Specification Number: ES-1648

Revision Number: 2





TABLE OF CONTENTS



Paragraph Page


1.0 Scope 1

2.0 Codes and Standards 1

3.0 Deviations and Discrepancies 2

4.0 Instrument Identification 2

5.0 Controllers 2

6.0 Transmitters 3

7.0 Primary Elements 5

8.0 Recorders 7

9.0 Indicators (Gauges) 8

10.0 Switches 9

11.0 Instrument Installation 10

12.0 Control Valves 13

13.0 Control Valve Installation 15

14.0 Actuated Block Valves 17

15.0 Relief Valves 18

16.0 Alarms and Trips 19

17.0 Safety 20

18.0 Instrument Panel Board 21

19.0 Analyzers 21



Specification Number: ES-1648
Revision Number: 2




20.0 Instrument Air 22

21.0 Drawings, Data Sheets and Calculations 23

22.0 Inspection 24







































ES-1648 ii


Specification Number: ES-1648
Revision Number: 2


ES-1648 1

GENERAL INSTRUMENT SPECIFICATION


1.0 SCOPE

This specification describes application guidelines and selection criteria for control and/or
measurement instrumentation required in an industrial process plant. Instrument suppliers,
plant designers and installation contractors must adhere to this specification. It covers field
mounted TRANSMITTERS, local and remote panel mounted INDICATORS, RECORDERS,
CONTROLLERS, SWITCHES, PRIMARY ELEMENTS, CONTROL VALVES, RELIEF
VALVES, AND ANNUNCIATORS. It does not cover DISTRIBUTED CONTROL SYSTEMS,
PRINTERS OR DATA ACQUISITION SYSTEMS.

Instrumentation associated with specific engineered items, such as BOILERS, STEAM
TURBINES, CONDENSERS, and DEAERATORS may be specified with these items and
their criteria for selection will be based on the manufacturer's standards with Solars
approval.


2.0 CODES AND STANDARDS

Instrument shall conform in design basis, material and performance to the latest edition of
the listed standards including addenda and revisions or supplements. These codes and
standards shall be considered a part of this specification.

2.1 Instrument Society of America (ISA)

ISA-S5.1 "Instrumentation Symbols and Identification"
ISA-S20 Specification Forms for Process Measurement and Control
Instruments Primary Elements and Control Valves

2.2 American Society of Mechanical Engineers (ASME)

Section I "Boiler and Pressure Vessel Code, Power Boilers
Section VIII "Boiler and Pressure Vessel Code, Unfired Vessels

2.3 American National Standards Institute (ANSI)

B16.25 "Butt Welding Ends"
B16.34 "Steel Valves"
B16.5 "Steel Flanges"
B31.1 "Power Piping"
B31.3 "Chemical Plant and Petroleum Refinery Piping"
B31.8 "Gas Transmission and Distribution Piping Systems"
B40.1 "Gauges, Pressure and Vacuum, Indicating Dial Type"



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ES-1648 2

2.4 National Society of Corrosion Engineers (NACE)

MR-01-75 Sulfide Stress Cracking Resistant Metallic Materials for
Oilfield Equipment

2.5 American Petroleum Institute (API)

RP-14C "Analysis, Design, Installation and Testing of Basic Surface
Safety Systems on Offshore Production Platforms"
RP-520 Parts I & II, "Design and Installation of Pressure Relieving
Systems in Refineries"
RP-550 Parts I - IV, "Installation of Refinery Instruments and Control
Systems"

2.6 American Gas Association (AGA)

Rpt. No. 3 "Orifice Metering of Natural Gas"

2.7 Solar Standard Specifications (ES)

ES-1645 "Design of Process and Utility Piping Systems"
ES-1647 "General Electrical Specification"
ES-1649 "Instrument Calibration and Checkout"


3.0 DEVIATIONS AND DISCREPANCIES

Proposed deviations from this specification and proposed resolution of discrepancies
between the specifications, standards, codes, drawings and other documents shall be
referred to Solar for approval, and the result shall be expressed in writing.


4.0 INSTRUMENT IDENTIFICATION

The instrumentation identifiers, symbols, and the numbering system used shall conform to
ISA Standards. Numbering system shall be sequential 2, 3, or 4 digit numbers.


5.0 CONTROLLERS

Instrument controllers for variables requiring constant attention for normal operation,
shutdown or during a plant fault condition shall preferably be located on a control panel.

The controller shall normally indicate the measured variable, set point and controller output.
Controller operational modes may be ON-OFF, Proportional only, Proportional plus Integral
(Reset) or Proportional-Integral plus Derivative (Rate).


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ES-1648 3


5.1 Pneumatic Controllers will normally be "flapper/nozzle" (fixed/variable orifice) type
and will be operated with clean dry air or gas. Dewpoint of supply medium shall be
as a minimum 20
o
F below the lowest ambient temperature for the area recorded
during the preceding 10 years.

5.1.1 Local Mounting such as pressure controllers yoke mounted to control valves
and liquid level controllers integral mounted to displacer/torque tubes are
acceptable. Installations with excessive vibration should be avoided.

5.1.2 Remote Mounted controller process sense lines shall be a minimum
diameter of 1/2 inch and shall have a slope of 1 to 10 when connected in a
horizontal run. Slope should be downward to controller for liquid filled
process lines and upward to controller for gas filled process lines. If the gas
service slope cannot be achieved, condensate pots with isolation and drain
valves may be used.

5.2 Electronic Controllers may be either analog or digital type controllers. The
microprocessor based digital controller is preferred for complex control loops. The
single loop application that utilizes analog input and output signals is best suited for
the analog controller. Normal analog input or output signals shall be either 4 to 20
mA or 1 to 5 Vdc. The digital controller shall also accept and output discrete signals
as well as the analog signals. Normal power supply shall be 24 Vdc.

