED THE CONCEPT FOR CABLE ENTRANCE IN CCL AND CIC AND CEMS ITEMS REVISED WHERE INDICATED
DATE DESIGN
REV. 0
REV. A
REV. B
REV. C
REV. D
REV. E
03-30-07
06-08-07
08-21-08
01-08-09
01-25-09
24-07-09
AB-PQF/UPB/ES
REV. G
AB-PQF/UPB/ES AB-PQF/UPB/ES/AEI AB-PQF/UPB/ES/AEI AB-PQF/UPB/ES/AEI AB-PQF/UPB/EE/AEI
EXECUTION
ORESTES
RICARDO
RICARDO
ORESTES
ORESTES
MARCIO
CHECK
RICARDO
ORESTES
ORESTES
DILERMANDO
DILERMANDO
ORESTES
FERNANDO
FERNANDO
DILERMANDO
FERNANDO
FERNANDO
DILERMANDO
APPROVAL
REV. F
THE INFORMATION CONTAINED IN THIS DOCUMENT IS PETROBRAS PROPERTY AND MAY NOT BE USED FOR PURPOSES OTHER THAN THOSE SPECIFICALLY INDICATED HEREIN. THIS FORM IS PART OF STANDARD PETROBRAS N-381-REV. G ENGLISH ANNEX A – PICTURE A-1.
REV. H
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
2 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
CONTENTS 1.
OBJECTIVE ......................................................................................................................6
2.
APPLICABLE STANDARDS ............................................................................................6 2.1.
PETROBRAS ..............................................................................................................................6
2.2.
ABNT (Associação Brasileira de Normas Técnicas). ......................................................9
2.3.
API (American Petroleum Institute). ..................................................................................10
2.4.
NFPA (National Fire Protection Association)..................................................................11
2.5.
IEC (International Electrotechnical Commission). .........................................................11
2.6.
ANSI ( American National Standards Institute )..............................................................12
2.7.
ASME (The American Society of Mechanical Engineers). ...........................................12
2.8.
ASTM (American Society for Testing and Materials). ...................................................13
2.9.
ISA (Instrumentation, Systems and Automation Society). ..........................................13
2.10. IEEE (Institute of Electrical and Electronic Engineers). ...............................................16 2.11. MSS (Manufacturers Standardization Society of the Valve and Fittings Industry Manufacturers Association)................................................................................16 2.12. NAMUR ......................................................................................................................................16 2.13. NR (Normas Regulamentadoras de Segurança e Saúde no Trabalho Ministério do Trabalho e Emprego). ..................................................................................16 2.14. ISO (International Organization for Standardization)....................................................17 2.15. EIA (Electronic Industries Association) ...........................................................................17 2.16. EEMUA (The Engineering Equipment and Materials Users Association)................17 2.17. UL (Underwriters Laboratories) . ........................................................................................17 2.18. Open Connectivity Organization (OPC). ...........................................................................17 2.19. Fieldbus Foundation (FF). ....................................................................................................17 2.20. INMETRO ( Instituto Nacional de Metrologia, Normalização e Qualidade Industrial)..................................................................................................................................18 2.21. AGA ( American Gas Association) .....................................................................................19 3.
DEFINITIONS..................................................................................................................19
4.
ENGINEERING UNITS ....................................................................................................20
5.
INSTRUMENTATION DESIGN CRITERIA......................................................................21 5.1.
GENERAL CONDITIONS........................................................................................................21
5.2.
INSTRUMENTS IDENTIFICATION........................................................................................24
5.3.
DESIGN DOCUMENTATION .................................................................................................26
5.4.
GENERAL REQUIREMENTS FOR DESIGN AND SPECIFICATION OF INSTRUMENTS. .......................................................................................................................44
5.5.
TEMPERATURE INSTRUMENTS SPECIFICATION .........................................................47
5.6.
PRESSURE INSTRUMENTS SPECIFICATION..................................................................48
5.7.
FLOW INSTRUMENTS SPECIFICATION............................................................................50
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
3 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION 5.8.
LEVEL INSTRUMENTS SPECIFICATION..........................................................................50
5.9.
CONTROL VALVES SPECIFICATION. .............................................................................51
5.10. SALFETY AND RELIEF VALVES SPECIFICATIONS ......................................................53 5.11. PROCESS ANALYZERS SPECIFICATIONS......................................................................53 5.12. MARSHALLING CABINET .....................................................................................................73 5.13. FIRE AND GAS DETECTION.................................................................................................74 5.14. RESERVE CRITERIA ..............................................................................................................75 5.15. INTERLOCKING AND EMERGENCY SHUTDOWN SYSTEM ........................................75 5.16. PROGRAMMABLE LOGIC CONTROLLER FOR GENERAL APPLICATIONS...........77 5.17. PROGRAMMABLE LOGIC FOR SAFETY SYSTEM.........................................................79 5.18. INSTALLATION OF INSTRUMENTS....................................................................................79 5.19. PACKAGE UNITS ....................................................................................................................83 5.20. MOTORIZED VALVES TELECOMAND SYSTEM..............................................................86 5.21. MEASUREMENT STATION FOR CUSTODY TRANSFER – LIQUID EMED ................90 5.22. EMED for measurement of gas ...........................................................................................94 5.23. CONTINUOUS EMISSION MONITORING SYSTEM - CEMS ..........................................96 5.24. EMERGENCY ISOLATION VALVE – EIV..........................................................................110 6.
7.
8.
9.
GAS COMPRESSORS AUTOMATION.........................................................................110 6.1.
SCOPE .....................................................................................................................................110
6.2.
GENERAL REQUIREMENTS...............................................................................................110
6.3.
RECIPROCATING COMPRESSORS. ................................................................................119
6.4.
CENTRIFUGAL COMPRESSORS ......................................................................................122
FIRED HEATERS AUTOMATION.................................................................................122 7.1.
SCOPE .....................................................................................................................................122
7.2.
GENERAL GUIDELINES ......................................................................................................122
7.3.
FUNCTIONAL REQUIREMENTS AND INTERFACES....................................................123
7.4.
LOGIC SEQUENCE DESCRIPTION...................................................................................125
7.5.
GENERAL REQUIREMENTS...............................................................................................131
7.6.
GENERAL NOTES .................................................................................................................132
PUMP AUTOMATION ...................................................................................................132 8.1.
SCOPE .....................................................................................................................................132
8.2.
GENERAL GUIDELINES ......................................................................................................132
8.3.
FUNCTIONAL REQUIREMENTS ........................................................................................132
8.4.
INTERFACES AND ADDITIONAL INSTRUMENTATION...............................................134
8.5.
BLOCK DIAGRAMS FOR PUMP AUTOMATION ............................................................135
8.6.
LARGE SIZE PUMP CONTROL ARCHITECTURE .........................................................139
AIR COOLER AUTOMATION .......................................................................................143
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
4 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION 9.1.
SCOPE .....................................................................................................................................143
9.2.
GENERAL GUIDELINES ......................................................................................................143
9.3.
FUNCTIONAL REQUIREMENTS AND INTERFACES....................................................143
9.4.
LOGIC SEQUENCE DESCRIPTION...................................................................................145
9.5.
BLOCK DIAGRAMS: AIR-COOLED HEAT EXCHANGERS AUTOMATION .............146
10.
BOILER CONTROL AND SAFETY REQUIREMENTS..................................................147
10.1. SCOPE .....................................................................................................................................147 10.2. GENERAL GUIDELINES ......................................................................................................147 10.3. CONTROL STRATEGIES .....................................................................................................148 10.3.1. Steam flow control..............................................................................................................148 10.3.2. Water level control in the steam drum ..........................................................................148 10.3.3. Steam temperature control...............................................................................................149 10.4. REQUIREMENTS FOR PROCESS INSTRUMENTATION .............................................149 10.5. PROCESS ALARMS REQUIREMENTS ............................................................................151 10.6. FIELD INSTRUMENTATION ................................................................................................152 10.7. SAFETY REQUIREMENT - SIS ...........................................................................................153 10.8. FUNCTIONAL REQUIREMENTS AND INTERFACES....................................................155 11.
LOCAL CONTROLLER ROOM (CCL) AND CONTROL INTEGRATED CENTER (CIC)..............................................................................................................................156
12.
SUPERVISION AND CONTROL SYSTEMS .................................................................158
12.1. SUPERVISION SYSTEMS....................................................................................................158 12.2. CONTROL SYSTEMS ...........................................................................................................158 13.
FOUNDATION FIELDBUS SPECIFICATION................................................................159
13.1. SCOPE .....................................................................................................................................159 13.2. . DEFINITIONS........................................................................................................................159 13.3. INSTALLATION CRITERIA ..................................................................................................159 13.4. FIELD DEVICES .....................................................................................................................160 13.5. HOST SYSTEM.......................................................................................................................161 13.6. SEGMENT DESIGN ...............................................................................................................162 13.7. CONFIGURATION TOOL .....................................................................................................166 13.8. MAINTENANCE TOOL..........................................................................................................167 13.9. DOCUMENTATION................................................................................................................168 13.10. ACCEPTANCE TESTS..........................................................................................................169 13.11. TRAINING ................................................................................................................................169 13.12. SPARE PARTS .......................................................................................................................170 13.13. FOUNDATION FIELDBUS SEGMENT RISK MANAGEMENT ......................................170 14.
DATA COMMUNICATIONS ROUTES - VCD ................................................................171
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
5 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION 15.
MODERN CONTROL STRATEGIES.............................................................................172
16.
THE ENTERPRISE-CONTROL SYSTEM INTEGRATION ............................................172
17.
DYNAMIC PROCESS SIMULATOR..............................................................................172
18.
TRADE AUTOMATED SYSTEM – TAS ........................................................................173
19.
ELECTRIC POWER SYSTEM FOR INSTRUMENTATION ...........................................175
20.
TANKING GAUGING SYSTEM.....................................................................................178
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
6 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
1.
OBJECTIVE
The objective of this Technical Specification is to present the Instrumentation and Automation Design Criteria additional to those mentioned in the PETROBRAS standards, for the Basic and Detailed Design, of the RIO DE JANEIRO PETROCHEMICAL COMPLEX in Itaboraí, Rio de Janeiro State, Brazil. 2.
APPLICABLE STANDARDS
The following list of standards shall be applied for design and specification of equipment or materials that are to be used in the current project. In case of doubts, PETROBRAS shall be consulted. This Technical Specification complements and is complemented by the Specification Technique I-ET-6000.67-0000-700-PDY-001 - Design Criteria - Electricity.
2.1.
E
PETROBRAS
N-0058
Símbolos Gráficos para Fluxogramas de Processo e Engenharia
NI-0058
Graphic Symbols for Process and Engineering Flow-sheets
NI-0298
Graphic Symbols and designations employed in detailing drawings of industrials electrical instalations
N-0381
Execução de Desenhos e Outros Documentos Técnicos em Geral
NI-0381
Execution of Drawing and Other Technical Documents
N-0839
Pote para Instrumentação
N-0858
Construção, Montagem e Condicionamento de Instrumentação
N-1600
Construção, Montagem e Condicionamento de Redes Elétricas
N-1735
Pintura de Máquinas, Equipamentos elétricos e Instrumentos
N-1882
Critérios para elaboração de Projetos de Instrumentação
NI-1882
Criteria for Preparing Instrumentation Design
N-1883
Apresentação de Projeto de Instrumentação
NI-1883
Presentation of Instrumentation/Automation Design
N-1931
Material de Tubulação para Instrumentação
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
7 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
N-1939
Formulários p/ Construção, Montagem e Condicionamento de Instrumentação
N-1996
Projeto de Redes Elétricas em Envelopes de Concreto e com Cabos Diretamente no Solo
N-1997
Redes Elétricas de Bandejamento para Cabos – Projeto, Instalação e Inspeção
NI-1997
Electrical Networks in Cable Tray Systems- Design, Installation and Inspection
N-2065
Elaboração de Informações Básicas de Empreendimentos do Abastecimento
NI-2065
Preparing Basic Information for Refining Projects
N-2160
Atuador Elétrico para Válvula
NI- 2160
Electric Valve Actuator
N-2166
Classificação de Áreas para Instalações Elétricas em Refinarias de Petróleo
N-2194
Controlador Programável
NI-2194
Programmable Controller
N-2236 Pessoal
Inspeção de construção e montagem em Instrumentação – Qualificação de
N-2247
Válvula Esfera em aço para Uso geral e Fire-Safe
N-2268
Verificação, Calibração e Teste de Instrumento de Nível
N-2270
Fabricação e Montagem de Linhas de Impulso
N-2271
Teste Pneumático para Linha de Alimentação e Sinal
N-2272
Montagem de Linha de Alimentação e Sinal Pneumático
N-2276
Teste Hidrostático e Pneumático para Linha de Impulso
N-2277
Teste de Isolação e Continuidade Elétrica de Circuito de Instrumentação
N-2279
Inspeção de Placa de Orifício
E
N-2316 Fornecimento de Instrumentação para Unidade em Pacote e “SKID”NI-2316 Supply of instrumentation for package and skid mounted units
E
N-2368
Inspeção, Manutenção, Calibração e Teste de Válvula de Segurança e /ou Alívio
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
8 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION E
E
E
E C
N-2384
Cabo Elétrico de InstrumentaçãoNI-2384
Electric instrumentation cable
N-2547
Conversor de Freqüência para Controle de Rotação de motor Elétrico até 660 VCA
NI-2547
Frenquency converter for speed control of electric motor up to 660 VAC
N-2595
Critério de Projeto e Manutenção para Sistemas Instrumentados de Segurança em Unidades Industriais
NI-2595 Design and maintenance criteria for safety instrumented systems in industrial unitis N-2669 Configuração de Rede de TelecomunicaçõesNI-2669 network configuration
Telecomunications
N-2747
Uso de Cor em Instalações Industriais Terrestres e Marítimas
NI-2747
Use of Color in Industrial Onshore e Offshore Facilities
N-2760
Sistemas Ininterruptos de Energia para Uso Industrial
NI-2760
Uninterruptible Power System for Industrial Use
N-2761
Critério de Segurança para Projeto de Sistemas de Detecção e Alarme de Incêndio e Gás no Refino
NI-2761
Safety Criteria for Design of Fire and Gas Detection and Alarm System in Refining Units
N-2778
Sistemas Ininterruptos de Energia para Uso Industrial – Folha de Dados
NI-2778
Uninterruptible Power System for Industrial Use – Data Sheet
N-2781
Diretrizes de Engenharia de Confiabilidade
NI-2781
Reliability Engineering Guidelines
N-2784
Confiabilidade e Análise de Riscos
NI-2784
Reliability and Risk Analysis
N-2802
Folha de Dados de Instrumentação Coletânea
N-2833
Formulários e Listas para Projetos de Instrumentação
NI-2833
Forms and Lists for Instrumentation Design
Diretriz Técnica – AB-RE/ES/TEE – DT-AB-RE/ES/TEE-001 – Instalação de Dispositivos de Segurança em Vaso de Pressão Technical Guideline - AB-RE/ES/TEE - DT-AB-RE/ES/TEE-006 - “Use of spaired PSVs”
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
9 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Technical Guideline – EB-RE/ES/TEE – DT-AB-RE/ES/TEE-013 – Requirements for Process and Storage of Aromatics Products
2.2.
ABNT (Associação Brasileira de Normas Técnicas).
NB 284
Válvulas de Segurança e/ou Alívio de Pressão – Aquisição , Instalação e Utilização
NBR 1333
Controle de Acesso para Segurança de Instalações Físicas de Processamento de Dados
NBR 5363
Equipamentos elétricos para Atmosferas Explosivas – Tipo de proteção “d” – Especificação
NBR 5410
Instalações Elétricas de Baixa Tensão
E C
IEC-NBR-60079-12 -Equipamentos elétricos para Atmosferas Explosivas – Invólucros com Pressurização ou Diluição Contínua - Tipo de proteção “p”
E
IEC-NBR-60079-0 Marcação de Equipamentos Elétricos para Atmosferas Explosivas
E
NBR 8447
Equipamentos elétricos para Atmosferas Explosivas de Segurança Intrínseca – Tipo de proteção “i”
NBR 9441
Execução de Sistemas de Detecção e Alarme de Incêndio
IEC-NBR-60079-7 Equipamentos elétricos para Atmosferas Explosivas – Segurança Aumentada Tipo de Proteção “e” NBR 10861 Prensa cabos NBR 11515 Critérios para Segurança Física de Armazenamento de Dados NBR 12313
Sistema de combustão – Controle e Segurança para Utilização de Gases Combustíveis em Processos de Baixa e Alta Energia
NBR 13225
Medição de Vazão de Fluídos em condutos fechados, Utilizando Placa de Orifício e Bocais em Configurações Especiais
NBR 10300
Cabos de Instrumentação com Isolação Extrudada de PE ou PVC para tensões de até 300 Volts
NBR 10700
Planejamento de Amostragem em Dutos e Chaminés de Fontes Estacionárias
NBR 10701
Determinação de pontos de Amostragem em Dutos e Chaminés em Fontes Estacionárias
NBR 14565
Procedimento Básico para Elaboração de Projetos de Cabeamento de Telecomunicações para Rede Interna Estruturada
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
10 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
NBRIEC60529 Graus de Proteção para Invólucros de Equipamentos Elétricos (Código IP) NBRIEC60079-14 Equipamentos Elétricos Para Atmosferas Explosivas – Parte 14 Instalação Elétrica em Área Classificada (Exceto minas) NBRIEC60079-17 Equipamentos Elétricos Para Atmosferas Explosivas – Parte 17 Inspeção e Manutenção em Áreas Classificadas (Exceto Minas) NBRIEC60079-27 Conceito Fieldbus Intrinsecamente Seguro (FISCO) e Conceito Fieldbus Não Acendível (FNICO) NBRNM-IEC60050-426 Equipamentos Elétricos para Atmosferas Explosivas Terminologia NBRISO5167-1 Medição de Vazão Fluídos por Meio de Instrumentos de Pressão (Parte 1 – Placas de Orifício, Bocais e Tubos Venturi) E
NBRISO/IEC 27002 Tecnologia da Informação – Técnicas de Segurança – Código de Prática para a Gestão de Segurança da Informação
2.3.
API (American Petroleum Institute).
API RP 520 parts 1 and 2 Sizing, Selection and Installation of Pressure Relieving Devices in Refineries E
API STD 521
Guide for Pressure Relieving and Depressuring Systems
E
API STD 526
Flanged Steel Pressure Relief Valves
E
API STD 527
Seat Tightness of Pressure Relief Valves
E
API RP 536
Post Combustion-NOX for Fired Heater Equipment in General Refinery Services
API RP 540
Electrical installations in Petroleum Processing Plants
API RP 551
Process Measurement Instrumentation
API RP 552
Transmission Systems
API RP 553
Refinery Control Valves
API RP 554
Process instrumentation and Control
API RP 555
PART 1-2-3 Process Analyzers’
API RP 556
Instrumentation and Control Systems for fired Heaters and Steam Generators
API RP 557
Guide to Advanced Control Systems
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
11 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION E
API STD 598
Valve Inspection and Testing
API STD 670 Vibration, Axial Position and Bearing Temperature Monitoring System API RP 2001 Fire Protection in Refineries API STD 2000 Venting Atmospheric and Low-Pressure Storage Tanks Nonrefrigerated and Refrigerated API PUBL 2218 Fireproofing Practices in Petroleum and Petrochemical Processing Plants
E
API MPMS
Chapter 1 Vocabulary
API MPMS
CHAPTER 2 Tank Calibration
API MPMS
Chapters 3.1B and 3.3 Automatic Tank Gauging
API MPMS
Chapters 4.1 to 4.8 Provers and Proving Systems
API MPMS
Chapters 5.1 to 5.8 Measurement by Meters
API MPMS
Chapter 6.1 Lease Automatic Custody Transfer
API MPMS
Chapter 6.6 Pipeline Metering System
API MPMS
Chapter 7 Temperature Determination
API MPMS
Chapter 14.1 and 14.3.1. to 14.3.4 - Natural Gas Fluids Measurement
2.4.
NFPA (National Fire Protection Association).
75
Standard for the Protection of Information Technology Equipment.
85
Boiler and Combustion System Hazards Code
101
Code for Safety to Life from Fire in Buildings and Structures.
496
Purged and Pressurized Enclosure for Electrical Equipment.
2.5.
IEC (International Electrotechnical Commission).
IEC 60300
Reliability and Maintainability Management
IEC 60300-1
Dependability Program Management
IEC 60300-2
Guidelines for Dependability Management
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
12 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
IEC 60300-3 parts 1 to 14 Dependability and Reliability Management Programs IEC 60751
Industrial Platinum Resistance Thermometers Sensors
IEC 60770 parts 1 to 3 Transmitters for Use in Industrial-Process Control Systems IEC 61000 parts 2 to 4 Electromagnetic Compatibility IEC 61508
Functional Safety of Electrical/Electronic/Programmable Electronic Safety- Related System
IEC TR61131-8 Guidelines for the Application and Implementation of Programming Language IEC 61131-3
Programmable Controllers – Programming Languages
IEC 62453-1
Field-bus Device Toll (FDT) Interface Specification – Concepts and Description
IEC 62453-3
Field-bus Device Toll (FDT) Interface Specification – PROFIBUS
IEC 62453-4
Field-bus Device Toll (FDT) Interface Specification – HART
IEC 62453-5
Field-bus Device Toll (FDT) Interface Specification – Foundation Field-bus
IEC TR61158-1 Digital Data Communications for Measurement and Control Fieldbus for Use in Industrial Control System - Overview and Guidance over IEC 61158 IEC 61158 parts 2 to 6 Digital Data Communications for Measurement and Control E
E C E
IEC 61285
Industrial-Process Control – safety of Analyzers Houses
IEC 61784-1
Digital Data Communications for Measurement and Control
ISO/IEC 7498-1
Information Technology – Open Systems Interconnection - Basic Reference Model
IEC TR 61831 On-line Analyzer Systems – Guide to Design and Installation 2.6.
