instrumentation design basis

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL

ADDAR Specialty Chemical Production Plant, Jubail (Greenfield Project) DESIGN BASIS – INSTRUMENTATION AND CONTROL

Project No. Document No. Date

: P002429-001 : 2429.1-00-IC-DAB-001 : 06-09-2013

L&T Integrated Engineering Services LARSEN & TOUBRO LIMITED L&T Knowledge City, SEZ (IT/ITES) rd 3 Floor, West Block-II N.H No. 8, Vadodara-390019 Gujarat, India Fax: +91 265 670 5353 www.Lnties.com

Doc. No. 2429.1-00-IC-DAB-001

Page 1 of 49


SYNOPSIS This document presents the Design Basis for Instrumentation & Control for the Specialty Chemical Production Plant, Liquid Sulphur Dioxide (SO2) Plant, Centralised Utility Building and Offsite Storage facilities. This Design Basis shall be used for detailed engineering design of this project.

PROJECT P002429-001 P002429-001 ADDAR SPECIALITY CHEMICAL PRODUCTION PLANT REV

DESCRIPTION

ORIGIN

REVIEW

L&T-IES DATE APPROVAL

VS/RD

MM

SBA

15-02-2013

Issued for Design

KD

MM

SBA

25-03-2013

1

Re-issued for Design

KD

MM

SBA

30-03-2013

2


KD

MM

SBA

06-09-2013

C

Issued for client comments

0

Doc. No. 2429.1-00-IC-DAB-001

CLIENT DATE APPROVAL

Page 2 of 49


SYNOPSIS This document presents the Design Basis for Instrumentation & Control for the Specialty Chemical Production Plant, Liquid Sulphur Dioxide (SO2) Plant, Centralised Utility Building and Offsite Storage facilities. This Design Basis shall be used for detailed engineering design of this project.

PROJECT P002429-001 P002429-001 ADDAR SPECIALITY CHEMICAL PRODUCTION PLANT REV

DESCRIPTION

ORIGIN

REVIEW

L&T-IES DATE APPROVAL

VS/RD

MM

SBA

15-02-2013

Issued for Design

KD

MM

SBA

25-03-2013

1


KD

MM

SBA

30-03-2013

2


KD

MM

SBA

06-09-2013

C

Issued for client comments

0

Doc. No. 2429.1-00-IC-DAB-001

CLIENT DATE APPROVAL

Page 2 of 49


DISCLAIMER This report has been prepared on behalf of and for exclusive use of ADDAR and is subject to and issued in accordance with the agreement between ADDAR and L&T-IES. L&T-IES accepts no liability or responsibility whatsoever for it in respect of any use or reliance upon this report by any third party. Copying this report without the permission of ADDAR or L&T-IE S is not permitted.

Doc. No. 2429.1-00-IC-DAB-001

Page 3 of 49


Table of Contents 1

Introduction

7

2

Scope of Document

8

3

General Information 3.1 Abbreviations 3.2 Units of Measurement 3.3 Reference Documents 3.4 Legends

9 9 10 11 11

4

Codes, Standards, Specifications and Regulatory Requirement 4.1 General 4.2 Codes and Standards 4.3 Client Specifications and Standards 4.4 Regulatory Requirements 4.5 Statutory Requirements

12 12 12 15 15 15

5

Environmental and Geotechnical Data 5.1 Site Conditions 5.1.1 Wind 5.1.2 Earthquake (Based on local regulation) 5.1.3 Temperature 5.1.5 Barometric Pressure 5.1.6 Rainfall 5.1.7 Altitude 5.2 Site Information

16 16 16 16 16 17 17 18 18

6

General Basis of Design

19

7

Hazardous Area 7.1 Certifications 7.2 Classification 7.3 Protection Type 7.4 Accessories 7.4.1 Intrinsic Safety Barriers

20 20 20 20 20 20

8

Instrument Air & Power Supply 8.1 Instrument Air Supply 8.2 Power Supply

22 22 22

9

Operation and Control Philosophy

23

10

Field Instrumentation

24

11

Electronic Transmitter

26

Doc. No. 2429.1-00-IC-DAB-001

Page 4 of 49


12

Flow Measurement 12.1 Orifice Plate 12.2 Flowmeter Types

27 27 28

13

Level Measurement 13.1 Level Gauges 13.2 Level Switch 13.3 Level Transmitters

30 30 30 31

14

Pressure Measurement 14.1 General 14.2 Pressure Gauges 14.3 Pressure Switches 14.4 Pressure Transmitters