6.0 TRANSMITTERS

2 Notes
1. Instrument piping or stainless steel tubing may be used to connect process
medium to be measured to the transmitter. Minimum diameter shall be 3/8
inch, 1/2 inch for flow measurements, with length not to exceed 50 feet.
Piping shall be in accordance with project piping specifications. 3/8 inch
O.D. tubing shall have minimum wall thickness of 0.035 inch, 1/2 inch O.D.
tubing shall have minimum wall thickness of 0.049 inch.

2. Filled instrument tubing such as chemical seal tubing and temperature
capillary should not exceed 25 feet.

3. Effort should be made to minimize the use of lagging, tracing and similar
ancillary materials and techniques.

4. In general, transmitters shall be for 2" pipe stand mounting.

5. Transmitter wetted parts shall be stainless steel unless otherwise dictated
by the composition of the measured fluid.

6.1 Pneumatic Transmitters


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ES-1648 4


Notes
1. Output signal of 3 to 15 psi or 6 to 30 psi shall be proportional to
process variable.

2. Transmitters will normally be non-indicating unless specifically
requested to be indicating.

6.1.1 Temperature Transmitters will usually be flapper/nozzle type that provide
pneumatic output proportional to temperature range as flapper is positioned
by temperature change.

6.1.2 Pressure Transmitters may be motion balance type or force balance. The
force balance type is preferred.
6.1.3 Flow Transmitters shall be differential pressure type. Differential element
may be either the force balance type or dual bellows type.

For turndown requirements greater than 3 to 1 dual transmitters may be
used for increased accuracy at low flows.

6.1.4 Level Transmitters shall be the displacer-torque tube actuated type up to a
48" range. For larger ranges, differential pressure type shall be used.

6.2 Electronic Transmitters

Notes
1. Output signal of 4 to 20 mA dc shall be proportional to process
variable. Transmitters shall not be the smart type unless specifically
requested to be smart.

2. Output meter shall be provided whenever indicating transmitter is
specified. Indication shall be 0 to 100% linear except for flow
applications. 0 to 10 square root will be used for flow.

3. Input/Output terminals and electronic boards will be isolated from each
other in separate compartments to allow access to the terminal
connections without exposing electronics.

4. Continuously adjustable zero and span adjustments shall be external
but covered.

5. Electronics enclosure shall be weatherproof, NEMA 4X as a minimum.
In hazardous locations, the enclosure shall be suitable for the area
classification and shall be clearly labeled to that effect.

6.2.1 Temperature Transmitters shall provide an RFI-insensitive 4 to 20 mA dc


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ES-1648 5

output for either RTD or thermocouple inputs. Thermocouple models will be
supplied with electrical isolation to allow for grounding of input signals.
Accuracy shall be +/- 0.25% of calibrated span for RTD's. Thermocouple
accuracy shall be +/- 0.25% of calibrated span or 0.02 millivolts, whichever
is greater.

6.2.2 Pressure Transmitters shall be capable of full zero suppression and
elevation. They shall have adjustable damping and a range turndown of at
least 5 to 1. The output signal shall be 4 to 20 mA dc linear with the
process. Accuracy shall be +/- 0.25% of calibrated span. Operating
temperature range shall be -20
o
F to +180
o
F with overpressure limit of 2000
psig for ranges up to 1000 psig and 4500 psig for ranges to 3000 psig.

Absolute pressure transmitters shall have an overpressure limit of 2000 psig
with a maximum zero suppression of 500% of calibrated span.

6.2.3 Flow Transmitters shall normally be differential pressure type with up to
600% elevation and 500% suppression. All differential pressure flow
transmitters shall be supplied complete with 3 or 5 valve manifold.

Other types such as magnetic, positive displacement and turbine meters will
be considered.

6.2.4 Level Transmitters shall be the displacer-torque tube actuated type up to a
48" range. For larger ranges, differential pressure type shall be used.

Other types, such as capacitance probes, thermal dispersion probes and
ultrasonic types will be considered.



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7.0 PRIMARY ELEMENTS

7.1 Temperature Elements

Notes
1. Thermowells MUST be used except for surface temperature
measurement or for very rapid response time. Connections shall be in
accordance with the governing piping specification. When flanges are
used, normal size will be 1-1/2 inches. Screwed connections may be
either 3/4 or 1 inch NPT in accordance with the piping specification.

2. Thermowells shall be stainless steel unless otherwise dictated by the
composition of the measured fluid.

7.1.1 Liquid or Gas expansion filled systems shall not be used where fill (if
leakage occurs) may adversely affect process stream or react with the
atmosphere.

Provide metallic-armored capillary of a material unaffected by the
atmosphere. Maximum length shall be 25 feet.

7.1.2 Resistance Elements (RTD's) shall be used for maximum accuracy at
temperatures below 400

F. Do not use if high vibration is present.

3 or 4 wire systems may be used. RTD's shall conform to International
Resistance vs. Temperature Standard - 100 ohms at 0

C.

7.1.3 Thermocouples shall be used for temperatures above 400

F and where
high vibration will be encountered. ISA thermocouple types J, K, E and T
may be used, however, Type K, Chromel-Alumel, should normally be used.

7.1.4 Both RTD's and Thermocouples shall be supplied assembled with a
terminal housing and terminal strip. Terminal housing shall be weatherproof
and suitable for the area classification.

7.2 Pressure Elements

Notes
1. Use damping devices where pressure pulsations will adversely affect
the instrument.

2. Use Pigtail Siphons to protect element from high temperature
processes (up to 1000

F).

3. For corrosive process fluids, element materials are to be certified to


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ES-1648 7

NACE MR-01-75. If not available, diaphragm seals with filled systems
shall be used.

