Professional Documents
Culture Documents
Table of Contents
1. General Design Basis 2. Units of Measurement, Scales, Charts, and Nameplates 3. Measurements 4. Centralized Controls 5. Instrument Piping and Connections 6. Instrument Field Installation 7. Heat Tracing, Sealing and Purging 8. Power Supply, Alarm and Shutdown Systems 9. Control Valves 10. Safety and Relief Valves 11. Reference Specifications and Standards 12. Typical Drawings Symbol explanation (*) Feature Required (o) Feature Not Required or Applicable (x) To Be Specified by Detailed Engineering Contractor
(o)
Pneumatic
(o)
Electronic (Analog)
(*)
(o)
(*)
(o)
(*)
(o)
Pneumatic
(o)
1.2.3 Transmission of analog measurement and control signals will be: For pneumatic instrumentation:
Cenels
Others
General
(*)
EN 50 014
(o)
Flameproof
(Eex-d)
(*)
EN 50 018
(o)
Intrinsic safe
(Eex-i)
(*)
EN 50 020
(o)
Increased safety
(Eex-e)
(*)
EN 50 019
(o)
Pressurized
(Eex-p)
(*)
EN 50 016
(o)
Nonsparking
(Ex-dn
(*)
(x)
per local
standards
(*)
All instrumentation as far as possible in non hazardous and zone 2 areas: Ex-n, Zone 1 areas: Ex-d
(o)
(o)
Flow
Liquid
kg/hr
Flow
Steam
kg/hr
Flow
Gas
kg/hr
Level
(percent of range)
Pressure
Gauge
bar g
Pressure
Absolute
bar a
(100 kPa)
Pressure
Compound
-1-0-
Temperature -
(Degrees centigrade)
Analyzers
application.
Viscosity
Density
Velocity
m/s
2.2 Graduation
Graduation of indicating scales shall be as follows:
Oriffice meters :
Rotameters
0-100 uniform
Pressure
direct reading
Level
0-100% uniform
Temperature
direct reading
Appropriate chart and/or scale factor will be shown on integral name-plates. Reading on the digital control system are as follows:
Flow meters
Pressure
direct reading
Level
0-100 uniform
Temperature
direct reading
Analyzers
direct reading
Minimum
-20C
Maximum
38C
2.4 Nameplates
Nameplates shall be in the English language. Instrument nameplates on the panel shall read instrument tagnumber, service and chart/scale factor. Instrument nameplates on back of panel and field mounted instruments or Instruments components shall read the instrument tagnumbers only.
Minimum straight piping upstream and down stream of orifice shall be minimum as specified in (*)ISO 5167 (o) Straightening vanes will not be used. Straigh runs for other flow meters types will be as per manufactueres instructions. For lines sizes smaller than 2 inch orifice plates will be installed in special prefabriceted meter runs. In this case the purchaser will provide further details.
(*)
0-250
mm H2O
(*)
0-2500
mm H2O
(*)
0-500
mm H2O
(*)
0-5000
mm H2O
(*)
0-1250
mm H2O
Internal displacer level instrument with stilling tubes will only be used in special cases. The internal type shall not be used in vessels with spargers. For installation see typical details.
The requirements for pressure elements shall be identical to process gauges except: - Pressure elements shall be phosphor bronze. - Connection shall be 1/4 inch NPT male. Scale graduations over 0.2 - 1.0 bar g range shall be consistent with graduations as given in paragraph 2.2.
3.6 Analyzers
Analyzers systems shall be in accordance with design requirements applicable for the project. Fast loop circuit shall be calculated for the application involved considering the speed of response required under actual prcess conditions and location of the analyzers/sample take-off points. Delicate/complex analyzers will be centralized in prefabricated analyzer houses. Simple analyzers (e.g. pH, conductivity redox, etc.) will be installed on line.
4. Centralized Controls
The engineering flow digrams will indicate which instruments are located in conditioned enclosed spaces as, the control room, auxiliary room or sattelite house(s). No hydrocarbons, chemicals or other process fluids shall enter these conditioned enclosed spaces, nor local panels containing electrical instruments. The enviromental conditions for process measurement and control system shall comply with ISA-S71.04 by latest edition.