ANSI ( American National Standards Institute )
ANSI/FCI 70.2 - Standard for Control Valve Leakage Classification 2.7.
ASME (The American Society of Mechanical Engineers).
ASME B1.20
Pipe Threads, General Purpose.
ASME MFC-2M Measurement Uncertainty for Fluid Flow in Closed Conduits
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
13 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
ASME MFC-3M Measurement of Fluid Flow in Pipes Using Orifice, Nozzle and Venturi ASME MFC-4M Measurement of Fluid Flow by Turbine ASME MFC-5M Measurement of Fluid Flow in Pipes Using Transient-Time Ultrasonic Flow-meters ASME MFC-6M Measurement of Fluid Flow in Pipes Using Vortex Flow-meters ASME MFC-7M Measurement of Gas Flow by means of Critical Venturi Nozzle ASME MFC-9M Method for Estimating Installation Effects on Flow-meters ASME MFC-14M Measurement of Fluid Flow by Coriolis Mass Flow-meter ASME MFC-16M Measurement of Fluid Flow by Electromagnetic Flow-meter ASME MFC-16M Measurement of Fluid Flow by Variable Area Meter ASME PTC 19.3 Instruments and Apparatus : Temperature Measurement ASME PTC 19.13 Determination of Rotary Speed ASME PTC 19.16 Density determination of Solids and Liquids ASME PTC 19.17 Determination of the Viscosity of Liquids Instruments and Apparatus
2.8.
ASTM (American Society for Testing and Materials).
E-119
Standard Test Methods for Fire Tests of Building Construction and Materials.
E
D 3764
Standard Practice for Validation of Process Stream Analyzers
E
2.9.
ISA (Instrumentation, Systems and Automation Society).
ISA 5.1
Instrumentation Symbols and Identification
ISA 5.2
Binary Logic Diagrams for Process Operations
ISA 5.3
Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems
ISA 7.0.01
Quality Standard for Instrument Air
ISA 18.1
Annunciator Sequences and Specifications
ISA 20
Specifications Forms for Process Measurement and Control Instruments
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
14 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
ISA 37.16.01 A Guide for the Dynamic Calibration of Pressure Transducer ISA 50.00.01 Compatibility of Analog Signals for Electronic Industrial Process Instruments ISA 50.02Parts 2,3,4,5 e 6 Fieldbus Standard for Use in Industrial Control Systems ISA 71.01
Environmental Conditions for Process Measurement and Control Systems : Temperature and Humidity
ISA 71.02
Environmental Conditions for Process Measurement and Control Systems : Power
ISA 71.03
Environmental Conditions for Process Measurement and Control Systems : Mechanical Influences
ISA 71.04
Environmental Conditions for Process Measurement and Control Systems : Airborne Contaminants
ISA 75.01.01
Flow equations for Sizing Control Valves
ISA 75.02
Control Valve Capacity Test Procedure
ISA 75.05.01
Control Valve Terminology
ISA 75.08
Installed Face-to-Face Dimensions for Flanged Clamp or Pinch Valves
ISA 75.08.01
Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (Classes 125, 150, 250, 300 and 600)
ISA 75.08.02
Face-to-Face Dimensions for Flangeless Control Valves (Classes 150, 300 and 600)
ISA 75.08.03
Face-to-Face Dimensions for Socket Weld-End and Screwed-End Globe-Style Control Valves (Classes 150, 300, 600, 90, 1500 and 2500)
ISA 75.08.05
Face-to-Face Dimensions for Butweld-End Globe-Style Control Valves (Classes 150, 300, 600, 900, 1500 and 2500)
ISA 75.08.06
Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (Classes 900, 1500 and 2500)
ISA 75.08.07
Face-to-Face Dimensions for Separable Flanged Globe-Style Control Valves (Classes 150, 300 and 600)
ISA 75.08.09
Face-to-face Dimensions for Sliding Stem Flangeless Control Valves (Classes 150, 300 and 600)
ISA 75.11.01
Inherent Flow Characteristic and Rangeability of Control Valves
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
15 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
ISA 75.08.13
Method of Evaluating the Performance of Positioners with Analog Input Signals and Pneumatic Output
ISA 75.17
Control Valve Aerodynamic Noise Prediction
ISA 75.19.01
Hydrostatic Testing of Control Valves
ISA 75.22
Face-to-Centerline Dimensions for Flanged Globe-Style Angle Valve Bodies (ANSI Classes 150, 300 and 600)
ISA 75.23
Considerations for Evaluating Control Valve Cavitation
ISA 75.25.01
Test Procedure for Control Valves
ISA 75.26.01
Control Valve Diagnostic Data Acquisition and Reporting
ISA 77.20
Fossil Fuel Power Plant Simulator
ISA 84.00.01
Parts 1, 2 and 3 – Functional Safety : Safety Instrumented System for Process Industry Sector
ISA 88.00.02
Batch control part 2- Data Structures and Guidelines for Language
ISA 88.00.03
Batch control part 3- General and Site Recipe Models and Representation
ISA 88.00.04
Batch control part 4- Batch Production Records
ISA 88.01
Batch control Part 1 – Models and Terminology
ISA 95.00.01
Enterprise-Control System Integration Parts 1, 2 and 3
ISA TR99.00.01 Security Technologies for Manufacturing and Control Systems ISATR99.00.02 Integrating Electronic Security into the Manufacturing and Control Systems Environment ISA 100.11a
Wireless Industrial Automation Network
ISA 60079-0
Electrical Apparatus for Use in Class 1, Zones 0,1 and 2 Hazardous Locations : General Requirements
ISA 60079-1
Electrical Apparatus for Use in Class 1, Zone 1 Hazardous Locations : Type of Protection Flameproof “d”
ISA 60079-5
Electrical Apparatus for Use in Class 1, Zones 1 Hazardous Locations : Type of Protection Powder Filling “q”
ISA 60079-6
Electrical Apparatus for Use in Class 1, Zones 1 and 2 Hazardous Locations : Type of Protection Oil Immersion “o”
ISA 60079-7
Electrical Apparatus for Use in Class 1, Zones 1 and 2 Hazardous Locations : Type of Protection Increased Safety “e”
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
16 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
ISA 60079-11 Electrical Apparatus for Use in Class 1, Zones 0, 1 and 2 Hazardous Locations : Intrinsic Safety “i” ISA 60079-15 Electrical Apparatus for Use in Class 1, Zone 2 Hazardous Locations : Type of Protection “n” ISA 60079-7
Electrical Apparatus for Use in Class 1, Zones 1 Hazardous Locations : Type of Protection Encapsulation “m”
ISA MC96.1
Temperature Measurement Thermocouples
2.10. IEEE (Institute of Electrical and Electronic Engineers). IEEE 802.3
Standard for Local and Metropolitan Area Networks – CSMA/CD
IEEE 802.11-A and B
Standards for Local and Metropolitan Area Networks – Wireless LAN
2.11. MSS (Manufacturers Standardization Society of the Valve and Fittings Industry Manufacturers Association). MSS SP-72
Ball Valves With Flanged or Butt-Welding Ends for general Service
MSS SP-99
Instrument Valves
2.12.
NAMUR
NE 107-“Self-monitoring and Diagnosis of Field Devices”. 2.13. NR (Normas Regulamentadoras de Segurança e Saúde no Trabalho Ministério do Trabalho e Emprego). NR 10
Instalações e Serviços em Eletricidade.
NR-13
Caldeiras e Vasos de Pressão.
NR 15
Atividades e Operações Insalubres – Anexos 1 e 2.
NR16
Atividades e Operações Perigosas.
NR 17
Ergonomia.
NR-18
Condições e meio ambiente de trabalho na indústria de construção.
NR-23
Proteção contra incêndios.
NR-26
Sinalização de segurança.
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
17 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
2.14. ISO (International Organization for Standardization). ISO 11064 Parts 1,2,3,4 and 6 Ergonomic Design of Control Centers
2.15. EIA (Electronic Industries Association) . EIA/TIA RS-232 Interface Between Data Terminal Equipment and Data communication Equipment Employing Serial Binary Data Interchange EIA/TIA RS-422 Electrical Characteristics of Balanced Voltage Digital Interface Circuits Balanced Digital Multipoint Systems EIA/TIA RS-485 Electrical Characteristics of Generators and Receivers for use in Balanced Digital Multipoint Systems
2.16. EEMUA (The Engineering Equipment and Materials Users Association). E
Publication 138
Design and Installation of On-Line Analyzers System
Publication 191
Alarms Systems – A Guide to Design, Management and Procurement
Publication 201
Process Plant Control Desks Utilizing Human-Computer Interfaces
2.17. UL (Underwriters Laboratories) . UL 2196
Safety Tests for Fire Resistive Cables
UL 1709
Fire proofing Pratices in Petroleum and Petrochemical Processing Plants
2.18. Open Connectivity Organization (OPC). OPC UA parts 1 to 11 Unified Architecture – Concepts, Services, Data Access, Profiles, Historical Data, Alarms and Security
2.19. Fieldbus Foundation (FF). FF-103
Common File Format
FF-131
Standard Tables
FF-569
Host Interoperability System Test Procedures
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
18 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
FF-593
High Speed Ethernet Redundancy
FF-581
System Architecture
FF-586
Ethernet Presence
FF-588
Field Device Access (FDA) Agent
FF-589
HSE System Management
FF-801
Network Management Specification
FF-803
HSE Network Management
FF-806
Data Link Protocol Specification Bridge Operation Addendum
FF-816
31.25 kbit/s Physical Layer Profile Specification
FF-821
Data Link Layer Services Subset Specification
FF-822
Data Link Layer Protocol Specification
FF-880
System Management Specification
FF-870
Fieldbus Message Specification
FF-875
Fieldbus Access Sublayer Specification
FF-890
Function Block Application Process - Part 1
FF-891
Function Block Application Process - Part 2
FF-892
Function Block Application Process - Part 3
FF-893
Function Block Application Process - Part 4
FF-894
Function Block Application Process - Part 5
FF-900
Device Description Language Specification
FF-940
31.25 kbit/s Communication Profile
FF-941
HSE Communication Profile36
2.20. INMETRO ( Instituto Nacional de Metrologia, Normalização e Qualidade Industrial). Portaria número 83 do INMETRO Regulamento de Conformidade de Equipamentos Elétricos para Atmosferas Potencialmente Explosivas, nas Condições de Gases e Vapores Inflamáveis
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
19 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
2.21. AGA ( American Gas Association) Report 3 P1 Orifice Metering of Natural Gas and Other Related Hydrocarbons Fluids – part 1 – General Equations and Uncertainty Guidelines Report 3 P2 Specifications and Installation Requirements 3.
DEFINITIONS
a) MCC –Acronym of Motor Control Center. The electrical equipment responsible for the electrical motors protection and control. b) CEMS – Acronym of continuous emissions monitoring systems that is the complete systems for monitoring toxic gas emissions with origin in the furnaces, heaters and boilers. c) CIC – Portuguese acronym of “Casa Integrada de Controle” that means Integrated Control Center. From that house the operators supervise and operate all refinery process and utility units. The main equipment located in it is the DCS human machine interface. d) DCS – Acronym of Distributed Control System. System responsible for process data acquisition, control and disposal of process unit information to operator for supervision. e) EMED – Acronym for custody measurement station that is the set of equipment with controlled accuracy responsible for the measurement of liquid and products to be sold to third party. f) FF – Acronym of Foundation Fieldbus. g) HMI – Acronym of Human Machine Interface. h) LCP – Acronym of Local Control Panel. Local Control Panel is any instrumentation control panel, other than Remote I/O, located at field with control, interlock and/or process data acquisition purpose for a specific process systems or equipment. That panel can contain a PLC and any other specific equipment as well as a human machine interface (HMI). i) LP - Acronym of Local Panel. Local Panel is any instrumentation panel, located at field with the purpose to provide operator’s local supervision of a specific process systems or equipment through a Human Machine Interface (HMI). That panel has not any control or interlock function, but can contain an independent instrument or equipment with it purpose that was installed in it just making good use of the available enclosure. j) MC – Acronym of Marshalling Cabinet. Marshalling Cabinet is located at CCL and is used to re-arrange the cables coming from the field to match the wiring terminations of DCS controllers, PES or RCP. k) PASE – Acronym of “Protection and Automation of Electrical System”. The PASE is the equipment responsible for protection, load shedding and motor acceleration.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
20 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
l) PES – Acronym of Programmable Electronic System. Certified equipment developed to be applied as logic solver of a SIS. m) PLC – Acronym of Programmable Logic Controller. Equipment responsible for control and data acquisition of a specific system or equipment. n) RCP - Acronym of Remote Control Panel. Remote Control Panel is any instrumentation control panel, other than DCS and PES, located at CCL with control, interlock and/or process data acquisition purpose for a specific process system or equipment. That panel can contain a PLC and any other specific equipment as well as a human machine interface (HMI). o) RUPS – Acronym of Redundant Uninterruptible Power Supply. Is a full redundant uninterruptible power supply for 120Vac. E
p) CCL – Portuguese acronym of “Casa de Controladores Local” that means Local Controllers Room. That room shelter the main instrumentation equipment that interfaces the field instrumentation, of one or more process unit, for control and data acquisition purpose. q) SIL - Acronym of Safety Integrity Level. r) SIS – Acronym of Safety Instrumented System. System composed of sensors, logic solver, and final control elements for the purpose of taking the process to a safe state when a predetermined condition is violated. s) STVM – Portuguese acronym of “Sistema de Telecomando de Válvulas Motorizadas” that means Motor Operated Valve System. System composed of motor operated valves with smart actuators connected through a network for data acquisition and control purpose. That system is connected to DCS. t) TGS – Acronym of Tank Gauging System. System composed of smart level and temperature measurement instruments connected through a network for process data acquisition purpose. That system is connected to DCS. u) VCD – Portuguese acronym of Via de Comunicação de Dados – Data Communication Route that means the fiber optics routes for connecting parts of the digital networks DCS, SCMD , PLC Remote Maintenance Network, Monitoring Vibration of Machines and HART Asset Maintenance Network. v) VSD – Acronym of Variable Speed Driver.
4. E
ENGINEERING UNITS
The units of the process variables to be adopted to principals measurements are the following ones:
NO
TECHNICAL SPECIFICATION AREA:
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
21 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Process Variable
Unit
Temperature
o
Flow (volumetric liquid)
m3/h (water) or m3/d @ 20o C
Flow (mass liquid)
Kg/h
Flow (Steam)
t/h
Flow (Gas)
m /h corrigido @ 1atm e 20C
Pressure
Kgf/cm
Vacuum and Low Pressure
mmH2O
Vacuum and Low Pressure
mm H2O (blowers’ discharge, vacuum in heaters and boilers) and mm Hg (in condensers)
Level
0 – 100 (%)
Density
kg/m
Viscosity
Cp
C
E E
E 3
2
E 3
Others variables to be measure shall follow the SI – Sistema Internacional de Unidades, published by INMETRO. 5.
INSTRUMENTATION DESIGN CRITERIA
5.1.
GENERAL CONDITIONS
5.1.1 This document is not intended to define the scope of work but only general criteria for detailing. In case of doubt, PETROBRAS shall be consulted at all times. 5.1.2 The development and presentation of the instrumentation and automation design shall comply with the standards listed beneath. a) presentation of design as per NI-1883; b) detailing of instrument and automation design as per NI-1882; c) detailing of underground networks as per N-1996; d) detailing of cable tray systems as per NI-1997; e) detailing of SIS units design as per N-2595; f) instruments identification as per ISA SP 5.1; g) codified numeration of the engineering technical documents as per N-1710;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
22 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.1.3 For the purchase of instruments and automation equipments the data sheets standardized in the PETROBRAS standards shall be used, as well as the associated specifications. 5.1.4 For the purchase of materials, the data sheets standardized in the PETROBRAS standards shall be used, where applicable.
E
5.1.5 Equipment and materials shall be chosen bearing in mind the classification of areas and the conditions of aggressiveness of the surroundings, at the installation site. In places subject to intense humidity, provision shall be made for drains in the casings of panels for outdoor installation. The requirements of Standard ABNT NBR-5410 shall be considered. Electronics parts of the instruments and panels shall be protect against fungus due the possibility of the humidity or condensate happening. 5.1.6 The detail designer shall issue the whole of the documents stipulated in standard NI-1883, observing the minimum degree of detailing and the form of presentation of information called for therein. The fact that similar documents will be issued by equipment suppliers does not do away with the need for issuance of these items by the detailing designer. 5.1.7 Data Sheets, Technical Specifications and Materials Requisitions (RM) supplied by PETROBRAS as an integral part of the documentation issued for contracting purposes shall not be used directly for the purchase of instruments. 5.1.8 Except for the PETROBRAS standards and drawings referring to installations already in existence, no technical document on instrumentation and automation supplied by PETROBRAS shall be used over or directly revised by the detailing designer. All documents shall necessarily be issued by the detailing designer and shall include all contractual technical requirements. 5.1.9 When the design is developed for locations where there are PETROBRAS industrial facilities already constructed that have interfaces with this project, the following requirements shall be met: a) existing documents shall be revised and the whole of the remaining correlated documents affected by the revision shall also be updated, even if this means merely the inclusion of a reference; b) where there is lack of space or legibility in design documents already existing, or yet incompatibility of those with projects issued with the use of the computer, new documents shall be issued. These new documents, besides including the new information, shall consolidate the information existing in prior projects so as to avoid the need for consulting a number of documents to obtain a given piece of information; c) the designer shall conduct a complete field survey to develop the project, checking, amongst other items, the following factors: - actual situation of the installations and interferences that shall be avoided or overcome;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
23 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- availability of existing installations (for example : spaces for enlargements), including issuance of a notice to PETROBRAS in case some specification prepared by the latter needs to be modified as a result of a field survey and the execution of the detailed design; -
all existing drawings involved to be revised.
5.1.10 Where applicable, the criteria and solutions adopted in the detailed design and in the selection of materials shall be compatible with the usual solutions adopted in the existing facilities. 5.1.11 Basic guidelines related to safety and health established in the Regulatory Standard NR 10 of “Ministério do Trabalho e Emprego – MTE” (Labor and Employment Ministry), shall be applied to the instrumentation and automation power supply design. 5.1.12 CONTRACTOR shall issue and furnish to PETROBRAS a Technical Appraisal, elaborated by a qualified Electrical Engineer, attesting that all the materials, equipment, project services, assembly services and the instrumentation and automation power supply system installed are in accordance with the requirements of the Regulatory Standard NR 10 of MTE and the ABNT Standards, mainly the Standard NBR 5410 Instalações Elétricas de Baixa Tensão . E
5.1.13 The CONTRACTOR shall generate the documentation electronically using a integrated Computer Aided Design – CAE software
E
5.1.14 The use of programs Autodesk AutoCAD and Microsoft, ACCESS, EXCEL and WORD for WINDOWS, last versions can be used, since they are authorized by PETROBRAS, in writing. 5.1.15 The BID analysis of the following instruments shall be submitted to the approval of PETROBRAS: - analyzers; (conductimeters, chromatograph, densimeters, viscometers, photometers, etc);
E
- pressure, differential pressure and temperature transmitters (applied to Level, Flow or Pressure measurement); - control valves and valve positioners; - shut-off valves and solenoid valves;
E
- EIV, Emergency Inventory control Valve; - safety valves; - programmable logical controllers (PLC’s); - intelligent electric actuators - STVM;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
24 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- radar or servo-operated level meters- TGS; - distributed control system - DCS; - programmable electronic system - PES; - server computers, switches, routers and firewalls; - advanced control software, reconciliation production data software, historical production data software, process alarm management software, control loop tunning and auditing software; - combustion emissions monitoring system – CEMS; - custody and transfer measurement station – EMED; - Dynamic Process Simulator; - Automated System for Selling Products.
5.2.
INSTRUMENTS IDENTIFICATION
5.2.1 Each instrument or Loop function shall be identified by an alphanumeric code or TAG classifying it functionally and sequentially, in accordance with ISA 5.1 Standard and I-DE-6000.67-0000-941-PDY-001 Standards drawings and specifications piping service & special identification. 5.2.2 To facilitate the use of data banks the following pattern for identification of instruments shall be followed: ID_FUNC v m
ID_LOOP
f f f
ID_FUNC v m fff
= = = =
SUFIX
- a a a a n n n Functional Identification (maximum 5 characters); Measured variable or starter (1 character) ; Modifier letter or variable (1 character); Function of instrument;
ID_LOOP = Identification of the loop (7 numbers) – Based on a range established by PETROBRAS; aaaa = area or unit – 4 digits; nnn = sequential number of loop; SUFFIX (optional) = letter used to differentiate instruments with the same functional and loop identification.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
25 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.2.3. For each process variable beginning with letter of ISA 5.1 table, sequence shall have all the range from 001 to 999. Instruments for the same service shall use the same sequential and a letter sufix. E
5.2.4 Exceptionally at 3200 area, the tag numbering shall be according to following rule: The main area - 3200 - will be break according to the next sub-areas: 3210 Feed Pre-heat and Furnaces 3220 Primary Fractionation and Quench 3230 Cracked Gas Compression (includes the Depropanizers, The Hydrogenation reactors, the Dehydrators and the Caustic tower) 3240 Cold Fractionation (Demethanizer, Deethanizer and C2 Spliter) 3250 Hot Fractionation ( C3 Spliter and Debutanizer) 3260 Refrigeration Systems 3270 spent Caustic Treatment 3290 Utilities 3550 C4 Hydrogenation 3600 Butadiene Extraction The construction of the instrument numbering criteria (tag number) shall be modified as: General tag construction = XX-AABBCCCDE, where: XX from 2 to 5 letters to identify instrument type, AA 2 numbers to identify the unit main part of the unit number 32, BB the subsystem identification, as showed on “a” sub item above, CCC serial number, 3 digits is mandatory, from 001 to 999, D suffix identification, 1 letter if necessary, it’s prohibited to a hyphen before suffix, E suffix modifier, 1 number, only if necessary;
5.2.5. Control and safety loops using the same primary element, such as orifice plate, the whole loop shall use the same sequential with letter suffix. In case of distinct instruments for control and safety loops at the same point, those for control shall have different tagging from those for safety. 5.2.6. Valve position transmitters, switches and indicators shall use the same number of the valve, with the inclusion of a letter suffix when required. The duplicity in other process variable shall be verified at the moment of use of ZS´s. 5.2.7. TAG number for motorized and electric-hydraulic valves shall be consistent with their respective loop.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
REV.