2 7.2.1 Bourdon Tubes shall normally be used with indicators. They may also be
used in pneumatic pressure controllers. The tube material shall be selected
based on the process fluid.

7.2.2 Bellows elements will normally be used for pressures below 15 psig and are
mandatory for pressures below 30 inches of water column.

7.2.3 Other elements may be considered when deemed to be more suitable for
transmission service.

7.3 Flow Elements

Notes
1. Locate an indicating flowmeter for a locally and manually controlled
stream within 6 feet of the valve so that it can be seen from the valve.

2. For corrosive process fluids, element materials are to be certified to
NACE MR-01-75.

7.3.1 Differential Pressure. Normally square edged concentric orifice assemblies
with flange taps shall be used. Raised face weld neck orifice flanges shall
be used unless specified otherwise in the governing piping specification.
Where possible, use a Beta Ratio of 0.7 to determine upstream and
downstream straight pipe runs in accordance with AGA Standards.

Orifice plate calculations shall normally be based on 100 inches of water
column pressure drop with a Beta ratio between 0.25 and 0.75.

Corner Taps, Venturies, Nozzles and Annubars will also be considered
where they are superior to flange taps.

7.3.2 Positive Displacement meters shall normally be used for liquid service when
totalized flow is required. Materials of construction shall be dictated by
process fluid requirements.


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7.3.3 Turbine meters will be considered for applications requiring attention to
linearity, range, resolution, long life, and signal generation (Liquid Service).

7.3.4 Magnetic Flow Meters will also be considered for all the above reasons and
are preferred on Feedwater, Condensate and Cooling tower make up water
applications requiring transmitter output signals.

7.4 Level Elements

Notes
1. Chamber (Cage) and body materials to be equal in quality to or better
than the vessel material.

2. Trim material to be stainless steel or better quality alloy.

3. Where process fluid temperatures exceed 400

F use air fin

extensions.

4. Provide a drain valve not less than 1/2 inch in size at the bottom of the
instrument.

7.4.1 Displacement type shall normally be with external cage for use on liquid
service in closed vessel with level range less than 48 inches. Instrument
head to be rotatable with respect to vessel.

Cage connection shall normally be side and side with minimum connection
size of 1-1/2 inch NPT. Flanges will be used when required by the vessel
specifications. Use 2 inch connections for 900# ANSI cages and above.
Flange rating shall be in accordance with the piping specifications.

7.4.2 Internal displacement type will be considered for special circumstances -
e.g., extreme temperatures, viscous or corrosive liquids, or where excessive
boiling may occur in external cage.

7.4.3 Float (Mechanical) type may be used on open sumps or vented tanks when
sufficient leverage can be obtained to insure positive action.

7.4.4 Differential Pressure will be considered for any suitable application in any
range available. Refer to Pressure and Flow Primary Elements.



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ES-1648 9


8.0 RECORDERS

Notes
1. Charts shall be 0 to 10 square root for differential type flow and direct
reading for all other variables.

2. Multipoint temperature recorders shall have 12-inch strip charts. A width of
4 inches is preferred for other variables.

3. A 30-day supply of charts shall be supplied along with one ink set for each
recording instrument.

8.1 Mechanical - locally mounted recorders shall be equipped with 24-hour circular
charts on an 8-day spring wound chart drive with a combination hub for either 7-day
or 24-hour rotation.

8.2 Electronic - board mounted recorders shall be strip charts with electric chart drives.
Ink path may be either vertical or horizontal. Chart width of 4 inches with no more
than 3 pens is preferred.


9.0 INDICATORS (GAUGES)

Notes
1. Pressure Gauges shall be made in accordance with ANSI B40.1 (Gauges,
Pressure and Vacuum, Indicating Dial Type-elastic element).

2. Minimum scale size, length or diameter, shall be 4-1/2 inches. Differential
pressure may use 2-1/2 inches. Where digital meters are used, 3-1/2
inches x 1-1/2 inches shall be the minimum requirement.

3. Range shall be selected so that the maximum continually operating process
condition shall fall within the middle 33% of the range.

4. Overrange protection shall be included if system pressure can exceed
maximum range of gauge.

9.1 Temperature Indicators

9.1.1 Direct Mounted shall have bimetallic element with silicone dampening for
minimum pointer vibration. Dial face shall be fully adjustable to provide
360

rotation and 180

angle viewing. 5-inch dial is preferred however,

3-inch will be considered. Accuracy shall be 1% full scale or better.

9.1.2 Remote mounted shall have filled (liquid or gas) element and capillary.


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ES-1648 10

Capillary shall be stainless steel with stainless steel armor and shall not
exceed 25 feet. Dial case shall be weatherproof with adjustable pointer.
4-1/2 inch dial with accuracy of 1% full scale.

9.2 Pressure Indicators

9.2.1 Pressure gauge case shall have solid front and be designed for liquid fill for
high vibration applications. Process connection shall be 1/2 inch NPT -
bottom connection for local mounting and rear connection for panel
mounting.

9.2.2 Pressure gauges shall be installed with block valves on process connection
and shall have means of venting pressure when closed off. Gauges
installed on nearby pressure instruments may use a common process
connecting point but require individual block and bleed valves at the
instrument.

9.2.3 Differential pressure indicators may be either the bellows or piston type.
Overpressure protection shall be equal to the maximum allowable working
pressure of the body.

9.3 Level Indicators

9.3.1 Tank Gauges - Atmospheric product storage, small process and utility tanks
shall normally use float type gauges with an external target (locate target at
ground level).

9.3.2 Gauge Glasses shall be used on process pressure vessels to cover the full
operating range of level, including the spans of level controllers and level
alarm switches.

