PS 100 015 001 A4 Instrument General Specification
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ENGINEERING CENTER DIREKTORAT PENGOLAHAN
JOB NO.
E20200-10-04B DATE PREP'D
PROJECT SPECIFICATION
DOCUMENT NO.
REV.
0
PS-100-015-001-A4
April 2010
SHEET
1 OF 73
JPH
CHK'D APP'D
INSTRUMENT GENERAL SPECIFICATION
PENAMBAHAN 1 (SATU) UNIT TANGKI CRUDE KAP. 20.000 KL LENGKAP DENGAN ASESORIESNYA DI RU II DUMAI, INDONESIA PT. PERTAMINA (PERSERO)
0
7 Mei 2010
ISSUED FOR APPROVAL
JPH/ ASB
JPH
SDC
0
April 2010
ISSUED FOR COMMENT
JPH/ ASB
JPH
SDC
RU II
REV.
DATE
PREP'D
CHK'D
APP'D
CLIENT
PAGE
DESCRIPTION
RU II
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TABLE OF CONTENT
SECTION
PAGE
1
SCOPE .............................................................................................................3
2
APPLICABLE CODES, STANDARDS AND DRAWINGS .........................3
3
ENGINEERING DESIGN PHILOSOPHY .....................................................9
4
CONSTRUCTION PHILOSOPHY...............................................................56
5
DOCUMENTATION ....................................................................................63
ATTACHMENT I
FABRICATION DRAWING OF ORIFICE FLANGE
ATTACHMENT II
PIPING ARRANGEMENT AT ORIFICE PLATES
ATTACHMENT III
FABRICATION DRAWING OF THERMOWELL ( 150#300#-600# RATING ) FABRICATION DRAWING OF THERMOWELL ( 900#AND OVER RATING ) FABRICATION DRAWING OF THERMOWELL ( FOR HEATER )
ATTACNMENT IV
NUMBERING OF INSTRUMENTS
ATTACNMENT V
FUNCTIONAL IDENTIFICATION OF INSTRUMENT
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1. SCOPE
1.1
This project specification establishes the general requirements to be met in the selection, design and installation of the Instrumentation for the instrumentation for New Crude Tank cap. 20.000 KL c/w accessories.
1.2
If, there are any conflicts or differences between this specification and the individual instrument data sheets or drawings, the data sheets or drawings shall have priority.
1.3
This specification is not applied for the packaged equipment such as steam boiler, power generator, rotating equipment etc, however the specification of Instrumentation Requirement for Package Unit shall be applied for packaged units.
1.4
If there are any special requirement and/or difference for the tie-in or modification work on Utility, Off-site facilities from this specification, supplement specification will be issued separately.
2. APPLICABLE CODES, STANDARDS AND DRAWINGS The codes and standards, which are applied as a part of the instrument engineering requirement, shall be selected from the following list according to that of manufacturer’s countries. 2.1.Electrical Codes (1)
National Fire Protection Association (NFPA) ANSI/NFPA70-05-HB National Electrical Code Handbook ANSI/NFPA496-2008 Standard for Purged and Pressurized Enclosures for Electrical Equipment, 2008 Edition
(2)
Instrument Society of America (ISA) ISA-RP12.01.01-1999 Definitions and Information Pertaining to Electrical Instruments in Hazardous (Classified) Locations ISA-RP12.4-1996
Pressurized Enclosures
ISA-RP12.06.01-2003 Recommended Practice for Wiring Methods for Hazardous (Classified) Locations Instrumentation Part 1: Intrinsic Safety ISA-S18.1-1979
(3)
Annunciator Sequences and Specifications (R2004)
National Electrical Manufacturers Association (NEMA).
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ICS6-1993(R 2001) (4)
Enclosures for Industrial Controls and Systems
British Standard (BS)
BS EN 60079-14: 2003
Electrical apparatus for explosive gas atmospheres. Electrical installations in hazardous areas (other than mines). Requirements for construction, testing and marking of electrical apparatus with type of protection “n”.
BS EN 60079-10: 2003
Electrical apparatus for explosive gas atmospheres. Classification of hazardous areas
BS EN 60079-0: 2004
Electrical apparatus for potentially explosive atmospheres. General requirements for the construction, testing and marking of electrical apparatus and Ex components intended for use in explosive gas atmospheres.
BS EN 60079-2 : 2004
Pressurized apparatus 'p' Requirements for the design, construction, testing and marking of electrical apparatus with pressurized enclosures, of protection type “p”, for use in explosive gas atmospheres.
BS EN 60079-1 : 2004
Flameproof enclosure 'd' Apparatus placed in an enclosure that can withstand an internal explosion of a explosive mixture without igniting an explosive atmosphere surrounding the enclosure.
BS EN 60079-7 : 2003
Increased safety 'e' Specifies the requirements for the design, construction, testing and marking of electrical apparatus with type of protection increased safety "e" intended for use in explosive gas atmospheres. This European Standard applies to electrical apparatus with a rated value of supply voltage not exceeding 11 kV r.m.s. a.c. or d.c. Additional measures are applied to ensure that the apparatus does not produce arcs, sparks, or excessive temperatures in normal operation or under specified abnormal conditions.
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BS EN 60079-11 : 2007
(5)
Intrinsic safety 'i' Specifies the construction and testing of intrinsically safe apparatus intended for use in an explosive gas atmosphere and for associated apparatus, that is intended for connection to intrinsically safe circuits that enter such atmospheres.
Institute of Petroleum Model Code of Safe Practice in the Petroleum Industry (IP) Part 1-1988 Electrical Safety Code
2.2.Materials American Society for Testing and Materials (ASTM) and/or equivalent. 2.3.Flanges and Fittings for Instruments American National Standards Institute (ANSI) ANSI/ASME B16.5-2003
Pipe Flanges and Flanged Fittings
ANSI/ASME Bl.20.1-1983 (R 2001)
Pipe Threads, General Purpose (INCH)
2.4.Orifice Flanges Assembly American National Standards Institute (ANSI) ANSI/ASME B16.36-2006
Orifice Flanges
2.5.Temperature Elements (1)
American National Standards Institute (ANSI) ANSI/ISA MC96.1-1982
(2)
Temperature Measurement Thermocouples
Deutsches Institute fuer Normung e.V. DIN 43760-1987
Electrical Temperature Sensors; Reference Tables for Resistors and Resistance Elements (RTD's)
2.6.Thermowells Per Attachment-III
Fabrication Drawing of Thermo wells
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2.7.Flow Elements Calculation and Piping Arrangements at Orifice Plates Principles and Practice of Flow Meter Engineering by L.K. Spink and Attachment-II. Piping Arrangements at Orifice Plates. 2.8.
Orifice Plates Per Attachment-I
2.9.
Fabrication Drawing of Orifice Plates
Positive Displacement Meters, Turbine Meters, Coriolis mass Flowmeter and Meter Provers American Petroleum Institute (API) Manual of Petroleum Measurement Standards/MPMS Chapter 4-1988 Proving Systems
2.10.
Chapter 5.2-1987
Measurement of Liquid Hydrocarbons by Displacement Meters
Chapter 5.3-1987
Measurement of Liquid Hydrocarbons by Turbine Meters
Chapter 5.6-2002
Measurement of Liquid Hydrocarbon by Coriolis Meters
Pressure Gauges American National Standard Institute (ANSI) ANSI/ASME B40.1 -1985.
2.11.
Gauges-Pressure Indicating Dial Type-Elastic Element
Tank Gauges American Petroleum Institute (API) MPMS 3.1A
Manual of Petroleum Measurement Standards Chapter 3 - Tank Gauging Section 1A - Standard Practice for the Manual Gauging of Petroleum and Petroleum Products First Edition
MPMS 3.2
Manual of Petroleum Measurement Standards Chapter 3 - Tank Gauging Section 2 - Standard Practice for Gauging Petroleum and Petroleum Products in Tank Cars First Edition
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2.12.
MPMS 3.3
Manual of Petroleum Measurement Standards Chapter 3 - Tank Gauging Section 3 - Standard Practice for Level Measurement of Liquid Hydrocarbons in Stationary Pressurized Storage Tanks by Automatic Tank Gauging First Edition
MPMS 3.4
Manual of Petroleum Measurement Standards Chapter 3 - Tank Gauging Section 4 - Standard Practice for Level Measurement of Liquid Hydrocarbons on Marine Vessels by Automatic Tank Gauging First Edition
Control Valves (1)
(2)
Instrument Society of America (ISA) ANSI/ISA-S75.01.01-2007
Flow Equations for Sizing Control Valves
ANSI/ISA-S75.08.01-2002
Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (ANSI Classes 125, 150, 250, 300 and 600)
ANSI/ISA-S75.08.06-2002
Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (ANSI Classes gay, 1500 and-2500)
American National Standards Institute (ANSI) ANSI/FCI70-2-1976 (R1982)
2.13.
Control Valves Seat Leakage
Safety Relief Valves (1)
American Petroleum Institute (API) RP 520
Sizing, Selection and Installation of Pressure Relieving Devices in Refineries
Part 1-2000
Sizing and Selection, Fifth Edition
Part 2-2003
Installation, Third Edition
RP-521-1999
Guide for Pressure-Relieving and Depressurizing Systems
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ANSI/API Std.526-2002
(2)
Flanged Steel Safety-Relief Valves
ANSI/API Std.527-1991
Commercial Seat Tightness of Safety Relief Valves with Metal-to-Metal Seats
Std.2000-1998
Venting Atmospheric and Low Pressure Storage Tanks
American Society of Mechanical Engineer (ASME) 2007 ASME Boiler & Pressure Vessel Code - Section VIII - Pressure Vessels - COMPLETE 3-Volume SET (VIII-DIV 1, VIII-DIV 2, VIII-DIV3)
2.14.
Installation of Instruments (1)
2.15.
American Petroleum Institute (API) API RP.551
Process Measurement Instrumentation
API RP.552
Transmission System
API RP.554
Process Instrumentation and Control
API RP 556
Instrumentation and Control System for Fired Heaters and Steam Generators
API RP 555
Process Stream Analyzers
Instrumentation Symbols Instrument Society of America (ISA) ANSI/ISA-S5.1-1984(R1992)
Instrumentation Symbols and Identification
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3. ENGINEERING DESIGN PHILOSOPHY 3.1.Design Considerations 3.1.1
General
3.1.1.1
The instrumentation for measurement and control shall be designed such that optimum operation of the process concerned can be realized at minimum operational and maintenance cost.
3.1.1.2
The instrumentation and the installation methods shall further be designed for ease of operation, maximum simplicity, reliability and minimum maintenance. Direct connections between process fluids and the control room are not carried out.
3.1.1.3
Each instrument which required pressure piping shall have individual connections to and isolating valves from the process.
3.1.2
Control Systems
3.1.2.1
The operating philosophy for the Crude tank is based on Control Room, controlling that areas from a same room. This room will be called Control Room.
3.1.2.2
The control and operation of the plant shall be via a Distributed Control System (DCS). The DCS shall not only act as the operation interface but also provide and process measurement data base that will allow to apply control strategies, energy management, and management Information systems.
3.1.2.3
The DCS shall consist of operator console groups in the Control Room Note: Operator console Collection of a number of operator station. The operator station need not be physically together. The console is a logical collection, and not a physical collection. It also includes auxiliary console which contains auxiliary devices such as switches, push buttons etc.
3.1.2.4
A combined automatic and manually initiated emergency shutdown (ESD) system shall be provided.The ESD system shall operate as a stand alone system. Status and alarm shall be monitored and recorded by the DCS. The override switches for input and output of the ESD system shall be provided for on-line testing
3.1.2.5
Fire and gas detection system and the sequence system of the package shall operate as a standalone system. Local panels compressors etc shall be used for local operation. It's common status and alarm shall be monitored and recorded by the DCS.
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3.1.3
Measuring Units and Scales
3.1.3.1
Measuring units shall be in accordance with the metric system. All instruments shall read out in the following units: Flow Liquid.
Steam, chemical.
: kg/hr or T/h, (use kg/hr less than 1 T/h) m³/hr (at l5 °C ) for metering proving system : kg/hr, T/hr, (use kg/hr less than 1 T/h) except for Metering Proving System
Gas and Vapor.
: Nm3/hr at 0.0°C and 1 atm
Pressure Gauge.
: kg/cm² G
Absolute.
: kg/cm² abs
Low pressure, draught or differential pressure
: mm H 2 O
Low absolute pressure.