The field junction box will in general be located in the unit. Multicore cabling between the field junction box and the main control room will be rounted underground. Signal cables, in general, will be laid together in common trenches or trays for instrument signal lines. Refer to typical layout sketch. Trenches will be kept away from power cables, transformers and electric motors whenever possible. The distance of instrument cable trenches relative to power cables will be 0.6 m minimum when run in parallel. Segregation of instrument cables in trenches will be executed per typical drawing. Multicore cables will be used to the maximum possible extend. High and low voltages will not be combined in one multicore cable. In general, spare wires in multicore cables will be connected to terminals. Cabling shall include for approximately 20% overall spares.
Conductors will be stranded 0.5 sq.mm for electronic signals and solid 0.8 mm OD for the T/C signals. Conductor size for power supply cable will be as required by the load of the individual user. Electric signal cables will be twisted a 5 cm lay and be provided with an overall mylar tape screen. T/C cables and digital pulse cables will be twisted and be provided with mylar tape screen, per individual signal. Date highways will use coaxial tables, specifications as per vendors recommendation.
All local panels will be suitably protected for use outdoors in a potentially corrosive atmosphere. Process fluids, including water, seal tube and lube oil shall not be piped into local panel units containing electrical circuitry. Panels shall be installed complete with all equipment and accessories for system operation, and fully wired.
4.3.2 Accesibility
Panel design shall permit satisfactory access to all components, instruments, terminal boxes, etc., for operational and maintenance procedures but nevertheless comply with area classification requirements.
4.3.4 Segregation
Instrument signal wiring and cabling shall not be shared with power supply cabling in the same junction box. To permit easy routing of field cabling and control/auxiliary room interconnecting cabling between the various systems, a false floor will be considered. The minimum distance, for access, between cabinets shall be 700 mm, or as required by local codes. Panel and cabinet shall include for approximately 10% overall spare space.
4.4.2 Screening
A consistent priciple of interconnection of the cable screens is of paramount importance to minimize interference. The basic priciple is to have screens isolated at instrument/field junction box and interconnected at the control center only to the dedicated signal ground.
5.1.1 Tubing
Seamless carbon steel, soft annealed or type ANSI 316 of European equivalent stainless steel where required. Tubing shall be 12 mm OD x 10 mm ID, sample lines for analyzers may be executed in 6 mm OD x 4 mm ID.
5.1.2 Fittings
Carbon steel or stainless steel tube fittings, compression type.
Service Flow
or 5 valve manifold) Block, drain/vent valves (2 valve manifold) Block, drain/vent valves (4 valve manifold), no equalizing valve
7.2 Sealing
Sealing will be foressen when heat tracing is not possible or not economical, such as in case of: - Extremely high viscosity - Solidification at zero flow - Different liquid phases in the process fluid - When entrapping vapour may occur in the meter piping due to overheating Sealing shall be avoided on flow instruments.
7.3 Purging
Purging will be foressen when heat tracing and sealing are not possible, such as in case of: - To prevent plugging of instrument and instrument piping when polymerization may occur - To avoid damage to the instrument by corrosive liquid and or gasses - When solids are present in process liquids. A check valve will be installed in all instrument purge applications, provided by the instrument department. Purge flow will be reguleted to ensure a sufficient low flow, to insure that there is no pressure drop fluctuation effecting the read-out.
8.2 Alarm
The annunciator system will be: (o) Dedicated annunciator system(s) (o) Integrated in the shutdown system (*) Integrated in the main control system (o) Alarm system shall be fail safe, utilizing normally closed alarm contacts, which open on fault. Where one off normal signal causes a chain reaction of off normal signals in an interrelated alarm system (for example compressor systems), only the first alarm shall give a visual and audible alarm. An acknowledge button and (lamp) test switch will be provided for each operating station. Alarm signals will generally be actuated from the control loop transmission signal except when vital (safety) for the process or when no transmission signal is available, in which case direct measuring switching devices will be used. Vital process alarm will have separate process tappings and separate activating deviced.