9.3.3 Gauge glass column shall not exceed 48 inches. For greater lengths use
multiple units.

9.3.4 Use transparent type gauge glasses (double glass) for service in which a
level may not be readily distinguishable such as interface fluids surfaces,
fluids of high viscosity or solid content.

9.3.5 Use reflex glasses if pressure exceeds 25 psig or the vessel temperature is
outside the range of 0-100

C. Use illuminators for interface surfaces only.

Provide a frost shield if vessel temperature is less than 0

C.

9.3.6 Gauge body materials shall be equal in quality to or better than the vessel
material. The use of ductile iron covers shall be avoided.

9.3.7 Gauge cock body material shall match gauge body material. Trim shall


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ES-1648 11

normally be stainless steel with renewable seats and ball checks. Gauge
cock vessel connections shall normally be female, 3/4 inch NPT.


10.0 SWITCHES

Notes
1. Switch enclosures shall be weatherproof and explosion proof unless
otherwise specified.

2. Switch mechanisms shall be snap-acting and hermetically sealed in an inert
gas or epoxy encapsulated. Conventional switch mechanisms shall be
considered. Mercury switches shall be avoided.

3. Switches shall always be either single-pole-double-throw (SPDT) or
double-pole-double-throw (DPDT). When available, double-pole-double-
throw shall be used.

4. Switch contacts shall be rated for 0.5 A at 24 Vdc as a minimum.

5. Dual set point switches in the same housing may not be used.

6. As much as possible, switches shall have their set-point located in the
middle third of their calibrated range. All shall have a means for field
calibration adjustment.

10.1 Temperature switches shall normally have vapor pressure thermal elements. They
shall be supplied with thermowells (see 5.1 Note 1).

10.2 Pressure switch elements and pressure port materials shall be determined by the
application and operating pressure. Elements may be Diaphragm, Piston, Bellows,
Bourdon Tube or Belleville spring types.

10.3 Flow switches will normally be vane actuated (field adjustable), Thermal Dispersion
(field adjustable) or Rate of Flow Magnetic Type (factory adjusted). All types will be
considered and selection based on application.

10.4 Level switches

10.4.1 Switches shall be externally mounted, displacer or float operated. For high
vibration applications, displacer types are preferred.

10.4.2 Switch connections shall normally be 1 inch, installed with 1 inch pipe,
isolation valves and fill tee with plug. Connection type shall be in
accordance with the governing vessel specification.



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ES-1648 12

10.4.3 Internal floats may be used in services where they can be removed for
maintenance without a major shutdown, where performance is superior, or
where physical limitations require their use.


11.0 INSTRUMENT INSTALLATION

Notes
1. All instruments and related measuring elements shall be installed such that
they are easily accessible from floors, platforms or walkways.

2. All instruments shall be installed such that they are not subject to excessive
vibration and/or exposed to high temperature.

3. No sense line shall slope less than 1 in 10 in a horizontal run. When the
process is liquid the slope is to be to the instrument. When the process is
vapor the slope is to be to the process pipe or vessel.

4. The piping configuration shall be arranged so that gas and liquid blocks
(pockets) will not occur.

5. Condensate pots with drain valves shall be provided where condensation
may occur.

6. A blow-down facility with drain valve shall be provided where sedimentation
may occur. The minimum valve size shall be 1/8".

7. Plugged tees shall be provided for rotting out where solid deposition may
occur.

8. For piping where condensate will exist during plant operation, filling tees
and drains at the lowest points shall be provided. Where the highest
instrument process piping points are higher than the process connection,
vents shall be provided.

9. A transmitter shall be located as closely as possible to its process
connection having proper regard to maintenance access. Particular
attention shall be paid to making the instrument process piping as short as
possible for viscous fluids. Transmitters shall not be mounted on the
pipeline. For each transmitter local isolation must be provided at the
transmitter if the process isolation (root) valve cannot be reached while
standing at the transmitter. Pressure transmitters and gauges shall be
provided with vent valves after the isolation valve for zero checking.

10. Sealing liquids may be used to isolate instrument parts from the process
stream if other techniques of protection and connection are not reasonable


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ES-1648 13

or practicable.

11. All instrument lines shall be properly supported.

11.1 Instrument Connections

The preferred size of instrument process connection shall be as indicated in the
relevant instrument details. Where possible instrument process connections shall
meet the requirements of the appropriate piping specification.

11.2 Instrument Process Piping

11.2.1 Instrument process connections shall not be less than 1/2 inch. When
connections to other sizes are required, i.e., 1/4 inch connections to
instrument manifolds, appropriate and compatible fittings shall be used.

11.2.2 The pipe wall thickness shall be sized for the application and in accordance
with the relevant piping standard.

2 11.2.3 3/8 inch O.D. x .035 inch wall thickness stainless steel tubing and approved
compression fittings will be generally used for all impulse lines unless
process conditions dictate otherwise. (Where required 1/2 inch O.D. x .049
inch minimum wall thickness stainless steel tubing will be used.) Tubing
shall be fully annealed per ASTM-A-269.

11.2.4 For high temperature or pressure and where screwed or flanged fittings are
not permitted in the process piping the instrument piping shall meet the
process piping specifications up to and including the first block valve.

11.2.5 Piping and fittings materials shall be in accordance with the project piping
specifications.

11.2.6 Isolation (Root) Valves: Shall be a minimum size of 1/2 inch with a
minimum port size of 1/8 inch. Valves shall be located at the process
connection and be capable of being closed even though they remain open
for long periods. If the isolation valve is inaccessible or if the instrument
process piping must be longer than 15 feet, then a second isolation valve
shall be installed at the instrument.