: mm Hg abs
Specific Gravity 15.6/15.6 °C.: dimensionless
3.1.3.2
Density at operating temperature and pressure
: kg/m³ or gr/cm³
Temperature.
: °C
Level.
: % (percent of range)
Length.
: m or mm
Charts and scales
The following chart and scale ranges shall apply: (1)
For Panel Mounted Indicators and Recorders Variable
Charts
Scales
Flow (diff. press.)
0 - 10 sq.rt.
0 - 10 sq.rt.
Flow (linear signal)
0 - 100 unif.
0 - 100 unif.
Level.
0 - 100 unif.
0 - 100 unif.
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Pressure
0 - 100 unif
Direct reading
Temperature.
0 - 100 unif.
Direct reading
Other variables.
0 - 100 unif.
Direct reading
Combination of flow (d/p) and other variables
0 - 10 sq.rt. & 0 - 100 unif.
Direct reading
Recorder charts need not be direct reading, appropriate chart and/or scale factors be shown on the integrally mounted nameplate of the recorder. (2)
For Field Mounted Indicators Indicators such as remote indicators, integral mounted indicators on the transmitters and controllers (PIC, TIC, FIC) shall have a 0-100 unif. or 0 - 10 sq.rt. scale with reading factors.
3.1.4
Electric Transmission and Control
3.1.4.1
The electric signal of electronic instruments shall be unified by 4-20 mA, DC 24 V or standard protocol (Hart protocol, etc) except for tank gauges system, turbine meters, metering proving system, positive displacement meters and special analyzers.
3.1.4.2
Electronic instruments shall conform to the requirements set by the electrical safety code of the Institute of Petroleum unless local rules require more stringent requirements.
3.1.4.3
Even where electric transmission and control is used, the truly local control loops and the actuation of all control valves shall be pneumatic.
3.1.5
Pneumatic Transmission and Control
3.1.5.1
The pneumatic signal of pneumatic instruments shall be unified by 0.21.0 kg/cm2.
3.1.5.2
Provision shall be considered for proper transmission and control depends on length of signal tubing and response time of device.
3.2.General Requirement for Instruments 3.2.1.
Distributed Control System (DCS)
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3.2.1.1.
The control monitoring shall be achieved by the use of a microprocessor based system for process control functions and manipulation of data. Access to and manipulation of variables shall be achieved by the use of CRT displays and associated keyboards.
3.2.1.2.
The DCS shall be augmented by auxiliary instrumentation systems (e.g., hard wired annunciator units, emergency shutdown system, recorders, auxiliary monitor , power distribution system etc.).
3.2.1.3.
As a rule, operator interfaces such as CRT stations and auxiliary monitor shall be installed in the Control Room, and process interfaces such as controllers, process I/O units and auxiliary instrumentation system shall be installed in the auxiliary room. Communications between operator interfaces and process interfaces shall be executed mainly via redundant data communication bus using DCS manufacturer's standard co-axial, twisted-pair or optical fiber cables.
3.2.1.4.
If the process Licensor will have mandatory requirement for special instrumentation systems, these systems shall be installed independently from the DCS. However, the signals as per the licensor’s requirement shall be taken into the DCS.
3.2.2.
Field-Mounted Instruments
(1)
All field instruments shall be suitable for installation in the climatic conditions specified below and be tropicalized as per manufacturers standard procedure. All parts subject to moisture, fungus growth, or insect attack shall be treated with suitable coating to inhibit such corrosion attack. Suitable weather protection, NEMA 4 or equivalent as minimum, shall be provided. Site Conditions - Ambient temperature
- Maximum 37 °C - Minimum 18 °C
- Relative humidity
- maximum 100 %
- Maximum wind velocity
- 35 m/sec
(2)
Instruments for off-line mounting shall be provided with mounting bracket suitable for 2" stanchion, except where installed in panels.
(3)
As a rule, all electric transmitters shall be provided with an integral mount local indicator, however, blind transmitter can be used when separate remote output indicator in the field is installed.
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(4)
The smart transmitter shall be used.
(5)
Accuracy of instruments shall be within ± 0.2% of the span, sensitivity 0.05% and repeatability ± 0.1% of the span for electronic transmitters as maximum, and accuracy ± 1.0% of the span for other instruments, unless otherwise specified.
(6)
Each pneumatic instrument shall have an air filter regulator with a supply gauge and a blind pneumatic transmitter shall be furnished with a local indicator.
(7)
All indicating instruments shall have white dials with black figures and graduations unless otherwise specified. Normal reading/indicating position shall be approximately 70% of full range of flow and in the middle third of the span for other variables.
(8)
Alarm and shutdown switches shall be provided with bypass for permitting on-line testing and maintenance.
(9)
By pass switch shall be key switch and mechanically retained in the operated position (type of switch unique key lock).
(10)
Each by pass switch shall cause a separate individual signal lamp to be illuminated at trip system to inform the operator that by pass switch has been actuated.
(11)
All field electrical instruments shall be furnished with wiring connection terminals for termination.
(12)
All instrumentation using radioactive materials shall be properly sealed or shielded for protection to human and/or equipment.
(13)
Vent/drain normally opened to the atmosphere should be provided with protection from rain, wind, sand and bug.
(14)
Vent/drain connections shall be omitted (blind type) from transmitter bodies for 600# and above rating hydrogen service.
3.2.3. (1)
Nameplates All field-mounted instruments shall have nameplates. Manufacturer's standard corrosion resistant nameplate shall be provided showing Manufacturer Name, Tag No., Serial No., Model No, etc.
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(2)
Panel mounted instruments and panels shall have service nameplates on the front of the panel by white labels with black text, stating the tag number and the service written in English. The service nameplates shall be stuck in front of the panel.
(3)
Adhesive type nameplates, so called dymo tape or equivalent is not allowed.
(4)
Service-nameplates shall be furnished for field mounted controllers stating tag number and service description on laminated black coloured plastic with white lettering engraved.
3.2.4.
Colour and painting of Instruments and Equipment
(1)
The colour of instruments shall be manufacturer's standard, unless otherwise specified.
(2)
Operator consoles and system cabinets for the distributed control system shall apply manufacturer's standard colour.
(3)
The colour of auxiliary cabinets and local panels etc. shall be decided confirming with Owner during the detail design phase.
(4)
All instrument and equipment shall be painted at the manufacturer's shop with his paint system suitable for site condition specified in para. 3.2.2 (1) above, and for service conditions, if required. The manufacturer's standard shop coat shall be applied, however, two coats of primer and two coats of finish shall be applied in the manufacturer's shop.
(5)
Housing or cases of field instruments associated with interlock and safety systems, shall be coloured red, with the exception of valves.
3.2.5.
End Connections
(1)
All threaded connections shall be NPT as per ANSI Bl.20.1-1983.
(2)
All flanged connections, flange ratings and flange face finishes shall be in accordance with associated piping and vessel specification, unless otherwise specified.
3.2.6. (1)
Instrumentation in Electrical hazardous Location Instrumentation shall be suitable for the use in the specified electrical area classification.
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(2)
“The use of non-incendive type (Type N) electronic transmitters, thermocouples and resistance bulb elements is preferable in Class 1, Div-2 locations."
(3)
Purged and pressurized air protection ( > 2.54 mm WC) stipulated by NFPA, BS, etc. may apply for enclosures such as local panels in hazardous location. However, using the purged and pressurized protection shall be minimized so as to minimize the maintenance work.
(4)
Electrical equipment installed in hazardous location shall be approved or certified by the appropriate authorities and be designed based on International Codes and Standards.
3.2.7.
Accessibility and Maintainability
(1)
All instrumentation equipment shall be designed so that they are accessible, and their installation shall have a proper space for maintenance and removal of equipment.
(2)
Field-mounted equipment and instruments shall generally be located such that they are accessible directly from grade, platforms, walk ways, or fixed ladders. Line mounted instruments shall be located no more than 2.5 m vertically and no more than 0.5 m horizontally away from plat-form / walkway, or no more than 4.5 m vertically from grade, considering the accessibility by temporary ladder.
(3)
Control valves shall always be operable from grade or platform level.
(4)
Local indicating and recording instruments shall be installed with center line of window at an elevation of 1.35 m above grade or walk way and in an easily readable position.
(5)
Remote-mounted output indicators from the transmitters shall be installed for all flow control and pressure control instruments. The other services shall be as per Piping and Instrument Diagrams.
(6)
The direct process mounting type pressure transmitter shall be used wherever applicable.
3.2.8.
Selection of materials
(1)
The material of the wetted parts of instruments shall be selected to satisfy the operating conditions.
(2)
The selection of materials for in-line instruments (orifice assemblies, control valves, thermowells, etc.) which are subject to operating pressure, temperature, erosion and corrosion shall generally follow the specification for the associated piping materials, and the selection of materials for
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on-line instruments (external displacer type level instruments, gauge glasses, etc.) which are subject to operating pressure, temperature and corrosion shall follow the specification for the associated vessel materials. However, in both cases more suitable materials than those specified for piping or vessels shall be selected for instruments. (3)
Off line instruments (most transmitters for flow, pressure, etc), which are subject to the operating pressure and corrosion shall generally be of carbon steel or AISI 316 stainless steel, unless the process conditions require a more suitable material.
(4)
Installation materials of impulse lines between process connections and off-line instruments shall be of AISI 316 stainless steel and/or materials stipulated in the associated piping material specification.
3.2.9. (1)
Utility Instrument power supply shall be as follows; Power
For
AC 120 V 50 Hz (UPS)
General instrumentation including both Local Panels, Analyzers, Fire Alarm System, Tank gauging system
AC 230 V 50 Hz
Receptacles, lighting on cabinets and panels. Illuminators for level gauges.
DC 125 V with battery. back up
Emergency Shutdown System.
Note: DC 24 V power shall be provided within the system such as DCS etc. from UPS as required. (2)
Instrument Air SUPPLY Instrument air supply pressure is normally kept at about 7.0 kg/cm2 G and design pressure is 11.0 kg/cm2 G. However, all pneumatic actuators for control valves etc. shall be designed to operate at minimum of 5 kg/cm2 G air supply pressure.
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3.3.Distributed Control System (DCS) 3.3.1. -
General A computer control system should be the latest product, not prototype and the system is not absolute for next ten years and should be supported for min 15 years. The system shall support open architecture with industrial standard packages (Utilize operating system like Unix, NT, OPC supported etc) The DCS system should be completed with self diagnostic system , where the failure of each DCS component will be display on the CRT.
-
3.3.2.
Control System Philosophy
3.3.2.1.
Control
The DCS shall be used for process control, monitoring and manipulating normal process control such as steady state (PID), process monitoring such as H/L checking shall be executed by DCS controllers or process interface units. Some kinds of controls such as PID gap, cascade, selector, etc. shall also be executed by the DCS controller. Emergency shutdown and interlock sequences shall be provided by the TMR/redundant PLC, which are installed separately from the DCS.
3.3.2.2.
Manipulating and Monitoring
The interface between the operators and the plant shall mainly be an operator station, which shall consist of a CRT, keyboard and printer. Hardwired annunciators, hard wired recorders and operator intervention switches, which shall be mounted on an auxiliary console beside the operator console which assist the operator for supervising and manipulating more efficiently. Graphic displays on the CRT shall be useful and of powerful assistance to operators. Digital temperature indication shall be displayed on CRT station of the DCS. The following are the main functions of DCS. Functions a) Process control b) Process monitoring
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c) Operator manipulation d) Graphic display e) Reporting by bulk memory storage 3.3.2.3.
Management Information System
The DCS shall be capable of communicating with a higher level computer system, which may be installed at the letter date for the purpose of Management Information System. 3.3.2.4.
The DCS installation should be provided by Internal Lightning protection.
3.3.2.5.
Hardware System Configuration
Main equipment of the DCS shall consist of the following items. 1)
Operator Monitor Operator station 21" CRT with keyboard with bulk memory Hard disk Fan unit Floppy disk drive Accessories for software loading and restoring system such as streamer or cartridge tape Video copier (color printer) Auxiliary monitor including annunciator lamps, push buttons, switches. Two (2) printers (One for alarm printer and the other for log printer).
2)
Process Connected Device Controller
3)
Data Communication Bus
4)
Gateway if necessary
3.3.3.
Distributed Control System (DCS) Structure
The DCS consists of monitor, process connected devices and system communications 3.3.3.1. (1)
Monitor Each monitor identical with keyboard unit.