E
26 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.2.8 if the identification cannot be held down to 14 characters due to the limitations imposed by the Digital System, reduce the number of characters used for functional identification. The following fields shall appear in the structure of the data banks: Field TAG UNIT ID FUNC / LOOP SUFFIX
Number of Characters 14 4 9 2
How it is filled in normal TAG; adapted TAG; adapted TAG; adapted TAG.
b) Examples of functional identifications: • Transmitters and valves: FT, LT, PDT, TT, LV, PV; • Converters: TY, LY, PY; • Indicators: FI, FFI, PDI, PI, TI, LI, AI, DI, CI; • Controllers: FC, FFC, PDC, FQC, IDC, TC, PC, AC, FFC; • Alarms: PAH, PAHH, PDALL, PAL, ZAL, ZAH; • Positioners: ZT, ZSL, ZSH, ZLL, ZLH; Note : In undefined cases, modifying letters H and L shall not be used. Hand switches are HS or HMS (instantaneous). 5.3.
E
DESIGN DOCUMENTATION
The technical documentation that shall constitute the instrumentation detailed design, is that defined in PETROBRAS Standard NI-1883, which shall be integrally followed. See the minimum of documents but not restricted at the table below. ITEM
DOCUMENT
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BASIC DESIGN PROCESS FLOW DIAGRAM (DE) PROCESS DATA SHEET (FD) CAUSE AND EFFECT MATRIX (DE) PRELIMINARY LIST OF INSTRUMENT (LI) PRELIMINARY ENGINEERING FLOW SHEET (DE) SAFETY LOOP CLASSIFICATION REPORT INSTRUMENTATION DESIGN CRITERIA (ET) LOGIC DIAGRAM (DE) SYSTEM ARCHITECTURE (DE) DATA SHEET FOR SPECIAL INSTRUMENTS (FD) TECHNICAL SPECIFICATION FOR SPECIAL SYSTEMS (ET) PROCESS CONTROL DIAGRAM (DE) CONTROL LOOP DESCRIPTION (MD) DESCRIPTIVE MEMORANDUM FOR INSTRUMENTATION SYSTEM (MD)
1 2 3 4
DETAILED DESIGN PROJECT SCHEDULE (CR) LIST OF DESIGN DOCUMENTS (LD) LIST OF INSTRUMENTS (LI) LIST OF CABLES (LI)
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
27 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
LIST OF MATERIALS (LI) LIST OF SETPOINTS (LI) LIST OF ALARMS (LI) LIST OF INPUTS AND OUTPUTS (LI) COMMUNICATION LIST ( LI ) TECHNICAL SPECIFICATION FOR SUPERVISORY AND CONTROL SYSTEM (ET) TECHNICAL SPECIFICATION OF SAFETY INSTRUMENTED SYSTEM (ET) CALCULATION SHEET FOR SIZING PRIMARY FLOW ELEMENTS (MC) CALCULATION SHEET FOR SIZING CONTROL VALVES (MC) CALCULATION SHEET FOR SIZING RELIEF AND SAFETY VALVES (MC) PIPING AND INSTRUMENTATION DIAGRAM (DE) INSTRUMENT MATERIAL SPECIFICATION (ET) ELECTRICAL INTERCONNECTION DIAGRAM (DE) CONTROL ROOM LAYOUT PLAN (DE) PNEUMATIC INSTRUMENTATION PLAN (DE) ELECTRICAL INSTRUMENTATION PLAN (DE) PLAN SHOWING ROUTING OF MULTI-CABLES IN CONTROL ROOM (DE) LOOP DIAGRAM (DE) LOGIC DIAGRAM (DE) PROCESS INSTALLATION DETAIL (DE) PNEUMATIC INSTALLATION DETAIL (DE) ELECTRICAL INSTALLATION DETAIL (DE) FUNCTIONAL DIAGRAM (DE) LIST OF ELECTRICAL LOADS FOR INSTRUMENTATION (LI) GENERAL ASSEMBLY DETAILS (DE) SUPERVISORY SYSTEM ARCHITECTURE DRAWING (DE) INSTRUMENT DATA SHEET (FD) MATERIAL REQUISITION (RM) TECHNICAL REPORT (PT) DOCUMENTATION ISSUED BY MANUFACTURERS MANUFACTURING SCHEDULE EQUIPMENT, INSTRUMENT OR MATERIAL DRAWINGS LIST OF DOCUMENTS TEST REPORTS CERTIFICATES
The following items contain the modifications, inclusions and observations that shall be applied to documents. 5.3.1. LIST OF INSTRUMENTS E
Form : A3 - standard NI-2833; by engineering program output, spread sheet or data base; Notes : a) the instruments shall be grouped by variable in alphabetical order, for loop nº. in the ascending order and according to item 5.2.2; b) it shall include all instruments of the Unit, including those of “Package Unit”, c) the documents shall only be included in the list after its issuance;
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
28 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
d) for instruments for which no documents will be issued (process/pneumatic/electrical details, loop diagram, etc.) the respective column shall be filled out with a line; e) the instrument list shall show the current situation of the project, being revised whenever a listed document is revised. 5.3.2. CONTROL ROOM LAY-OUT PLAN Form : A2 to A0 – standard N-381 Notes: a) all equipment shall be represented including the future ones; b) the equipment shall be represented in scale and with the indication of the maximum height; c) space shall be allowed for circulation, equipment inlet and outlet, maintenance, view of the process unit, etc; d) it shall be showed section views of the arrival of cables, of trenches, etc; e) the auxiliary systems shall be indicated (battery, telecommunications, conditioned air, pressurization, etc.); f) reference documents shall be listed. 5.3.3. ARRANGEMENT AND DETAILS OF PANEL AND / OR CONTROL DESK Form: A2 to A0 - standard N-381 Notes: a) the panel type shall be in accordance with the guidelines of the project; b) the layout of the instruments, commands and signals shall follow the main flow of the process; c) all instruments, commands, signals and tags shall be identified; d) the heights of the instruments, commands, etc., shall be identified; e) the tag inscriptions shall be identified; f) a detail of the panel fixture shall be indicated; g) a list of reference documents shall be indicated. 5.3.4. LOGIC DIAGRAM Form : A3 – standard N-381
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
29 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Notes: a) the used symbols shall be defined in a “symbols sheet”, according to Code ISA 5.2; b) all indicated events in the cause and effect diagram and / or in the descriptive memorial shall be indicated in the diagram; c) reference documents shall be listed. 5.3.5. FUNCTIONAL DIAGRAM Form : A3 – standard N-381 Notes : a) symbols shall be in accordance with standard N-898; b) electrical supply for instruments shall be indicated along with their switches, fuses and terminals; c) the physical connection of the logic shall be indicated whenever it is executed by relays, showing field switches, terminals, relays and final elements; d) when a relay is indicated, the contacts of this relay shall be identified related to its position in the functional diagram , through table of addresses in the same vertical of its coil. 5.3.6. LOOP DIAGRAM Form : A3 – standard N-381 Notes: a) pneumatic local loops that does not passes through junction boxes shall not be represented in this diagram , because it would be a repetition of the pneumatic installation detail; b) it shall be represented in the document the symbols system and codification; c) instruments and terminals shall be located in columns according to its location (field, junction box, rack, behind the panel, front of the panel, etc.); d) the cables, multi-cables, junction boxes, terminals, strips of terminals, number of the section of the panel, etc, shall be identified; e) the electrical supply of the instruments, with its switches, fuses and grounding bar shall be represented; f) indicate cables and multi-cables shields insulated next to the instrument and to the cabinets of the DCS, respectively;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
30 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
g) indicate general shields of the multi-cables originated in the field and of the cabinets of DCS connected in the grounding bars of the marshalling cabinets, for analog, thermocouple and digital signals; h) for analog signals diagrams, the individual shields of the individually connected pairs / terns shall be indicated in the terminals (terminals A and B in the marshalling cabinets) or alternatively in the vertical grounding bars (also individually) in the marshalling cabinets, for both the pairs / terns originated in the field as for those originated in the DCS or PES; i) the CONTRACTOR shall prepare the complete loop diagram, filling out the applicable information related to the DCS, such as: terminals, location, logical address based in the information generated by the configuration team; j) it is in the scope of the CONTRACTOR responsible for the detail design , the interconnecting design FIELD/DCS in the terminals marshalling cabinet based on Loading Table defining the connections in the DCS; l) it is in the scope of the CONTRACTOR responsible for the detail design , the interconnecting design FIELD/PES in the terminals marshalling cabinet based on Loading Table defining the connections in the PES; m) it is within in the scope of the CONTRACTOR responsible for the activity of construction and assembly the interconnection FIELD/DCS in the terminals of marshalling cabinet; n) it is within in the scope of the CONTRACTOR responsible for the activity of construction and assembly the interconnection FIELD/PES in the terminals of marshalling cabinet; m) it shall contain TAG’S index sheet. o) a loop diagram design with H1 Foundation Fieldbus segments shall be as the following examples: - General notes and symbols.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
31 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- FIRST PART: Segments per gateway H1 to HSE with junction boxes and devices.
-
SECOND PART :Loop diagram
E
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
E
32 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.3.7. LOCATION DISTRIBUTION
PLAN
FOR
PNEUMATIC
INSTRUMENTS
AND
AIR
Form : A2 to A0 – Standard N-381
E
The location plan for pneumatic instruments and air distribution shall be extract by the 3D model – PDMS design. The ground of drawing shall have the equipments and principals pipes with the valves on their real positions. The equipments and pipes shall be represented with a thin line in a light gray scale and the instruments, instrument air distribution pipes and accessories shall be represented with a strong line to intent a contrast among then. Notes:
E
E
a) the scale of the drawing and its limits preferably shall be the same of the equipment layout plant. The scales 1:50, 1:331/3, 1:25 can be used depending on the largest or smaller complexity of the drawing; b) the drawing shall include reference, axis, structure, equipments and principals points such as battery limits, grade, adjacent drawings, etc; c) the symbols used in the identification of the instruments shall be identified; d) the design north arrow shall be indicated on the drawing;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
33 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
e) in case there are more than two drawings, a key plan shall be represented on the title block of the drawing with the location of the respective drawing hatched; f) it shall be identified the elevation of the instruments and air distribution pots ;
E
g) it shall be identified on the drawing data such as width of the pipes and trays, elevations, elevation changes, quantity and identification of the tubes and multi-tubes in the tray, size of the pipes, etc.;
E
h) individual tubes of signal transmission shall be directed through reinforced fiberglass channel (perforated);
E
E
i) a list of materials shall be referred on the reference documents also containing the materials for supports in addition to those used in the Mounting and air distribution system ; j) represent the main air line and their extensions with their respective diameters, instrumentations tie-ins and elevations;
E
k) reference drawings shall be listed; E
E
a) air distribution pots shall be design with a block and drain valves, listed their consumers, two types will be applied: a. type 1 prepare for 6 consumers and their respective block valve and let one spare outlets . b. type 2 prepare for 12 consumers and their respective block valve and let two spare outlets . m) installation between air distribution pots and consumers shall be represented on the pneumatic hook ups;
E
n) specials consumers shall be detailed on the plan;
E
5.3.8. LOCATION PLAN FOR ELECTRIC INSTRUMENTS, LOCALS PANELS, SPECIALS SYSTEMS AND CABLES ROUTING Form : A2 to A0 – standard N-381
E
The location plan for electric instruments, locals panels, specials systems and cable routing, shall be extract by the 3D model – PDMS design. The ground of drawing shall have the equipments and principals pipes with the valves on their real positions. The equipments and pipes shall be represented with a thin line in a light gray scale and the instruments, panels, junction boxes, cable trays, conduits, specials instruments and accessories shall be represented with a strong line to intent a contrast among then. Notes:
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
34 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
a) the scale of the drawing and its limit preferably shall be the same of the equipment layout plant. The scales 1:50, 1:33 1/3 and 1:25 can be used depending on the largest or smaller complexity of the plant; E
b) the drawing shall include reference, axis, structure, equipments and principals points such as battery limits, grade, adjacent drawings etc; c) the symbols used in the plant shall be identified; d) the design north arrow shall be indicated on the drawing; e) in case there are more than two drawings, a key plan shall be represented on the title block of the drawing with the location of the respective drawing hatched;
E
E
E
E
f) it shall be indicated the elevation of the instruments, junction boxes, local panels, specials instruments, electrical conduits, cable trays and specials items represented on this drawing; g) it shall be identified on the drawing data as size and cables in the conduits, width and service of the cable trays, signal type, quantity and identification of cables and multicables, elevations and changes of elevations, junction boxes, locals panels, specials items, etc.; h) electronic signal cables shall be separated from the electrical sources according to the indicated distance in API RP 552; i) the electrical equipment installation shall be in accordance with the electric classification area; j) the symbols and coding of the electrical instalation shall be made according to N-298;
E
k) The cables and multi-cables routing, in the field, shall be made through according to follow rules:
E
1. Main cable routing – cable trays with 200mm minimum width, installed along to main pipe-rack, interconnecting areas and/or linking equipments inside the areas as: I. from junction boxes to local control room, II. from Local control to CIC. III. from Local panels to local control room, IV. networks
E
2. Secondary cable routing – cable trays, with 100mm minimum width, installed inside the areas, at auxiliary pipe racks and structure to interconnecting internals instruments and components : I. from instruments to junction boxes II. from Local panels to junction boxes. III. from Local power supply panels to local consumers,
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
35 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
The maximum width allowed for the cable tray shall be 600mm, the height shall be 100mm, The bend radius shall be 300mm
E
3. Tertiary cable routing – Aluminum conduits, from ¾ to 2 inch size, to carry cables from cable trays to instrument or equipment, This kind of installation shall be applied to carry and distribute signals in the area.
E
E
E
l) The cables shall be connected to the instruments and to the junction box through cable-press, at the end of the conduit shall be applied a bush to protect the cable; m) at least 3 different signal levels, far between 400 mm of distance trays with the following signal distribution shall be considered: 1ª tray: electronic signals (4-20 mA) and thermocouple 2ª tray: digital signal as Foundation Fieldbus, RS-485, RS-232 3ª tray: discrete signals – 24 Vdc and feed for instruments (24Vdc)
E
E
E
E
Duplicated level of cable trays can be considered when the great number of cables requires, n) The fiber optics shall be mechanically protected, installed in aluminum conduits, running beside at the cable trays, the redundant route shall be installed in a alternative way, avoid to lost of the communication in case of accident. o) Avoid installing cable tray systems in regions with high fire-potential equipments, as defined in API 2218. In those cases in which routing cannot be avoided (see sections 5.2.1 up to 5.2.5, sections 9 and 10 of this standard), additional protection shall be installed for the cable tray system using covers resistant to direct hydrocarbon fire such as protective blankets or paint systems with fire-retardant characteristics dependent on Petrobras approval, in accordance with this Standard and the cable shall be calculated for this kind of installation.; p) as basic criteria cables trays near these great an medium fire risk area shall be avoided; q) the junction boxes shall be identified in the following way: CJ (A)-(B) (C) where: A D F T X
(A) signal type
Analog signals Digitals signals Digitals signals Low Level Power supply
4-20mA, electronic instruments 24 VDC, discrete instruments Fieldbus Foundation instruments Temperature instruments (mV or ohm) 120 Vac Instruments feeds
(B)
- number of the Unit (primary element)
(C)
- sequential number of the junction box unit
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
REV.
E
36 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
r) the junction boxes shall be located preferably in areas of little electrical noise and of good natural illumination, considering the load distribution and whenever possible out of the electrical classified area; mounted at a structural steel rack in a easy access area.
E
s) the inlet to the CCL shall be made through aerial cable trays;
E
E
t) consider 30% of spare pairs / terns in the multi-cables from the junction boxes in the field to the marshalling cabinets. These spare pairs / terns shall be connected to the terminals in both, marshalling cabinets and junction boxes, In the marshalling cabinets and junction boxes there shall be plus 20% of spare terminals over the pairs / terns effectively connected; u) as criterion for grouping the signals of the multi-cables originated in the junction boxes there shall be, segregation by signal type and function, analog and digital signals of the same voltage level, terminal for solenoid, etc.) facilitating, this way, the marshalling to be done at the control room; at CJD’s, connecting digitals inputs and outputs shall be segregated in different terminals blocks and different multi cables. v) the electric feed cables for instruments 120 Vca, shall always be segregated of the signals cables; x) this document can be incorporated to the pneumatic routing plan , provided it will not be too congested; y) each VCD of the digital networks DCS, PES and Asset Management designed in different documents.
E
shall be
z) The cable color code below shall be followed to facilitate the identification during the construction, maintenance and future expansion. Signal type
Analog signals
Instrument Type Explosion proof instruments Intrinsically safety instruments
Over jacket color Black Blue
Thernocouple signals
According to ISA/ANSI MC-96.1
RTDs signals
Black
Digitals signals
24 VCC
Black
Fieldbus Fundation signals
FF instruments network
Orange
Profibus signals
Profibus network
Violet or purple
Hard wired cables
By MAC
Fiber optics cables
By MAC
Power supply
Instruments and panels
Black
Fire and Gas signals
Fire & Gas Systems
Black
Temperature signals
Industrial Network
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
37 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
5.3.9. PLAN SHOWING PANELS AND CABINETS POSITION AND ROUTING OF MULTI-CABLES IN CONTROL ROOM Form: A2 to A0 - standard N-381 Notes:
E
E
E
a) This draw could be extract from 3D-model or drawn in 3D-CAD with the same coordinates (reference point) of the CCL on the 3D-model, the routing of the cables inside the control room shall be done through cable trays, aerial, under false floor or areas being allowed according to the design guidelines. The electric conduits use is only allowed to network route; b) The draw shall show the route of cable trays in plan, view and details, cabinets and panels lay-out, interconnection with others draw indicating the cables and multi-cables coming to CCL. c) the cable trays and / or electric conduits shall be independent according to the level of signal. The separation of the cables shall be as described in API RP 552;
d) the grounding point for the instruments and cables shall be exclusive, and the connection of this point to the grounding bars shall be done by insulated and independent cables for each bar according to API-550 and NI-1882; e) The cabinets, panels and cable tray shall be grounded at electrical ground at the CCL;
E
E
f) a summary of the material used for the assembly shall be included (trays, supports, etc.); g) The cable tray inside CCL, shall be perforated type and fabricated in carbon steel hot dip galvanized,
E
E
h) The cabinets and panel shall be fixed in the carbon steel structural support; 5.3.10.CABLES / MULTICABLES LIST AND INTERCONNECTION DIAGRAM Form : A3 – standard N-2833
E
The cable list and diagram interconnection could be done on the same document, but the principals information shall be follow: Cable List information: a) identify the origin and the destination of the each cable or multi cable, b) shall be grouped in separated sheet by junction box, signal type, cable type;
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
38 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION c) Indicating the estimated length for each circuit; d) The summarize the quantity of each type of used cable; e) Plan of cables reel;
E
Interconnection Diagram information: a) This document shall be use to interconnecting all cables and multi cables from field to CCL; b) identify all interconnection from the field instruments to marshalling cabinet, c) Only one multi cable shall be showed per sheet; d) Junction box, multi cables and terminal block at marshalling cabinet, shall be mnemonic;
E
The cables, multi cables, junction boxes and terminal block shall be identified according to the follow criteria: a) For Hardwired cables: a. Cables from instrument to junction box use the instrument tag as cable tag; b. If the instrument has a power supply use prefix “X” to indicate electric feed to instrument and use a suffix “24” or “120” to indicate the power level, for ex: X-AIT-2200001-120; it means: electric feed to AIT-2200001 with 120V c. For junction boxes see item 5.3.8; in case of the junction box need to use two or more terminals block, these accessories shall be identify by letters “A”, “B”, ect; d. Multi cables from junction box to marshalling cabinets shall be identified with the same number of the junction box, for ex: Junction box = JBA-3200-01 Multi cable = MCA-3200-01, if there are more than one multi cable from this junction box, the multi cable shall have the follow identification = MCA-3200-01A; MCA-3200-01B, etc according to the terminal block it is connected; e. Terminal block at marshalling cabinet shall be identified according to the multi cable number, for ex:
MCA-3200-01 Multi cable, RBA-3200-01 terminal
block; f.
each multi cable shall be interconnected in only one terminal block, i.e., is forbidden to split the multi cable in many terminals block;
E
b) For fieldbus foundation cables: a. Cables from instrument to junction box use instrument tag with a prefix “S” indicating the connection from instrument to spur. b. Fieldbus junction boxes, in the same segment all junction box shall be identified with the same sequential number plus a suffix “A”, “B” or “C”, for ex: one segment on 3100 area has a three junction boxes, these identification shall be: JBF-310001A + JBF-3100-01B+JBF-3100-01C
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
39 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION c. Cables interconnecting between trunks in different junction boxes use the Fieldbus junction boxes plus a suffix indicating both junction boxes to be interconnected, for ex: using the same example above the cable interconnecting JBF-3100-01A to JBF-3100-01B will be T-3100-01-AB, where T indicating trunk interconnection. d. Cable interconnecting segment junction boxes to controller use a prefix “FF” plus area and sequential, for ex: FF-3100-01, according to the above showed. e. Cable interconnecting one terminal strip side “B” from marshalling cabinet to only one DCS controller shall be directing connected, it is forbidden split the multi cable in many terminals strip and or DCS controllers;
Notes: a) all signal cables (analog and digital) shall be totally shielded; b) the shielding shall have electric continuity when passing by a junction box through terminal terminals; c) the multi-cables of analog signals shall have individual and total shielding as well as double cover layer and PVC anti-flame (internal layers and covering); d) for standardization shall only be used multi-cables of 12 and 24 pairs, except for the interconnection between DCS and the “B” terminal of the marshalling cabinet, where 08 or 16 pairs multi-cable shall be used. E
e) For triplet cables, the multi cables shall be standardization in 8 or 12 triplet 5.3.11.DETAILS OF ELECTRIC INSTALLATION
E
Form : A3 – standard N-2833 Note: a) the abbreviations of the form shall be suppressed because they are only applied for process installation detail; b) this drawing represents typical electric installation detail between the instrument and the electric conduit (design limit between this detail and the electric location plan); c) the design detail and the installation material shall comply with the electric area classification;
E
d) union and flexible electric conduit shall not be used; for connection of the cable to instrument or equipment shall be used cable press, and conduits end shall has a washer to protect the cable,
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
40 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
e) a materials description table shall be used with their individual quantities by detail and total by sheet; f) the material code shall be in accordance with N-298; g) a material summary shall be included considering all sheets of the installation detail. 5.3.12.PNEUMATIC INSTALLATION DETAIL Form : A3 - standard N-2833
E
Notes : a) this drawing represents typical details of pneumatic installation between the instrument and the block valve of air supply (detailing limit between this detail and the pneumatic location plan); b) this drawing shall indicate in a single page the whole field connection. In case the panel instrumentation is also pneumatic this field representation shall be to a junction box;
E
c) a materials description table shall be used with their individual quantities by detail and total by sheet; d) special consumers shall have detailed on this set; like pressurized system for panels; instrument air supply to analyzers, etc. e) a material summary shall be indicated including all sheets of the installation detail.