32 32 32 33 33

15

Temperature Measurement 15.1 Temperature Gauges 15.2 Resistance Temperature Detector (RTD) 15.3 Thermocouple 15.4 Thermowells 15.5 Temperature Transmitter

35 35 35 36 36 36

16

Analytical Instruments

37

17

Weighing Instruments

38

18

Valves 18.1 General 18.2 On/Off Valves 18.3 Control Valve 18.4 Solenoid Valves 18.5 Limit Switches

39 39 39 39 40 40

19

Cables 19.1 Cable Type 19.2 Cable Specification 19.3 Cable Glands 19.4 Cabling Philosophy

41 41 41 42 42

20

Junction Box

43

21

Control and Automation System

44

22

Cabinet and Enclosures

46

23

Cable Trays

47

24

Installation 24.1 Instrument Installation 24.2 Cabinet Installation

48 48 48

Doc. No. 2429.1-00-IC-DAB-001

Page 5 of 49


25

Spare Philosophy

49 List of Tables

Table 3-1 Commonly Used SI Units .................................................................................... 10 Table 4-1 Commonly Used Standards ................................................................................ 12

Doc. No. 2429.1-00-IC-DAB-001

Page 6 of 49


1

Introduction “Arab House for Industrial Consultancy” a business unit of ADDAR GROUP (hereinafter referred to as “ADDAR”) plans to design and execute grass root project for Specialty Chemical (SA) Production Plant with annual capacity of 6000 MT in Jubail Industry city, Kingdom of Saudi Arabia (KSA). Along with this facility, ADDAR is also setting up 15000 MT per year Sulphuric Acid Plant, 4000 MT per year Liquid Sulphur Dioxide (SO 2) Plant and 450 Nm3/hr capacity Hydrogen Plant for own consumption. In addition to above mentioned four Process Plant Buildings, The project will have Centralised Utilities, off-site Storage, Administrative Buildings and Infra-structure facilities. “Larsen & Toubro Integrated Engineering Services” (hereinafter referred as “L&T-IES”) shall provide detail engineering services for two process plants namely, Speciality Chemical Plant & Liquid Sulphur Dioxide (SO2) Plant, Centralised Utilities, Off-site Storage and Administrative Buildings & Infra-structure.

Doc. No. 2429.1-00-IC-DAB-001

Page 7 of 49


2

Scope of Document The purpose of this document is to cover the design basis, standard engineering practices for Instrumentation and Control shall be followed during engineering activities.

Doc. No. 2429.1-00-IC-DAB-001

Page 8 of 49


3

General Information

3.1

Abbreviations The list of abbreviations and their meanings that are used in this document are as mentioned below: ANSI

:

American National Standard Institute

API

:

American Petroleum Institute

AWG

:

American Wire Gauge

ASTM

:

American Society for Test and Materials

MPMS

:

Manual for Petroleum Measurement Standards

ASME

:

American Society of Mechanical Engineers

ATEX

:

Atmosphere Explosives

BS

:

British Standard Institute

ISA

:

Instrumentation, Systems and Automation Society

IEC

:

International Electro-Technical Commission

ISO

:

International Organization for Standardisation

BASEEFA

:

British Approval Service for Electrical Equipment in Flammable Atmospheres

NACE

:

National Association of Corrosion Engineers

NEMA

:

National Electrical Manufacturers Association

NFPA

:

National Fire Protection Association

FCI

:

Fluid Control Institute

DCS

:

Distributed Control System

PLC

:

Programmable Logic Controller

EMC

:

Electromagnetic Compatibility

FM

:

Factory Mutual

UPS

:

Uninterrupted Power Supply

IP

:

Ingress Protection

HART

:

Highway Addressable Remote Transducer

Doc. No. 2429.1-00-IC-DAB-001

Page 9 of 49


3.2

SASO

:

Saudi Arabian Standards Organisation

*

:

L&T IES shall confirm during detailing

**

:

ADDAR to confirm/specify

Units of Measurement Units of measurement shall be in accordance with ISO requirements and refer to: •

BS ISO 1000 – SI Unit Recommandations,

•

BS 350 – Conversion factors for units.