21-inch color CRT display, CPU and a
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(2)
Each monitor shall be equipped with one log printer. One printer for alarm/event/messages to be used as common printer. In the event of malfunction, the operator shall be able to switch printers.
(3)
The monitor equipment shall be of the manufacturer's standard type, including software loading and restoring system.
(4)
The monitor shall provide the following displays and functions. (a) Overview display with deviation alarm (b) Group display (eight loop displays at the same time) in which control loop will be manipulated. (c) Detail display ( for parameter tuning) for each instrument loop (d) Alarm display (group or/and summary) (e) Trend display (f) Graphic display (with periodic real time process data) (g) System display for system building and maintenance (including devices diagnostic, communication system status) (h) Shift report (averaged and accumulated process data). (i) Daily material balance report (averaged and accumulated data) (j) Monthly material balance report (averaged and accumulated data)
3.3.3.2.
Process Connected Devices
3.3.3.2.1
Controllers
(1) A microprocessor-based digital controller shall manipulate a maximum, eight (8) to eighty (80) control loops depending upon the manufacturer's standard. (2) Each controller shall be backed up by an Uninterruptible Automatic Control System (fully redundant 1:1) for CPU, power supply and communication bus. (3) Input/Output Modules The Channels of the I/O should be isolated or separate isolators need to be provided. Where more than 2 control and/or 4 inputs outputs are shared in one electronic card for signal conditioning, multiplexing, or A/D conversion, or D/A conversion, then a fully redundant card (1:1) shall be provided as a backup. The system shall have the capability for automatically transferring the functions to this redundant card on the loss of the main card. If I/O modules have max channel capacity 4 (4 control loop), the control loop should be arrange as well as possible, so the failure of any module shall not affect more than two (2) control loops ( 1 critical loop and 1 non critical loop). Design of I/O load shall be approved by the Owner's Engineer
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Contractor should supply 20 % Installed I/O module spare (4) If any module is fail, the replacement of failure module should be able on line without switching off the power. (5) Closed loop control shall be executed. (6) Controllers shall provide the following functions. (a) Accepting plant inputs (b) Steady state control (c) Simple calculations, addition, subtraction, multiplication, Hi/Lo signal selection, etc. (d) Alarm generation (Hi, Lo or deviation) 3.3.3.2.2
Process Interface Unit (PIU)
The Process Interface Unit shall contain microprocessor-based multiplexers, which provide the following functions. (a) Interface for non-control loops, high level analog, low level analog and digital plant input (b) Engineering unit conversions (c) Alarm generation (Hi, Lo) 3.3.3.2.3
System Communication
(1) A fully redundant communication system shall be provided to interconnect all devices within DCS. (2) The communication system shall be designed to be automatically self checking and to reveal to the operator when any fault might occur. The system shall be arranged for automatic switching on a periodic basis. (3) The communication system shall be a "token-passing" not "ethernet". (4) Communication hardware and protection system shall be of the manufacturer's standard types. (5) Communication is executed via co-axial, twisted pair or optical fiber cables. 3.3.3.3. (1)
Redundancy and Security The DCS shall be designed for high integrity. No single fault shall result in the loss of the complete system, or local system, or local cabinet/console. Control loops shall be configured to minimize and localize the effect of equipment failure.
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The effect of common mode failure shall be considered whenever inputsoutputs and controller files are allocated to hardware channels. (2)
3.3.4.
The following hardware and software configuration shall apply. a)
Each monitor shall consist of a screen, a keyboard (s) and power supply, and shall have a minimum 2 sets of processors which shall be backed-up each other. Each monitor shall be capable of assuming the operations functionality of others monitor. It shall be possible to control all plant sections from any monitor.
b)
Each monitor shall be capable of accessing the entire operating data and control functions of the complete system, but normally locked out of each other's database.
Auxiliary Instrumentation
The auxiliary instrumentation system shall consist of hardwired annunciators, interlock shutdown system, analog instruments and other auxiliary instruments. 3.3.4.1
Hardwired Annunciators
1)
Important alarms, such as shutdown, shall be generated by the hard wired annunciator units, and not by the DCS.
2)
Annunciation indicators shall be grouped on the auxiliary monitor, close to their associated monitor.
3.3.4.2
Emergency Shutdown System
1)
Emergency shutdown system for major equipment or major process units as per P & ID's shall be implemented by redundant PLC, which are separated from the DCS.
2)
Start-up bypass switches Emergency shutdown switches etc. requiring operator intervention shall be provided for each system and located on the auxiliary monitor mentioned before.
3)
Maintenance override switches shall be installed in the Emergency Shutdown System Racks.
3.3.4.3
Logic Control System
The discrete control function of DCS shall perform automatic sequences and interlocks to ensure proper operation of the electromechanical equipment. The discrete control function system shall provide:
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- Automatic operation of field equipment: - Start - stop of the pumps, motors, air actuated and motorized operating valves (MOV) - Level regulation of the operating tanks - Protection against hazardous operating conditions, checking of safety parameters and initiation of the corresponding alarms.
3.3.4.4
Analog Instruments
1)
Auxiliary analog instruments, (e.g., mV/I converters, RTD/I -converters,) shall be mounted in auxiliary instrument racks and shall be provided as required.
2)
Where the process licenser specify ”a records” and/or "a totalizer" digital storage method to be undertaken by the DCS, not dedicated hard-wired recorders or totalizers, shall be provided.
3.3.4.5
Others
1)
Marshaling racks with enters terminals between field and control room shall be installed in rack room.
2)
Instrument/Electric Interface relay racks shall be provided for conditioning of digital input output.
3)
Power distribution panels shall be installed in rack room. Transformers may be furnished with the panel to provide the required voltage to meet the equipment requirements, if necessary.
4)
Special recorders for analyzers shall be installed on the analyzer rack in outstation or rack room.
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3.4.Programmable Logic Controller (PLC) 3.4.1
General
Programmable Logic Controller (PLC) is microprocessor base of equipment, which will be used for executing sequential logic in the shutdown-interlock system. The Programmable Logic Controller (PLC) consist of : − Processor − I/O unit − Power Supply Unit − Engineering Station − SER (Sequence of Event Recorder) 3.4.2
Redundancy − The PLC should redundant − Power Supply, communication card and communication cable with DCS system, should be redundant − Replacement of any failure module should be able to be done without interrupting process control/switching off the power
3.4.3
Processor Unit − In the case of power failure, processor should be able to keep the memory for minimum 6 months. − Execution time : The processor execution time is defined as the requirement time for scanning input, executing user defined function and updating the output. Maximum execution time = 100 msec. Fault/failure of redundant component should not influence the execution time.
3.4.4
I/O Unit − I/O unit should be modular type, where replacement of the module should be done on line (without switching of the power) and no affecting to the operation of the system. − I/O module should be equipped with mechanical key to avoid miss installation. − For commissioning purpose, system should be equipped with I/O simulation (Force) and the usage of this facility should be protected by password, avoiding mall operation by un authorized person. − Discrete input module. a. Every discrete input shall be equipped with LED as status input indicator. b. Input signal shall be filtered (low pass filter) for reduce noise effect.
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c. Opto isolator with minimum voltage rating 600 VDC shall be installed between input signal and microprocessor. d. Resistance input for discrete input shall be minimum 20 mega ohm e. Every discrete input shall be equipped with individually fuse and indication (fast blown fuse indication). f. Resistance input for frequency (pulse) input shall be minimum 1 mega ohm and able to handle pulse signal until 50,000 Hz. − Discrete output. a. Every discrete output shall be equipped with LED as status output indicator b. Opto isolator with minimum voltage rating 600 VDC shall be installed between every output signal and microprocessor. c. Every discrete input shall be equipped with individually fused and indication (fast blown fuse indication).Load power supply must be separate from PLC power supply. − Analog input module a. Standard signal for analog input is 4 – 20 mA or 1 – 5 volt DC and the A/D converter precision minimum 12 bit. b. Thermocouple input must be equipped with reference junction compensation and linearization c. Analog input must be equipped with signal filtering and protected from inadvertent grounds. − Analog output module The analog output will be able to generate output signal 4 – 20 mA and the minimum accuracy 0.5 %. 3.4.5
Power Supply − Power supply minimum dual redundant − Replacement of the failure module should be able to be done without interrupting process control/switching off the power − Power supply must be equipped with over temperature protector, integral fuse and LED for indicating failure.
3.4.6
Engineering Station − PLC must be equipped with personal computer (PC) for engineering station. − System must have the ability for on line maintenance and modification. − PLC program shall be completed with protection system (i.e. password, key lock switch) to protect from unauthorized changes.
3.4.7
Sequence of Event Recorder (SER). − SER system shall be back up by dot matrix printer, and have the capability to store 100.000 time stamped event in one circular file. Time stamp must be same with PLC clock time when alarm occur. − Time stamping on SER print out must come from PLC.
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3.4.8
Safety Certificate. − Soft ware or Hard ware of the PLC must be approved by TUV Product Service GmBH for AK 6 level or other Authorize International Organization. Certificate & Report shall be attached. − I/O card must be approved (certificated) by TUV for fail save operation. − If interposing relay is used for safety application, must be approved (certificated) by TUV or Authorized International Organization.
3.4.9
Communication − PLC must be able to communicate with DCS.
3.4.10
Alarm Signal Handling − PLC should be equipped with simulation facility for signal output alarm. − Shutdown alarm display in the operating console, consider first signal come out. − PLC should be equipped with self diagnostic system.
3.5.Instrumentation for Packaged Units 3.5.1.
Instrumentation for packaged units, including pre-assembled equipment containing instrumentation shall be furnished by the package Vendor as a complete package.
3.5.2.
All instruments in packaged units shall be supplied fully piped and wired. All wiring or pneumatic tubing for remote transmission shall be terminated in junction boxes and/or the local panel at the package skid.
3.5.3.
The relay logic system associated with the packaged unit may be installed locally close to the unit with the consideration of the proper protection for high radiation temperature and humidity etc. In principle, a common failure alarm shall be provided for a remote transmission. Alarm contacts shall-be closed during plant normal operation.
3.5.4.
Instruments and components in packaged units shall be per the package Vendor's recommendation and which shall be approved by the Purchaser. However, design requirements specified in the applicable requisition/specification for each packaged unit and Specification PS-42015-009-A4 (Instrument Requirement for Packaged Unit) shall follow for selection and installation of instruments and components.
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3.6.Local Panels 3.6.1.
Local panels shall be enclosed, self-supporting cubicle type panels, suitably gasketed to render them dust and moisture proof. Sun-shades/weather hoods shall be provided over local panels. Localized hoods over annunciators shall be considered to prevent glare on the annunciator legends.
3.6.2.
Where local panels contain relay and/or alarm logic system, consideration shall be given to the climatic conditions. A common group alarm shall be provided in the control room, if the annunciation is given on the local panel.
3.6.3.
Where the size of the cubicle would be disproportionate to the requirement, open panels with weather protective cover should be considered.
3.6.4.
All pneumatic tubing inside the panel shall be of 1/4" O.D copper tubing/SS tubing.
3.6.5.
All panels shall be constructed regarding to area classification. Purging and pressurizing air protection ( > 2.54mm WC ) may apply to meet the electrical hazardous condition if required. However, such protection shall be minimized so as to minimize the maintenance work.
3.6.6.
Each piece of panel-mounted instrumentation shall be wired or tubed to suitable terminals mounted in the panel.
3.7.Panel-Mounted Instruments (analogue) and Panels in Control Room 3.7.1.
Panel Mounted Instruments
3.7.1.1.
Panel-mounted instruments shall be of the miniature or sub-miniature type, except for analyzers and be suitable for flush mounting in steel panels or monitors.
3.7.1.2.
Chart sizes shall be in accordance with manufacturer's standards.
3.7.1.3.
Miniature recording instruments shall have electric chart drive. Chart speed shall be approx. 20 mm per hour with 2 to 2-1/2 hours of record visibility.
3.7.1.4.
Pens for recorders shall be of the capillary type with a reservoir for 1 month ink supply.
3.7.1.5.
Automatic-manual transfer switches for controllers-shall be provided and shall enable balance less and bump less transfer.
3.7.1.6.
Indicators shall be vertical fixed scale type with movable pointer and shall conform in general appearance to indicating controllers.
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3.7.1.7.
Continuous recorders shall be three (3) pen maximum.
3.7.2.
Instrument Panels
3.7.2.1.
Instrument panel shall generally be console or flat-faced type with underground interconnections.
3.7.2.2.