E
5.3.13.PROCESS INSTALLATION DETAIL Form : A3 - standard N-2833 Notes: a) All instruments connected to the process line by impulse line shall have their installation detailed on this document;
E
E
b) Analyzers and specials instruments, which will be connected to the process line or equipment shall have these impulse line detailed on these details;
E
c) Specials materials and accessories for sample conditioning system shall be listed on these detail, if no detailed or listed by the supplier;
E
d) the limit of responsibility between the piping and the instrumentation installation shall be clearly represented indicating in these details, in case of the instrument installation in equipment, the first block valve (root valve) shall be installed by piping department, the orientation of the connections for the flow measurement (differential pressure flow elements) shall be represented on the detail with the high and low pressure connections;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
41 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
e) in the level details, the orientation of the connections and their respective elevations in the assemblies with “stand pipe” shall be represented; for the level instrument by differential pressure instruments, the high and low pressure taps shall be represented;
E
f) in the detail indication of inclination of the tubes in the remote assemblies (not directly in the line) shall be represented; g) materials description table shall be used with their individual quantities by detail and total by sheet; E
E
h) the material type selection shall be in agreement with I-ET-6000.67-0000-800PDY-004; i) an index shall be included (tag x page x rev.) organized by process variable and sequential numeric, when there are great amount of sheets in the detail; j) a material summary shall be represented including all sheets of the installation detail and the materials of the supports; k) the description of the material in the detail sheet can be simplified and the NM – (número do material) PETROBRAS identification numbering of material on the code position;
E
l) transmitters of differential pressure that use integral “manifold” shall be supported by the “manifold” in order to facilitate the maintenance; m) the flushing system shall be detailed by piping department and connected near to the instrument pressure tap using a block valve;
E
n) The seal fluid to fill the impulse line, shall be indicated on the detail sheet, and the will be used the drain connection of the manifold valve or drain point in the instrument to fill impulse line;
E
E
o) When the toxic fluids will be measure, the vent and/or drain point shall be direct to safety or closed system;
E
p) The insulation and energy conservation of the impulse lines shall be according to the process necessity; E
E
q) The EPC shall indicating on these documents the limits of the pressure test (hydro or pneumatic) shall be applied at the impulse lines; r) When the process installation require welds, the weld condition, tests and approvals shall be specified according to welding procedure technical specification issue by the mechanical department; 5.3.14.GENERAL ASSEMBLY DETAILS Form : A3-A0 - standard N-381 Notes :
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
42 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
a) include in these details metallic structures (local panels), typical assembly supports (“manifold” of instruments, electric conduits, trays, etc.) except for the supports of instruments already included in the process installation detail; b) a material summary shall be included with approximate amount of material used in the assembly fixation of the supports; c) indicate the amount of each typical support represented in this drawing. d) At the instrument supports the structure to fix the drain valve shall be detailed;
E
e) All supports shall be prepared and painted before installation according to painting procedure by EPC contractor;
E
f) Specials instruments shall be a covered to protect against direct sun light in yor LCD and rain;
E
5.3.15.SET POINTS LIST Form : A4 – Standard N-381, by spread sheet or data base;
E
It shall contain the instrument tag, the process measurement range, the instrument range, the type of alarm (if applicable) and the setpoint, in engineering units and range percentage. This list shall include all instruments having some type of calibration and those having alarms configured in supervisory, control or safety systems. Notes: It shall be Included all data configuration in other to deal with control and I/O blocks failure and change operation modes.
E
5.3.16. LIST OF ALARMS E
Form : A4 – Standard N-381, by spread sheet or data base; Notes: Alarms shall be in accordance to Technical Specification no I-ET-6000.67-0000-800-PDY003 - REQUIREMENTS FOR ALARM DATA BASE.
5.3.17. CALCULATION SHEETS. E
Form : A4 – out put of calculations program, The CONTRACTOR shall deliver calculation sheets in the following cases:
E
E
E
a) control Valves: Calculations according to NI-1882 recommendation and ISA 75.01.01 , 75.17 and IEC 60534-8-4 - CV; - noise level; - critical velocity of fluids; - control range; b) safety Valves:
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
43 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
- orifice calculation, reaction force, selection. Calculations according to NI-1882 recomendation and API RP 520. c) pressure and vacuum valves : - calculation of relief flow (pressure and vacuum) in agreement with API- STD 2000; d) flow primary elements: - dimensional calculation, including thickness; - calculation of the maximum and / or differential flow for existing and / or standard elements in agreement with the following standards :
E
E
E
- Standards : Square edge orifice plate - ISO 5167 (NBR-ISO 5167); Restriction orifice - ISO 5167 (NBR-ISO 5167) ; Venturi - ISO-5167 (NBR-ISO 5167); Annubar - ISO-5167 (NBR-ISO 5167); Flow Nozzle – ASME – MFC-3M Orifice plates of quadrant edge, conical inlet and eccentric orifice ABNT NBR 13225. For gas measurements in custody transfer applications use: AGA 3 for orifice plate; Mass balance flow measurements using orifice plates, the meter tube, orifice fitting, flow conditioner and uncertainty calculation shall be consider to improve the global mass balance; e) critical speed for thermo-wells : - calculation in agreement with ASME PTC 19.3. 5.3.18.MATERIAL REQUISITION. Form : A4 – standard N-2833
E
The technical documentation to be supplied by the manufacturers of equipment and instruments, shall be described in the Materials Requisition. 5.3.19. DATA SHEETS. E
Form : A 4– standard N-2802 and ISA TR 20 Notes : a) the data sheets shall be issued in the specific forms that complies with ISA 20; b) for those not standardized , use the form standardized by N-381 for its issuance; c) the data sheets electronically elaborated shall follow the standardization of the original format of the specific form.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
44 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.3.20. E
LIST OF INPUT/OUTPUTS
Form : A4 - spread sheet or data base out put Notes :
E
a) this document shall list all instruments, digital functions or electrical accessories to be connected to digital systems hardwired or via digital communications, organized per type of signal, per digital system and per signal transmission (hardwired or digital serial communication); b) the designer shall issue this document at about six months after the beginning of design. 5.3.21. LOADING SIGNALS TABLE
E
Form : A3 – spread sheet or data base out put; Notes : a) this document shall consider all instruments connected to the digital system as PES, DCS and etc.. b) it shall identify for each instrument cable, the cabinet, chassis, module and terminals where it is connected. 5.4. GENERAL REQUIREMENTS FOR DESIGN AND SPECIFICATION OF INSTRUMENTS.
E
E
The EPC CONTRACTOR will not issue a new design criteria, shall be used this document; 5.4.1 The design shall comply with PETROBRAS Standard NI-1882 and these recommendations. 5.4.2 The instrumentation shall be of the electronic type. Metering and Control Signals connected to PES and PLC´s of package units transmitted from the field shall be in 4 20 mA with the HART serial protocol in the same cable, fed at 24 VDC. 5.4.2.1 For analog instruments designed for control and monitoring connected to DCS , they shall specified with Foundation Fieldbus protocol compatibility . 5.4.2.2 For discrete instruments like limit switches and solenoid valves, the design shall consider Foundation Fieldbus devices, if there is no approved device available an alternative can be used a connection to multi input/output discrete to Foundation Fieldbus Converters and connected to DCS.
E
5.4.2.3 The start/stop push buttons for the electric motors the design shall consider the connection direct to MCCs.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
45 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.4.3 In the case of 4 to 20 mA transmission, the option is for two wire type, with use of the four-wire system being accepted if the first option is not available in the market, and for a specific application. In that case the 4 -20 mA signal shall be galvanically insulated. 5.4.4 Transmitters shall be of the intelligent and microprocessor-based type. Handheld programmers shall be provided for configuring these instruments, considering 1 (one) programmer for every 25 (twenty five) transmitters from that manufacturer. In case the number of transmitters is less than 25 units, at least 01 (one) programmer shall be supplied per instrument manufacturer. 5.4.5 Absolute, gauge or differential pressure transmitters shall have digital output signal indication in engineering unit in the transmitter itself. 5.4.6 Pressure switches and thermostats shall not be used unless previously authorized by PETROBRAS. Flow switches shall only be used to detect the presence of flow where reliability is not important. Transmitters shall be used instead of level switches, pressure switches, thermostats, etc.
5.4.7 All field instruments shall have permanent stainless steel plates indicating the instrument TAG number. 5.4.8 Do not specify instruments under development or whose use is not yet consolidated. 5.4.9 Do not acquire instruments for the same function from different manufacturers.
5.4.10 Regulating filters shall have output pressure indication in Kgf/cm2. 5.4.11 All electronic instruments and equipment shall be built to display immunity to electromagnetic and radio frequency interference (EMF-RFI), as follows: induction less than 1% of SPAN, based on 5W/470MHz at 1 meter away. E
5.4.12 When more than one valve or flow transmitter is necessary for the same service , the engineering flow sheets shall show all the instruments and be submitted to PETROBRAS for approval. 5.4.13 Valves intended for special applications such as, for example, isolation valves, fire-safe valves and tight shut-off valves shall be selected according to the specifications of the basic design and submitted to PETROBRAS for approval. 5.4.14 The shut-off valves shall be design with approved gasket kit to warranty no leakage when the process fluid is toxic, volatile or others(as defined in environment criteria). 5.4.15 Instruments installed outdoors and in non-classified areas shall have enclosures with a degree of protection of IP 65, in accordance with NBR IEC 60529.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
46 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.4.16 The use of intrinsically safe (Ex-i) or EX na [L] instrumentation with FNICO or FISCO Foundation Fieldbus Concepts in classified areas as zone 0 , 1 and 2 shall complies with IEC 60079-27 . For 4-20 mA instruments the enclosure may be certified as Ex d bud submitted to PETROBRAS for approval. 5.4.17 Electrical instruments and electrical equipments shall be compatible with the electrical classification of the area and have a Conformity Certificate. This certificate shall also contain the degree of protection (IP) of the enclosure. 5.4.17.1 This Certificate of compliance shall be supplied according to regulation “Portaria numero 83 de 03 Abril de 2006” published by INMETRO, to attend Brazilian laws. 5.4.17.2 This certificate shall be issued by an Accredited Certification Organization (OCC), that is an entity accredited by INMETRO responsible by the issue of the conformity certificates and by the inspections of the certified products, attesting the similarity of the analyzed requirements, with the dispositions of the resolution mentioned above. The accredited certification organizations are the following: • CEPEL - Centro de Pesquisas de Energia Elétrica Escritório de Certificação de Produtos - ECPS Address: Av. 1, s/nº - Ilha da Cidade Universitária 21941-590 - Rio de Janeiro - RJ -Brasil Tel. + 55-21-598-2442 or 598-2461 Fax. + 55-21-598-2443 Contact: Mr. Marcelo Appel Silva • UCIEE – União Certificadora de Indústria Eletro-eletrônica Address: Av. Brigadeiro Faria Lima, 613, 2º andar São Paulo - SP -Brazil Tel. + 55-11-820-7144 Fax. + 55-11-820-2674 Contact: Mr. Paulo Vieira
E
• CERTUSP – Serviço Técnico de Certificação do IEE/USP (Instituto de Eletrotécnica e Energia da USP) Address: Av. Prof. Luciano Gualberto, 1289 Cidade Universitária - São Paulo - SP CEP 05508-900 – São Paulo – SP - Brazil Tel. + 55-11-818-4912 Fax. + 55-11-212-9923 Contact: Mr. Jean Bodinaud http://www.iee.usp.br e-mail:
[email protected] 5.4.17 For services with H2S and H2 the piping criteria and standards N-76 and N-1882 shall be followed. The following general requirements shall be considered: a. threaded process connections may not be used;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
47 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
b. if use of welded connection is necessary, use socket weld. Sealing weld is not acceptable; c. for pressure gauges use integrated diaphragm seal; d. piping criteria such as radiography, non-destructive tests, etc. shall be evaluated and used in the installation of instruments. These criteria shall be defined in the installation details; e. the use of diaphragm seals associated with capillaries shall be avoided, and will only be adopted with prior approval by PETROBRAS; f. the condition “H2 or H2S Service” shall be indicated on the Data Sheets of instruments and supplementary requirements of materials, tests and certificates required shall be included. 5.4.18 The current consumption of instruments shall be 20 mA (max.). 5.4.19 The AI function block execution time of temperature Foundation Fieldbus instruments shall be 60 ms maximum and 30 ms (max.) for other types. 5.4.20 The response time (time constant + dead time) of instruments shall be 250 ms (max.).
E
5.4.21 All intelligent instruments shall be able to make self-diagnose.. All licenses nedded for achieve the advanced diagnoses shall be supplied with the instruments. Including the licenses nedded in the Asset Managment System, if applicable.
5.5.
TEMPERATURE INSTRUMENTS SPECIFICATION
5.5.1. SELECTION CRITERIA 5.5.1.1 Specify K type (chromel / alumel) thermocouple loops as standard for the entire unit. E
4.5.1.2 Specify RTD class A for temperature compensation with an operating temperature below 400 oC and for indicating or recording for operating temperatures below 60 oC. 5.5.1.3 All the temperature loops shall have a thermocouple connected to the temperature transmitter for the signal transmission to the digital monitoring, safety and control system.
E
5.5.1.4 Indication temperature shall be design with multiplexer transmitter. This indication can’t be used to advanced process control. The distribution design of thermo elements shall consider that the lost of one multiplexer transmitter don’t cause the lost of information of one level of towers, one pass of fired heater and others group of indication raise difficulties of operating the unit.
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
48 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.5.1.5 Do not use instruments with bulb and capillary (sealed expansion systems). 5.5.1.6 Use terminal block with compression spring, union and head in cast aluminum IP65 enclosure, NPT thread connection;
E
5.5.2. PROTECTION OF PRIMARY ELEMENTS 5.5.2.1 Temperature metering units on sulfur lines shall be installed so that the sensor is immersed at all times in the liquid. 5.5.2.2 The designer shall present calculation sheets giving the resistance and vibration of thermometric wells, considering the maximum speed of fluid under operating conditions and performing the check in accordance with ASME PTC-19.3 Part 3. If wells under high vibration conditions are identified in this checking procedure, the well shall be resized according to the recommendations of the aforesaid code. 5.5.2.3 All flanged wells shall use a full penetration weld between the well and the flange. 5.5.3. THERMOCOUPLES 5.5.3.1 In control and safety functions, the thermocouples shall be double type. Thermocouples shall have mineral insulation presenting a minimum insulation of 20 M~ @ 600 °C, with magnesium oxide or alumina with a le vel of purity of 99.6%. 5.5.3.2 In thermocouples for measuring the temperature of furnace tubes, use shall be made of wells with the end opened and welded to the piping and flexible thermocouples to be inserted and removed with the furnaces in operation. If this type of installation is not possible, use a skin point as an alternative as per API RP 551. E
5.5.3.3 In thermocouples for measuring multiple temperature points of hydroprocessing (hydrocracking and hydrotreating), isomerization, catalytic reforming regenerators and fixed bed reactors, use shall be made of flexible sheath/thermowell with up to 9 thermocouples located along the length. 5.5.4. RESISTANCE BULB (RTD) 5.5.4.1 The RTD shall correspond to the following performance: Stability: +/- 0.025 °C/ year of op eration
E
Repeatability: 0.025% or 0.05 °C ( whichever is the greater) E
5.5.4.2 In control and safety functions, the resistance bulbs shall be double type.
5.6.
PRESSURE INSTRUMENTS SPECIFICATION
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
49 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.6.1. SELECTION CRITERIA (EXCEPT FOR ELECTRONIC TRANSMITTERS) 5.6.1.1 For measuring very low pressures or vacuums, bellows or sensors shall be used.
diaphragm type
5.6.1.2 The selection of the pressure sensor range shall cover a possible rise in pressure in the system and instantly absorb at least 1.3 times the maximum working pressure. 5.6.1.3 The pressure sensor shall withstand a direct or reverse overpressure equal to the maximum nominal static pressure without affecting calibration or displacing zero. 5.6.1.4 Any output variation caused by a static pressure variation equal to 100% of the nominal pressure of the element shall not exceed 1% of SPAN. 5.6.2. PRESSURE INSTRUMENT ACCESSORIES 5.6.2.1 Accessories such as pressure limiters, separators and pulsation dampers shall be used only when absolutely necessary. 5.6.2.2 Where there is intense vibration on the process line the instrument shall be provided with a pulsation damper or a seal with capillary extension for installation on a pedestal.
E
5.6.2.3 All differential pressure instruments shall have an integral manifold with connection to the instrument through ½” oval flange, without dispensing the blocking of the line adjacent to the process connection. When the instrument is applied in H2S or H2 service, ½ “ oval flange shall be applied on both sides of the manifold; 5.6.2.5 All pressure gauges shall be installed using multi-valves with a built-in drain. 5.6.3. PRESSURE TRANSMITTERS 5.6.3.1 For all differential pressure metering instruments the high and low pressure connections shall be clearly and visibly indicated. 5.6.3.2 Pressure transmitters (absolute, gauge or differential shall be intelligent and programmable with an IP65 enclosure, Ex d, Ex i or Ex nA[L], capacitive or piezo-resistive sensor, foundation fieldbus or 4 – 20 mA output signal plus Hart, where applicable. 5.6.3.3 The transmitters shall be selected in accordance with the following ranges: a) gauge pressure transmitters: (-0.6 – 1.0 to 20.0 Kgf/cm2 ) or (0 – 1.0 to 20.0 Kgf/cm2 ) or (0 – 20.0 to 120.0 Kgf/cm2 ) or (0 – 120 to 250 Kgf/cm2 ) or (0 – 250 to 350 Kgf/cm2 ); b) absolute pressure transmitters: :(0 - 50 to 750 mmH2O)
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
50 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
b) differential pressure transmitters:(0 - 12 to 100 mmH2O) or (0 – 250 mmH2O to 1000 mH2O ) or (0 – 1000 to 10000 mmH2O) or (0 – 1.0 to 5.0 Kgf/cm2 ) or (0 – 5.0 to 30.0 Kgf/cm2 ). 5.7.
FLOW INSTRUMENTS SPECIFICATION
For FIs in the field, BARTON cells shall not be used. Use transmitters with local indication on the transmitter itself or on a separate indicator or both when necessary. 5.7.1. DIFFERENTIAL PRESSURE TYPE METERS - ORIFICE PLATES 5.7.1.1 For flow rangeability greater than 9 to 1, the use of Ultrasonic, Vortex, Coriolis effect or thermal effect meters shall be preferably evaluated, avoiding the use of plate holders. 5.7.1.2 For arrangement of multiple instruments for the purpose of voting 2oo3 in the SIS system, the criteriais to specify two orifice flanges with connections for two transmitters each in serial installation. 5.7.1.3 When it is not possible to use the solution described above the design shall consider an arrangement of the orifice flanges with connections for four transmitters. 5.7.2. ORIFICE PLATE CALCULATIONS 5.7.2.1 The minimum dimension of the line for meters in conventional metering services is 2”. If the process lines are smaller than 2”, the lines shall be increased to 2”. 5.7.3. ULTRASONIC AND CORIOLIS METERS 5.7.3.1 In the installation of ultrasonic and coriolis meters the upstream and downstream distances specified by the manufacturer shall be respected. 5.7.3.2 Special attention shall be paid to the piping arrangement for liquid measurement since the line shall work permanently full for proper operation of the instrument. 5.7.3.3 The intrusive meter (spool) shall be used where an accuracy of 1% or less is required. 5.7.3.4 The non-intrusive ultrasonic meter (clamp-on) will be used only for measurements in which its service is only intended for operational follow-up and which do not require a high level of accuracy. E
5.7.3.5 the non-intrusive ultrasonic meter (clamp-on) shall be protected with a cover.
E
5.8.
LEVEL INSTRUMENTS SPECIFICATION
5.8.1. LEVEL GAUGES. 5.8.1.1 Level gauges for services in hydrogen vessels at high pressure shall be installed using double blocking arrangements in accordance with PETROBRAS standard NI1882.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
51 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
5.8.1.2 The arrangement with stand-pipe shall not be used but when approved by PETROBRAS it shall have a block valve in accordance with the piping spec. between the vessel and the stand-pipe and another block valve of the ball type between the stand-pipe and the instrument according to the piping specification and with an operation blocking device. 5.8.1.3 The arrangement without a stand-pipe shall have double blocking arrangements between the vessel and the instrument, the first one being a gate valve and the second a ball valve. 5.8.2. LEVEL TRANSMITTERS. 5.8.2.1 Displacement level instruments shall be electronic, except in areas with temperature problems, in which case the pneumatic type shall be used. 5.8.2.2 The detailed design shall check the location of the nozzles on equipment drawings. 5.8.2.3 The elevation and orientation of nozzles shall be distributed around the entire vessel. 5.8.2.4 Care shall be taken to avoid concentrating the nozzles in a single region, thereby making it hard to access the instruments and do maintenance work. 5.8.2.5 Stand-pipes shall not be used for the installation of level instruments. For any reason if the application is recommended the design shall be submitted for approval.