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11.3 Pre-Testing

11.3.1 Generally, instruments shall be tested by the manufacturer before shipment
and calibrated at job site.

11.3.2 Electronic equipment shall be powered up for at least 1 hour prior to test.

11.4 Accessibility and Visibility

11.4.1 All dials and scales of field-mounted instruments shall be easily read from
grade level or platform level.

11.4.2 All Instruments shall be located to allow ready maintenance access.

11.4.3 Permanent platforms and ladders shall be provided for access to elevated
instruments except pressure gauges, dial thermometers and thermocouples
or RTD's.

11.5 Instrument Protection

11.5.1 Instruments shall be installed in a position where mechanical damage is
unlikely and the effects of vibrating equipment are minimized.

11.5.2 Instruments shall be installed so that corrosive effects of atmosphere (either
from normal or abnormal plant operation) are eliminated by using suitable
protective coatings and seals, or a corrosive proof enclosure. Also weather
protection shall be provided by selection of weatherproof instrumentation or
by provision of a weatherproof enclosure.

11.5.3 Instrument panels and cabinets in exposed conditions shall be provided with
overhead shelter extended to keep wind-swept rain from the instruments.

11.6 Mounting and Identification

11.6.1 Instruments mounted on any local instrument panel shall be flush mounted.
Those separately mounted in other locations may be surface, yoke or
bracket mounted.

11.6.2 A permanent nameplate or stainless steel tag shall be provided for each
instrument.


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ES-1648 15


11.6.3 Local panel-mounted instrument locations shall be labelled at the front and
rear of the panel.

11.6.4 Nameplate and legend plate wording shall be horizontal.

11.6.5 All vendor installed instrument connections (pneumatic and electric) shall be
identified at all tubing and cabling ends. Tag numbers shall be in
accordance with the installation drawings.


12.0 CONTROL VALVES

12.1 Sizing and Characterizing

12.1.1 Control valve body sizes generally shall not be less than 1 inch. In
accordance with the piping specifications, bastard sizes shall be avoided.

12.1.2 Control valves shall be sized to operate at no more than 65-75% open
under maximum design flow rates and process conditions.

12.1.3 Calculations shall be made for the range of anticipated plant operational
rates and process conditions as specified on the Process Flow Diagrams
(PFD's).

12.1.4 The characteristic of a valve shall be selected to be most suitable for the
control system and plant and process conditions.

12.1.5 Special care shall be taken to consider the possibility of cavitating and/or
flashing service when sizing valves for liquid applications.

12.2 Valve Type

12.2.1 Generally, globe valves with cage guided trims shall be used. For liquid
service, characterized plug globe valves may be used. Other types of
valves may be used if their application is superior to those of globe valves.

12.2.2 Butterfly valves should be considered for flows requiring a C
v
of 300 or
more.

12.2.3 Angle valves should be considered for such arduous services as high
pressure drop (300 psi or more), flashing liquid, slurry, anticipated ice and
hydrate service.

12.2.4 Diaphragm or pinch valves should be considered for slurry and corrosive
fluid.


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12.3 End Connections - Valve body end connections shall conform to the valve and piping
specifications. Exception may be made relative to weld end connections if plant
and/or process operating conditions dictate that flange or screwed connections
should be used.

12.4 Bonnets and Bellows Seals - Shall be selected based on the valve manufacturers
recommendations for the specified service.

12.5 Materials for Construction

12.5.1 Generally the body material shall be equal in quality or better than the
material in the contiguous piping. However, cast iron may be considered for
common fluids at low temperatures and pressures (between 0

C and
150

C and between atmospheric pressure and 125 psig), or in a service

where cast iron is best suited.

12.5.2 The valve trim and other wetted parts (except the valve body) shall be
stainless steel unless this is unsuitable for the fluid or the process
conditions, then a suitable compatible material shall be selected. Trims for
valves in corrosive services shall be in accordance with NACE MR-01-75
requirements.

12.5.3 When wear is likely to be excessive, stellate trim or the manufacturer's
equivalent hardened trim shall be used.

12.6 Actuators

12.6.1 The power of an actuator shall not be less than required to seat the valve
against the maximum shut off pressure. Unless otherwise specified,
maximum shut off pressure shall be the maximum flange pressure rating.

12.6.2 Actuators shall normally be the Spring and Diaphragm type, with the pring
driving the valve to the fail safe position as specified on the data sheets.
Piston type and double acting actuators will be considered.

2 12.6.3 Where available air supply pressure exceeds the maximum allowable
pressure of the actuator, a pressure regulator (and relief valve) will be
provided.


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ES-1648 17


12.7 Positioners

Notes
1. Electropneumatic positioners shall be used for electronic control
systems and pneumatic actuators. Electronics enclosure shall be
suitable for the area classification.

2. A positioner bypass is not permitted where the valve operating range
and the positioner input range are not compatible.

3. A positioner with a bypass and three gauges or booster relay shall be
used under specified conditions.

12.7.1 Positioner with bypass shall be used in a control loop whose controller
requires a proportional band setting of 500% or more.

12.7.2 Positioner with bypass shall be used for flashing service in which
vaporization of the fluid flowing through the valve is 10% by mass or
greater.

12.7.3 Positioner without bypass shall be used in split range service.

12.7.5 Positioner with or without bypass and three gauges or booster relay shall be
used when valve is 6 inches or larger.

12.7.6 Positioners with bypass and three gauges shall be used with butterfly valves
and ball valves.

12.8 Control Valve By-Passes - Generally, a control valve shall not be provided with a
by-pass valve except when Standards or Regulations specify the requirement.

When a by-pass valve is required, block valves of line size, shall be provided to allow
the by-pass valve to be operated with the control valve blocked from operation, and
the by-pass valve shall be sized for its specific duty (generally a globe valve one size
less than the line valve).

