AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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CONTENTS 1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 SCOPE TECHNICAL REQUIREMENTS TO BE SPECIFIED BY ENGINEER DEFINITIONS REQUIREMENTS AIR REQUIREMENTS AIR QUALITY AIR EQUIPMENT FILTERING ACCUMULATORS AIR DRIERS AIR COOLING AIR PIPING RETICULATIONS QUALITY ASSURANCE PROVISIONS

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APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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SCOPE
The scope is for the establishing of the quality of Instrument Air Supply from which a Project Specific document shall be generated. The scope includes for the reticulation of pipelines and testing requirements It furthermore draws the mandatory attention of the C&I Engineer to the following: The awareness of and adherence of the C&I Engineer to the standard electrical supply and control voltages dictated by the Client for this project The referencing and attaching associated documents to this standard and which will form part of this document The obtaining of an Approved Suppliers List list from the Client where this exists Obtaining of a Project Painting Specification applicable to control valves The creating of a Specification regarded as Project Specific for equipment referred to in this document Creation of data sheets reflecting all ambient, plant, environmental conditions and technical data pertaining to equipment reflected in this document

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY ENGINEER

The following information shall be specified in all tenders, contracts or orders: The reference number and issue number of this specification

DEFINITIONS
For the purposes of this specification the following definitions shall apply: BOQ : Bill of Quantity reflecting the C&I field hardware, cabling and cable racking to be installed on a construction site inclusive of supporting steel, terminations, storage etc. Central Control Room normally housing the PLC, SCADA and I/O cubicles etc. The end user who will take final custody of the plant after formal hand-over Constant Voltage Transformer A C&I Document reflecting the condensed but exact requirements of a piece of equipment to perform a certain duty and The Engineering, Procurement & Construction Management company with whom the responsibility for the total project is lodged and which responsibility includes all documentation, drawings, as-built drawings data sheets, O&M manuals and associated project documents up to the Close-Out Report
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CCR CLIENT CVT DATA SHEET EPCM

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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FRS

Functional Requirements Specification. This is the process description and method of creating a document reflecting the process controls, sequence starting/stopping of drives, interlocking and event logging of a process or multiple processes. This FRS in conjunction with the P&ID is used to write the software for the PLC and design the SCADA graphics and tags with. Human Machine Interface such as PC keyboard & monitor combinations or panel mounted operator stations Hydraulic power pack for e.g. apron feeder drives Optic Link Module used for signal conversion of copper signals to fibre optic signals Process Flow Diagram (Created by Process Engineer) Proportional, Integral & Derivative control mode (Three term controls) Quality Assurance representative; an independent surveillance agency appointed by the Engineer A field mounted enclosure housing remote Input/output modules with their power supplies and signal converting units, terminals etc. Service Level Agreements for contracts with potential afterdelivery services and maintenance agreements A C&I Document which is deemed Project Specific reflecting the exact technical requirements of equipment required to perform a specific function in terms of its technical criteria The person(s) or business group(s) who have a vested interest in a project and whose approval(s) shall be sought for the various decisions, documents and directives The successful supplier of equipment & instruments culminating from enquiries, tenders and adjudication processes Similar to SUPPLIER but normally supplying packaged deal equipment that may be utilised as self-contained and stand-alone equipment and which contains the hardware to connect to the main plant with simplistic interfacing

HMI HPP OLM PFD PID QAR RIO

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SLA SPECIFICATION

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STAKEHOLDER(S)

SUPPLIER VENDOR

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The following terms are defined in the General Conditions of Contract: Anglo American, Approved, Company, Contractor, Engineer

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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4 4.1

REQUIREMENTS AIR REQUIREMENTS

Pneumatic instrument manufacturing tolerances do not allow for air laden with oil, dust particles and water. When the instrument air does not conform to the requirements laid down by manufacturers, plant malfunction, excessive maintenance and component replacements follow with the related financial impacts. The following is the ideal air quality specification that shall be strived for. There are, however curbing factors within estimates and it shall be the decision of the C&I Engineer as to what level of sacrifice is to be made to accept air quality lower than the specification below.

4.2

AIR QUALITY
Instrument air shall conform to the specification below: Dew point Particle size Entrained oil Operating pressure Pressure drops: -25OC <5 micron after filtering <3 parts per million 700kPa Tolerances for allowing potential pressure reduction shall be project specific and shall be at the discretion of the C&I Engineer

4.3

AIR EQUIPMENT
Supply of air compressors on a project is generally the domain of the Mechanical Engineer and instrument air is then normally obtained from a distribution manifold together with other distribution points considered as plant air. This specification shall exclude parameters associated with compressors and shall treat the equipment required for cleaning and drying of air after the compressor or manifold.