A list of commonly used SI units in process calculations is shown in the Table 3-1 below: Table 3-1 Commonly Used SI Units Unit Name Kilogram per centimetre square(gauge) bar(gauge) Millimetre bar (gauge) Cubic metre Litre Normal Cubic metre Degree Celsius Hertz Joule Kilogram Tonne Inch Milimeter Meter Metre per second Milligram per litre parts per million Millisecond Second Minute hour Newton Ohm Square metre Square cm Square mm

Doc. No. 2429.1-00-IC-DAB-001

Quantity

Notation Standard

Pressure

Kg/cm (g) bar (g) mmbar(g)

2

Volume Temperature Frequency Energy Mass Length Velocity Concentration

Time Force Resistance Area

m litre 3 Nm o C Hz J kg t Inch (’’) mm Mtr m/s mg/l ppm ms s min hr N Ω

m 2 cm 2 mm

Page 10 of 49

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL Unit Name Millivolt Volt Watt Cubic Metre /Hour Liter/minute Kilogram / Hour Kilogram /Cubic Meter Millimetre water column Micro Siemens/m Percentage Ampere Percentage Centipoise

3.3

Quantity Electrical potential Power Volumetric Flow Mass Flow Density Differential Pressure Conductivity Relative Humidity Current Level Viscosity

Notation Standard mV V W m / hr l/min Kg/hr Kg/ m mmWC µS/m % A % cP

Reference Documents •

Section 13420

– Royal Commission Guideline – Specification For Instruments

•

Section 13430

– Royal Commission Guideline – Specification For Boxes, Panels

And Control Centers Section 13440

•

– Royal Commission Guideline – Specification For Indicators,

Recorders And Controllers Section 13450

•

3.4

– Royal Commission Guideline – Specification For Central Control

Legends Following marks shall be checked in the relevant bracket:

[ √ ]

:

Applicable

[ M]

:

Mostly Applicable

[ P]

:

Partially Applicable

[

]

:

Not Applicable

[ D]

:

To be decided at the Detailed Engineering stage

Doc. No. 2429.1-00-IC-DAB-001

Page 11 of 49


4

Codes, Standards, Specifications and Regulatory Requirement

4.1

General The precedence applying for use of the Codes, Standards, Specification, Regulatory & Statutory requirements for this project is as follows: •

Statutory & Regulatory Requirements

•

International Standards

•

L&T-IES Specifications and Standards

•

Accepted Industry Practice / Good Engineering Practice

In the event of an inconsistency, conflict or discrepancy between any of the Standards, Specifications and Regulatory, the most stringent and safest requirement applicable to the project will prevail to the extent of the inconsistency, conflict or discrepancy. Any inconsistencies critical to the design shall be brought to the attention of the Project Manager for resolution with ADDAR.

4.2

Codes and Standards The design, construction and installation shall comply with relevant recognised international standards and recommended practices such as those from ASME or API. If no standard is specified the default shall be the relevant L&T-IES / Royal Commission Standard. The following codes and standards shall be used for process design. Table 4-1 Commonly Used Standards TITLE Pipe Threads, General Purpose (Inch) Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Wound, and Jacketed Flow Equations for Sizing Control Valves Face-to-Face Dimensions for Flangeless Control Valves (ANSI Classes 150, 300 and 600)

REF ANSI B1.20.1 ANSI B16.20 ANSI/ISA 75.01.01 ANSI/ISA 75.04

Control Valve Terminology

ANSI/ISA 75.05.01

Face-to-Face Dimensions for Flanged Globe-Style Control Valve

ANSI/ISA 75.08.01

Bodies (ANSI Classes 125, 150, 250, 300 and 600) Doc. No. 2429.1-00-IC-DAB-001

Page 12 of 49

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL TITLE

REF

Inherent Flow Characteristic and Rangeability of Control Valves

ANSI/ISA 75.11.01

Face-to-Face Dimensions for Flanged Globe- Style C ontrol Valve Bodies (ANSI Classes 900, 1500 and 2500) Hydrostatic Testing of Control Valves Face-to-Centre line Dimensions for Flanged Globe- Style Angle Control Valve Bodies (ANSI Classes 150, 300 and 600) Considerations for Evaluating Control Valve Cavitations

ANSI/ISA 75.16 ANSI/ISA 75.19.01 ANSI/ISA 75.22 ANSI/ISA RP75.23

Graphic Symbols for Process Displays

ISA S5.5

Quality Standard For Instrument Air

ISA S7.3

Manual of Petroleum Measurement Standards - Chapter 3 Tank Gauging Section 1A: Standard Practice for the Manual

API MPMS 3.1A

Gauging of Petroleum and Petroleum Products. Tank Gauging Section 1B: Standard Practice for Level Measurement of Liquid Hydrocarbons in Stationary Tanks by

API MPMS 3.1B

Automatic Tank Gauging Temperature Determination - Static Temperature Determination Using Fixed Automatic Tank Thermometer.