12.9 Valve Position on Power Failure. Whether a valve shall travel to an open or shut
position, or remain unmoved on failure of the actuating medium shall be determined
from the process and safety requirements.



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ES-1648 18

12.10 Control Valve Noise

Notes
1. If a control valve may pass fluid at or near sonic velocity, or if
cavitation or flashing may occur at the valve, or if the valve situation is
designed for flashing service, then its operational noise level shall be
calculated.

2. If the predicted noise level is greater than 85 dbA measured 1 meter
from the valve, then preventative or corrective or restraining measures
shall be taken to insure that ambient noise developed by the valve
operation shall be no greater than allowable by local codes and shall
cause no mechanical damage to the valve.

3. If in-line items are installed as a corrective or restraining measure then
the design of the control valve situation shall account for the presence
of such items over the full operating range of the plant.


13.0 CONTROL VALVE INSTALLATION

13.1 Orientation and Location

13.1.1 Where possible, for each control valve, space shall be allowed for the future
installation of a line size control valve.

13.1.2 When allowed by the process configuration, a level controller and its control
valve shall be located at the same operating level and in sight of the level
indicator.

13.1.3 Generally a by-pass valve, if required, shall be installed in the same
horizontal plane as its control valve.

13.1.4 Valve should be installed so that stem is vertical (unless valve is designed
for rotating shaft).

13.1.5 Valve should be located where maintenance access and valve removal will
not be hindered, preferable on ground or operating level.

13.1.6 Valve should be fitted with a flexible, extendable gland cover where
excessive dust build-up around stem may occur from external sources.

13.1.7 Generally, in flashing service, the valve shall be installed close to the down
stream end of the pipe.


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ES-1648 19


13.2 Drains, Traps and Pressure Tappings

13.2.1 Drains installed at control valves shall be furnished with 1/2 inch ball valves
which shall be stopped with plugs.

13.2.2 For a single-seated valve which opens on failure of the actuating medium, a
drain between the control valve and the upstream block valve (if they exist)
shall be installed.

13.2.3 For a single-seated valve which closes on failure of the actuating medium, a
drain on each side of the control valve between it and the block valves (if
they exists) shall be installed.

13.2.4 For a double-seated valve irrespective of the final position of the valve on
failure of the actuating medium, a drain between the control valve and
upstream block valve (if it exists) shall be provided.

13.2.5 For control valves without block and by-pass valves, low-point drainage only
of the lines shall be provided.

13.2.6 For control valves installed with steam traps, the trap should be connected
to the line up stream of the control valve so it will drain the line whether the
control valve or a by-pass valve is in service.

13.2.7 Pressure taps for a pressure regulating valve shall be located in a straight
run of piping not less than ten pipe diameters upstream or downstream of
the valve whichever is required by the valve service. If the pipe line is
horizontal, the taps shall be made on its upper surface.


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14.0 ACTUATED BLOCK VALVES

14.1 Valve Types

14.1.1 Generally, ball valves rated for tight shut-off service shall be used. Fire
Safe ball valves shall be in accordance with the applicable piping
specification.

14.1.2 Ball valves may be the trunnion mounted or floating ball type in accordance
with the applicable piping specification.

14.2 Valve Size

14.2.1 In all cases, the valve size shall be equal to the size of the contiguous
piping.

14.2.2 In general, trim size shall equal the full bore size of the valve. Reduced size
trims will be considered as long as pressure drop across the valve does not
adversely affect the process.

14.3 End Connections - Shall be flanged and conform to the valve and piping
specifications. Weld end connections will be considered.

14.4 Materials for Construction

14.4.1 Generally the body material shall be equal in quality or better than the
material in the contiguous piping. However, alloy materials may be
considered for extremely corrosive services.

14.4.2 The valve trim and other wetted parts (except the valve body) shall be
stainless steel or nickel plated carbon steel unless this is unsuitable for the
fluid or the process conditions, then a suitable compatible material shall be
selected. Trims for valves in corrosive services shall be in accordance with
NACE MR-01-75 requirements.

14.5 Actuators

14.5.1 In general, block valve actuators shall be the spring fail, pneumatic scotch-
yoke piston type. Double-acting pistons, electric motor, spring and
diaphragm and other actuator designs may be used for special applications,
but the control logic must be fail safe.

14.5.2 Pneumatic rack and pinion actuators may be used for valves 2 inches and
smaller.


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14.5.3 Actuators shall be sized in accordance with the manufacturer's
recommendation using a 1.25 safety factor. Unless otherwise specified,
maximum shut off pressure for actuator sizing shall be the maximum flange
pressure rating.

14.5.4 Actuators shall be sized based on 80 psig minimum instrument air pressure.

14.5.5 Actuator design shall prevent the entry of water, dirt and dust during normal
operating conditions. Actuator shall be capable of operating in a corrosive
atmosphere.

14.6 Control Accessories - Valves shall be equipped with control accessories which will
allow for the remote electrical control and monitoring of the valves. Electrical
components in hazardous locations shall be suitable for the area classification.

14.6.1 Solenoids shall be the three-way type with cadmium plated valve bodies.
Stainless steel bodies shall be considered. Coil shall be potted and
normally operating at 24 Vdc. Bolting shall be stainless steel.

14.6.2 Valve actuators shall be supplied with pressure regulator, output gauge and
relief valve if normal operating pressure exceeds maximum actuator
operating pressure. Supply pressure will normally be 100 psig.

14.6.3 Position switches will be provided for remote position monitoring. Switches
will generally be single-pole-double-throw, hermetically sealed or epoxy
encapsulated, and mounted in an enclosure with terminal strip and local
position indicator.

14.6.4 Speed controls shall be provided. Actuation speed for valves 2 inches and
smaller shall be 2 seconds or less. Actuation speed for larger valves shall
be 1 second per inch of valve bore.