Colour of instrument panels shall be defined during the detailed engineering stage.
3.7.2.3.
At least 10% spare panel space shall be provided at the Factory acceptance Test (FAT) stage.
3.7.2.4.
The instruments shall be accommodated side by side in four (4) rows on each panel. Auxiliary instrument equipment shall be installed in auxiliary racks or instrument panel racks.
3.7.2.5.
For connection terminals to outside, terminal strips shall be provided on lower section of panel inside.
3.7.2.6.
The ventilation fan may be installed on the upper-side of each panel, when required.
3.7.2.7.
Nameplates shall be provided for those instruments which are installed on the panel. They shall, as a rule, be located just beneath each instrument.
3.7.2.8.
Each nameplate shall have the instrument Tag Number and service designation written in English.
3.7.2.9.
The nameplate shall be made of clear plastic plate, black letter, white ground and black engraved.
3.7.2.10.
Each terminal shall be provided with tag plate having its terminal number.
3.7.2.11.
Wiring
1)
All field-mounted panels and cubicles shall have bottom cable entry.
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2)
All wiring to/from the panel shall employ a terminal block which is located on panel frame for connection to the panel and the wires shall be laid in PVC duct.
3)
Wiring over short distances between the PVC ducts and the instrument termination blocks shall be protected by − plastic trunking or − spiral round vinyl protective strips, as appropriate.
4)
Wire size shall generally be minimum 1.13 square mm stranded with PVC insulation except for any Vendor's special wiring requirements, and for power cables.
5)
The color of PVC wire sheath shall be as follows except for any vendor's special wiring requirements. (a) AC 120 V Black (AC power) White (neutral) (b) AC 230 V Black (AC power) White (neutral) (c) DC 125 V Brown (+) Blue (-) (d) DC 24 V Grey (+) White (-) (e) Grounding Green (f)
RTD
(g)
2 wire (4-20 ma, 1-5 V pulse) T/C
(h)
3.7.2.12.
Black White Red Grey (+) White (-) Yellow (Type -K) Red Black (Type- R) Red
Power Distribution
1)
All switches shall be grouped and mounted on their respective panels, the main switch alone shall be a non-fuse breaker.
2)
Electric power for electric instruments, analyzers, temperature instruments, relay units and annunciators shall be fed separately in the panel. Individual isolation shall be provided for each control loop.
3)
All switches shall be housed in a switch box, which is installed at the upper position of each panel where one switch shall be provided for each loop individually and each switch shall have its own nameplate.
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3.7.2.13.
All make and break contacts shall be hermetically sealed as much as possible, regardless of electrical classification, to ensure proper operation in refinery atmospheres. The Vendor to propose whether he can provide or not. This requirement is to minimize open contacts.
3.7.2.14.
Instrument Air Piping and Tubing
1)
Air supply piping Vendor shall provide two sets of 2" air supply piping systems with two air filters, regulators and block valves in parallel for the instrument panels. Individual take-off ¼ inch size for each user shall be brazed. Each take-off shall be valve and be provided with nameplate to show instrument tag number. Ten percent spare valve and plugged take-off shall be provided for future use. Flange or union shall be provided or the header between panel sections for interconnection in the field. A valve drain connection (bottom of header) shall be provided at the end of the header remote from the reducing station. Pipe material shall be galvanized or brass and take-off valves of bronze. A header pressure gauge shall also be required so the regulators can be adjusted along with a relief valve to protect against over-pressure.
2)
Air tubing a.
All air tubing inside the panel shall be of ¼" O.D copper tubing.
b.
The tubes shall be marked on the instrument side, with relevant tag number and port number of the instrument by manufacturer standard.
c.
Control and transmission lines and interconnecting lines between panels and field shall be brought to bulkhead fittings.
d.
Twenty percent spare bulkhead connections shall be provided for future use.
3.8.Flow Instruments 3.8.1.
General
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3.8.1.1.
For the measurement of flow, the principle of differential pressure type measurement shall be applied wherever possible. Turbine meters, displacement meters and similar proper measurements may be applied where high accuracy is required. Flow measurement shall be suitable for the service conditions.
3.8.1.2.
The other types of flow meters such as turbine, positive displacement or ultrasonic types etc. shall only be used where special circumstances exist to justify their use.
3.8.1.3.
Where a flow totalizer is specified, DCS software totalizing is applied, except for metering proving system.
3.8.2.
Differential Pressure Type Flow Instruments
3.8.2.1.
Differential pressure instruments shall be force balance, differential capacitance, strain gauge or resonant wire type with continuous adjustable range. A valve manifold block assembly shall be provided with those transmitters.
3.8.2.2.
Bore calculation and selection of orifice plates shall be based an the latest edition of the “ Principles and Practice of Flow Meter Engineering” by L.K. Spink-1975. The calculated d/D ratio shall be within the limits between 0,25 and 0,70. In any case, actual orifice bore shall not be less than 5 mm, except specified by process licenser. The minimum size shall be 1-1/2” except integral mount type orifice. For pipe size less 1-1/2”, a special calibrated meter run shall be considered. Drain or weep holes shall be provided for orifice plates which have a bore larger than 1”. Orifice plate shall be fabricated as per attached “Fabrication Drawing” (Attachment - I). Minimum straight length shall be per attached “Piping Arrangements at Orifice Plates” (Attachment-II)
3.8.2.3.
Flange taps shall be used for 12” and smaller flow runs. Pipe taps shall be used for 14” and larger flow runs, where taps are located 2.5 diameters upstream and 8.0 diameters down stream from orifice plate.
3.8.2.4.
The differential pressure range, orifice diameter and type of device shall be calculated and selected in such a way that the normal flow shall be recorded or indicated at approximately 7 - 7.5 on a 0 - 10 square root chart or scale, and the maximum flow does not exceed 10 on chart. The
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differential pressure range shall generally be of the range of 125, 150, 625, 1250, 2500. and 5000 mmH2O. 3.8.2.5.
Orifice flange assemblies shall generally be provided with pressure taps. Orifice flange assemblies shall be as per ANSI 16.36 and have ANSI 300 lb weld neck type or slip-on type flanges for pipe tap connection unless conditions require a higher rating. Pressure taps shall be equipped with ½” NPT plugs for 600# and lower services and ¾” NPT plugs for 900# and above rating. The material of plugs shall be same to flanges.
3.8.2.6.
Round-edge, eccentric and segmental orifice plates, pitot, venturi tube, flow nozzle, etc, may be used where the process conditions require measuring elements other than square-edge concentric orifice plates.
3.8.2.7.
Material of orifice plates shall be type 316 stainless steel, unless other special materials are required by the process fluid.
3.8.3. 3.8.3.1
Rotameters Rotameters with a metal tapered tube shall be applied. Glass tube type may only be used for the fluid of air, inert gas, or water at the low pressure condition.
3.8.3.2
Rotameter shall always be mounted in a truly vertical position and in such a way that strain or stress caused by the weight of unsupported lines or by thermal expansion is kept to a minimum.
3.8.3.3
The maximum flow rate shall coincide with th maximum flow rate obtainable with a standard tube and float. Normal flow rate shall be between 60% and 80% of capacity, provided anticipated minimum and maximum flow rates shall be between 10% and 95% of capacity.
3.8.3.4
Fluid which may contain solids must be adequately filtered upstream of rotameters.
3.9.Level Instruments
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3.9.1. 3.9.1.1
3.9.1.2
General External displacer and differential pressure type instruments shall generally be used for measuring ranges up to 48”. For ranges greater than 48", differential pressure type instruments shall be used. Local gauge glasses shall be provided for all level transmitters.
3.9.1.3
When the above instruments do not satisfy the job requirements, the application of, radioactive, capacitance, ultrasonic or internal displacer level instruments and similar devices may be considered.
3.9.1.4
The rating of all gauge glasses shall be equal to or greater than vessel design pressure and temperature.
3.9.1.5
Following instruments for 600# and above hydrogen service shall be furnished with flanged vent/drain connections, with welded (SW) nozzles as shown in the attachment IV fig 1. - Displacement type level instrument - Gauges glasses - Level switches
3.9.2.
Gauge Glasses
3.9.2.1
Gauge glasses shall generally be armored type unless otherwise specified, and reflex type or transparent (through-vision) type, and their visible length shall cover the whole of the vessel's liquid level operating range, or the entire range of the vessel's level transmitter (s) whichever is the greater. Side connections shall be used as a rule. Individual isolation valve shall be provided for gauge glass installation.
3.9.2.2
Reflex type gauge glasses shall be used in general for all services. However, the transparent (thru-vision) type shall be used for the following services: - Liquid-liquid interfaces - Dark-colored liquid such as HGO and heavier - Liquid containing gum, sediment, or other solid materials which may coat the flutes of a reflex glass.
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3.9.2.3
Protective shields shall be used where process fluid shall attack glass.
3.9.2.4
Frost shields shall be used if specified operating temperature is below 0°C.
3.9.2.5
Where freezing or congealing of the process fluid may be encountered, a steam-traced gauge glass shall be used.
3.9.2.6
When two or more gauge glasses are required to cover a monitoring range, they shall be arranged in such a way that the visible lengths overlap by at least 25 mm and shall be placed on a stand pipe.
3.9.2.7
Tubular type gauge glasses shall be 3/4" diameter tempered glass with steel guard rods. gauge valve shall be forged (Jerguson No. 56 or equal) with ball check, 3/4” male tank connection, and 1/2" threaded female vent or drain connection opposite the tubular glass connection. Tubular glass shall be used in special application only specified by Licenser.
3.9.2.8
Gauge valves shall be furnished with all gauge glasses, unless otherwise noted in the individual instrument data sheet
3.9.2.9
Through-vision type will be provided with illuminator. When required, gauge glass lighting shall be provided by the gauge manufacturer and be explosion proof. Electrical power supply to the illuminators shall be as follows: Distribution system : Supply voltage : Wattage :
1 phase 2 wires 230 volt AC, 50 Hz 40 watts as a min.
3.9.2.10
Process connection shall be 3/4" flanged and flange rating shall be in accordance with Project Piping Specification.
3.9.2.11
Gauge glass shall have 1/2" drain valve and plugged vent connection for general purpose service. Details about drain/vent piping connections for other services are shown in the P&ID. Drain Valves to be supplied by piping.
3.9.3. 3.9.3.1
Tank Gauging System Following provided tanks shall be incorporated into Remote Tank Gauging System in off-site central control room. − Import/inter-unit tanks − Products tanks − Miscellaneous tanks
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3.9.3.2
As for the custody transfer tanks, the following equipment shall be furnished for each: − A servo balanced type tank gauge with a built-in digital transmitter − A mean (average) temperature sensor − A local indicator for liquid level A temperature sensor shall be mounted on the top of the tank. A local indicator shall be mounted on the ground for easy access.
3.9.3.3
For the other tanks except for custody transfer tanks, the following shall be furnished individually. − A spring balanced type tank gauge with a digital transmitter and local dial indicator for liquid level − A spot temperature sensor
3.9.3.4
Transmission signals for liquid level, temperature shall be of two way - two wire system by digital pulse.
3.9.3.5
CRT display and a printer with a manufacturer's standard software shall be installed in the Control Room.
3.9.3.6
Required total system accuracy of liquid level indication on the receiver shall be within ±2.0 mm.
3.9.3.7
Liquid level of the tank shall be monitored locally and remotely.
3.9.3.8
Tank gauges for local read out only shall generally be of the float type.
3.9.3.9
Applicable code for RTD temperature measurement shall be of DIN 43760.
3.9.4.
Displacement Type Level Instruments and Float Type Level Switches
3.9.4.1
Displacement type level instruments shall generally be externally mounted type. When the transmitter only is required, electronic type shall be applied.
3.9.4.2
The standard range of displacement type instruments shall be of 14"
3.9.4.3
(356 mm,) 32" (813 mm) or 48" (1,220 mm) unless otherwise specified.
3.9.4.4
The mid range of the instruments shall generally be located at the normal operating liquid level in vessel or column.
3.9.4.5
The plain extension and the radiation fin shall be provided as per services requirement.
3.9.4.6
The connection flanges for external type displacers shall be 1½”. The flange rating shall be in accordance with the piping Specification. For internal displacers, the connection shall be 4".
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3.9.4.7
Displacers shall be stainless steel AISI 316, with torque tube made of inconel or AISI 316 or equal. Other materials may be used, if required by service conditions.