API MPMS 7.4

Chapter 16 - Measurement of Hydrocarbons Fluids by Weight or Mass - Section 2: Mass Measurement of Liquid Hydrocarbons in

API MPMS 16.2

Vertical Cylindrical Storage Tanks By Hydrostatic Tank Gauging Installation of Refinery Instruments and Control Systems Part 1 Process Instrumentation and Control

API RP 550 P1

Process Measurement Instrumentation

API RP 551

Pipe Flanges and Flanged Fittings

ASME B16.5

Face-to-Face and End-to-End Dimensions of Valves

ASME B16.10

Surface Texture (Surface Roughness, Waviness and Lay

ASME B46.1

Temperature Measurements Thermowell installations in power and process piping

Doc. No. 2429.1-00-IC-DAB-001

ASME PTC 19.3 ASME PTC 19.3 TW

Page 13 of 49

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL TITLE

Bourdon Tube Pressure & Vacuum Gauges

Recommendations for Design of Scales and Indexes on Analogue Indicating Instruments

REF

BS 1780

BS 3693

Instrumentation Cable

BS 5308

Specification for Electromagnetic Flow Meters

BS 5792

Code of Practice for Instrumentation in Process Control Systems: Design and Practice. Electromagnetic Compatibility. Generic Immunity Standard Part

BS 6739 EN50082-2

2: Industrial Environment Control Valve Seat Leakage

FCI 70-2

Test on bunched wires or cables

IEC 332

Degree of Protection Provided by Enclosure

IEC 60529

Electrical Apparatus for Explosive Gas Atmosphere IEC 60079-14 Electrical Installation in Hazardous Area Standards Control Valve Manifold Designs (Carbon Steel Valves only) for Maximum Flexibility Specification, Installation, and Calibration of Turbine Flow meter Petroleum Liquids and Liquefied Petroleum Gases-

ISA RP4.2 ISA RP31.1 ISO 5024

Measurement-Standard Reference Conditions Measurement of Fluid Flow by Means of Pressure Differential Devices-Part 1: ISO 5167-1 Orifice Plates, Nozzels and Venturi tubes Inserted in Circular Cross-Section, Conduits Running full Measurement of Fluid Flow-Estimation of Uncertainty of a FlowRate Measurement

Doc. No. 2429.1-00-IC-DAB-001

ISO 5168

Page 14 of 49

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL TITLE Petroleum and Natural Gas Industries-Materials for Use in H2S-

REF NACE MR 01 75

Containing Environments in Oil and G as Production-ISO 15156Part 1, Part 2, and Part 3 Enclosures for Electrical Equipment (1000 Volts Maximum) National Electrical Code

4.3

NEMA 250 NFPA 70

Client Specifications and Standards It is understood that ADDAR have no specific requirements on their specifications and standards. Therefore, applicable national (Royal Commission) / International standards shall be used.

4.4

Regulatory Requirements All aspects of the Project shall comply with the requirements of the latest versions of all relevant regulatory requirements i.e. Royal Commission.

4.5

Statutory Requirements ADDAR shall be responsible for obtaining all statutory approvals, as applicable for all instruments and control systems.