E
5.9.
CONTROL VALVES SPECIFICATION.
5.9.1. SELECTION CRITERIA. 5.9.1.1 The selection criteria shall complies with NI-1882 and the preference is for the globe cage valve. 5.9.1.2 Types of valves such as rotary eccentric plug type, split body type, diaphragm type, ball valves and low noise valves are accepted where necessary. 5.9.1.3 In electronic loops use a microprocessor-based electro-pneumatic positioner. The positioner shall be immune to electromagnetic field. All positioners shall be intelligent and programmable with Foundation Fieldbus protocol. 5.9.1.4 The flow characteristic of the valve shall be selected from the valve positioner or plug. E
5.9.1.5 Special seal gaskets with constant load using plate and coil shall be used when the process fluid is toxic (benzene, aromatics, H2S etc) in accordance to Technical Guideline - AB-RE/ES/TEE - DT-AB-RE/ES/TEE-013 – Requirements for Process and
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
52 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Storage of Aromatics products. The construction shall be certified by TA-Luft and tested according to standard ISSO-15848 parts 1&2. 5.9.1.6 The minimum cycles without adjusting shall be required on the data sheet as complementary information at the applications with toxics fluids;
E
5.9.2. ACTUATORS. 5.9.2.1 All valves shall be supplied with a plug/stem travel indicator. 5.9.2.2 All actuators shall be capable to stroke with the minimum pressure of the air supply – 4,5 kgf/cm2;
E
E
E
5.9.2.3 Piston actuator shall be capable to adjust the velocity of opening or closing by air vent adjustable plug; 5.9.2.4 For the diaphragm actuator the supplier shall inform the useful life of the diaphragm in cycles; 5.9.3. ACCESSORIES (SWITCHES, HAND WHEELS AND SOLENOIDS). 5.9.3.1 Where required, position switches shall be easily adjusted at the desired operating points. 5.9.3.2 The nominal electrical capacity of the switch contacts shall be at least 50% greater than that requested for normal operation, 2 A at 24 VDC. 5.9.3.3 All position switches of control valves or dampers shall be of the magnetic type (reed switch sensor) without mechanical contact. 5.9.3.4 For elements with monitoring of the two positions (open and closed) when the valve is in the intermediate position there shall also be indicative signaling in the DCS. 5.9.3.5 Hand wheels shall be used for control valves installed without by-pass, except in the case of valves whose sole function is to ensure the safety of the system in which they are installed, or self-operated valves for temperature and pressure control. In the latter case local indicators shall be provided to check the controlled variables. 5.9.3.6 All solenoid valves connected with XVs, except where determined by the basic design, shall not use field resetting arrangements. Resetting will be via the DCS. 5.9.3.7 Solenoid valves shall have low power, limit consumption of 2.0 watts at 24 VDC. 5.9.3.8 Solenoid valves used in interlocking and safety systems shall be energized during normal operation, except the vent valves of gas header of furnace SIS. For solenoid valve of the SIS the selection criteria shall consider the SIL level of the safety function and the requirements for “partial stroke capacity” and the reliability.
E
5.9.3.8 all fittings and tubing shall be supplied in Stanley steel and fittings shall be supplied with double ferrule type;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
53 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION E
5.10. SALFETY AND RELIEF VALVES SPECIFICATIONS 5.10.1.SAFETY VALVES INSTALATION 5.10.1.1 In systems with pressure control with relief to flares, control valves cannot be considered to be safety equipment. 5.10.1.2 Do not align the discharge of PSV´s working with flammable or toxic products to the atmosphere. 5.10.1.3 The basic design shall define the services where more than one PSV is necessary and in this case where the switching on-line device is necessary. 5.10.1.4 The basic design shall define which PSV must have a device to indicate the opening of it and alarming in the DCS. 5.10.1.5 In critical process units systems where maintenance demand of valves is done without stopping the whole unit paired PSVs shall be used according to Technical Guideline - AB-RE/ES/TEE - DT-AB-RE/ES/TEE-006 - “Use of paired PSVs”. E
5.11. PROCESS ANALYZERS SPECIFICATIONS For additional information see ET-6000.67-0000-850-PDY-001, Sistemas de Amostragem, I-ET-6000.67-0000-951-WAP-028 – SPECIFICATION FOR PROCESS ANALYZER SYSTEMS AND NETWOR 5.11.1.DEFINITIONS a) Analyzer - An instrument which measures some material quality or property other than temperature, pressure, level or flow. b) Analyzer Cabinet - An enclosed housing that protects a small number of analyzers. Maintenance is performed from outside the cabinet with the door(s) open. c) Analyzer Shelter – Can be of the two types: Three sided shelter structure consisting of a roof and one to three walls and Closed shelter – structure like a container with door , both provides weather protection for one or more analyzers and for maintenance personnel. d) Analyzer System – A set of Analyzers, equipment, instruments, accessories and others, assembled together to form a whole system. e) Calibration – The manual or automatic action of adjusting analyzer output to agree with the reading expected from the calibration sample introduced. f) Calibration Sample – The material used to calibrate the analyzer, which quality or property is known. The calibration sample may have been analyzed in a local laboratory or purchased with a certificate of analysis. g) Contractor - The ones responsible for the supply of the material and/or services to PETROBRAS, and shall comply with any local rules or regulations which are specified.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
54 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
h) Manufacturer – The ones who manufacture or assemble equipments, instruments, modules or part of these ones. i) Response time – Response time for each stream is the period between two consecutive analyzer results. j) Sample Conditioning System (SCS) - A combination of modules installed directly upstream of an analyzer’s inlet to modify and adjust sample parameters according to those required by the analyzer. Modules commonly used in sample conditioning systems include filters, separators, vaporizers, scrubbers, reducing regulators and temperature controllers. k) Sample Tap - A connection point where samples are taken from a process stream. l) Sample Transport System - A piping system used to transport the sample from the sample tap to the SCS, to Sample Return System and back to process. m) Validation – The manual or automatic action of comparing (rather than adjusting) the analyzer’s output to the reading expected from the sample introduced. Validation results are kept on a control chart to demonstrate that the analyzer is operating in statistical control. n) Validation Sample – The material used to validate the analyzer, which quality or property is known. The validation sample may have been analyzed in a local laboratory or on the existing analyzer, or purchased with a certificate of analysis. If any definition of this document needs to be changed by contractor, PETROBRAS shall be consulted to approve it. 5.11.2.ANALYZER GENERAL 5.11.2.1 The detailed design shall determine the location of sample connections based on the specifications of the basic design and on the response time required by the process. 5.11.2.2 The required response time is the sum-total of the time for analysis and circulation of the sample from the process line to the input into the analyzer. E
E
5.11.2.3 Electric power supply for Process Analyzers shall be provided by the Instrumentation Supply System. 5.11.2.4 A single integrating company shall be contracted for supply of each process analyzer of the project. The integrating entity will be responsible for the supply, installation, including a sampling system, consumers and start-up of the analyzers in accordance with analyzers specifications. 5.11.2.5 The protection shall be specified according to the product, importance, environmental and safety conditions and may be of the case, cabinet, shelter or house type.
E
E
5.11.2.6 The protection involves specification of the ventilation (natural or forced) system, closed drains, safety vents, monitoring as to gas leakage and requirements for alarms. 5.11.2.7 For analyzers installed at a distance from the sample connection, sampling carrier systems shall be specified. These systems shall be designed in fast loop and sample recovery regime so as to minimize product loss. Calculations involve pressure
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
55 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
drop, flow speed, line dimensions and fluid properties. Avoid removing fast loop connections on control valves. 5.11.2.8 Bypass systems shall be used in cases of vaporization of liquids for analysis of gases. E
5.11.2.9 For automatic control, single stream analyzers are recommended. Multiple stream analyzers may only be used after an evaluation is made demonstrating that system reliability is not jeopardized. 5.11.2.10 The design for the sampling system and installation shall complies with EEMUA Publication 138. 5.11.2.11 FAT (factory acceptance test) and SAT (site acceptance test) shall be performed for analyzers with all validation process that complies with ASTM D 3764. 5.11.2.12 A Notebook and/or Handheld computer shall be provided for access and connection to application programs for configuration and maintenance of this analyzer, including shelter monitoring and control systems such as PLCs. 5.11.2.13 Present a list of spare parts for two years of operation, covering all systems contained in the shelter such as: analyzer, PLC, sampling system and air conditioning system. 5.11.3.SCOPE 5.11.3.1 The Analyzers System shall be designed for continuous and efficient operation. The consumption and wastage of process samples and utilities shall be minimized. 5.11.3.2 Design practices shall be logical and consistent throughout the project. Consideration shall be given to uniformity in the selection and use of materials, components, and equipments. Construction materials shall be specified as noncorrosive and noncombustible in normal plant operating environments. 5.11.3.3 The analyzers shall be furnished in accordance with the project requirements. The Contractor may propose additional or alternative analyzers or methods for PETROBRAS approval. 5.11.3.4 PETROBRAS shall approve the analyzers data sheets completed by the manufacturer. Note: Plant upset conditions and extremes must be included in addition to normal process variations. 5.11.3.5 The analyzers manufacturers shall inform the sample temperature, pressure and flow requirements for the proper operation of the analyzers, as well as the sample components (with concentrations) that may cause damage or degradation to the analyzers. 5.11.3.6 The environmental variations (barometric pressure, temperature, humidity, etc.) shall be considered for the performance criteria assessment. Note: The manufacturer shall be responsible for installation of any device necessary to correct or compensate the environmental influence on the system performance.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
56 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.3.7 The sample system and analyzer shall be designed to recover automatically from upsets at the specified design limits. Note: The analyzer need not maintain its specified accuracy outside the specified normal operating range. 5.11.3.8 Analyzers and associated equipment shall meet the requirements of applicable national and local codes. The Contractor shall certify in writing that all of these requirements have been met. Any deviation from requirements must be submitted to PETROBRAS for approval prior to purchase and installation. 5.11.3.9 Drawing symbols shall conform to ISA 5.1. 5.11.3.10 The total analyzer system shall meet the electrical classification of the area in which it is installed. 5.11.3.11 All materials shall be suitable for the sample stream and the surrounding atmosphere. Nonmetallic materials or low-melting alloys shall not be used in lines handling hydrocarbon or other flammable substances. 5.11.3.12 A system for purging and cleaning the analyzers, sensors and sampling system shall be supplied to prevent deposits on the sensors during shutdown. 5.11.3.13The supply a return taps for all analyzers shall be defined in the P&ID. 5.11.3.14 The Analyzers System shall consist of sampling system, sample conditioning system, auxiliary equipments and accessories, as required to monitor and provide the necessary data for proper process operation. All related services as technical and engineering, assemblage, commissioning, start-up, pre-operation, and training shall be included. 5.11.3.15 The analyzers, sampling system, and related equipment shall be mounted and interconnected with utilities and accessories as required for continuous and unattended operation. 5.11.3.16 The Analyzers System shall include devices and facilities to provide convenient operation and maintenance. 5.11.4.MANUFACTURERS RESPONSABILITIES. 5.11.4.1 The manufacturers shall be responsible for the design from the process sample tap to the output signal wiring and include all aspects required for proper operation of the Analyzers System as well as the interconnecting piping, tubing, and wiring as required for installation of the Analyzers System at the jobsite. 5.11.4.2 The manufacturer shall be responsible for: a) the correct design and proper operation of the Analyzers System;
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
57 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
b) compliance with technical specification; c) PETROBRAS technicians training; d) pre-operation, start-up, and assisted operation of the Analyzers System. 5.11.4.3 The manufacturer shall be responsible for all activities related to the design, assembly and installation of the Analyzers System. The extent of work shall include, but not be limited to the following: a) engineering design and specification of the Analyzers System; b) preparation of design drawings for Analyzers System; c) coordination and expedition of all purchase orders for calibration standards and equipment related to the Analyzers System.
materials,
Notes: 1) the purchase orders necessary for the sample transport line (fast loop), may be emitted by CONTRACTOR in accordance with the manufacturer design specifications; 2) the purchase orders necessary for the cylinders and calibration standards shall be emitted to Brazilian companies (AGA, White Martins, etc); 3) all calibration standards shall have validation expiration date at least 6 months after plant start up. 5) assembly of Analyzers System according to design drawings and specifications; 5) test and inspection of all Analyzers System, at the factory and at the plant site; 5.11.4.4 The manufacturer shall be responsible for packing the Analyzers System properly for maritime and road transport. 5.11.5.CONTRACTOR RESPONSABILITIES. 5.11.5.1 CONTRACTOR shall be responsible for the following works, in accordance with the manufacturer design: a) civil work; b) sample transport line and utilities pipe work; c) installation of power and signal cables (serial, analog and discrete communication) between analyzers system and control room, including conduit and cable trays. 5.11.6.CONTRACTOR AND MANUFACTURER RESPONSABILITIES.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
58 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.6.1 On-site analyzers system installation. 5.11.6.2 Coordinate the manufacturer for preparation and submitting to PETROBRAS comments of any analyzers system documentation which could be defined later between PETROBRAS and CONTRACTOR. 5.11.7.ANALYZERS SPECIFICATION 5.11.7.1 MEASUREMENT AND OUTPUT SIGNAL. 5.11.7.1.1 The required analysis measurement and output signals are given in the Analyzers Data Sheet. 5.11.7.1.2 The analyzers shall include a local multifunction indicator to display the measured values according to the specified range. 5.11.7.1.3 The alarm signals to the monitoring system, related to analyzers, shall be briefed in one discrete signal and sent as an individually isolated contact closure. The contact shall open on status change or power failure to analyzers. (Fail-safe action). 5.11.7.1.4 The Analyzers shall have an output status signal to validate the analyses output signal as “good/not good”, resulting from auto diagnosis, according to the data sheets. 5.11.7.2 SPECIAL ACCESSORIES. 5.11.7.2.1 The manufacturer shall inform all needs on special accessories and auxiliary equipment required for installation, operation, and maintenance of the analyzers (i.e., interconnecting cable, consumable material, or calibration kits). E
5.11.7.2.2 All cylinders to be applied as carrier gas, combustion gas or other finality, shall be furnished at least two cylinders per function, with a double stage reduction valve and an automatic change over and a pressure sensor to alarm when the change occur. These cylinders shall be supplied in quantity necessary for all tests, commissioning, start-up and enough for a period of 5 months after acceptance. 5.11.7.2.3 The gas cylinders, and calibration standards, if required, shall be supplied by the manufacturer, as defined at item 4.11.4.3 sub-item “c”. 5.11.7.3 CALIBRATION STANDARDS
E
5.11.7.3.1 The Standards shall be supplied in quantity necessary for all tests, commissioning, start-up and for one calibration per week during 4 months after acceptance. It shall be furnished at least two cylinders per standard, the standard composition shall be certified and the certificates shall traceable through NIST or NMI. 5.11.7.3.2 The standards certification shall inform: - Standard manufacturer name;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
59 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- Cylinder identification; - Filling date; - Analysis date; - Certificate expiration date; - Composition; - Method of analysis; E
- Validity; - Name of the person who is responsible for certificate. 5.11.8.SAMPLING SYSTEM 5.11.8.1 GENERAL
E
5.11.8.1.1 The Sampling System includes extract probes and transport lines, conditioning and disposal systems. It shall be designed to provide a representative process sample under conditions which are compatible with the operation of the analyzers. 5.11.8.1.2 The Sampling System shall be designed to minimize the consumption of process sample, thereby reducing product wastage and relieving potential hazards in the event of a leak. 5.11.8.2 DESIGN 5.11.8.2.1 The sampling systems shall be provided with filters, moisture removal, with control of sample temperature, pressure and flow, if required for proper operation of the analyzers. 5.11.8.2.2 Consideration shall be given to sampling streams for which temperature and pressure control are critical to maintain the dew or bubble point, and to prevent deterioration of the sample; Note: To guarantee the system performance, the manufacturer shall recommend, design and install special standard cylinders, line tracing, thermostatic cabinet, pressure control and any other devices to prevent system miss performance and malfunction. 5.11.8.2.3 In addition to these general design requirements and considerations, the Sampling System shall include the following specific features: a) samples shall be collected in order to guarantee representative information at the analyzer. The sample probe shall include a manual shut-off valve to allow isolation of the sample line at the tap;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
60 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
b) the Sample Transport and Conditioning Systems, if required, shall be designed to provide the least transport lag time from sample tap to analyzers entrance. The Sampling System shall incorporate a fast-flow loop to minimize transport lag time, if the analyzer is not close to the sample point; c) sample transport lines requiring heating shall have thermal insulation and steam tracing. Consideration shall be given to the operation and maintenance of heated sample systems without causing sample condensation. Sampling Systems requiring heating shall be installed in insulated enclosures; d) high temperature sample lines shall be insulated for personnel protection, according to piping thermal insulation standards recommendation; e) the analyzer shall be installed as close as possible of the sample tap, considering the analyzer limitations and personnel accessibility for maintenance and calibration; f) sample Conditioning Systems, if required, shall be mounted in IP-65 enclosures with thermal isolation and glass windows to observe and adjust the gauges inside without opening the cabinet doors; g) all sample indicators (temperature, pressure, or flow) shall be sized such that indication is in the second third of the scale under normal operating conditions; h) unless otherwise specified, primary sample filters and coalescers shall have a small internal volume; i) Sampling Systems shall include facilities for manual and automatic introduction of calibration samples to the analyzers, according to the data sheets; j) the design and assembly of Sampling Systems shall give proper consideration to the logical and consistent organization and configuration of component parts. Special consideration shall be given for sloping of lines, low point drains, condensation prevention, sample cross-contamination, dead-end pockets, and accessibility to maintenance items such as filter elements; k) a blocking system shall be supplied for the analyzers and for all the components of the sampling system (filters, coalescers, etc.) to allow maintenance work; l) a laboratory sample point shall be included in the analyzer system at an accessible point, near each analyzer to ensure that the laboratory sample is fresh and comparable to the sample supplied to the process analyzer. Note: Acquisition of a laboratory sample shall not interfere with the continued operation of the process analyzer. 5.11.8.3 COMPONENTS
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
61 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.8.3.1 Sampling Systems shall be designed and assembled with components for easy maintenance and/or replacement. Uniformity of component selection shall be a prime consideration in order to minimize the spares parts stock. 5.11.8.4 MATERIALS OF CONSTRUCTION 5.11.8.4.1 All materials in contact with process samples shall be corrosion resistant. E
5.11.8.4.2 In general component construction shall be stainless steel (type 316 or better, as required) with TEFLON (or equivalent), considering the maximum temperature of the sample. 5.11.8.4.3 No copper, zinc, or silver bearing alloys shall be allowed in contact with process samples. 5.11.8.4.4 Sample tubing shall be type 316, seamless, stainless steel with a minimum 0.89 mm wall thickness. 5.11.8.4.5 Where other material is required for a specific application, it shall be identified on the sample system drawing.
5.11.8.5 EFFLUENT SAMPLE RETURN/VENT 5.11.8.5.1 Analyzers effluent samples or fast loop streams shall be preferably returned to process. If returning to process is impossible the sample shall be directed to flare system through a pressure regulator valve, that guarantees the pressure upstream 7 psi above the maximum flare pressure. 5.11.9. THREE SIDED SHELTER, CLOSED SHELTER AND CABINET 5.11.9.1 GENERAL 5.11.9.1.1 The cabinet shall be supplied as a completely assembled package suitable for installation on a concrete pad at ground level. 5.11.9.1.2 All equipment including tubing, wiring and supports shall be installed so as not to interfere with the operation, maintenance or removal of the analyzers, sampling system, and related items. 5.11.9.1.3 Accessibility for operation and maintenance shall be taken into first consideration on the design and assembly of the Analyzers System.
5.11.9.2 THREE SIDED SHELTER , CLOSE SHELTER AND CABINET FABRICATION 5.11.9.2.1 Cabinet - The cabinet shall be an enclosed housing in which analyzers are installed singly or grouped together in a small number. Maintenance is carried out from outside the
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
62 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
cabinet with the door(s) open. - The monitor cabinet shall be designed to be weather and corrosion resistant. - The cabinet shall have glass windows to permit the visualization of the alarms and variables indication from outside. 5.11.9.2.2 Three Sided Shelter - The shelter shall be a structure consisting of a roof and one to three walls, that provides weather protection for one or more analyzers and for maintenance personnel. - The shelter roof shall extend over all the analyzer monitor cabinet, the calibration system and cylinder, at least 1.5 m at the front and back sides. 5.11.9.2.3 Closed Shelter The house shall be an enclosed container containing one or more process analyzers and associated equipment where streams for analysis are brought in and which is regularly entered by authorized personnel. The maintenance of the analyzer is normally carried out from within the closed shelter. 5.11.10.PIPING AND TUBING WORK E
5.11.10.1 The utility headers shall meet the following design requirements: a) utilities headers shall be sized according to the required capacity with spare allowance. The minimum size for headers shall be 1” pipe; b) they shall slope to a low point and include a drain/blown down valve, if required; c) connections to headers shall be at the top or side of the pipe; d) each header connection shall have an individual shut-off valve; e) steam and condensate headers shall be insulated; f) The gap between headers supports shall be 1.5 m at most; 5.11.11.TUBING 5.11.11.1 All interconnecting tubing shall be type 316, seamless stainless steel. All tube fittings shall be type 316 stainless steel, ½” and 0,065 inch thickness of wall. The tube fittings shall be double type. 5.11.11.2 Tubing for steam supply, tracing, and condensate return shall be insulated. 5.11.11.3 Tubing runs shall be organized and installed in logical groups and in a manner that allows easy identification;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
63 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.11.4 Tubing runs shall be supported every 1.5 m at most; 5.11.12.ELECTRICAL AND WIRING WORK 5.11.12.1 Electrical equipment, devices, and wiring shall comply with applicable codes and standards, and be suitable for the specified electrical area classification. 5.11.12.2 AC POWER. 5.11.12.2.1 AC Power will be available for the Analyzers System powering nominal voltages in accordance with Data Sheets. 5.11.12.2.2 Lighting inside the cabinet shall be supplied by fluorescent lamp fixtures. The light switches shall be located inside the cabinet. Note: Number required for 100 Lumens at working surface, vapor tight, industrial grade, Div.2. 5.11.12.2.3 The external lighting of the cabinet shall consist of fluorescent lamps, correctly supported for proper and adequate illumination of shelter inside and external panels. The light switches shall be located inside the shelter. 5.11.12.2.4 One convenience receptacle outlet shall be provided inside the shelter, besides the analyzers’. 5.11.12.3 ANALOG SIGNAL WIRING 5.11.12.3.1 DC signal wiring shall be run in a separate cable tray or conduit system and segregated from AC power wiring. A minimum of 300 mm separation shall be maintained with crossing made at a perpendicular angle. 5.11.12.3.2 DC signal wiring shall be cables with a twisted pair of wires and shield, unless special multi-conductor cables are required. 5.11.12.4 DISCRETE SIGNAL WIRING. 5.4.8.12.4.1 Discrete signal wiring shall be cables with pairs of conductors and run in a raceway system separate from AC power and DC signal wiring. 5.11.12.5 TERMINALS BLOCKS. 5.11.12.5.1 Terminal blocks shall be barrier type with tubular clamp connections and made of a non-hygroscopic material. 5.11.12.5.2 Terminal blocks shall be mounted on rails and installed in columns. 5.11.12.5.2 A minimum of 100 mm clearance shall be allowed for connection to terminal blocks.