4.4

FILTERING
It is advisable to install a pre-filter in the air supply line before the accumulator. The correct type of filters will clean the air from dust prior to accumulation Air filters shall be sized for the correct pressure and volume required by continuous use and filters shall be the removable type with filters in a by-passing configuration to allow on-line servicing of filters. Filter elements shall be able to be cleaned and dried for re-use. In the event of disposable elements the quantity shall be monitored so as to minimise shortfall

4.5

ACCUMULATORS
Instrument air shall be stored in accumulators dedicated to C&I air supplies
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Accumulators shall be sized to the correct volume and pressure and shall be tested and certified in accordance with the applicable manufacturing code. (Typically ASME VIII etc.) As far as practicably and economically possible accumulators shall be corrosion treat internally to minimise rust in the event of condensation Accumulator shall be fitted with a moisture trap and drain system at the bottom of the accumulator which shall preferably connected to a timing system to allow for automatic cyclic and regular discharge of moisture Accumulators shall be corrosion protection treated on the outside in line with the Project Corrosion Protection Specifications Pressure indicators of the project specified type, material and ranges shall be deployed at all accumulators and strategic points in the plant

4.6

AIR DRIERS
Air driers shall preferably of the twin column type, each column filled with desiccant and heater elements Functioning shall be that the one column is in service supplying air to the plant whilst the other is in a desiccant drying cycle. The local control panels and timers shall be part of this system. Controls may be via the main PLC which will be at the discretion of the C&I Engineer All equipment related to the driers shall be of corrosion resistant materials and correctly rated for the design pressures The C&I Engineer shall ensure that the Project voltage requirements are reflected in the specifications

4.7

AIR COOLING
This equipment is of major importance and the specifications shall be clear in terms of cooling temperatures to achieve the dew point mentioned at the start of this document Cooling equipment is highly specialised and economics should not jeopardise selections in favour of inferior equipment The C&I Engineer shall ensure that the Project voltage requirements are reflected in the specifications

4.8

AIR PIPING RETICULATIONS

Air piping reticulations shall be galvanised steel up to the last isolating valve servicing a piece of equipment. Use may be made of PVC or stainless steel tubing for the last run but shall not exceed 2 meters. Fittings for PVC and stainless steel tubing shall conform to the dictations of the C&I Engineer Main air headers above 50NB shall be flanged. These flanges may be screwed, flat faced fitted with gaskets specified in the Project piping specifications 50NB and below may be screwed using unions as approved by the C&I Engineer

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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All screwed joints shall be sealed using PTFE tape. No fibrous material or red lead shall be used Where headers enter buildings of a number of floors or levels, each level shall be fitted with a catch pot reflected in the AA STD 673013 Each floor or level shall be furnished with manifolds as shown on the above Installation Standard hook-up drawing. Tap-off connection points on these manifolds shall feed individual user points Each user point shall furthermore be furnished with a filter-reducer unit. The filter shall be fitted with draining facilities as well as being able to be cleaned Take-off points from any header or sub-header shall be from top entries. Bottom connection points have a potential for condensation accumulation and shall be avoided Each take-off point shall be fitted with an isolation valve conforming to the design and specifications of the C&I Engineer to enable work done on one piece of equipment without disturbing other user points All air reticulations shall be leak-tested with a solution of soap and water. No plant shall be taken over from the contractor without definitive proof and certification of each and every section of piping on the plant. Refer to the Project Commissioning

QUALITY ASSURANCE PROVISIONS

The requirements of AA_STD_100 shall apply

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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APPENDIX A: RELATED DOCUMENTS

AA SPEC 673038 Instrument Air Supplies

The latest issue of the following documents is deemed to form part of this specification: AA STD 100 AA STD 673013 Project Corrosion Specifications Project Piping Specifications The following is a list of international standards at the disposal of the C&I Engineer: AASHO ANSI ASME ASTM BS DIN IEC IEEE IES IPCEA ISA ISO NEC NEMA NFPA OSHA SABS SAMA SANS UL : : : : : : : : : : : : : : : : : : : : American Association for State Highway Officials American National Standards Institute American Society of Mechanical Engineers American Society of Testing Materials British Standards German International Standards International Electrotechnical Commission Institute of Electrical and Electronic Engineers Illuminating Engineering Society Insulated Power Cable Engineers Association Instrumentation, Systems and Automation Society International Organisation for Standardisation National Electrical Code National Electrical Manufacturers Associates U.S. National Fire Protection Association Occupational Safety and Health Association South African Bureau of Standards Scientific Apparatus Makers Association South African National Standards Underwriters Laboratories : : Quality Requirements for Suppliers of Critical Equipment Instrument Installation reflecting air related hook-up drawings

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AA SPECIFICATION INSTRUMENT AIR SUPPLIES

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APPENDIX B: RECORD OF AMENDMENTS Issue 0 : New document written by JJ Fourie, July 2009

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