Doc. No. 2429.1-00-IC-DAB-001

Page 15 of 49


5

Environmental and Geotechnical Data

5.1

Site Conditions

5.1.1 Wind PARAMETER

Jubail Value

Principal wind direction (for March-November)

N,NNW

(For December-February)

-, NW

Max wind speed (m/s)

42.7

5.1.2 Earthquake (Based on local regulation) Design specifications for seismic Seismic Zone - 0

5.1.3 Temperature 5.1.3.1 Ambient Temperature PARAMETER

Jubail Value

Maximum Recorded shade temperature (°C)

52°C

Average daily maximum dry bulb temperature

42.1°C

Design Dry Bulb Temperature in Summer

46.0°C

Design Wet Bulb Temperature in Summer

30.0°C

Average daily minimum temperature

11.1°C

Maximum temperature on record

49.9°C

Minimum temperature on record

2.9°C

Doc. No. 2429.1-00-IC-DAB-001

Page 16 of 49


5.1.3.2 Design Temperature

5.1.4

PARAMETER

Jubail Value

For Air Compressor / Blower (°C)

60

For Air Coolers (°C)

60

Minimum Design Temperature for all Equipment’s (°C)

2

Relative Humidity Air PARAMETER

Jubail Value

Summer season relative humidity (%)

10 - 50

Winter season relative humidity (%)

10- 100

Daily average relative humidity (%)

38 - 65

At maximum design temperature of 60°C, the relative humidity to be considered for design is 50%. At normal design temperature of 34°C, the relative humidity to be considered for design is 75%.

5.1.5 Barometric Pressure PARAMETER

Jubail Value

Maximum barometric pressure (mbar)

1011.0

Minimum barometric pressure (mbar)

1008.8

Annual Average barometric pressure (mbar)

1010.0

5.1.6 Rainfall PARAMETER

Jubail Value

Monthly maximum rainfall in one hour (mm)

145

Annual maximum rainfall in 24 hours (mm)

225

Design rainfall in one hour (mm)

50

Doc. No. 2429.1-00-IC-DAB-001

Page 17 of 49


5.1.7 Altitude Altitude above Mean Sea Level (M.S.L): 2.58 Mtr Lowest Low Water Level (L.L.W.L.) below mean sea level: 0.6 Mtr Highest High Water Level (H.H.W.L.) above mean sea level: 0.6 Mtr

5.2

Site Information STATE

Jubail Value

Nearest Important Town & Distance

Jubail, 25 km

Nearest Railway Station & Distance

Dammam, 110 km

Nearest Port & Distance

Jubail, 20 km

Nearest Airport & Distance

Dammam, 105 km

Doc. No. 2429.1-00-IC-DAB-001

Page 18 of 49


6

General Basis of Design Control System: [ √ ]

DCS

Field Circuit Design: [ √ ]

Non-Hazardous area

[ D ]

Hazardous area

Electric Rules for Control & Acquisition: [ D]

IEC

Following points must be considered while designing basic instrumentation & control system:i)

Instrumentation shall be complete in every respect and liberal to the extent of providing data on all operations and variables sufficient for the safe, efficient and easy operation of the plant.

ii)

The design and installation of instruments shall be generally in accordance with ISA/API

recommended

practices

and

other

applicable

standards.

Material

specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. iii)

All instruments and equipment shall be suitable for use in a hot, humid and tropical industrial climate in which corrosive gases and/or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof and weather proof to IP-65 and secure against the ingress of fumes, dampness, insects and vermin. All external surfaces shall be suitably treated to provide protection against corrosive plant atmosphere.

Doc. No. 2429.1-00-IC-DAB-001

Page 19 of 49


7

Hazardous Area

7.1

Certifications

7.2

[ √ ]

Certification

[ D ]

BASEEFA

[ D ]

ATEX

[ D ]

PTB

[ D ]

FM

Classification [ M ]

7.3

Hazardous area, Refer hazardous area drawing

Protection Type [ √ ]

Intrinsically Safe - Ex’ia’( to suit specified hazardous areas)

[ √ ]

Increased Safety - Ex’e’( to suit specified hazardous areas)

[ √ ]

Weather Proof - IP 65 (minimum) for field instruments/ junction boxes

7.4

Accessories

7.4.1

Intrinsic Safety Barriers [ √ ]

Analog Input

[ √ ]

Analog Output

[ √ ]

Digital Input

[ √ ]

Digital Output

Following points must be considered while designing an intrinsically safe system:i)

All intrinsic safety barriers shall be active isolating type only and shall have isolation between input, output and power supply.

ii)

Barriers must be selected based on entity concept. Cable parameters shall also be considered while matching entity parameters.