3.9.4.8
Side-and-side connection shall be used where possible. However, top and bottom or top and side connections shall be used for measuring liquid-liquid interface. When side-and-side connections are used, the displacer chamber shall be provided with 3/4" NPT threaded internal taper vent/drain connection for general purpose services. Details about drain/vent piping connections for other services are shown in the P&ID.
3.9.4.9
Rotatable head construction is required for external displacers
3.9.4.10
Proportional control action adjustable to l00% maximum proportional band and without automatic reset shall be provided for level control applications where the outflow liquid goes to sewer or storage directly (through no process equipment), and for level ranges corresponding to ten seconds or less holdup time. For all other level control applications, proportional action adjustable to 300% proportional band minimum and reset adjustable down to 0.05 repeats per minute or less shall be provided.
3.9.4.11
3.9.5.
Connections for level switches shall be flanged 11/2” and the flange rating shall be in accordance with piping specification. Differential-Pressure Type Level Instruments
3.9.5.1
Differential pressure instruments for level measurement shall be force balance type (pneumatic) or solid-state electronic type.
3.9.5.2
Differential pressure instruments on level service shall be executed with a suppression or elevation feature. Suppression or elevations shall be adjustable when the instrument is in service and under pressure.
3.9.5.3
Flange rating for flange-mounted type shall be in accordance with the piping specification.
3.10.
Pressure Instruments
3.10.1 General
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3.10.1.1
Pressure and differential pressure instruments used in instrument air service or any other similar non corrosive service may have bronze bellows measuring elements.
3.10.1.2
Pulsation dampeners of micro needle type or snubber shall be furnished for all pressure gauges on discharge of reciprocating pumps and on suction and discharge of reciprocating compressor.
3.10.1.3
Pressure taps on horizontal lines shall not be located on the bottom part of the line.
3.10.1.4
In general, Pressure range shall be such that normal pressure shall be in the middle third of the span. Pressure elements measuring a steady pressure should not normally be operated above 75% of maximum range, and for measuring a fluctuating pressure should not be operated above 60% of maximum range.
3.10.1.5
Instruments shall have over-range protection to the maximum pressure to which they may be exposed.
3.10.1.6
Local pressure controller- shall be provided with indication of measured value and set point and auto-manual station
3.10.1.7
Process connection shall generally be 1/2" NPT male or female.
3.10.2 Pressure and Vacuum Gauges 3.10.2.1
Measuring element shall generally be the bourdon tube type. For measurement of slurries and viscous and corrosive fluid, diaphragm seal type shall be used.
3.10.2.2
The minimum dial size shall generally be minimum 100 mm and accuracy shall be ± 1.0% of F.S
3.10.2.3
The measuring elements and movements shall be type 316 stainless steel unless process fluid requires the use of other metal. In case of instrument air or non-corrosive service can be used bronze element. It shall withstand over-ranging to a pressure 1.3 times the maximum scale reading but if any more pressure rise might be anticipated, the mechanical protection for the sensing element shall be equipped.
3.10.2.4
Gauge connection shall be ½" NPT male and be provided with wrench flats, unless diaphragm seal type.
3.10.2.5
Gauge pointer shall be adjustable without removing it from its shaft.
3.10.2.6
The case shall be weatherproof and furnished with a blow-out back or blow-out disc in the back. The case material shall be phenolic resin with a screwed ring or stainless steel with bayonet lock ring.
3.10.2.7
Draft gauges shall be slack diaphragm type.
3.10.2.8
Siphons Siphons shall be 1/2" seamless schedule 80 (minimum) steel pipe. They may be either the pigtail or coil pipe type.
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3.10.2.9
Normal operating condition shall be considered as the design basis and the scale range shall be selected from the following table in such a manner that its working range falls between the values stated in Para.3.9.1.4. Scale Range 0 0 0 0 0 0 0 0 0 0 0 0 0
3.10.2.10
-
1 2,5 4 6 10 16 25 40 60 100 160 250 400
kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G
Scale Range -76 cmHg -76 cmHg -76 cmHg -76 cmHg -76 cmHg
-
0 0 0 0 0
-
1.5 3 5 9
kg/cm2G kg/cm2G kg/cm2G kg/cm2G kg/cm2G
Pneumatic Air Receiver Indicating gauges − Gauges used on instrument air supply and air transmission signals from transmitters may use phosphor bronze measuring elements. − A stop pin is required on all pneumatic receiver gauges at 110% of the range. − Connections shall be ¼" NPT (M).
3.10.2.11
Pressure gauges other than above such as air supply gauge, output gauges and etc. installed on the instrument shall be manufacturer's standard.
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3.10.3 Pressure and Differential Pressure Instruments 3.10.3.1
Pressure instruments measuring elements may be bourdon tube, spiral, bellows or diaphragm type, depending upon the severity of the process service.
3.10.3.2
Pressure transmitters shall be force balance, differential capacitance, strain gauge or resonant wire type.
3.10.3.3
Pressure and differential pressure instruments other than pressure gauges and pressure switches shall have elements and/or wetted parts of 316 stainless steel unless the service requires a different material.
3.10.3.4
For services requiring a range between - 76 cmHg and 2 kg/cm2 differential-pressure instruments shall be used as static pressure instruments
3.10.4 Pressure Switches and Differential Pressure Switches 3.10.4.1
Measuring elements shall generally be of the bourdon tube, bellows, or diaphragm type.
3.10.4.2
Pressure switches shall be provided with SPDT or DPDT contacts with their set-point internally adjustable and fixed or adjustable differential as required.
3.10.4.3
Pressure element materials shall be suitable for the service.
3.10.4.4
Liquid filled bellows type differential pressure instrument shall be considered for very low pressure measurement.
3.11.
Temperature Instruments
3.11.1
General
3.11.1.1
Filled system type primary elements may be used for local controllers, local recorders, and alarm indication.
3.11.1.2
Resistance temperature detectors shall be used only where thermocouples do not meet accuracy requirement.
3.11.1.3
Multipoint temperature indicators shall be incorporated into the C.C.S.
3.11.1.4
The temperature measuring element shall be installed such that the sensitive part is always fully immersed in the medium to be measured.
3.11.1.5
All temperature instruments shall generally be provided with a thermowell except embedded bearing temperature element and unless specifically noted.
3.11.1.6
Thermocouple or resistance bulb heads shall be of cast iron or equal. Cover shall be threaded and gasketed with retaining chain to body.
3.11.2
Temperature Gauges
3.11.2.1
Temperature gauges shall be bi-metallic type or filled type with everyangle feature, suitable for mounting in threaded or flanged thermowell.
3.11.2.2
The dial size shall generally be minimum 4".
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PS-42-015-001-A4 SHEET 40 of 73
3.11.2.3
Immersion length of temperature gauges shall be in accordance with the length of the thermowell.
3.11.2.4
Manufacturer's standard ranges shall be used to the maximum possible extend.
3.11.2.5
The case material shall be stainless steel for corrosive atmosphere or aluminium for non corrosive atmosphere
3.11.2.6
Normal operating condition shall be considered as the design basis and the scale range shall be selected in such a manner that the working range falls between 30 % - 70 % of the full scale.
3.11.2.7
The accuracy of thermometers shall be within at least ± 2% of full scale unless noted.
3.11.3
Filled System Temperature Instruments
3.11.3.1
Ranges and their limits of filled system temperature instruments shall be in accordance with the manufacturer's standard, but the application shall be limited to a maximum operating temperature of 538 deg. C. however, filled system type shall not be adopted for low temperature services.
3.11.3.2
The bulbs shall be provided with extension with adjustable union and bushing having 1/2" male thread for connection to a thermowell.
3.11.3.3
The capillary tubing shall be of AISI 316 stainless steel in accordance with the manufacturer's standard.
3.11.4
Resistance Temperature Detector (RTD) Instruments
3.11.4.1
Resistance-type self-balancing instruments may be provided for high accuracy and narrow span requirement service of temperature measurements up to and including 650 deg.C.
3.11.4.2
Platinum resistance elements shall have a nominal resistance of 100 ohm at 0 deg C. The temperature resistance characteristics shall be per DIN 43760.
3.11.4.3
A three wires system shall be used.
3.11.5
Thermocouples
3.11.5.1
For temperature measurements, all thermocouples for temperature 0 - 1100 deg.C service shall be Type-K (chromell-alumel) and metal sheathed, mineral insulated.
3.11.5.2
The temperature EMF characteristics and tolerances shall be according to ANSI MC 96.1.
3.11.5.3
Thermocouple extension wires shall be as per ANSI C 96.1 including colour coding.
3.11.5.4
Thermocouples for measuring skin temperature of furnace tubes shall be knife edge type, refer to Fig. 1. Generally, these couples shall be connected to the multi-point temperature indicator.
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PS-30-015-001-A4 SHEET PAGE 42 OF 73
E20500-02-02
PS-30-015-001-A4 SHEET PAGE 45 OF 73
3.11.6
Thermowells
3.11.6.1
Construction of thermowells shall be based on the attached "Fabrication drawing in Attachment III. However, Vendor shall clarify if the thermowells have suitable performance for the resonance effect under the operating conditions. Thermowells shall gsnerally be interchangeable between resistance bulbs, thermocouples, test wells and temperature gauges.
3.11.6.2
Depending on the pipe and vessel specifications, thermowells shall be suitable for mounting on 1½" flanges nozzles, or in 1" screwed bosses. (Refer to Para.3.14)
3.11.6.3
Material for thermowells shall be type 316 stainless steel, unless other special materials are required by the process fluid.
3.11.6.4
The thermowell material and tag no. shall be clearly stamped on the body (wrench flat) or flange.
3.11.6.5
The length of the thermowell shall generally be as tabulated below: Nominal
Dimension "L", mm Flange Pipe Size Screw SW* Weld Neck* Class < 1500# 2500# up to 6” 150 210 260 280 8 " to 12" 200 260 310 330 14" up 250 310 360 380 Tower or vessel mounting 450 500 520 Furnace or reactor as specified * marks are flange types of piping nozzle 3.11.6.6
3.12.
For temperature measurement in applications such as furnace, flue gas ducts, combustion chambers, etc., the thermowells to be used shall be made of seamless pipe (refer to Attachment III - detail J). Control Valves
3.12.1 General 3.12.1.1
Control valves shall be pneumatically operated receiving 0.2 - 1.0 kg/cm² air signal. The spring range other than 0.2 - 1.0 kg/cm² may be used when necessary to provide thrust for specific applications. Control valves shall be sized by the ISA formula or Manufacturer's Standard.
3.12.1.2
Direction of flow shall be cast or steel-stamped on the body.
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3.12.1.3
PS-30-015-001-A4 SHEET PAGE 45 OF 73
Valve body colour shall be silver.
3.12.2 Size and Rating 3.12.2.1
All control valves shall have flanged connections except for large size butterfly valves, which are used for non flammable services. The rating for valves shall be in accordance with piping specification.
3.12.2.2
The following body sizes shall be used: 1, 11/ 2 , 2, 3, 4, 6, 8, 10, 12 inch and larger.
3.12.2.3
The smallest body size to be used shall be 1" except for 3/4" Lines where 3/4" valves may be used. If a smaller port area is required, reduced trim shall be used.
3.12.2.4
The minimum flange rating of control valve shall be class 300# , unless otherwise specifically noted.
3.12.3 Materials 3.12.3.1
Body material shall be carbon steel, unless process conditions require a more suitable material.
3.12.3.2
Control valve trim material shall generally be of type 316 stainless steel, unless another material is more suitable for the particular process conditions. Trim materials for globe and angle valves shall be selected from Table 1-1 following the guide lines given in Table 1-2.
3.12.3.3
Gland bolts shall be 13 Cr minimum.
3.12.3.4
Unless specific reason exist, the material of gland packing shall be of teflon-asbestos. Necessity of lubricator with isolating valve shall be as per manufacturer's recommendation, however, if required, the lubricator shall be of "ball and spring type" for human safety point of view or providing with a caution plate.
3.12.3.5
Valve spring shall be made of carbon steel and shall be coated black lacquer.