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
64 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.12.5.3 A minimum of 50% spare terminals shall be provided. 5.11.12.5.4 Connection of more than one wire to one terminal is prohibited. 5.11.13.ELECTRICAL AREA CLASSIFICATION 5.11.13.1 All of the equipment shall be in accordance with the electrical area classification. 5.11.13.2 The enclosures shall be used in order to allow convenient access for maintenance. 5.11.13.3 Explosion-proof enclosures are acceptable for electrical devices and equipment that does not require access for routine maintenance, or for electrical components that are supplied with explosion-proof enclosures as a standard for hazardous areas. 5.11.13.4 Under no circumstances shall purging be used with an explosion-proof enclosure. 5.11.14.SAFETY REQUIREMENTS 5.11.14.1 The Analyzers System shall be designed and assembled to minimize the exposure of personnel to hazard. 5.11.14.2 Suitable signs shall be provided to warn personnel of potential hazards (e.g., sources of radiation, high temperature, pressure, or voltage). 5.11.14.3 The installation shall include, but not be limited to, the following hazard reducing procedures: a) protective guards shall be installed over sources of high temperature or voltage; b) high pressure sources shall not be located in areas of normal occupancy. In general, high pressure sources, like cylinders, shall be located outside the shelter; c) the quantity of hazardous samples (toxic or flammable) entering the shelter / cabinet shall be minimized; d) pockets or void spaces where hazardous gas could accumulate shall be eliminated; e) Sampling Systems shall include facilities for draining prior to maintenance. 5.11.15.TAGGING 5.11.15.1 All connections, components, devices, analyzers, and related equipment in the Analyzers System shall be identified as follows:
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
65 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.15.2 There shall be identification for : a) all termination points for field connections; b) analyzers, with the service, sample streams and measurements; c) sample system components, with the service and normal operating set-point; d) Power switches and circuit breakers, with the corresponding service; e) terminal blocks; f) all wires, with permanent wire markers; g) field mounted equipment, with the corresponding service. 5.11.15.3 It shall be furnished an additional identification or advising tag written in Portuguese besides each tag written in English. The translation of all texts shall be approved by PETROBRAS. 5.11.16.INSPECTION AND TESTS AT THE FACTORY 5.11.16.1 PETROBRAS shall be notified thirty days in advance of factory tests. 5.11.16.2 The Analyzers System shall be verified and tested prior to shipment, in order to assure the conformity with the design, and the proper installation and operation. 5.11.16.3 The checkout and testing shall include, at least, the following items: a) visual inspection of all work to assure mechanical completeness and compliance with all design drawings and specifications; b) visual inspection of all nameplates and tags to verify correct identification; c) point-to-point check of all wiring and tubing to verify proper interconnection; d) continuity and isolation test of all electrical wiring; e) pressure test of all piping and tubing; f) functional test of all electrical equipment, output signals, piping equipment, sampling system, analyzers and related equipment; g) calibration test of analyzers; h) Any other test agreed between PETROBRAS and manufacturer. 5.11.17.INSPECTION AND TESTS AT THE JOBSITE
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
66 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.17.1 PLANT ACCEPTANCE TEST (PAT) 5.11.17.1.1 Plant Acceptance Test is a repetition of the Factory Acceptance Tests verifying the system operability and fixing possible damages occurred during the transportation, after the analyzer system delivery and installation at the definitive site and interconnected to DCS. 5.11.17.2 PERFORMANCE TEST 5.11.17.2.1 The analyzers system shall be considered ready for this test when it has being totally assembled, connected to process/utilities, integrated to plant control system, and all non-conformities found during the Plant Acceptance Test (PAT) have being solved . 5.11.17.2.2 During the assisted operation period, the following tests shall be performed Availability - Validation - Stability a) Availability Test The system under test shall be considered available when all of its parts (sampling system, analyzers, safety systems, controllers and all other associated equipment and systems) are working in conformity with the specification. All the system will be brought into operation for a period of 168 hours. After that period of time, the Individual Analyzer Availability (IAA) shall be higher than 95%. The calculations for this index are shown in the next table.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
67 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
If this index is not reached within a maximum period of 30 days, considering 15 continuous days of test, the system will be considered not acceptable. This test shall include all purchased equipment and software. b) Performance Evaluation The analyzer system will be considered as performing satisfactorily, if the results obtained during the test run are lower than the standard levels defined in item 5.11.17.2.2. If one of them is higher, the test shall be repeated to verify if the analyzer system is working satisfactorily, and the analyzer system final acceptance shall be issued only when the performance criteria have been achieved. 5.11.18.SHIPMENT 5.11.18.1 The Analyzers System shall be prepared and shipped to the jobsite, with the following minimum protection measures: a) lines shall be cleaned; b) all external connections shall be capped or plugged to prevent entrance of foreign material; c) fragile or sensitive equipment and components shall be removed and packaged separately; d) all movable parts shall be secured or supported with shipping braces to prevent damage from vibration; e) all loose equipment shall be packed in shipping crates or cartons suitable for shipment. 5.11.19.ANALYZER SPARE PARTS 5.11.19.1 Spare parts shall be supplied for two years operation, for all Analyzers System equipment and accessories. 5.11.19.2 Manufacturer shall recommend spare parts and consumable for the complete analyzers system, including, if necessary, but not limited to the following: - Electronic boards: 1 of each type; - Relays: 1 of each type Switches and circuit breakers: 1 of each type; - Switches and circuit breakers ( for CEMES ): 1 of each type; - Lamps: 10% of total (at least 1 of each type);
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
68 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- Gaskets, O-Rings, Valve Packing: 10% of total (at least 1 of each type) ; - Diaphragms and other elastomer parts: 10% of total (at least 1 of each type); - Thermocouples and RTD: 1 of each type; - Electronic equipment ventilators: 1 of each type Power supply modules: 1 of each type; - Fuses: 50% of total (at least 3 of each type); - Analyzers Detectors: 1 of each type Analyzers sources: 1 of each type ; - Gas Detector Sensors: 1 of each type; - Analyzers light sources (for CEMES) : 1 of each type - Electronic display: 1 of each type; - Solenoid valves: 1 of each type ; - Solenoid valve coils: 1 of each type; - Micro-motors: 1 of each type Sample conditioning system spares; - Sample recovery system spares; - Recommended analyzer shelter spares. 5.11.19.3 Spare parts for Analyzers interface microcomputers will not be necessary. 5.11.19.4 Spare parts shall be delivered clearly identified with name and part number. 5.11.19.5 The proposals shall list spare parts in detail, with name, part number and prices. 5.11.20.SERVICES SPECIFICATION 5.11.20.1 The technical services shall be developed and executed by the manufacturer to facilitate the installation, start up and operation of the Analyzers System. 5.11.20.2 Scope of Field Services shall include, at least: - sample and utility lines inspection; - remote system inspection, such as probes and field station; - signal and electric power lines inspection;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
69 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- gas containers and accessories inspection; - process and sampling pipelines cleaning. 5.11.20.3 Analyzers System Pre-start up, Calibration and Test shall include, at least : - field work management of tubing, wiring, gas container and accessories connections; - functional inspection of all analyzers and equipments; - calibration and operation of analyzers to assure performance guarantees; - analyzers output signal transmission validation; - connecting the Analyzers to process, after the process is operating. 5.11.20.4 Process Connected Analyzers Start up shall include, at least: - analyzers calibration with standard samples validation; - analyzers sampling systems start up; - analyzers operation connected to process stream; - analyzers operation stability supervision for final acceptance. 5.11.21.TRAINING
E
5.11.21.1 The training for Maintenance, Operation and Engineering people shall be conducted as classroom instructions, concerning shelter safety and operation, sampling system project, analyzers operation, calibration and maintenance, including the presentation of drawings and specifications (this training may be held by analyzers manufacturers) at the refinery site . Training shall be at least 40 hours duration in a Portuguese language. 5.11.21.2 MAINTENANCE. 5.11.21.2.1 The trainee shall be able to identify, diagnose, repair, document and report any problem or calibration deviation of all analyzers system, including analyzers, probe, transport and conditioning system, and all other associated systems; 5.11.21.2.2 The trainee shall be able of calibrating any of the analyzers of the system. 5.11.21.2.3 Training shall include theoretical and practical parts. 5.11.21.2.4 Theoretical part shall include: analytical principles, block diagrams of the analyzers and the system and the external influences that may cause any damage to the whole system, results evaluation, safety systems and calibration of all systems with statistical analysis.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
70 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.11.21.2.5 Practical part shall include: identification of each part of the system, presentation of the most common problems and its solutions; warning to special care with the system; preventive maintenance (routine indicative frequency and parts to be normally checked); mounting and dismounting of electronic devices; practical training during analyzers calibration and testing and during analyzers start up; standard introduction to the analyzers. 5.11.21.2.6 The trainee shall be able to identify, diagnose, repair, document and report any problem with the House and Analyzers Control System. 5.11.21.3 OPERATION. 5.11.21.3.1 The trainee shall be able to start and stop analyzers operation, as well as associated systems, and also replace standard cylinders or vessels; 5.11.21.3.2 Training shall include theoretical and practical parts. 5.11.21.3.3 Theoretical part shall include: analytical principles, block diagrams of the analyzers and the system, and a explanation of the external influences that may cause any damage to the whole system and results evaluation. 5.11.21.3.4 Practical part shall include: standard introduction to the analyzers, and practical operation of all system, making all the alignments. 5.11.22.ENGINEERING DOCUMENTS 5.11.22.1 The manufacturer shall send the project documents list to PETROBRAS, before delivering the first technical document, and issue, at least the following drawings and/or documents: a) Data Sheet of analyzer, equipments, instruments, auxiliary systems, valves, filters, manometers, rotameters, and other parts which compose the Analyzers System; b) Material Requisition associated to the designed items; c) Analyzers System Schematic Drawing presenting the architecture and details of the equipment functions which compose analyzers, sampling system, interface, with components identification, lines dimensions, and operating set-points; d) Analyzers System details, comprising: - analyzers’ cabinet and shelter drawings with dimensions, plot plan showing the principal equipments and location of all field connections; - point to point wiring diagrams with internal connection details of each analyzer, interface and safety system;
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
71 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- analyzers tubing interconnection drawings with utilities identification, and lines dimensions; - Analog and digital input/output connecting board drawings; - list of system modules interconnecting cables. e) Electric Power Wiring and Grounding Diagrams for analyzers, interface, illumination, load and AC power distribution, cable specifications, junction box terminal identification, and area classification; f) Arrangement and Dimensions of analyzers, sampling system and interfaces; g) Project Basic Criteria for each equipment which compose the Analyzers System including, at least, the following information: - calculation sheet for instruments, - head loss and system response time; - electrical power system requirements; - grounding system requirements; - requirements and instructions for sampling transport lines assembling; - Installation requirements and instructions. h) Verification Criteria including the measurement points and the outline values to be analyzed by the time of Commissioning, in order to verify if the Basic Criteria of the Project is reached. 5.11.23.TRAINING MATERIAL 5.11.23.1 The manufacturer shall provide training manuals, postscripts and all documents which integrate the training courses documentation, with copies to each trainee. One additional copy of this documentation shall be issued to PETROBRAS for appreciation. Note: The training manuals shall be written in English or Portuguese. 5.11.23.2 SPECIAL TECHINICAL DOCUMENTS a) test procedure for factory inspection, indicating the reference documents; b) test reports executed during the factory inspection including all events, actions or solutions adopted; c) plant acceptance test procedures indicating the reference documents; d) plant acceptance test reports including all events, actions or solutions adopted. e) transport procedure and cautions;
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
E
72 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
f) description of special cautions that must be adopted, in case of equipment temporary storage at PETROBRAS, before definitive installation; g) Training Program for Maintenance and Operation courses; h) instruments calibration certifications; i) performance tests procedures indicating the reference documents; j) performance tests reports including all events, actions or solutions adopted; k) as-built final drawings, in CD-ROM, in electronic files format. 5.11.23.3 Analyzers System Maintenance and Operation Instruction Manuals, including at least: a) tubing schematic and electric diagrams; b) analyzers wiring; c) Drawings with material identification and part numbers of mechanical, electronic and electrical parts with part number and commercial identification of all components. 5.11.23.4 Configuration and Calibration Manuals, including at least: a) Specification of the analyzers calibration standards, procedure and data tests; b) All programs and configuration lists (analyzers, interface, etc.). 5.11.23.5 Operation Manuals, including at least: a) All the associated analyzers and equipment, with special operation instructions, including the sampling system and other special systems. 5.11.23.6 Maintenance Manual, including at least: a) All the diagrams and electric scheme with part number indication and all components commercial designation, procedures and routines for preventive maintenance, inspection with indication frequency, corrective maintenance, calibration, and tests for all associated analyzers and equipment; b) A list of all necessary equipment and kits for first level maintenance (circuit boards replacement), and special tools for mechanical and electrical maintenance; c) Services information which: - can not be executed by PETROBRAS technicians; - shall be executed by third part;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
73 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
- shall be executed by the manufacturer at the factory; - Shall be executed by the manufacturer at the plant. d) Hardware Configuration Manual of electronic systems boards presenting the disposition of keys, jumpers, straps and other configuration devices. 5.11.24.FINAL ACCEPTANCE 5.11.24.1 The analyzers system will be considered accepted, with the emission of the Definitive Acceptance Certificate by PETROBRAS, if the following requirements have been reached: 5.11.24.2 DOCUMENTS 5.11.24.2.1 All the documents shall be in accordance with item 5.11.22. 5.11.24.3 TRAINING 5.11.24.3.1 The Training Acceptance Certificate will be emitted by PETROBRAS if all needs of maintenance, calibration, operation and engineering training are reached, in accordance with item 5.11.21. 5.11.24.4 PERFORMANCE 5.11.24.4.1 The system will be considered approved if during tests periods, as defined in item 5.11.17, all the criteria are reached, as defined in the same item. 5.12. MARSHALLING CABINET 5.12.1 The marshalling cabinet shall be equipped with a duplicated terminal block, namely: - Input block (side “A”) for connecting wiring from the field; - Output block (side “B”) for interconnecting with the Monitoring System. 5.12.2 The internal re-arrangement shall be made between the blocks of side “A” and “B”. The block of side “B” shall mirror the interconnections with the I/O modules of the DCS or PES according to the loading table. 5.12.3 All shielding of cables and multi-cables shall be insulated in instruments, and shall be grounded only in the Marshalling Cabinet. Terminals shall be provided for interconnecting drain wires. E
5.12.4Terminal blocks and wire ways shall be separated for the circuits of different signal levels. 5.12.5 All wiring inside the cabinets shall be routed in PVC wire-ways with covers, conveniently distributed and sized, considering in all cases 30% (thirty per cent) of reserve capacity.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
74 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.12.6 Electrical continuity of all component parts of the cabinet structure shall be ensured. To obtain efficient grounding there shall be provided a connector for the grounding cable and an insulated copper bus-bar in the lower inside part of the cabinet. E
5.12.7 Terminal block and multicables shall be identified according to item- 5.3.10, using a compression and indirect tightening with tubular clamp; double terminal is not permitted to use; 5.12.8 The cables on the field side shall be identified with the instrument TAG and its wires with the number of the terminal to which it is connected. In the internal part between blocks “A” and “B” with the terminal number, and on the side of the DCS the identification of the card to which it is interconnected shall be adopted. 5.12.9 A lighting system shall be installed inside the cabinet with a fluorescent lamp and a service receptacle at 120 V ac, 60 Hz. 5.12.10 Only two conductors may be connected per terminal, one on each side. If there is a need for more conductors connected in parallel, a fixed bridge shall be used. 5.12.11 The cabinets shall be provided with doors occupying the entire front area, with hinges opening to 120 degrees. The doors shall be fitted with latches with locks,. 5.12.12 All cabinet components shall be corrosion-resistant, and the anti-corrosive treatment shall consist of pickling, phosphatization, neutralization and final painting with polymerization and cooling. The color of the cabinets shall be the same as that of the DCS panels to be installed in the Equipment Room. 5.12.13 The paintwork shall comply with PETROBRAS standard N-1735. 5.12.14 Wiring shall enter and leave the cabinets through the bottom part. 5.12.15 There shall be no mixing in one and the same cabinet of different types of signals: - high level analog signals (4-20 mA); - low level analog signals (mV); - discrete signals – 24 V dc. 5.13.
FIRE AND GAS DETECTION
5.13.1 When required, the instruments of the fire and gas detection system shall have their own junction boxes, cables and multi-cables and the same resources of the process instrumentation shall not be used. 5.13.2 The criteria adopted for reserve, routing, materials, etc. shall be the same as those used for the process instrumentation.
NO
TECHNICAL SPECIFICATION AREA:
REV.
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
E
75 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.13.3 The fire and gas detection and alarm system design shall comply with standard NI-2761 and I-ET-6000.67-5423-855-WAP-001 “Fire and Gas Detection System Specification”
5.14. RESERVE CRITERIA 5.14.1 In all systems, junction boxes, cables, multi-cables, cabinets, panels, etc. provision shall be made for reserves for modifications during startup and to meet occasional needs arising during commissioning. In addition, space for expansions shall also be considered. ITEM Valves for pneumatic supply Capacity of pneumatic supply header, multicables, etc. Cable Trays Marshalling Cabinets DCS, PLC, PES Input and outputs DCS , PES, PLC memory and processing capacity
Used in design 90 % 70 %
Installed Reserve 10 % 30 %
Space for future -
60 % 70 % 80 % 60 %
40 % 30 % 20 % 40 %
15% 10% -
Where : Used in design: resources used in the design. Installed reserve: resources actually available without the need for mounting or wiring. Space for future: area physically available for assembly in relation to the total installed area. 5.14.2 Switchboards for electrical circuits for instrumentation shall have 20% of reserve circuit breakers or four units, whichever is greater. 5.15. INTERLOCKING AND EMERGENCY SHUTDOWN SYSTEM 5.15.1 The system is divided into three main sections: input, logic and output. The input is basically the point of arrival of all signals coming from the process sensors and pushbutton stations. The logic is the section capable of providing the whole of the interlocking necessary to permit the required actions of interlocking and emergency shut-down. The output is the section that has to provide the necessary interface elements with the elements subject to the above-mentioned activities, that is, the solenoids, panels and electrical equipment, and to provide signals for monitoring of the plant through the dry contacts.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
76 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.15.2 Equipment design shall be handled in such a manner as to provide visibility and ease of access for replacement of any component in case of a breakdown. Cabinets shall be fitted with hinges so as to provide ready access to the interconnecting wiring between components. 5.15.3 Command failures shall be alarmed. 5.15.4 The system shall permit a state in which maintenance and reprogramming can be carried out on-line without stopping the process. 5.15.5 By-pass logics shall not be used, with preference being given to timers or repositioning of sensor elements. 5.15.6 The interlocking and emergency shutdown system shall be of the fail-safe type, meaning that the circuits shall be energized under normal conditions and de-energized under abnormal and/or emergency conditions. For de-energizing of the system under normal conditions, means of detection of continuity (line monitoring) shall be provided. 5.15.7 Transmission of safety interlocking / emergency signal in communication network is not accepted. 5.15.8 By definition, alarm is a visual and sound signaling to alert the operator, following a predetermined sequence; event is any status modification occurring in the field, and interlocking is dependence on one event for another to occur, and this can be in the control area (on/off) or safety area (shutdown). 5.15.9 In those cases in which to meet the demand it is necessary to use two transmitters, one for control and the other one for interlocking, separate connections shall be provided for orifice plates, that is, a pair for control connections and another pair for interlocking. In those cases in which, according to N-2595, three transmitters in voting are necessary for safety interlocking, provision shall be made for the installation of another orifice plate for measuring the same variable in order to meet the needs of a total of four transmitters (01 for control and 03 for interlocking). 5.15.10 INPUTS 5.15.10.1 The design shall make provision for terminal blocks duly identified for all inputs. The terminals shall have capacity for wires of up to 2.5 mm2 of straight crosssection 5.15.10.2 Input signals will be from instruments installed in the process unit and connected directly to PES. 5.15.10.3 No interlock shall be initiated by signal coming from digital communication. 5.15.11 LOGIC 5.15.11.1 The logic of the system shall implement all commands required in the logic interlocking diagram and/or cause and effect diagram.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
77 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.15.11.2 The safety interlocking logic will be implemented by means of an equipment selected in line with the criteria set out in IEC-61511. 5.15.12 OUTPUTS 5.15.12.1 A fuse shall be provided for each output. 5.15.12.2 Outputs for electrical equipment using a voltage different from that used for instrumentation shall be physically separated from the other outputs, using another terminal block. 5.15.12.3 Terminal block shall have capacity for wires up to 2.5 mm2 . 5.15.12.4 The basic design shall consider the outputs where is mandatory the application of partial stroke device for tests on-line off shut-off valves. 5.15.13 ALARM SYSTEM 5.15.13.1 Any abnormal condition that may cause a shutdown action shall alarm before shutdown occurs. 5.15.13.2 In the case of equipment (compressors, generators, etc.) having their own annunciators in local panels, individual alarms shall be reproduced in the DCS. If control over these equipment items is effected by means of PLCs, serial communication with DCS shall be preferably provided. 5.15.13.3 The designer shall consider the first cause alarm for all the equipments, subsystem and all the plant shut-down. 5.15.14 ASSET MAINTENANCE 5.15.14.1 The design shall consider the multiplex HART for all analog signals and connecting it to the HART remote maintenance network in each CCL (Panels room). 5.15.14.2 For the purpose of diagnostics a single fail shall not cause the shut-down and have an alarm in the DCS and/or a specific on-line maintenance asset network.