2 14.6.5 All tubing shall be 316 stainless steel, sized for the above outlined speed
requirements. Minimum wall thickness shall be 0.035" for 3/8 inch O.D. and
below and 0.049 inch for 1/2 inch O.D. Company approved fittings shall be
316 stainless steel.




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15.0 RELIEF (SAFETY) VALVES

15.1 Valve Types

15.1.1 Relief valves are characterized by their opening in proportion to the
increase in pressure over the setpoint.

15.1.2 Safety valves are characterized by their rapid opening or "pop" action at the
set point.

15.1.3 Spring loaded valves may be the conventional or balanced type. Balanced
valves shall be designed to minimize the effects of back pressure on the
valve characteristic.

15.1.4 Pilot operated relief valves shall be the preferred type for gas applications or
where premium seat tightness is required.

15.2 Codes - Valves shall be stamped with ASME Boiler and Pressure Vessel Code,
Section VIII or Section I. The capacities must be certified by the National Board of
Boiler and Pressure Vessel Inspectors for air or saturated steam service and/or
capacities for gas service.
They shall be designed to meet API Standard 526 for seat tightness and API RP 520
for installation.

15.3 Guidelines

15.3.1 Valves shall be sized to protect vessels and piping for maximum throughput
(blocked flow), fire exposure or thermal expansion, whichever is greater.
Sizing shall be in accordance with API RP 520 using the valve
manufacturer's coefficient of discharge.

15.3.2 Valves shall be sized and installed to protect both sides of exchangers
against overpressure due to liquid expansion, vaporization, tube failure or
leakage and fire.

15.3.3 Relief set point shall be no higher than the design pressure (MAWP) of the
weakest element protected, except as may be permitted by the ASME
Codes.

15.3.4 Bonnets for spring operated valves shall normally be the closed type.
Exposed spring bonnets shall be as required by the ASME Codes.

15.3.5 Generally, flanged connections shall be provided on all relief valves 1 inch
and larger. Screwed connections may be provided on thermal relief valves,
1 inch and smaller.



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15.3.8 Pilot operated relief valves for blocked flow (full flow) applications shall be
the modulating type.

15.3.7 Pilot operated relief valves shall be supplied complete with backflow
preventers and field test connections.

15.4 Materials of Construction will generally follow manufacturer's standards for the given
service except where there is a conflict with the pipe specifications. The pipe
specifications will rule. When required trim shall be supplied in accordance with
NACE MR-01-75.


16.0 ALARMS AND TRIPS (SHUTDOWNS)

Notes
1. Trip system fault detection devices shall be physically and electrically
separate from alarm and operating systems.

2. Alarm and trip system shall be basically 24 Vdc operated. Other power
systems may be considered in certain circumstances.

3. Sensing circuits shall be normally energized, i.e., the circuit shall open to
cause an alarm or trip.
16.1 Alarm Annunciation System

16.1.1 Local audible and visual alarms shall be annunciator type. Individual type
alarm units may be used for remote locations or where hazard requirements
so dictate. All alarms shall be both visible and audible.

16.1.2 Sequence shall be ISA-1 with First Out Sequence (FOS) Option.

16.1.3 An acknowledge reset button and lamp test switch shall be provided on
each annunciator cabinet.

16.1.4 Legend window displays shall be readable when the alarm light is off.

16.1.5 Annunciator shall be provided with at least 10% pre-wired or on line spare
capacity.

16.2 Trip (Shutdown) System

16.2.1 All safeguarding functions shall normally be derived via a PLC System with
Fail Safe features.

The input/output organization of various safety systems by the PLC shall be
modularly arranged to provide easy maintainability.


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16.2.2 In a system in which voltages other than 24 Vdc occur, e.g., because an
electric motor must be tripped, a relay which isolates one voltage circuit
from the other shall be provided.

A relay or other equipment with an impressed voltage greater than 32 volts
dc shall be located in a box or housing which physically isolates it from the
24 volt dc circuit area and from electrical interference from other sources.
The box or housing shall be prominently labelled with the high voltage in it.

16.2.3 In a High Integrity protective system sensing will be in triplicate with each
sending its digital signal to the PLC logic which in turn will produce a digital
output if two of the three digital input signals exceed the trip limit value.


17.0 SAFETY

The safety of operators and the operating plant and its systems, considered as a whole,
shall be the prime safety goal.

17.1 Safe Condition - A safe condition is a state in which no unreasonable hazard is
presented to a plant operator, plant or process.

17.2 Fail-Safe Condition - A fail-safe condition is one in which a system remains in a safe
condition after occurrence of process or plant faults or on failure of electric power,
instrument air or other source of energy.

18.0 INSTRUMENT PANEL BOARDS

18.1 Local Control Panels - Site-mounted control panels shall be used for specific
purposes, e.g. start up or compressor control or to centralize a number of site
instruments. The panels shall be adequately protected from the environment and
accidental damage.

18.2 Control Room Panels - Panels shall be located so that the face is prominent for
operator inspection and attention. Rear access for maintenance is preferred,
however, front access will be considered.

18.2.1 Where possible, instruments shall be grouped in a process sequence from
left to right. Alarms shall be located above process-related
instrumentation.

18.2.2 Instrumentation requiring close observation shall be between 28 inches and
72 inches from floor level. Miniature instruments for operator use or
requiring manual operation shall be located between 36 inches and 72
inches from floor level.


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18.2.3 The minimum spacing between instruments shall be the instrument
manufacturer's standard.

18.2.4 Terminals with an impressed voltage above 32 volts D.C. or any A.C. voltage
shall be fully shielded and labelled, noting voltage.