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PS-30-015-001-A4 SHEET PAGE 45 OF 73
TABLE I – 1 CONTROL VALVES (TRIM MATERIAL TABLE) GLOBE/ANGLE TYPES TRIM TYPE A1
A2
A3
B
316 SS
316 SS with STELLITE FACED SEATS
440B SS 630 SS
C
D
G
H&J
316 SS with STELLITE SHEATH
HARDENED MONEL
K
N
HARDENED MONEL
321 SS 347 SS
HARDENED MONEL
321 SS 347 SS
HARDENED MONEL
321 SS 347 SS
PART NAME VALVE PLUG
304 SS
PORTS
304 SS
SEAT RING
GUIDE BUSHING PACKING BOX BUSHING or RETAINER RING (IF USED) PACKING BOX SPRING (IF USED) and VALVE STEM VALVE LOCK PIN, PACKING BOX SPACER and GLAND PACKING BOX FLANGE, STUDS. And NUTS
316 SS
316 SS with STELLITE SHEATH
440B SS 630 SS 440B SS 316 SS with STELLITE SHEATH 630 SS
316 SS 316 SS with STELLITE SHEATH
316 SS
316 SS with STELLITE FACED SEATS
630 SS 440B SS
316 SS
316 SS with STELLITE BORE
440B SS 630 SS
316 SS with STELLITE BORE
MFR’S STD
MFR’S STD
MFR’S STD
MFR’S STD
316 SS
316 SS
316 SS
MFR’S STD
MFR’S STD
STEEL
STEEL
304 SS
440B SS, 316 SS with STELLITE SHEATH 440B SS 316 SS with STELLITE SHEATH
316 SS with STELLITE SHEATH
HARDENED MONEL
440B SS 316 SS with STELLITE SHEATH
316 SS with STELLITE SHEATH
HARDENED MONEL
440B SS 316 SS with STELL.BORE 416 SS 630 SS
316 SS with STELLITE SHEATH
MONEL
MONEL
316 SS with STELLITE SHEATH
MFR’S STD
MFR’S STD
MFR’S STD
MONEL
MONEL
MFR’S STD
316 SS
316 SS
316 SS
316 SS
MONEL
MONEL
321 SS 347 SS
MFR’S STD
MFR’S STD
MFR’S STD
MFR’S STD
MFR’S STD
MONEL
MONEL
MFR’S STD
STEEL
STEEL
STEEL
STEEL
STEEL
STEEL
HARDENED MONEL
STEEL
316 SS
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PS-30-015-001-A4 SHEET 45 OF 73
TABLE 1-2 THE SELECTION OF TRIM TYPE FOR C/V
Process
Operating condition
Trim type
CAUSTIC
10 kg/cm2 or less dp and below 50°C 10 kg/cm2 or less dp and above 50ºC 10 kg/-cm2 or above dp and any temp.
A2 A3 D
GENERAL
10 kg/cm2 or less dp and below 320°C 10 kg/cm2 or less dp and above 320°C 10 kg/cm2 or more dp and below 30 kg/cm2 dp and below 320°C 30 kg/cm2 or more dp and any temp.
A2 B B G
SLURRY SERVICE Below 320°C and any dp Above 320°C and any dp
D G
STEAM
7 kg/cm2 or less dp and below 320°C 7 kg/cm2 or more dp and below 320°C 7 kg/cm2 or less dp and above 320°C 7 kg/cm2 or more dp and above 320°C
B D D G
HF ALKY
Concentrated Acid Trace Acid or Treated Alky 17.5 kg/cm2 or less dp
K
EFPLUENT
H C
Notes: (1) Vendor shall confirm if trim types specified in the data sheet are suitable for the operating conditions and service. (2) When Process Licensers data sheets is used, the trim types shall be per Licensers instruction.
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PS-30-015-001-A4 SHEET 46 OF 73
3.12.4 Construction of Valves Valve bonnet and blind flange shall be of the same material as the body and of integral or bolted type construction with fully retained gasketing. Threaded bonnets are not acceptable. Gaskets shall be corrugated 316 SS, unless otherwise specified. Stuffing boxes shall be the bolted gland type. Valve stem shall be threaded and pinned to the valve plug and its connection to the diaphragm stem shall be adjustable, with positive locking of the adjustment. 3.12.5 Valve Selection 3.12.5.1
General Service Globe type valve shall be used wherever applicable. For small size control valves, single-port globe valves with heavy duty type plug may be used. Double-port-top and bottom guided or balanced-cage trim globe, or characterized-ball valves maybe used where the use of single-port globe valves is not appropriate. In general, cage guided globe valves are unacceptable for heavy/dirty products and dry gases.
3.12.5.2
For large sizes with low pressure drop and low line pressure of non flammable service, butterfly valves may be applied.
3.12.5.3
For slurry service, angle type valves shall be applied.
3.12.5.4
Control valves without bypass line shall be provided with side mounted hand-wheels.
3.12.5.5
Valves used in safety shutoff service shall be ball type with tight shut off.
3.12.5.6
Ball valves used in fire safety system shall be furnished with fire safety mechanism.
3.12.5.7
Special valve such as over-travel design, v-ball type valve etc. shall be per process Licenser's design.
3.12.6 Actuators 3.12.6.1
General
(1)
Diaphragm and spring return type actuators shall generally be used. However, piston type actuators shall be used where strokes or thrust are required in excess of those obtained with diaphragm actuators.
(2)
Colour shall be as follows: - Green for Air Fail/Solenoid valve de-energized Close (Muncell 10GY 4/6) - Red for Air Fail/ Solenoid valve de-energized Open (Muncell 5R 4/14) - Silver for Air Fail/Solenoid valve de-energized Lock
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PS-30-015-001-A4 SHEET 47 OF 73
(3)
Actuators shall be sized to operate against the shut-off pressure or maximum upstream pressure with the downstream pressure being taken as zero.
(4)
Actuators shall be designed to operate by minimum instrument air supply of 4.5 kg/cm²G.
(5)
Actuator sizing and selection shall be in accordance with the manufacturer's recommendation.
3.12.6.2
Construction of Diaphragm Actuators
(1)
Yoke shall be made of cast or ductile iron.
(2)
Diaphragm cases shall be bolted pressed steel or cast steel.
(3)
Diaphragm shall be nylon reinforced neoprene or Buna N.
(4)
Actuator-valve stem connection shall be a bolted-threaded split clamp.
(5)
Valve position shall be indicated on a scale, except for regulator.
(6)
Springs shall have linear characteristics permitting full stem travel for air signal ranges of 0.2 to 1.0 kg/cm² under the shut-off pressure.
3.12.7 Valve Fail Position The required fail position of a valve shall be determined by analysis of the process and Piping and Instrument Diagrams. 3.12.8 Positioners / Transducers 3.12.8.1
As a rule, electro-pneumatic transducers mounted on a separate stanchion shall be provided for all electronic control loop.
3.12.8.2
Actuators shall be provided with pneumatic valve positioners in any of the following cases.
a. b.
The valve size is 6 inches and over. The valve size is 2 inches and over with operating temperature outside the limits -20 deg C and +230 deg C. The valve has a rotary action Split range application by local control only.
c. d.
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PS-30-015-001-A4 SHEET 48 OF 73
3.12.8.3
The pneumatic valve positioners shall be easily converted from direct to reverse acting.
3.12.8.4
Pneumatic valve positioners shall be provided with an air-filter regulator and three pressure gauges to indicate the followings: -
3.12.8.5
Supply pressure Controller air signal Positioner output
Electro-pneumatic transducers shall be provided with two pressure gauges, to indicate the following: - Supply pressure - Output pressure
3.12.8.6
The pneumatic valve positioners having identical input and output signals shall be equipped with integral bypass. All other pneumatic valve positioners need not be furnished with integral bypass. This bypass device shall be so arranged that the controller air signal can be switched to the positioners output pressure connection for permitting maintenance of the valve, loop test, etc. using the controller signal.
3.12.9 Valve accessories 3.12.9.1
Fin/Extension Bonnets Radiation fins or extension bonnet shall be provided when the design temperature is below 0 deg C or above 230 deg C.
3.12.9.2
Bellows Seal Bonnets Bellows seal bonnets are to be used to prevent leakage of toxic materials along the valve stem and out of the packing box. Manufacturer shall verify the necessity and suitability for the bellows seal and pressure-temperature rating.
3.12.9.3
Hand-wheels and Limit Stops
(1)
Hand-wheel shall be of the side mounted type.
(2)
When limit stop is specified, the lock-nut type with protection cap (no hand wheel) shall be provided.
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(3) 3.12.9.4
PS-30-015-001-A4 SHEET 49 OF 73
Fuel oil and fuel gas control valves except safety shut-off vales shall be provided with mechanical minimum closing stop with protecting cap. Air Lock-up Devices Air lock-up devices acting on total instrument air failure shall be provided for the control valves with fail position of "Fail Lock.
3.12.9.5
Tubing and Tube Fittings Instrument air tubing shall be of 1/4" O.D PVC sheathed copper tube for signal of input to positioner and 3/8" O.D PVC sheathed copper tube for signal of output from positioner to control valve actuator with double ferrule compression type fitting. Where large size tubing/connection is required for fast stroking speed according to the process requirement, they shall be considered by manufacturer.
3.12.9.6
Pressure Reservoir (Volume Tank) Pressure reservoir, such as for double-acting piston actuator, shall have a capacity of one and half stroke of the control valve. Pressure reservoir shall be of vertical self standing type or of either vertical or horizontal actuator mounting type. Pressure reservoirs shall have the drain plug for any type and anchor bolts for self standing type. Pressure reservoirs shall be manufactured in accordance with code and standard of country of origin. The test record and the certificate shall be submitted to Purchaser. Pressure reservoir's design pressure shall be 11.0kg/cm2G, and the volume shall be determined by calculation with pressure being 4.5 kg/cm2G air supply pressure.
3.12.9.7
Valve accessories, such as air-filter regulator, limit switches, positioners, solenoid valves and booster relays, air tubing etc. shall be totally mounted on the control valves by valve manufacturer.
3.12.10
Regulators Use of a self-actuated or pilot operated regulator shall be considered under the following operating conditions:
3.12.11
(1)
The variable is pressure, level or temperature.
(2)
The variable may be directly sensed by the regulator or pilot.
(3)
Operating conditions do not require variable proportional band, automatic reset and/or derivative action.
Installation and Location
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PS-30-015-001-A4 SHEET 50 OF 73
Control valve location shall allow maintenance and manual control by means of the bypass valve or integrally mounted hand wheel, from ground level or platform. These shall have adequate clearance to allow the valve to be lifted free and removed, or, in the case of a double port access to the bottom plate shall be required. In detail, refer to Piping Specification. Control Valves shall be installed vertically, unless otherwise specifically noted. 3.12.12
Determination of Valve Size
3.12.12.1
Control valves shall be sized from the latest data available from process flow diagrams, hydraulic calculation sheets line designation tables and other sources. The sizing and selection of control valves shall be checked by the manufacturer.
3.12.12.2
Valve sizing
(1) All control valves shall be sized using the formula of ISA or manufacturer's standard formula. All control valves shall be sized based on (1.65 times normal flow) or (1.1 times maximum flow), which is greater. (2) All valves with linear flow characteristics shall be sized on the basis of operating range between 50% to 80% of valve opening. (3) All valves with equal percentage flow characteristics shall be sized on the basis of operating range between 60% to 90% of valve opening. (4) All butterfly valves for throttling service shall be sized so that design flow rate does not require a valve disc opening greater than 60°, unless technically accepted by Purchaser. 90° opening is permissible for valves in on-off service. (5) All valves shall be designed against for cavitation and flashing using the method recommended by valve manufacturer to avoid damage of valves. 3.12.12.3
All valves shall be designed to meet a maximum predicted noise level of 85 dBA at 1 meter downstream of the valve and 1 meter from the pipe surface under continuous operation, not start-up stage and emergency conditions. The calculation formula and reduction method shall be in accordance with manufacturer's recommendations.
E20500-02-02
3.12.13
PS-30-015-001-A4 SHEET 51 OF 73
Identification Valves shall have the following identifying information: − Equipment identification number (Tag number) − Pressure rating of pressure holding parts, on the valve body − Manufacturer's name, model, serial number, valve action, characteristic, stem travel, Cv value, materials of parts exposed to process fluids, size (body and inner valve), type of plug and spring range, etc., on the nameplate.
3.12.14
Bypass Valves Bypass valves size will be determined by Piping Engineer
3.13.
Safety Relief Valves
3.13.1 General 3.13.1.1
All safety relief valves shall generally be designed, sized, installed in accordance with the American Petroleum Institute Recommended Practice for the Design and Installation of Pressure Relieving System in Refineries (API RP 520 and 521, latest edition).
3.13.1.2
Generally safety relief valves which have an enclosed spring (except air and steam services) with bolted bonnet, screwed cap, and full nozzle (1" and larger) shall be used.