Doc. No. 2429.1-00-IC-DAB-001

Page 20 of 49

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT) DESIGN BASIS – INSTRUMENTATION AND CONTROL iii)

The signal transfer accuracy of barrier shall be at least equal to or better than the transmitter selected.

iv)

Each instrument in the hazardous area and the intrinsic barrier shall be certified for intrinsic safety by a statutory authority.

v)

Each input and output in a loop shall have separate barrier. No barrier shall be shared between two loops or input/outputs.

vi)

Any intrinsically safe loop requiring any device to be connected in the hazardous side permanently or temporarily shall also be intrinsically safe.

vii)

Configuration tools whenever required for any intrinsically safe item which forms part of the intrinsically safe item shall also be certified intrinsically safe.

Doc. No. 2429.1-00-IC-DAB-001

Page 21 of 49


8

Instrument Air & Power Supply

8.1

Instrument Air Supply i)

Moisture free Instrument air shall be distributed to various equipment of C&I system like pneumatic control valves, on-off valves etc. Pneumatic instrument connections for signal and air supply shall be 1/4" NPT.

ii)

Minimum design pressures of 5 bar (g) for instrument air to pneumatic actuator of the valves shall be provided.

8.2

Power Supply i)

Most of the field instruments shall be 2-wire, 24 V DC operated, loop powered.

ii)

Electrical power supply shall be standardized at 120 V AC+/- 5%, 60 Hz+/-1%, via redundant Uninterrupted Power Supply (UPS).

iii)

Non-UPS power supply shall be used for other utilities such as panel lighting.

Doc. No. 2429.1-00-IC-DAB-001

Page 22 of 49


9

Operation and Control Philosophy i)

The complete operation, control and monitoring of Speciality Chemical Plant, Liquid Sulphur Dioxide (SO2), Utilities and Offsites shall be performed from DCS located in the DCS room. The DCS shall consist of operator work stations and engineering work stations as required to be finalised during detailed engineering. The safety integrity level (SIL) shall be SIL 1 as a minimum.

ii)

iii)

Redundancy in control system shall be considered at following levels: •

Controller Level

•

I/O Card level (for critical signals)

•

Power supply level

•

Communication level

•

Client Server level

Sulphuric acid plant shall be operated from dedicated localised PLC located in the respective area,. Signals from sulphuric acid plant PLC shall also be sent to DCS for data acquisition purpose.

iv)

The Hydrogen Generation Plant shall be operated from a dedicated localised PLC placed in the rack room. An engineering/operating workstation shall be supplied & installed by Hydrogen Generation package vendor in the Control Room for controlling and monitoring the plant.

v)

The interface of the above mentioned localised PLC with DCS shall be done with Fieldbus protocol (type to be specifically defined during detailed engineering stage). Fieldbus communication shall be from PLCs /Remote Terminal Unit (RTU) and shall be directly connected to main DCS.

Doc. No. 2429.1-00-IC-DAB-001

Page 23 of 49


10

Field Instrumentation i)

Field mounted direct actuated flow and temperature switch shall not be used. Instead, receiver switch/trip amplifier shall be used along with flow element and temperature element. Whenever specified in job specification, flow and temperature transmitters may be directly connected to control system to achieve switch action.

ii)

Field instruments shall be as per P&IDs approved by Client during detailed engineering.

iii)

Ranges for instruments shall be selected in general, such that in normal process operation the indication is between 40% - 60% of span for linear and 60% - 80% of span for square root inputs.

iv)

All process switches shall be provided with sealed micro switch contacts rated for the specified application. Contacts shall be Single Pole Double Throw (SPDT) type unless otherwise specified. Contacts used shall be gold plated.

v)

Ranges for process switches shall be selected, in general, such that the set point falls preferably in the middle 30% of full adjustable range i.e. the set point shall fall between 35% - 65% of adjustable range.

vi)

For pressure switches, switch differential shall be selected as per operating conditions, it shall be less than 60% of difference between set value and operating value.

vii)

All field instruments, junction boxes and local panels located in hazardous area shall be intrinsically safe protection, however if intrinsically safe equipment are not available, then flameproof enclosure as per IEC shall be considered, if flameproof enclosure is not available then purging must be provided as per NFPA.

viii)

The makes and models of all different types of field instruments shall be standardized for better inventory control.

ix)

Material for sour service shall be certified in accordance with NACE MR 0175.

x)

All field instruments i.e. transmitters, switches, on-off valves, control valves and junction boxes shall be provided with SS tag nameplates.