19.0 ANALYZERS

The term analyzers shall include equipment for the measurement of composition of
substances and the measurement of chemical and physical properties, e.g. turbidity,
density, caloric value, conductivity, and pH.

19.1 Selection Guidelines

19.1.1 The type and make shall have a record of reliable service.

19.1.2 Accuracy and response time of analyzer system shall meet process
requirements.

19.1.3 The analyzer system shall be designed to facilitate maintenance and
calibration. System shall include a facility for calibration checking in
site.

19.1.4 For hazardous areas, the analyzer system and its installation shall meet
statutory requirements.

19.2 Sampling System

If a suitable in-line or immersion type analyzer head is not available for an
application, then a sampling system shall be provided. This system should include
but is not limited to the following features:

19.2.1 Designed to provide minimum sampling lags.

19.2.2 Use stainless steel or better for the sample pipe and tubing.

19.2.3 Provide a facility for purging sample tubing.

19.2.4 Provide for sample return to process where possible. When possible, pump
outlets and inlets should be used for sample delivery.

19.2.5 Analyzer vent gas or bypass flow shall normally be disposed or sent to flare.


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19.2.6 Insertion type probes shall be used. Isolation and by-pass valves shall be
provided around analyzer heads which are installed within the plant
piping system.


20.0 INSTRUMENT AIR

20.1 Air Supply Quality - Dewpoint of air shall be as a minimum 20

F below the lowest

ambient temperature for the area recorded during the preceding 10 years.

20.2 Air Supply Capacity - The capacity of the instrument air supply system shall be
greater than 55 times the number of connected flapper/nozzle mechanisms
expressed as ft
3
/hr at STD 60

F, 14.7 psig. A pneumatically actuated control valve

shall be considered as one flapper/nozzle mechanism for this calculation.

20.3 Air Supply Piping - Air distribution piping shall be galvanized carbon steel or stainless
steal and shall conform to the appropriate piping specification for instrument air.

20.4 Air Supply to Instruments - Each instrument shall have its own air isolation valve.
Each site-mounted instrument shall have its own supply filter/regulator.

In a local panel there shall be an air supply filtering and pressure regulating system
comprised of two sets of equipment (two filter/regulators in parallel). Each shall be
capable of supplying the dynamic needs of the instrument air users connected to it
and having block valves enabling it to be isolated for maintenance with the other is in
service. Pressure gauges shall be located upstream and downstream of this
filter/regulator system.

2 20.5 Pneumatic Tubing - Pneumatic tubing for air supply headers and between
instruments shall be 1/4 inch O.D. with 0.35 inch wall as a minimum. Stainless steel
tubing and fittings shall be standard. Other materials may be selected for non-
corrosive environments.

20.6 Air Pressure Alarm - A low pressure alarm shall be provided for the plant air supply
main.




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ES-1648 27

21.0 DRAWINGS, DATA SHEETS AND CALCULATIONS

As part of a "Request To Quote" package all or part of these items may be supplied to the
bidder or the bidder may be required to furnish all or part of these items as part of their
proposal. The proposed instrumentation scheme will be shown on a Piping and Instrument
Diagram and will be included with the RFQ.

21.1 Construction Drawings - The number and type of drawings required will be
determined by the complexity and type of instrumentation to be furnished on the
project. Normally only those drawings which are required to insure a correct
installation of the various instrument components will be required.

21.1.1 Instrument Index - Data shall include as a minimum the instrument tag
number, a brief service description, flowsheet location, I/O address or
cable number, specification number, purchase order number and
cross reference drawing numbers for instruments, piping and electrical
drawings.

21.1.2 Instrument Plot Plan - Shows the general location of all local mounted
instruments requiring pneumatic or electrical connections, control
panels, or other items as required.

21.1.3 Instrument Installation Details - Details shall show all commodity items
required for proper instrument hookup and shall include a Bill of
Material. This drawing should also include the pneumatic schematic for
simple local controls and identify boundaries of discipline interface.

21.1.4 Pneumatic Schematics - These may be required for complex control loops
such as emergency shutdown or compressor control panels. They
should show all components in the loop to enable an understanding of
the operation of the loop.

21.1.5 Electric Loop Diagrams - They shall be provided when interconnection is
required between field controllers, transmitters etc. and control panel
instruments. The loop diagram shall identify the field device tag
numbers, field junction boxes, electrical cable number, rear of panel
terminal strips and panel instrument connection details.

21.1.6 Control Panel Layout and Details - Details should show pertinent information
to allow for approval of instrument arrangement and to be suitable for
fabrication.


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21.1.7 Cause and Effect Analysis - A matrix drawing shall list all field and panel
mounted devices that sense or initiate an alarm or shutdown signal
along one margin with a description of the resulting action along a
cross referenced margin. Normal control switching is not required on
this drawing.

21.1.8 Safety Analysis Function Evaluation Chart (SAFE) - A matrix drawing shall list
all process components and their associated safety devices as
required by API RP 14C.

21.1.9 Miscellaneous Drawings - Certain additional drawings may be required when
other drawings do not provide sufficient information to insure correct
installation or are specifically requested.

21.2 Data Sheets - These will be required for all instruments and will include supplier's
data. Data sheets will conform to the Instrument Society of America S20 format.
They are to be completed and supplied by the design engineer.

21.3 Calculations - Calculations to determine size, capacity and characteristics shall be
required for primary elements, such as restriction orifice, and final elements, such as
control valve sizing and noise.


22.0 INSPECTION

The responsibility for inspection to compliance with the applicable codes and standards of
this specification rests with the supplier. However, Solar reserves the right to inspect, or
have its authorized representative inspect work in progress at the supplier's facility or at any
of his suppliers facilities to assure that materials and workmanship are in accordance with
this specification.