3.13.1.3
Metal to metal seats shall normally be used, and conform to "Commercial Tightness" as defined in API Standard 527, which stipulates maximum leakages at a specified percent of the set pressure.
3.13.1.4
Relief system for hydrocarbon streams shall be equipped with a spare relief valve which means “plus one additional valve”.
3.13.1.5
Flanged connections shall generally be provided on all safety relief valves. When flange connection is specified, the flange rating of the valves shall be in accordance with piping specification. However, the minimum rating of the inlet flange shall be of class 300#, unless otherwise specifically noted.
3.13.1.6
Screwed connections shall be used for thermal relief valves and where it is requested in specification sheet.
3.13.1.7
Valve body colour shall be of silver.
E20500-02-02
3.13.1.8
When ASME Section VIII (Pressure Vessel) is applied, the following standard orifice letter and areas shall be used and ASME Code symbol shall be stamped. Letter (Designation) D E F G H J K L M N P Q R T
3.13.1.9
PS-30-015-001-A4 SHEET 52 OF 73
Orifice Area (cm2) (sq. in) 0.71 1.26 1.98 3.24 5.06 8.30 11.86 18.41 23.22 28.00 41.16 71.29 103.23 167.74
110 196 307 503 785 1.287 1.838 2.853 3.60 4.34 6.38 11.05 16.0 26.0
Nameplates shall be per API RP 526.
3.13.2 Selection 3.13.2.1
Safety relief valve capacity shall usually be determined on the basis of a superimposed back pressure at the value no greater than
(1) 10% of the valve set pressure for a conventional (non-balanced) type valve or, (2) 30% of the valve set pressure for a balance bellows type valve. 3.13.2.2
Also, built-up back pressure up to 50% of the valve set pressure is allowed for a balance bellows type valve.
3.13.2.3
Thermal relief valve shall be provided where liquid lines that can be blocked on and the resultant increase in hydraulic pressure, due to heat inlet from external sources such as ambient temperature can occur .
3.13.3 Sizing 3.13.3.1
The sizing of safety relief valves shall be in accordance with API-RP 520.
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3.13.3.2
PS-30-015-001-A4 SHEET 53 OF 73
Size for thermal relief valves where the required flow capacity is not given shall be 3/4" x 1".
3.13.4 Materials and construction 3.13.4.1
All safety relief valves shall be carbon steel with stainless steel disc and guides, as a minimum, spring shall be carbon steel with rust proofing, unless the service requires other materials.
3.13.4.2
The design of pressure parts shall be based on the allowable stress of ANSI or equivalent.
3.13.4.3
Bolting shall conform to ASTM specification A193 Grade B7 for bonnet studs and A194 Grade 2H for bonnet studs nuts or equal.
3.13.5 Accessories 3.13.5.1
Plain lifting levers shall be furnished for all safety valves in air or steam services. No lifting levers are required for process valves, unless otherwise specified.
3.13.5.2
Test gags are not required for all safety relief valves. Manufacturer's standard screwed caps shall be furnished.
3.14.
Analyzers
3.14.1 General 3.14.1.1
Analyzers shall be provided as per Piping and Instrument Diagrams.
3.14.1.2
Care shall be taken in the design so as to provide a proper installation which results in trouble-free operation.
3.14.1.3
The following main requirements shall be considered: − To meet all safety requirements. − To make certain that accurate and reliable analysis can be attained. − To provide facilities for necessary testing, calibration, and isolation.
3.14.1.4
A proper representative sample shall be taken and processed by suitable sample conditioning system before analysis.
3.14.1.5
Sample conditioning systems shall be designed taking into consideration the following. − Necessity and configuration of a sample probe.
3.14.1.6
The analyzer shall be located as close as practicable to the sampling point.
3.14.1.7
The analyzer shall be located in suitable house or enclosure. − Necessity of a sample pre-conditioning system to obtain the moderate pressure and temperature condition.
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PS-30-015-001-A4 SHEET 54 OF 73
− Requirements of a fast loop, fast loop bypass, heat tracing, insulation, etc., of sample transport line, including the consideration of the response time.
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3.15.
PS-30-015-001-A4 SHEET 55 OF 73
Instrument Take-off Nozzles Instrument take-off nozzles shall be as follows unless noted: Instrument
Connection to piping
Connection to equipment
Diff. press. type flow instrument Thermo Flanged wells Screwed Note 2 Press. Instruments and gauges Thermo Flanged wells Press. instruments and gauges Level External type instrument disp. and float Internal type displ. and float Diff, press type Diff. press. type-direct flange mounted with flat diaphragm Diff. Press. type-direct flange mounted with extended diaphragm Gauges glasses
Note
Type and Size of Process Connection ½ ” or ¾ ” Note 4 1½ ” flange 1”NPT female ¾” Note 3 1½ ” flange Note 1
Type and Size of Block Valve
Instrument Connection
½ ” or ¾ ”gate or globe valve ¾ ” gate or globe valve
½ ” NPT ½ ” NPT
-
½ ” NPT
½” NPT
½ ” NPT
1½ ” flange Note 3
¾ ” gate or globe valve 1½ ”gate or globe valve
4 ” flange
-
4 ” flange
¾” Note 3
¾ ”gate or globe valve
½ ” flange
3 ” flange
3 ” gate or ball valve
Note 3
4 ” flange
Note 3
1 : Including air duct, flue gas duct. 2 : Non-hazardous fluids with 150# rating 3 : Per equipment & piping design. 4 : ¾” size shall be used for 900 # and above.
-
¾ ”gate or globe valve
½ ” NPT 1½ ” flange
3 ” flange
4 ” flange
¾ ” flange
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PS-30-015-001-A4 SHEET 56 OF 73
4. CONSTRUCTION PHILOSOPHY 4.1 4.1.1
Instrument Installation Accessibility and Maintainability, Location of Instruments
4.1.2.1 Accessibility and Maintainability Refer to Para. 3.2.7 of this specification. 4.1.2.2 Location of Instruments (1) The measuring instrument shall be so located that it is. (2) For process units:
Instruments shall be located close to the primary element.
Differential pressure type flow transmitters shall be line mounted where possible, except in cases where vibration occurs, in which cases the transmitters shall be remote mounted.
Instruments connected to 16" or above pipes shall be remote mounted.
(3) For utility facilities and oil-handling facilities: Instruments will generally be floor-mounted. 4.1.2
Impulse Lines
4.1.2.1 All impulse lines from the process connection to the instruments shall be designed based on the following criteria: a)
Stainless steel tubing shall be applied for connections up to class 300#, except the following services: − − − − −
Chloride service Hydrogen service 600# rating and above. Liquid above their auto ignition temperature Toxic substances (TEL/TML) Sour service.
b) The Instrument Pressure Piping Material for following cases: − The services mentioned above. − Class 600# and higher for other services. Should be according to Piping Specification.
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c)
PS-30-015-001-A4 SHEET 57 OF 73
The sizes of impulse lines, when is indicated in the P&ID, shall be followed as per Licensers specific requirement.
4.1.2.2 Drain and/or vent facilities shall be provided as required for the proper operation. 4.1.2.3 The impulse tubing or piping shall generally be arranged as follows:
4.1.3
−
For liquids, the instrument shall be mounted lower than the measuring point, to ensure automatic venting of any gas from the instrument and connecting pipe back into the process line. The tap direction of flow element shall be horizontal.
−
For gases, the instrument shall be mounted higher than the measuring point, to ensure automatic draining of any liquid from the instrument and connecting pipe back into the process line. The tap direction of flow element shall be vertical.
−
For steam, the instrument shall be mounted lower than the measuring point. For low displacement instrument, e.g. force-balance type, fitting tees are preferably installed without condensing pots, however fitting tees may be omitted for saturated steam. The tap direction of flow element shall be horizontal.
−
The flow element shall be located in a horizontal pipe. Otherwise it shall be installed in a vertical pipe with downward flow for liquid, gas and steam.
Heating, sealing and Purging
4.1.3.1 Where plugging of impulse lines due to solidification of fluids, etc., can occur, suitable protection shall be provided by means of heating, sealing or purging. 4.1.3.2 Where the tracing of the impulse tubing or piping shall be required, steam tracing shall be provided. 4.1.3.3 Process fluids which solidify at ambient temperature shall not be allowed to enter the instrument, and instrumentation in such services shall be protected by liquid seals, or liquid or gas purges. 4.1.3.4 Diaphragm seals shall be considered for corrosive applications for which no suitable sealing liquid can be selected.
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4.1.4
PS-30-015-001-A4 SHEET 58 OF 73
Instrument Air Supply Piping
4.1.4.1 Piping from the isolation valves on the main instrument air supply header to individual consumer shall be of galvanized carbon steel pipe and threaded fittings. Drain valves shall be installed at all low points of main header and on dead end. 4.1.4.2 The size of the air piping shall depend on the number of air pilots as follows: Number of Pilots
Size
1–4 5 – 10 11 – 25 26 – 80 81 – 150 151 – 300
½" ¾" 1" 1½" 2" 3”
4.1.4.3 The final connection to individual air filter regulator and instrument shall be of copper tubing same as pneumatic signal tubing. 4.1.4.4 Spare valve and plugged connections shall be provided on the main instrument air header. 4.1.4.5 Main branch header valves shall be as per piping specification, and individual isolating valves near instruments shall be of bronze or brass. 4.1.5
Pneumatic Signal Tubing
4.1.5.1 Pneumatic signal tubing shall be of ¼" OD PVC sheathed copper tube with double ferrule compression type fitting of brass. 4.1.5.2 Tubing shall be run in the perforated cable tray or along instrument air supply piping. 4.1.5.3 Multi core copper tube may be required for specific application. 4.1.6 4.1.6.1
Instrument Cabling Cables run in the paved area within process and utility units shall be buried in preformed concrete (solid concrete block type wall) trench and cables in the unpaved area shall be directly buried. The fire proofing by glass wool or equivalent will be applied to multi-core main cables exposed from the ground to the junction boxes and cables installed on the cable trays located on or close to high fire risk area, such as pumps handling hydrocarbon of which temperature is higher than the auto ignition point. prefer to Design Basis for Fire proof of Instrument cable Tray)
4.1.6.2
Cable runs from field junction boxes to individual plant-mounted instruments shall be run in galvanized perforated cable tray.
4.1.6.3
Multicore cables shall be used between the control room and field junction boxes, unless specially required. Separate multi core cables are required for:
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PS-30-015-001-A4 SHEET 59 OF 73
Analogue signals (DC 24V) Thermocouple signals Control & status signals (shutdown circuits) Intrinsically safe circuit signals
One continuous length cable (direct cable) shall be used between field instrument to control room, for following signals: (1) (2) (3) (4) (5) 4.1.6.4
Resistance Temperatur Detector (RTD) PD meters (pulse) Turbine meters (pulse) Motor operated valve ( On-site areas only) 4-20 mA signals associated to emergency shut-down system
Cables segregation in trenches: The following minimum spacing shall be maintained between cables of zone A and B, according to definitions below, if parallel runs cannot be avoided. Location
minimum separation between zone A and B
Process units
300 mm
Utility Units
300 mm
Oil handling facilities (Off site area)
600 mm
Zone A: a) Instrument power supply cables up to 110 VAC with a 10A rating b) Actuating logic systems, including solenoids annunciators (125 V DC) Zone B: a) Computer bus signals b) Thermocouples and resistance .temperature measurement c) Analyzer signals d) Electronic signals (4-20 mA) e) Turbine meter and P/D meters ( pulse train ) f) M O V, Tank gauging system, metering proving system, vibration proximitors.
Notes: 1) Where a cross-over between cables of zone A and B is unavoidable, the cables should be arranged to cross at right angles.
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PS-30-015-001-A4 SHEET 60 OF 73
2) Within zone B, computer bus signal cables should be laid on side remote from zone A cables, so that cables are installed far from instrument power supply cables. 3) Separation between trenches of electrical cables (for power and lighting ) and trench for instrument cables (cables of zone A and B) shall be normally 0.6 m. This separation shall be 2.0 m in case of 20 KV power cables and long parallel run. Cross-over with electrical cables shall be at right angles. The distance to be adhered shall be 0.3 m minimum. 4) Computer bus for master and bus for slave shall be routed through separate trenches as far as practical. 4.1.6.5
Intrinsically safe cables and their installation shall meet the barrier certification requirements and regulations of their country of origin based on International Codes and Standards. Outer sheath color shall comply the applicable codes.