The system cabinets are generally installed inside the auxiliary room of the control center.
no positioners, but use a booster when required to increase response time use positioners in all cases use positioners for all gas and vapor service and boosters for liquid pressure when required to increase response time use positioners in all cases
Control valves shall be sized for the available pressure drop at normal flow (refer BN-K070, design data - general), but based on a flowing quantity equal to normal flow times an oversizing factor of 1.8. The calculation will be checked for maximum flow with an oversizing factor of 1.1. The system friction loss (including other dynamic losses), excluding the control valve pressure drop, shall not exceed 2/3 of the control valve pressure drop in the wide open position. Control valve oversizing factor normal flow conditions will be as follows:
Oversizing
0.5
Control Valve DP
1.4
0.5
0.67
Control Valve DP
1.8
This calculation will be checked for maximum flow with an oversizing factor of 1.1. Control valve lift at minimum flow condition shall not be below 20% for equal percentage trims and not below 10% for linear trims. Control valve calculations shall be executed on a computer programme, which is based to latest ISA standards (ISA-S75-1).
- For critical services. In all other cases the valve shall be fitted with a side-mounted handwheel only, except valves in a safety shutdown service, unless specifically noted. The control valve manifold shall be shown on the engineering flow diagram. Control valve shall be installed in horizontal lines with diaphragm operators above the valves. Butterfly valves shall be installed with the vane-shaft in horizontal position. For control valve manifold design see paragraph 12.7.
The drain line shall have 3/4 inch valve, normally closed, to permit periodic draining of the discharge piping. In all cases, the discharge piping enter the header in the top or side. .2 Discharge to atmosphere All safety valves or vents discharging to atmosphere shall discharge at least 3 m higher than the top of the highest equipment within a radius of 15 m. A 3/4 inch drain hole shall be provided at the lowest point in the safety valve riser. Care shall be taken that a flame can not impinge on equipment or piping.
11. Reference Specifications and Standards 11.1 Company Specifications BN-SP-C2 : Piping Specification.
BN-SP-K2
BN-SP-K3
Engineering and Design Specification for the Limitation of Control Valve Noise.
BN-SP-K4
BN-SP-K5
BN-SP-K6
BN-SP-K7
BN-SP-K8
BN-SP-K9
BN-SP-K10
11.2 Other Specifications ANSI B 40.1 : Gauges - Pressure (and Vacuum). Indicating Dial Type.
API RP 550
API RP 520
Recommended Practice for the Design and Installation of Pressure Relieving System in Refineries.
API RP 521
API RP 526
ISA RP 3.2
Measurement.
ISA S 75.03
Uniform Face to Face Dimensions for Flanged Globe Style Control Valve Bodies.
ISA S 75.04
ISA RP 75.06
ISA S 5.1
ISA S 5.3
Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems
ISA S 75.01
ISA MC 96.1
ISO 5167
USAS B 16.5
ASME
12. Typical Drawings 12.1 Straight Length Requirements for Oriffice Flow Instruments
Minimum meter run for oriffice flow meters as per ISA 5167 figures are based on b = 0.75.
Downstream run
Orifice
Small disturbances
Control valves, globe valves and other valves which are used for throttling
Notes: 1. Minimum length of meter runs is based on ISO 5167 practices, for a maximum b ratio of 0.75. Where long meter runs interfere with practical piping layout and correct process design the upstream run might be determined using actual b ratio. Piping designer to consult the instrument engineer. 2. Take upstream and downstream meter run from the orifice. When pipe taps are used, increase upstream straight run with 2 diameters and downstream with 8 diameters. 3. Where two or more disturbances exist, the distance between any disturbance and primary element shall not be less than defined in paragraph 12.1. Therefore, it is required to consider also those disturbances more upstream, and not only the one close to the orifice. Refer to examples A and B below. 4. Install thermowells, instrument connections, etc., preferably downstream of the orifice. Example A Refer to paragraph 12.1. Note 3
However, the control valve must always be 88(44)D from the orifice plate. This is to be accomplished by increasing X, Y or Z or any combination of those.