5.16. PROGRAMMABLE LOGIC CONTROLLER FOR GENERAL APPLICATIONS 5.16.1 This item defines the basic requirements for PLC used only in the package units. These basic requirements shall to be in accordance with N-2194, and containing at least the following: • Basic architecture; • Composition and sizing; • Technical characteristics of PLC components;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
78 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
• Redundancy; • Availability; • Training; • Tests; • Warranty; • Technical Assistance; • Drawings and documents; • Spare parts. 5.16.2 The programmable controller shall be entirely of solid state design displaying a modular conception. 5.16.3 Provision shall be made for a self-diagnosis system residing in non-volatile memory, with periodical and automatic implementation covering the following requirements: • dedicated circuits; • programs for checking performance of all modules; • routines for handling errors. 5.16.4 Redundancy: a) There shall be CPU redundancy that will be implemented using two racks each of which containing: Source, CPU, I/O ,Processor and communications processor; b) On duplication of the CPU, the logic controller shall function on a hot-stand-by basis; c)Transfer of control from I/O to spare CPU shall take place automatically upon detection of any failure in the main CPU; d) There shall be a communications channel dedicated to the updating of the spare CPU data bank. 5.16.5 PLCs shall have an ETHERNET port for communicating with the refinery’s asset management network. 5.16.6 PLCs shall be obligatorily from manufacturers included in the Vendor List. No exceptions will be permitted regardless of the systems being applied. 5.16.7 When PLCs are purchased, aspects of exchangeability and network communication with the DCS shall be considered, and the scope of supply shall include
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
79 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
the drivers and switches needed for integration with the DCS. The selected protocol for this integration shall be the MODBUS-TCP Protocol. 5.16.8 The PLC configuration software shall be supplied in conjunction with a notebook for each type of PLC used with the respective licenses for the operating system and application programs. The configuration software shall preferably use LADDER or FUNCTION (FC) BLOCK type programming language, running in Windows environment with complies with IEC 61131. If the manufacturer uses another programming language, this matter shall be discussed in the phase for defining the supply with inclusion of training and supply of information for this language to be fully understood. Likewise, the software of Human-Machine Interfaces (HMIs) provided in the design shall be supplied. 5.16.9 Sequence of Event • •
The PLC system shall be able to apply time stamp with scan rate resolution of 1 ms even if events occur in different PLCs. Each PLC CPU shall have its own GSP to synchronize with a 1 ms resolution to be applied on alarms and events.
5.17. PROGRAMMABLE LOGIC FOR SAFETY SYSTEM 5.17.1 The SAFETY PLC shall be compatible with the safety level required by PETROBRAS standard N2595 and be TÜV Rheinland certified for SIL 3 it shall be for SIL3, as defined on IEC-61508. 5.17.2 The equipment shall be certified for application on TUV class VI, AK6. 5.17.3 The SAFETY PLC shall also have an ETHERNET port for communicating with the refinery’s maintenance network. This maintenance network shall have a centralized engineering workstation. 5.17.4 The interface to the DCS will be implemented using OPC - UA protocol. If there is no option for OPC-UA integration, MODBUS-TCP in redundancy mode maybe acceptable. The supplier have to furnish all the variable addresses, alias and other information needed to do the connection. 5.17.5 The SAFETY PLC shall be compatible with Technical Specification I-ET6000.67-0000-941-WAP-006 “Safety Instrumented System- SIS (Preliminary Programmable Electronic System - PES) Technical Specification and marshalling cabinets with all hardware and software items and engineering services for configuration”. 5.18. INSTALLATION OF INSTRUMENTS 5.18.1 INSTRUMENT CONNECTIONS E
5.18.1.1 Materials shall be selected according to the COMPERJ technical specification, I-ET-6000.67-0000-800-PDY-004, based on N-1931. In cases not covered by the
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
80 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
COMPERJ technical specification the designer shall create a material specification sheet corresponding to the piping specification and submit it to PETROBRAS for approval. 5.18.1.2 Connections of vessels and towers shall be on the sides to prevent clogging. Avoid installing connections at the bottom of vessels and towers. In special cases PETROBRAS shall be previously consulted. 5.18.1.3 Do not use a sealing pot on impulse lines. Instead of the latter, install a tee as indicated in NI-1882, item 10.3.15. 5.18.2 MOUNTING OF INSTRUMENTS AND VALVES E
This item is in addition to item 4.3.8, 4.3.13 and N-858; 5.18.2.1 Transmitters shall be installed so that maintenance activities may be carried out without the need for scaffolding. Locate close to ground level or build platforms, the height of instrument center line shall be 1,4 m from floor.
E
E
5.18.2.2 The pressure transmitter shall be installed on a pedestal wherever possible, welded supports and fixed at concrete structure may be acceptable if the instrument will be installed at place with easy access;. 5.18.2.3 Instruments shall not be attached to handrails, pipe-racks or other points subject to vibration, blows or other disturbances. 5.18.2.4 In the assembly of valves interference with process equipment and lines shall be observed. The installation shall allow access to maintenance, preventing the drain valves from being mounted too close to the ground level. 5.18.2.5 impulse lines above 60C in the instrumentation installation, shall be protected against injury;
E
E
5.18.2.6 A warning slab (150 x 50 mm) shall be installed at the instrument manifold to advertise the operator and maintenance when the process fluid is toxic, hot or flammable;
E
5.18.2.6 the tag of the instrument shall be painted on their pedestals;
E
5.18.2.7 the tag of control valve shall be painted on their actuators;
E
5.18.2.8 hydro test shall be done in impulse line; 5.18.3 PNEUMATIC INSTALLATION
E
This item is in addition to item 5.3.7, 5.3.12 and N-858; 5.18.3.1 Pneumatic signals shall not be transmitted over distances longer than 50m;
E
5.18.3.2 Individual pneumatic transmission tubes shall be protected by channel;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
81 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.18.3.3 When using cupper tubing there shall be a PVC overcoat protection; E
5.18.3.4 pneumatic test shall be done in the signal and air supply lines; 5.18.4 ELECTRICAL INSTALLATION.
E
This item is in addition to item 5.3.8, 5.3.11; 5.18.4.1 The electrical installation shall be in accordance with standard N-858 and NI1882. E
E
E
E
5.18.4.2 Junction boxes shall be provides as follows: a) Separate junction boxes shall be provided for each kind of signal or system, examples: temperature, analog, digital ,safety, interlocking signals and fire&gas detection; b) Junction boxes shall have a degree of protection of IP 65 and a cover for rain protection. Such boxes shall be made of corrosion-resistant material such as aluminum or reinforced fiberglass. c) Junction boxes of SIS shall be painted with safety orange color 5.18.4.5 Mechanical protection of cables shall be provided as follows:
E
a) in outdoor areas use fiberglass channels or aluminum conduits for individual cables and multi-cables of the instrument from the field to the junction box. b) for individual cables and multi-cables from junction box to marshalling cabinet (CCL) or panels, in outdoor areas, use fiberglass channels or cable trays.. And in crossover pipe-ways use aluminum conduits;
E
c) in aerial cable trays for multi-cables entrance in the CCL; E
d) For cable tray installed in indoors areas (buildings, substations, etc.) hot dip galvanized steel must be adopted, maximum width 600 mm. The cable trays will be in SAE 1008/1010 steel plate 12 ABNT (2,65 mm). 5.18.4.6 Do not install cable trays in areas of intense cargo handling activities and on top of equipment operating at high temperatures. 5.18.4.7 All terminals shall be of the indirect tightening type, with low resistance metal parts and protected against corrosion, with a minimum insulation of 500 V in high quality thermo-fixed or thermoplastic material.
E
5.18.4.8 Only two conductors may be connected per terminal block, one on each side. In case more conductors connected in parallel are needed, a fixed bridge shall be used. 5.18.4.9 All cables, wires and terminal blocks shall be identified in a fixed, permanent and indelible manner.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
82 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
E
E
E E
E
E
5.18.4.10 The electrical installation shall be in accordance with standard N-858 and NI1882. Four-wire instruments shall have bipolar fuses in the electrical power supply circuit. All 24 VDC cables that go to the field shall have individual bipolar fuses for each instrument. All fuse terminal shall have indication of circuit open. 5.18.4.11 All signals of a cable in conduit shall have the same voltage level. For grouping together signal cables, use the same segregation criterion adopted for junction boxes. 5.18.4.12 Electrical connections of two-wire instruments shall be in ½” NPT. The cable shall be connected to the instrument through of cable gland, avoiding the use of flexible conduits. The cable shall be routed from cable tray to instruments by aluminum conduit let open end near the instrument. 5.18.4.13 Digital signal cables interconnecting CJ-D with the field solenoids have a minimum gauge of 2 x 1.5 mm², with general shield. The maximum drop voltage acceptable is 5%. 5.18.4.14 Multi-cables shall be of 12 or 24 pairs for field application and with a number compatible with the number of channels of input/output modules of digital systems as PLC, F&G, SIS and DCS for interconnections with the marshalling cabinets. 5.18.4.15 4 to 20 mA signal multi-cables interconnecting CJ-A with the marshalling cabinets in the control room shall be of section 0.5 mm2 and shall obligatorily have twisted and numbered pairs with individual electrostatic shielding in aluminum tape, and total and other characteristics in line with N-2384, with at least 30% of spare pairs. 5.18.4.16 Cables interconnecting discrete instruments in the field to Foundation Fieldbus converters or interconnecting trip contacts from PES to the MCC in the substations shall have section of 1,0 mm2, in twisted numbered pair, with total electrostatic shielding, with at least 30% of spare pairs. 5.18.4.17 Cables and multi-cables shall be specified in accordance with PETROBRAS standard N-2384, and the gauge of conductors and number of pairs per multi-cable shall be defined according to the preceding items. 5.18.4.18 All other interconnections within a marshalling cabinet shall be in wires or single pairs without shielding having a minimum section of 0,75 mm2.
E
5.18.4.19 Interconnection shall be made with terminals (fork, tubular or eye types) as necessary for proper connection of wiring to equipment. 5.18.5 GROUNDING 5.18.5.1 Grounding shall be in accordance with PETROBRAS standard NI-1882 and with the specifications of the manufacturer of the Monitoring System and other equipments. The level of resistance of the grounding for Instrumentation shall not exceed 3 ohms.
E
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
83 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.18.5.2 metallic conduction of cables (conduits and cables tray) shall be grounded;
5.19. PACKAGE UNITS 5.19.1 GENERAL RECOMMENDATIONS 5.19.1 The instrumentation belonging to package units shall follow the vendor list of PETROBRAS. 5.19.2 This Technical Specification shall be fully followed with respect to the technical instrument selection criteria. 5.19.3 Provision shall be made for junction boxes which will serve as an interfacing element with the process units. If a local panel is used, use of junction boxes may be dispensed with, provided this is previously authorized by PETROBRAS. The designer shall consider recommendations of N-2316. 5.19.4 A list of inputs and outputs shall be prepared so as to permit the execution of the remainder of the design separate from the development of the package. This list shall contain at least the TAG number of the instrument, type of signal, destination and identification of terminal/terminal block of the interface element (junction box or local panel). 5.19.5 In the case of equipment (compressors, generators, etc.) with their own annunciators in local panels, individual alarms shall be reproduced in the DCS. If control over these equipment items is via PLCs they shall be provided with serial communication with DCS through Modbus-TCP communication protocol and provision shall also be made for use of an Ethernet port for interconnecting to the maintenance network of refinery.
E E
5.19.6 The HMI of local panel shall be used for monitoring purpose but it recommend to avoid implementation of commands and it is recommended to specify commands with push-buttons , in the package panel, multi led lamp shall be used as alarm lamp; 5,19.7 Protection against direct sun light on display or rain, shall be provided for field panels (with or without Man-Machine Interface), such as: roofs, covers, etc. 5.19.8 For the purpose of remote configuration of instruments all analog transmitters and positioners shall be connected directly to HART Input I/O cards and not to HART multiplexers. The exceptional use of HART multiplexers has to have the formal approval of Petrobras. In the case of the use of HART multiplexers, all the multiplexers shall be connected in a serial network and interconnected to HART engineering network mounted in the CCL. 5.19.9 The Vibration Monitoring system shall be connected to a Ethernet network mounted in the CCL. 5.19.10 All PLC´s shall have an Ethernet 802.3 port in processor control unit to be interconnect to the PLC remote maintenance network in the CCL.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
84 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.19.11 The same criteria established in the other items of this document are applicable. 5.19.12 Unless otherwise specified, the package unit control panel shall be located at CCL for maintenance and protection reasons. Then shall be called Remote Control Panel ( RCP). 5.19.13 Local Control Panels (LCP) in the field will only be accepted if there is any technical impediment to justify the same, In this case shall be approved by PETROBRAS. 5.19.14 RCP or LCP commands for electric motors shall be sent directly to MCC (Motor Control Center). 5.19.15 All PLCs related to critical equipment shall be TÜV Rheiland SIL3 certified as defined on IEC-61508. Critical equipment is an equipment whose failure can critically compromise safety, environment or asset aspects of the related process. 5.19.14 LOCAL PANEL (LP) AND LOCAL CONTROL PANEL (LCP) E
5.19.14.1 The minimum protection degree for LP and LCP shall be IP-55 in accordance with standard IEC 60529. 5.19.14.2 The LP and LCP shall be built in stainless steel AISI-304 enclosures. 5.19.14.3 LP and LCP shall be pressurized in accordance with standard IEC 60079-2 (flameproof shall be avoided). 5.19.14.4 All LP and LCP shall be electrically powered as defined in this specification. 5.19.14.5 Unless otherwise specified, LP and LCP shall be provided with a HMI, based on a flat monitor of 12”. 5.19.14.6 The HMI shall be provided with a canopy in order to prevent glare, which might preclude screen readability. 5.19.14.7 LCP shall be provided with a Hart processor in order to filter hart signals from the 4-20mA instruments and integrated in the Hart Instrumentation Maintenance System. 5.19.14.8 For the Vibration machine monitor specified to be supplied with the LCP, it shall be provided with an Ethernet Port for future connection with the On-line Machine Maintenance System . 5.19.15 REMOTE CONTROL PANEL (RCP) 5.19.15.1 Minimum protection degree for RCP shall be IP-31 in accordance with standard IEC 60529.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
85 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.19.15.2 RCP shall be electrically powered as defined in this specification. 5.19.15.3 RCP shall be provided with a Hart processor in order to filter hart signals from the 4-20mA instruments and integrated in the Hart Instrumentation Maintenance System. 5.19.15.4 RCP shall comply with DCS serial communication requirements defined bellow. 5.19.15.5 RCP shall comply with PLC requirements defined bellow. 5.19.15.5 For the Vibration machine monitor specified to be supplied with the RCP, it shall be provided with an Ethernet Port for connection with the On-line Machine Maintenance System . 5.19.15.6 Cable entrances shall be done through the control panel floor. 5.19.15.7 Terminal boards for cables coming from the field shall follow the same sequence of the junction boxes terminal boards in order to avoid cable pair crossings. 5.19.16 COMMUNICATION BETWEEN CONTROL PANELS (LCP / RCP) AND DCS 5.19.16.1 The operation of any package unit shall be carried out through DCS, and all signals required for supervision and operation of each package unit shall be available in the DCS. 5.19.16.2 The communication, for monitoring and alarm purpose, between the DCS and the Local Control Panel (LCP), shall be done through Ethernet communication using fiber optic cables with Modbus-TCP protocol, the DCS being master in this communication. 5.19.16.3 The communication, for monitoring and alarm purpose, between the DCS and the Remote Control Panel (RCP), shall be done through a Ethernet communication using fiber optical cables with Modbus-TCP protocol, the DCS being master in this communication. 5.19.16.4 For control and interlock purpose, the signals between the DCS and the LCP and RCP shall be done by hardwired connection. Serial communication is not permitted. 5.19.16.5 Remote commands to start and stop the package shall be done by hardwired connection; on the other hand, commands for auxiliary equipment, for maintenance and/or test purpose, can be done by serial communication. 5.19.16.6 Unless otherwise specified, the status (if it is in operation or not) of the package unit shall be provided for DCS by hardwired connection. 5.19.17 PROGRAMMABLE LOGIC CONTROLLERS (PLC’s) ( Package Units ) 5.19.17.1 Unless otherwise specified by basic design, control and/or logic solver functions of a package unit shall be done by a PLC, installed inside of a LCP or RCP.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
86 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.19.17.2 All PLC shall be provided with an Ethernet port for remote maintenance supervision purpose. 5.19.17.3 All PLC power supply sources shall be full redundant. 5.19.17.4 All PLC for non-redundant package units shall be provided with redundant CPU and redundant communication between CPU and I/O cards. 5.19.17.5 The PLC I/O cards shall be provided with a minimum of 10% spare for each signal type. 5.19.17.6 The general PLC used for package units shall follow the item 5.16 of this specification. 5.19.17.7 The safety PLC used for package units shall follow the item 5.17 of this specification. 5.20. MOTORIZED VALVES TELECOMAND SYSTEM 5.20.1 This technical specification establishes the necessary minimum functional, performance and hardware requirements for the design of the Motorized Valves Telecommand System (STVM). 5.20.2 The STVM shall be designed with Intelligent Electrical Actuators (AEI´s) coupled to the valves. 5.20.3 All operation commands of the valves shall be made through the Man-Machine Interface of the Digital Control System (DCS) and diagnosis and configuration functions will be performed by the engineering workstation of DCS. E
5.20.4. The basic design shall define the AEI´s that must have the fire-proof requirements for the great process barrier in case of fire. 5.20.5 The actuator shall be compatible with Foundation Fieldbus Protocol. The vendor shall prove the supply of more than 200 actuators with Foundation Fieldbus protocol with good performance certified by a client letter. 5.20.6 The electric actuator for process block valves and for emergency isolation valve (fireproof) shall be of the same vendor for each process unit. 5.20.7 FUNCTIONAL SPECIFICATION 5.20.7.1 The Motorized Valves Tele-command System (STVM) shall command the opening and closing of all valves interconnected of the system with the same performance requirement for all valves. 5.20.8 PERFORMANCE 5.20.8.1 STVM shall operate with minimum availability of 99,9%.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
87 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Note : Availability = 1 - non available time (h) x 100% / Sampling Time (720 h). 5.20.8.2 A command of valve operation shall act on the valve within 2 seconds at most . 5.20.8.3 In case of failure of any internal mechanism the valve may be operated by a hand-wheel. 5.20.8.4 The minimum warranty of the actuator must be 3 years. 5.20.9 FUNCTIONAL SPECIFICATION - AEI 5.20.9.1 The AIE shall have the following requirements. 5.20.9.2 Commands
E
a)
To open the valve partially or totally (local or remote);
b)
To close the valve partially or totally (local or remote);
c)
To stop the valve (local or remote).
d)
To move the valve for a continuous 0 to 100 % opening degree;
e)
To move to a pre-defined position (ESD).
f)
Partial stroke
5.20.9.3 Operation modes a)
Local
b)
Remote
c)
Local Manual using handwheel
5.20.9.4 Variables of supervision (digital and analog) a) Valve Position OPEN Detected by limit-switch; b) Valve Position CLOSED
Detected by limit switch;
c) Switch Position LOCAL / REMOTE; d) Valve Opening degree continuous 0 to 100 %; e) Valve in opening movement; f) Valve in closing movement;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
REV.
E
88 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
g) valve stopped in a middle position. h) Partial stroke sucesful
E
5.20.9.5 Interlocking 5.20.9.5.1 Torque switch action: immediate stop of the motor in opening or closing operation of the valve. 5.20.9.5.2 Limit switch action: immediate stop of the motor operation of the valve. 5.20.9.5.3 Motor overload
in
opening
or
closing
action: immediate stop of the motor.
5.20.9.5.4 Reversion action: to Inhibit command to OPEN with valve Closing as well as command of CLOSING with valve opening. Since it implies in the automatic sequencing: command of stop, timing and operation, in this order 5.20.9.5.5 Blocked rotor action: immediate stop of the motor 5.20.9.5.6 Lack of Phase action: immediate stop of the motor with inhibition of any other command. E
5.20.9.5.7 For valves that belongs to SIFs the detailing design shall determine that eletronic parts of the AEIs shall have independent power supply in order to interrupt energy related to power supply, open/close emergency commands and MCC independent drawer. 5.20.9.5.8 The AEI housing and all electric/eletronic accessories installed on field must comply with Brazilian standards ABNT NBR Exd IIB T4 and NBR IEC 60529:2005. The AEI housing shall have internal sealing between connections compartment and other internal pars of the actuator. 5.20.9.5.9 STVM shall command open and close of all valves of the network, shall monitor AEI and network state, handle commands and report abnormal events to DSC using the Foundation Fieldbus protocol. The actuator shall have the ITK 5.0 or latter interoperability certificate from Fieldbus Foundation. 5.20.10 SPECIFICATION OF HARDWARE - AEI 5.20.10.1 Enclosure IP 67.