4.1.6.6
The signal cable shielding between control room and plant area shall be earthed at control room side only. The multi core signal cable shall have a common shielding, not an individual pair shielding.
4.1.6.7
Approximately 20% spare conductors shall be provided in each multi core cable run, and these spares shall be terminated in the junction boxes.
4.1.6.8
All cables shall be marked clearly, durably and consistently at all terminal points.
4.1.6.9
All above ground instrument cables, except power supply cables may be laid in the same cable tray.
4.1.6.10 All field cables shall be armored, and shall be sized taking into account the applicable codes requirements of capacitance and resistance. All armoring shall be connected to the frame earthing system. 4.1.6.11 Above ground cables between junction boxes and galvanized cable trays shall be suitably supported and protected where necessary. 4.1.6.12 Cables leaving trenchers to JB or local panels shall be installed will enough slack at underground. 4.1.6.13 Cables in the field shall be connected using compression type cable glands of galvanized fitted with shroud. 4.1.6.14 When cables/wires are installed in locations where they are subject to damage, they shall be protected by an overall steel wire armour or flexible conduit. 4.1.6.15 Junction Boxes
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(1)
(2)
PS-30-015-001-A4 SHEET 61 OF 73
Field junction boxes shall be located such that the length of the single cable runs are as short as possible. The boxes shall be reasonably and safety accessible. The design of the Junction Boxes shall be: explosion proof and weather proof (Class 1 Div. 1 areas) increased safety and weather proof (non hazardous areas or Class 1 Div. 2 areas) according to area classification. -
(3)
Terminals shall be "Klippon" type or equivalent.
(4)
Interconnecting marshaling cabinets shall be installed in the control room and/or the auxiliary/instrument room for connecting all electric signal and control cables to and from the field.
4.1.6.16 Labeling (1)
All individual cores at termination points shall be identified by PVC wire markers (open-Type), "CRITCHLEY C-TYPE." or similar. All terminal blocks shall be numbered.
(2)
All junction boxes shall be labeled using stainless steel plate.
4.1.6.17 Cables (1)
All conductors shall be of copper except thermocouple extension wires and special cables.
(2)
Underground cables shall be of Cross-linked high- density polyethylene (XLHDPE) sheath or lead sheath with a galvanized steel wire armour. Aboveground cables shall be of PVC sheath with a galvanized steel wire armour. All indoor cables shall be of PVC sheath
(3)
Signal, except control & status, cables from field junction boxes to the control room shall be of multi-pair, and overall shielded. Signal, except control & status, cables wiring from the field junction boxes to local mounted instruments shall be by stranded copper, overall shielded as minimum, (sharing of signal cables, refer to Para. 4.1.6.3 of this specification). Control & status signal cables may not be of pair and overall shielded.
(4)
Wire size and type shall be in accordance with following: Analog, digital signal, control & status and thermocouple extension cables shall be stranded wire and AWG 16. The cable size for power supply to the instrument equipment shall be AWG 14 copper wire as a minimum. However, cables shall be sized taking into account
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PS-30-015-001-A4 SHEET 62 OF 73
consumption, cable length and equipment manufacturer's requirement. Maximum allowable voltage drop shall be within 5%. (5)
Cable color (outer sheath) Analog and digital signals
: Green for above ground, and Black with orange tracer for underground cables. (*)
Control & status signals and power : Black for above ground and under ground cables. Thermocouple extension cables
: ANSI standard colour for above ground, and Black with ANSI standard colour tracer for underground cables. (*)
Resistance Thermometer cables
: White for control rooms, and Black with White tracer for field cables (*)
(*)Note : For intrinsic safety cables : Light blue for above ground, and Black with light Blue for underground cable. 4.1.7
Instrument and piping Supports
4.1.7.1
All instruments shall be adequately supported to ensure proper operation. Where pipe stanchion supports are required, they shall be 2", Schedule 40 pipe.
4.1.7.2
All instrument leads to vessels, lines, or equipment shall be properly supported to relieve strain on connections at equipment and instrument. Care shall be taken to avoid anchoring of these leads to "moving" structures or piping such as expanding or hot piping systems. Remote-mounted instruments shall be fixed on column or structure, e.g. where settlement of ground is considered.
4.2
Field inspection and Testing for Instrumentation The specification "Test and Inspection for Instrumentation Work" shall be applied. (This document will be submitted on EPC contract).
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5
PS-30-015-001-A4 SHEET 63 OF 73
DOCUMENTATION
5.1
General
5.1.1
Sufficient schedules, drawings, sketches, and other data shall be provided to enable the instrumentation to be installed and operated in the desired manner.
5.1.2
The Contractor's standard format may be used for documents and drawings to be issued to the Owner.
5.1.3
The Contractor's standard computer-aided design may be used to the maximum extent, wherever applicable.
5.1.4
Documentation for packaged units may be manufacturer's standard as far as the field installation and future maintenance can be made referring to the documents.
5.2 5.2.1
Drawings/Specifications Instrument Data Sheets These instrument data sheets shall cover definitively decided specifications per tag number relating to the type, measurement range, transmission type, service, fluid to be measured, measurement conditions, connection conditions, etc. of instruments, digital control system and other instrument equipment.
5.2.2
Alarm/Trip Set Point List This list shall show tabulated setting values for functioning contacts per tag number of instruments which have alarm contacts or interlock contacts.
5.2.3
Instrument Loop Diagrams These drawings shall schematically show connections of detectors and control valves, and those of digital control system to be provided in the control room.
5.2.4
Interlock and Sequence Logic Diagrams These drawings shall show schematically interlock circuits and alarm circuits in the order of the lapse of time of the functioning of relays and opening and closing of contacts.
5.2.5
Instrument Power Supply diagrams The instrument power supply diagrams shall show schematically instrument power supply to operator consoles, cabinets, panels, compressor local panels, analyzers, etc.
5.2.6
Layout of Instrument Panels These drawings shall show front and rear arrangement of instruments at instrument panels and construction of panels.
5.2.7
Typical Installation Method for Instrument These drawings shall illustrate typical methods of instrument wiring and air piping work around the transmitter, controllers, converters, control valves and other major instrument equipment and indicate a typical materials table if necessary.
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5.2.8
PS-30-015-001-A4 SHEET 64 OF 73
Instrument Pressure Piping Hook-up Drawings These drawings shall give a summary of typical work methods of process piping to instruments among instrumentation work items, and show how these methods are applicable per tag number to instruments. These drawings shall show a typical materials table.
5.2.9
Analyzer Piping Hook-up Drawings These drawings shall illustrate instrumentation piping and wiring methods around the analyzer, and show sizes, symbols and quantities of piping, piping component parts, wiring materials and other work materials for the instrumentation.
5.2.10 Layout of Instrument Main Cable Way This drawing shall show a route of the instrument cable way in the plant, and contain dimensions (width, height), location (dimensions and height) and partial detailed drawings. 5.2.11 Layout of Instrument Main Cable These drawings shall show the above ground and underground routing and number of main instrument cables from their junction boxes in the field to their termination points in the control room. 5.2.12 Layout of Instrument wiring These drawings shall show the installing cables between Junction Boxes or local instruments, non-junction cables between main cableways and local instruments. 5.2.13 Layout of Instrument Piping and Tubing These drawings shall show the installing supply air piping between local instruments and the supply air main pipe branch valves, and signal air tubing among local instruments. 5.2.14 Layout of Control Rooms, outstations These drawings shall show arrangement of operator consoles, cabinets, panels and racks etc. in the control rooms and outstation. 5.2.15 Layout of Local Panel This drawing shall show front and rear arrangement of instruments at the panel and be prepared by package Vendor. 5.2.16 Layout of Field Instruments Superimposed on simplified plot plan, these drawings shall show the location of field instruments, local panels, junction boxes and instrument air supply piping. Elevations shall be also given where necessary.
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PS-30-015-001-A4 SHEET 65 OF 73
5.2.17 Instrument wiring Connection List These lists shall show cable connections at termination points in the control room and the field including tag numbers, cable number, pair numbers, colour code of wires, terminal identification etc. 5.2.18 Specification for Instrument Installation Material This material specification shall give names, main specifications of pressure piping, air piping, wiring and other instrument materials. 5.2.19 Summary of Instrumentation Cables This summary shall give quantity and main specifications of thermocouple extension wires, signal cables, and instrument power cables. 5.2.20 Analyzer System Data Sheets These data sheets shall contain for each analyzer arrangement requiring a sample conditioning system. 5.2.21 Control Valve Calculation Sheets These calculation sheets shall show calculation data, method of calculation and calculation results per control valve tag number. This sheet shall be prepared by the manufacturer. 5.2.22 Orifice Calculation Sheets These calculation sheets shall show calculation data, method of calculation and calculation results per orifice tag number. This sheet shall be prepared by the manufacturer. 5.2.23 Safety Valve Calculation Sheets These calculation sheets shall show calculation data, method of calculation and calculation results per safety valve tag number. This sheet shall be prepared by the manufacturer. 5.2.24 Instrument Manufacturer Documents for Instruments These drawings shall be outline drawings for instruments and/or equipment to be submitted by the manufacturer. 5.2.25 Instrument Instruction Manual for Major Instruments The instrument instruction manual shall give explanations of the principle of functioning, specifications, installation, calibration, operation and maintenance, spare parts list and electronic wiring diagram of instruments. However, it is not required the said documents except spare parts list for gauges, T/C's.
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PS-30-015-001-A4 SHEET 66 OF 73
ATTACHMENT I : FABRICATION DRAWING OF ORIFICE PLATES
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PS-30-015-001-A4 SHEET 67 OF 73
ATTACHMENT II : PIPING ARRANGEMENT AT ORIFICE PLATES
NOTES : 1. This standard applies only for Tapped Orifice Flanges. 2. Dimensions shown are minimum required. When possible they should be increased. 3. When bends are used instead of fittings to change direction, dimension of lines shall be to tangent line of bend. 4. All tabulated dimensions are based on the joint A.G.A – ASME fluid committee report 3 of April 1985, and maximum orifice diameter ratio (d/D) of 0.70. Dimensions shown are to the center or face of orifice plate.
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PS-30-015-001-A4 SHEET 68 OF 73
ATTACHMENT II : PIPING ARRANGEMENT AT ORIFICE PLATES
NOTE 5
: Except for flange taps and corner taps, the length of straight run shall be measured from the tap location, not from the orifice flange.
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PS-30-015-001-A4 SHEET 69 OF 73
ATTACHMENT III : FABRICATION DRAWING OF THERMOWELL ( 150 #, 300 #, 600 # RATING )
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PS-30-015-001-A4 SHEET 70 OF 73
ATTACHMENT III : FABRICATION DRAWING OF THERMOWELL ( 900 # AND OVER RATING )
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ATTACHMENT III
PS-30-015-001-A4 SHEET 71 OF 73
: FABRICATION DWG OF THERMOWELLS (FOR HEATER)
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ATTACHMENT IV :
PS-30-015-001-A4 SHEET 72 OF 73
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PS-30-015-001-A4 SHEET 73 OF 73
ATTACHMENT V : FUNCTIONAL IDENTIFICATION OF INSTRUMENT
A B C D
FIRST LETTER MEASURED MODIFIER VARIABLE ANALYSIS BURNER FLAME COMPENSATED DIFFERENTIAL
E
VOLTAGE
F
FLOW
G H I J
HAND (MANUAL) CURRENT POWER
K
TIME
L M N O
LEVEL MOTOR
Q
QUANTITY SPEED, FREQUENCY TEMPERATURE MULTIVARIABLE
V
VIBRATION, MECH, ANALYSIS WEIGHT, FORCE MISCELLANEOUS , STATUS
CONTROL
HIGH INDICATE SCAN CONTROL STATION LIGHT
LOW
ORIFICE POINT (TEST CONN)
INTEGRATE, TOTALIZE SAFETY, SHUTDOWN MULTIFUNCTIO N
SWITCH MULTIFUNCTIO N
TRANSMITTER MULTIFUNCTI ON VALVE, DAMPER, LOUVER
WELL SKIN RELAY, COMPUT, CONVERTER
Y Z
ALARM
RECORD (1)
U
X
MODIFIER
RATIO (FRACTION)
R
W
OUTPUT
PRIMARY ELEMENT
OPERATED
P
T
READOUT
GLASS, GAUGE
PRESSURE, VACUUM
S
SUBSEQUENT LETTER
POSITION
(1) : HARD WIRE RECORDER ON FIELD OR HISTORICAL RECORDING IN DCS
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