12.2 Instrument Connections on Piping and Vessels 12.2.1 Instrument Connections on Piping
.2 Close coupled flow transmitter for steam or condensable vapour service, meter below taps.
.3 Close coupled flow transmitter for gas service, meter above taps.
NOTES 1. Restrict impulse leads to minimum length. 2. Provide positive slope, at least 1 inch per foot for all leads to avoid possible pocketing and provide positive venting or draining. 3. Connect high pressure side of instrument to upstream tap. 4. For liquid service in vertical lines, up-flow is preferred to avoid vapor or trash build-up above the plate. 5. Install meters above taps for liquid, steam or condensable vapor service. 6. Install meters above taps for gas service. 7. For steam service both fill tees must be installed at same centre line elevation as upper tap. .4 Rotameter When rotameter has top outlet and/or bottom inlet use similar arrangement.
NOTES 1. Install seal pots for high displacement type instruments only. 2. Install additional block valve when required.
.3 Pressure transmitter
12.3.4 Thermowells
.1 Typical screwed thermowell installation
Elbow installation, use for 4 inch and smaller. 2 inch and smaller swage-up to 3 inch, as shown dotted.
45 installation, use for 4 inch and smaller lines 3 inch and smaller swage-up as shown dotted
.2 Typical flanged thermowell installation.
90 installation, use for all line sizes 3 inch and smaller swage-up to 4 inch. Line size 3
Elbow installation, use for 4 inch and smaller. 2 inch and smaller swage-up to 3 inch as shown dotted. 3 4 6 8 10 12 and Vessel
5 9
5 9
5 12
5 12"
larger 9 12
9 12
NOTE 1. :
2. :
3. :
4. :
5. :
Wells for dial thermometers shall be installed to insure good readability of thermometer from grade or platform.
Vital Electronic signal Processing systems, loops Central receivers, Annunciators, Electronic logic etc.
12.7 Control Valves NOTES: * Dimension A is given as guidance refer to manufacturer drawing. ** Refer to manufacturers drawing for dimensions B and C Dimens. A in mm (ISA RP 4.1/USAS B16.10) RATING/ USAS USAS USAS /SIZE 150 LBS 300 LBS 600 LBS 3/4 184 194 206 1 184 197 210 1 1/2 222 235 251 2 254 267 286 3 298 318 337 4 352 368 394 6 451 473 508 8 543 568 610 10 626 660 705
12 14 16
GENERAL DESIGN REQUIREMENTS
730 851 -
1. Reduction in line size shall take place as close to control valve as practical. Where lines sizes upstream and downstream are not the same, the upstream block valve is based on upstream size, and the by-pass and downstream block valves are based on downstream size. NOTE: By-pass valve might be sized larger when high capacity flow is required for flexibility. When by-pass controlability is important the by-pass size may be selected for a capacity of twice the selected control valve. 2. Block valves shall be at right angles to each other. 3. A 3/4 drain is installed between the upstream block valve and the control valve, on the bottom pipe. (Only necessary when on flow sheet). 4. Block, and by-pass valves shall be easily operable from grade or platform.
CONTROL LINE SIZE IN INCHES VALVE BODY 3/4 1 1 1/2 2 3 4 6 8 10 12 14 16 SIZE 3/4 3/4 1 1 1/2 2 Recommended minimum block and by-pass valve 1 1 1 1/2 2 2 size 1 1/2 1 1/2 2 2 3 2 2 3/2 3 4 3 3 4/3 4 6 4 4 6/4 6 8 6 When two valves are shown: 6 8/6 8 10 8 Left hand is block valve size and right hand is by-pass valve 8 10 / 8 10 12 10 size. 10 12 / 10 12 14 12 12 14 / 12 14 14 14 16 / 14 16 16 12.8 Grounding and Screening