E
5.20.10.2 Squirrel cage motor 480 VAC (+/-10%), 60 Hz @ 3 phases. 5.20.10.3 “Built-in actuator in the same enclosure.
and its electric and / or electronic accessories integrated
5.20.10.4 Certificate at least for classified area : Ex-d Gr II B T4.
TECHNICAL SPECIFICATION AREA:
NO
REV.
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
E
89 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
5.20.10.5.Local Signaling a) position indication : 0 to 100% continuous in an electronic display; b) open valve
: luminous in the green color;
c) closed valve
: luminous in the red color;
d) position and torque continuous indication (0% to 100% and Segment length, in meters Vc => Voltage at FPS output, in volts Vd => Minimum allowable voltage drop on a field device, in volts Isc => Limit current for short-circuit protection, one device, in ampères It => Segment total current minus the value for the lowest consumption device, in ampères R => resistance per cable length, in ohm / kilometer In the case of equation in item above is violated, a detailed calculation sheet for the segment voltage drop shall be generated to verify minimum allowable voltage drop.
13.6.4. TERMINATORS (T) 13.6.4.1. Terminators shall be located at the each end of the longest run of the trunk cable.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
164 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
13.6.4.2. In case no disturbance is observed in communications, terminators may be internal to FPS. 13.6.5. Segment devices and Function Blocks 13.6.5.1. The main Link Active Scheduler (LAS) shall be configured in the H1 interface. 13.6.5.2. Backup LAS shall be configured either in the redundant H1 interface when available or in a fieldbus device of the segment. The device shall have only monitoring function in the segment. 13.6.5.3 In case a monitoring device can not be chosen, backup LAS shall be configured in the segment device with the most available bandwidth (fewer function block external links). 13.6.5.4. All function blocks in a control loop shall be in the same segment. Deviations from these criteria shall be discussed with PETROBRAS. 13.6.5.5. Function blocks involved in control loops shall be configured as standard FF blocks. Any proprietary function block or parameter configuration must be submitted to PETROBRAS approval. 13.6.5.6. When the design consider the PID block running in the field device, the PID blocks shall reside in the final control device. In case of simple cascade PID control, if PETROBRAS accept a final control device without two PID blocks available, the slave controller shall reside in the final control device and the master in the primary control loop transmitter. 13.6.5.7. When the design consider the PID block running in the field device , similarly, for a single PID control plus an override control, the override PID controller may reside in the transmitter of the restriction variable. 13.6.5.8. When the design consider the PID block running in the field device , for split range control, the PID block shall reside in one final control device. The second final control device shall communicate with the PID block in the first one. 13.6.5.9. Valves shall be driven to last control position in case of communication malfunction, unless process conditions require otherwise. 13.6.5.10. Valves shall be driven to fail safe position in case of power supply failure and shorted segment. 13.6.5.11. There shall be a maximum of 10 devices per segment, including at most 2 control valves. This requirement shall hold, unless it conflicts with control loop performance as stated below. 13.6.5.12. Segments with only monitoring devices shall have neither redundant H1 interface nor LAS in field device. 13.6.6 Function Block Tagging 13.6.6.1. Function block tag shall follow the pattern below.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
165 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
DEVICETAG FUNCBLCKTYPE INDEX Examples: FT202_AI_1, TT110_PID_2 13.6.7. Segment Scheduling 13.6.7.1. Unscheduled communication time shall not be less than 70% of the macro cycle. Unscheduled time availability shall be verified for all segments. 13.6.7.2. Macro-cycle frequency shall be at least 3 times the frequency response of the process. 13.6.7.3. A calculation sheet with segment scheduling shall be provided for each segment. The calculation sheet shall include function blocks execution time, as well as scheduled and unscheduled time sizing criteria. 13.6.7.4. It shall be possible for the user to configure the macro cycle. 13.6.8. Control Performance 13.6.7.1. The following periods shall be considered for maximum control response time: Process Variable
Maximum control response time
Flow
1000 ms
Pressure and Differential Pressure
1000 ms
Temperature
3000 ms
Level
3000 ms
Analytical
3000 ms
Fast process
150 ms
Note: These values can be modified due to technology licensor requirements. 13.6.8.2. The macro cycle shall be discussed with PETROBRAS during detail engineering for each H1 segment. The response time shall be considered according to the diagrams below for each case, control in the field or in the host. Deviations from specified performance shall be discussed with PETROBRAS.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
166 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
13.7.
CONFIGURATION TOOL
13.7.1. Configuration tool shall be fully integrated to host system software. 13.7.2. Configuration tool shall be able to set all parameters associated with the FF device. The tool shall be able to configure the device using only the information contained in the device description and capabilities files, as registered at FF. 13.7.3. Configuration tool shall perform the functions listed below: a) display device parameters and download of new settings in field device in a single download operation; b) display information about all segments in an organized template; c) generate reports on segment and device information, in ASCII format. Report on field devices shall have all configuration parameters settings; d) store templates for function blocks and control/monitoring loops. Information on the configuration of the components of the template shall be accessible and have the option to be exported into ASCII format file;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
167 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
e) partial download for device and function block strategies, without upsetting segment operation; f) Access and configure loops connected to host system, which are not in FF segments. 13.7.4. Configuration tool shall be able to import templates and parameterization databases. 13.7.5. Configuration tool shall have all drives and support for integration with supervisory system, including OPC (OLE for Process Control) drive. System vendor shall give support for system integration. 13.7.6. The Configuration Tool’s communication protocol shall support OPC (OLE for Process Control). 13.7.7 The configuration shall be done on-line, via an Ethernet-TCP/IP interface. The Configuration Tool shall be able to change the programming of any H1 device, including the scheduler, without upsetting segment and host operation. 13.8.
MAINTENANCE TOOL
13.8.1. A maintenance system shall be supplied with capability of configuring, calibrating and performing diagnosis of the fieldbus system, including devices, hosts and communications. 13.8.2. This system shall provide: a) configuration of field devices, b) acquisition of on-line and historical device data, c) device monitoring for alerts, d) field device tracing, with configuration changes and device replacement reports, e) import and export of data base and configuration to files, f) test host function and status, g) test communication between host system, segments and devices, h) test the devices performance such as valves signature. i) calibration tracing, with calibration changes reports. 13.8.3. Asset management functions shall be performed by maintenance tool with full integration to host system software. 13.8.4. Maintenance tool shall be able to supply all information therein through OPC protocol. System vendor shall give all support regarding asset tool integration with OPC servers/clients. Supplied information shall comprise, at least, the functions cited in item 13.8.2.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
168 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
13.9.
DOCUMENTATION
13.9.1. Documentation shall include, but not be limited to, the items mentioned in this section. Calculation sheets and other documentation mentioned previously shall be included. 13.9.2 Documentation shall be supplied in electronic format. 13.9.3. The following documentation shall be issued to PETROBRAS for comments prior to project implementation: a) Instrument Segment Diagram: showing physical connections and layout of the segment, not including logic information (function blocks, configuration etc). The drawing shall include the details listed below : - segment identification and connections, including H1 interface, power sources, junction boxes, devices, terminators, etc; - segment back-up LAS and terminator location shall be clearly identified; - length of trunk and spurs; - voltage in each device; - current of the segment. b) Instrument Data Sheets: containing standard information on instrument plus the items below. - current load and minimum operating voltage; - LAS capability; - firmware DTM revision and DD revision; - channel description and associated task; - function blocks available, indicating those with enhanced capabilities; - function blocks configured in the device and their parameterization; c) Segment Layout Plan: showing instrument location and segments in the unit, in 3dimensional diagram. Cable runs and segments shall be clearly identified; d) Control Loops Description: shall include control strategies, describing function blocks links and configuration parameters; e) Maintenance manuals and procedures: shall cover fieldbus system components, including technical data and troubleshooting procedures; f) Calculation sheets shall be provided for cables regarding voltage drops for all segments. Minimum segment voltage shall be stated in the document;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
169 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
g) Wave form signature plots shall be provided for each segment, showing that the wave form is in accordance with the limits established by the IEC 61158 h) Calculation sheets shall be provider the macrocycle for all segments, with synchronous and asynchronous periods discriminated.
13.10. ACCEPTANCE TESTS 13.10.1. All acceptance tests shall be performed and approved by both Vendor and PETROBRAS representatives. 13.10.2. Factory Test 13.10.2.1. Each fieldbus system component shall be tested for functionality including, but not limited to, compatibility with host system, access to device function blocks and communication within segment. Tests shall also include setup and calibration. 13.10.2.2. Field device calibration and setup procedures shall be documented and submitted to PETROBRAS approval. 13.10.2.3. Devices with LAS capability shall be tested for loss of H1 interface. 13.10.2.4. H1 interface and power supply redundancy tests shall be performed in order to check for system operation mal-functions. All H1 interfaces and power supplies shall undergo this testing. 13.10.2.5. Host system shall be tested for all functions as described in item13.5.1. 13.10.2.6. The following strategies shall be configured for testing purposes: one simple PID loop, one cascade PID loop, one PID ratio loop, one override PID loop and one flow pressure plus temperature compensation loop. 13.10.3. Site Test and Commissioning 13.10.3.1. The test shall comprise the same scope of the factory test plus segment commissioning. 13.10.3.2. Waveform signatures for communication shall be performed for every segment, and checked for compliance with IEC 61158 standard. 13.10.3.3. Test acceptance shall depend on both factory and site test approval by PETROBRAS.
13.11. TRAINING 13.11.1. The training for Maintenance, Operation and Engineering people shall be conducted as classroom instructions, concerning fieldbus system operation, calibration and maintenance, including the presentation of drawings and specifications at Refinery. Training shall be at least 40 hours duration.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
170 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
13.11.2. Training shall cover, at least, the following topics: a) Fieldbus system fundamentals, including host, LAS and segment operation; b) Device, host and function blocks configuration; c) System diagnostics: network and devices; d) Criteria for loop configuration: procedures and recommendations; e) Critical alerts and alarms. f) Maintenance: use of troubleshooting tools and procedures; g) Access to trend information and data base management;
13.12. SPARE PARTS 13.12.1. Spare parts shall be supplied for commissioning and two (2) years of operation. 13.12.2. A list of recommended spare parts shall be supplied by system vendor.
13.13. FOUNDATION FIELDBUS SEGMENT RISK MANAGEMENT The following valve criticality rating and network/segment loading method shall be used. The valve and associated measurement criticality shall be defined for prudent loading of Fieldbus segments. The following ratings shall be assigned to each valve and segment. 13.13.1. Level 1 Valves and Networks Failure of a Level 1 valve will result in a total system trip, causing a shutdown of the entire unit, or other unavoidable losses in excess of $10M. Normal Valve failure mode is to be used for this classification. Design Requirements: Level 1 valves and their associated measurement device (transmitter) shall reside on H1 networks that are only used for Level 1 control. The segment may have one (1) Level 1 Valve and associated Transmitter when services are independent, or two (2) Level 1 Valves and associated Transmitters when services are dependent. Dependent means that either of the two (2) valves will shut down the same piece of equipment (example pass flows on a fired heater). 13.13.2. Level 2 Valves and Networks
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
171 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Failure of a level 2 valve will result in a total system trip, causing a shutdown of the entire unit, or other unavoidable losses in excess of $100K. However, the Level 2 valve’s process dynamics allow time for quick recovery from the failure, either by quickly fixing a fault or by taking manual control. The material and energy capacity of associated vessels, geographic location, and elevation/accessibility of such valves shall be considered. The difference in Level 1 and 2 valves are dependent on operations ability to respond to a single failure. Design Requirements: Level 2 valves and their associated measurement device (transmitter) shall reside on H1 networks/segments that are only used for control. The segment may have one Level 2 valve and associated transmitter when services are independent, or two Level 2 valves or a Level 2 and a Level 3 valve and associated transmitters when services are dependent. Dependent means that either of the two valves will shut down the same piece of equipment (example pass flows on a fired heater). 13.13.3. Level 3 Valves and Segments Failure of this valve will not result in any short-term risk of total unit shutdown or major operating losses. Level 3 valves can go to their fail position without requiring immediate operator action. Design Requirements: Level 3 valves can reside on cards or networks/segments with up to three other level 3 valves, or on a segment with a level 2 valve. Networks containing Level 3 control contain products from multiple (approved) vendors including measurement only devices. 13.13.4. Level 4 Segments – No Control Level 4 devices are measurement only devices that shall not be used for control and may be configured in a way that could interrupt control on a network/segment. This class includes MAI, MAO, MDI, and MDO block communication devices.” 14.
DATA COMMUNICATIONS ROUTES - VCD
14.1 – The design shall consider data communications routes for integration of the many Digital Systems parts. 14.1.1- The VCD for the DCS shall be redundant and be designed in accordance with the technology’s choice . 14.1.2 – The VCD for the Asset Management of HART instruments , PLCs , PES and STVM´s master-stations and shall cover all the CCL’s and complies with Ethernet 100BASE-FX at least. 14.1.3 – The VCD for the Vibration Monitoring Machine Asset Network shall cover all th CCL´s and complies with Ethernet 100BASE-FX at least.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
172 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
15.
MODERN CONTROL STRATEGIES
15.1 - The basic design shall consider the requirements for implementation of a modern control strategy based on Predictive Controllers. This project may use the API 557 as a reference. 15.2- All instruments including control valves, transmitters, analyzers and the mathematical calculations variables shall be identified in the basic design. 15.3 – A cost and profit evaluating for the modern control implementation shall be developed to indicate the opportunity of the investment. 15.4 – It must be provided a system integrated or not with DCS with possibilities for best tuning of PID control loops. It shall have possibilities for audit of control loops performance with on-line diagnostics.
16.
THE ENTERPRISE-CONTROL SYSTEM INTEGRATION
16.1 The implementation of the enterprise-control system integration shall consider a Plant Information system as Historical Process Data Deposit . 16.2 It shall consider the capability for integration with the Company Enterprise Supply Chain Management – ERP. 16..3- It shall consider the capability for integration with a computerized maintenance management system – CMMS. 16.4 – It shall consider the capability for integration with a Data reconciliation System for the audit and control of energy and mass balance. 17.
DYNAMIC PROCESS SIMULATOR
17.1 The basic design of the units shall specify all information to allow the development of process models to be implemented in a single dynamic process simulator . 17.2 One Dynamic Process Simulator shall be specified for operator training purpose. 17.3 The Process Simulator shall support four operators and one instructor in the system at the same time. 17.4 It shall have at least the requirements: a) allows efficient model development;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
173 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
b) permits easy model modification to reflect changes in the process or control systems; c) provides robust trainee/operator link/ interface to major DCS systems; d) provides instructor features to allow the most effective and efficient simulator training. 16.5 It shall provide functionalities to the operator, at least; a) training in use of plant specific DCS configuration and the actual DCS system; b) training in all essential skills needed to operate the plant in a safe , reliable manner; c) training for plant startup/shutdown; d) training for normal operation-maintaining production to target rate and product quality in the face of disturbances; e) training in the correct response to failures of equipment, either in the process hardware or the control system; f) training in operation for different conditions of the plant equipment; g) handling of process upsets originating from external factors. 17.6 The Process simulator shall be mounted and in operational status at the refinery one year before the operation start of the first process unit. And so on each process model shall be implemented in the simulator a year before the operation start date for each refinery unit. 17.7 The system specification shall consider all the equipment , software and engineering services. 18.
TRADE AUTOMATED SYSTEM – TAS
18.1 For the purpose of the trade relationship with customers a complete automation solution shall be specified. 18.2 It shall have the following requirements : a) complete trade automation within the Refinery; b) product receipt integration; c) automation and integration with product storage; d) monitoring & control of product movement within Refinery;
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
REV.
E
174 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
e) automation of tank truck / solid trucks/ rail car / ships loading & unloading operation; f) interface with ERP / Business System for Order to invoice integration; g) automated load scheduling; h) product accounting and stock reconciliation; i) inventory management with Tank Gauging Automation; j) automatic access control system to refinery site; k) remote valve control system ; l) pump operation optimization; m) solution expandable to pipeline automation on upstream and gas stations on downstream. 18.3 The following figure shows an example of a trade automated system.
Tank gauging sensors Level switches, Fire & Gas detectors, CCTV cameras
Ship
Schedule shipments, assign bay Monitor bay, meter, pump, valves Daily, monthly, MIS reports Communicate with field devices
Tank
MCC Batch controllers, Card readers Truck Safety devices (Overfill,grounding), ESDLoading Traffic light, CCTV
Fire&Gas detectors
Card readers (ID cards) CCTV cameras Physical verification Invoicing
Control room
Parking Check in counter, one for each
shareholder W e i g
h Guard
Load advice, Load ticket Weigh B in, out Remote display
Office Pump control PLC cabinet
18.4 The system specification shall consider all the components like : pumps, valves, gates, traffic lights, flow meters, weigh meters, card readers, transponder signals receiver, PLC, cameras and CCTV, printers, computers, printers, software, communications drivers to ERP Software and etc...
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001 SHEET:
GENERAL
REV.
175 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
18.5 The Interface with the ERP system may be represented as follow :
get loading data from Customers
Terminal Automation System Interface ERP Software
- Order processing - Delivery processing - Inventory management send loading data - Credit limit checking to Customers
send data
get loading data
Trade Automated System - Compatibility Check - Fill up processing - Entry check - Loading quantity check
18.6 The functionalities implemented in the ERP systems may be as following :
Send data TO/GET from TAS System
Send data TO Partner ERP System
LID Master Data Order Processing
Order / Contract Load Info forward Delivery Processing Shipment
Shipment Processing
ERP x TAS System Interface
19.
Load Info forward
Load Information
ELECTRIC POWER SYSTEM FOR INSTRUMENTATION
E
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
176 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
19.1 The instrumentation electric power system shall be composed with the following electrical sources. a) A 120 Vac at 60Hz from redundant uninterrupted power supply system (RUPS) named as “120 Vac RUPS Circuit”; - The 120 Vac RUPS shall be fed from critical MCC. - The RUPS shall be provided with a serial communication with DCS, for monitoring, and diagnosis purpose, through a Profibus DP protocol. b) A 125 Vdc from redundant battery charger named as “125 Vdc CB”. - The 125 Vdc CB shall be fed from Critical MCC. 19.2 The 24Vdc, for feed field instruments and any equipment inside a control panel, shall be converted from 125 Vdc to 24 Vdc into the respective control panel and comply with the following requirements: a) it shall be redundant, composed by redundant sources ; b) each source or set of source shall be fed by redundant 125 Vdc CB coming from different circuits so if a single failure point will not affect the operation of the instruments and equipments powered by it. 19.3 When using two sources, each source shall be sized to support the electrical nominal load more 30%. 19.4 When using two sets of sources, each set shall be composed of the necessary number of 24 Vdc sources so that each source is sized to support the electrical nominal charge with more 20%, plus one source (n+1 configuration). 19.5 The sources of each set shall be provided with a load sharing system. 19.6 The system shall be provided with online replacement cards, in order to permit the change of any 24 Vdc source in operation. 19.7 The nominal voltage levels and the circuit feeder to be used, for the instrumentation in the process and utility units, shall comply with the table below.
Equipments
Electrical Source
PES, DCS, LCP and RCP
Two feeders in 125 Vdc from redundant CB´s
LP (see note 1 below)
One feeder in 120 Vac from the 120 Vac RUPS
Two wire transmitters
24 Vdc
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
177 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
Four wire transmitters (including analyzers)
24 Vdc or 120 Vac from the RUPS
Discrete Inputs and Output.
24 Vdc
Solenoid Valves
24 Vdc
Dedicated Equipments for Control and Interlock (see note 1 below)
Two feeders in 125 Vdc from redundant 125 Vdc CB´s
Electric Hydraulic valves
480V 3Øf from critical MCC
Motorized actuators
480V 3Øf from critical MCC
Notes: 1) If LP has installed in it any four wire transmitter or dedicated equipment, either for control or interlock purpose, it shall follow the same criteria defined for it in the above table (Dedicated equipments for Control and Interlock). Example: for furnaces Local Panels its equipments for monitoring purpose shall be fed by 120 Vac RUPS from critical MCC and the flame rod monitors, that is a dedicated equipment for interlock, shall be fed by the two feeders in 120 Vac. 19.8 POWER DISTRIBUTION PANEL 19.8.1 The120 Vac Rups circuits for instrumentation shall be provided with a distribution panel to power individually each four-wire instrument, panel or any other load. 19.8.2 The 120 V ac distribution panel shall comply with the following requirements: a) a general input bipolar circuit breaker; b) each load shall have its individual bipolar circuit breaker. 19.8.3 125 Vdc CB circuits for instrumentation shall be provided with a distribution panel to power individually DCS, PES , LP , RCP or any other load. 19.8.4 The 125 Vdc distribution panel shall comply with the following requirements: a) a general input bipolar circuit breaker; b) each load shall have its individual bipolar circuit breaker. 19.9 GROUNDING SYSTEM 19.9.1 The grounding system shall be in agreement with NI-1882 standard (Installation of Grounding for Electronic Systems) of API-RP 552, as well as with each instrument or equipment manufacturer requirements.
TECHNICAL SPECIFICATION AREA:
NO
I-ET-6000.67-0000-800-PDY-001
GENERAL
SHEET:
REV.
E
178 of 178
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
20.
TANKING GAUGING SYSTEM
20.1 The TGS is designed to measure and calculate information about the products stored in tanks and Esphere Park, units U-6300, U-6100, U-6312 and U-6314, the COMPERJ. 20.2 Must be followed the recommendations of the Manual of Petroleum Measurement Standards, cap. 3 and 7 of the API 20.3 The design of the system must be according to I-ET-6000.67-6300-853-PDY-001 System of Measurement in Tanks and Spheres - TGS. 20.4 TGS Will be used in operations: a) • Calculation of inventory, b) • Monitoring the transfer of custody, c) • Monitoring movement of products, d) • Monitoring of mixed products. e) • Aid the identification of leaks. f) • Aid to protect against overflow.