Doc. No. 2429.1-00-IC-DAB-001

Page 24 of 49


xi)

For material selection, if any specific material of construction / wetted parts is not available for the instruments, then superior or suitable alternative materials compatible with the service fluid shall be used, also while selection it is to be ensured that dissimilar galvanic corrosion does not cause a decrease in the service life of the equipment.

xii)

For field instruments located in outdoor area, suitable mounting brackets and weather canopies for protection from direct sunlight/rain shall be provided.

xiii)

All circuit grounds, shields and drain wires shall be connected to the 'system ground' bus which is isolated from 'AC mains earth'.

Doc. No. 2429.1-00-IC-DAB-001

Page 25 of 49


11

Electronic Transmitter Type: [ √ ]

Smart Type

Signal: [ √ ]

4 to 20mA

Accuracy: [ M ]

+/- 0.1% or better

Enclosure: [ √ ]

Weather proof IP-65 or better

Power Supply: [ √ ]

24 VDC, 2 wire-loop powered

Cable Entry: [ √ ]

½” NPT

Programming Unit Calibrator: [ √ ]

Yes, HART

Display: [ √ ]

LCD (4-digit display)

Hand-Held HART communicator shall be provided for online maintenance and calibration of the electronic transmitters.

Doc. No. 2429.1-00-IC-DAB-001

Page 26 of 49


12

Flow Measurement

12.1

Orifice Plate Sizing Calculation: [ √ ]

As per ISO 5167

Plate Dimensions: [ √ ]

As per ISO 5167

Plate Material: [ √ ]

SS316 or better

Accuracy: [ √ ]

As per ISO 5168

Tapping: [ √ ]

Corner Tapping (less than 50 mm)

[ √ ]

Flange Tapping (50 to 400 mm)

[ √ ]

D, D/2 Tapping (400 to 1000 mm)

Orifice Flanges Material: [ √ ]

SS 316 or better

Jack Bolts: [ √ ]

Required

Tap Valves: [ √ ]

Required

Typical Differential Pressure Ranges: [ √ ]

2500 mmWC

[ M ]

500:1250:5000:10000 mmWC

i)

Differential Pressure Range for the orifice meter shall always be selected less than allowable pressure drop across the orifice.

Doc. No. 2429.1-00-IC-DAB-001

Page 27 of 49


ii)

Flow measurement shall normally be carried out using thin square edged concentric orifice plate mounted between a pair of weld neck flanges for line size 2" and above; however, for flow measurement in lines less than 2", integral flow assembly shall be selected.

12.2

Flowmeter Types Type: [ M ]

Electromagnetic Type Flowmeter

[ √ ]

Differential Pressure Type Flowmeter

[ √ ]

Rotameter

[ √ ]

Turbine meter

[ √ ]

Mass flow meter (Coriolis)

[ M ]

Vortex type Flowmeter

Wetted Material: [ √ ]

SS316 or better

Mounting: [ M ] i)

Remote/Head Mounted For all conductive fluid (more than 5 µS/m) (except gas/steam fluid), corrosive services, electromagnetic type meter to be used.

ii)

For application where density, temperature and viscosity are required along with flow, Coriolis mass flow meter shall be used.

iii)

For accurate flow integration for fiscal metering/custody transfer turbine meter/ Coriolis mass flowmeter shall be used.

iv)

For steam application and where high rangeability is required, Vortex type Flowmeter shall be used.

Doc. No. 2429.1-00-IC-DAB-001

Page 28 of 49


v)

For services where both unidirectional and bidirectional flow measurement is required, Coriolis type mass flow meter or Electromagnetic type flowmeter shall be used.

Doc. No. 2429.1-00-IC-DAB-001

Page 29 of 49


13

Level Measurement

13.1

Level Gauges Type: [ M ]

Reflex Type

[ M ]

Float operated magnetic type


SS316 or better

Process Connection: [ M ]

2” Flange

i)

Reflex type level gauges shall be used for colourless and clean services.

ii)

Magnetic type of level gages shall be used for corrosive, flammable, sour, toxic, viscous fluid, and in high pressure as well as high temperature applications.

13.2

Level Switch Type: [ M ]

Vibrating Fork

[ D ]

Float Type

Wetted Materials: [ √ ]

SS316 or better

Process Connection: [ D ]

1” NPT

Enclosure: [ √ ]

Weather Proof IP-65 or better

Electric Signal Cable Entry: [ √ ]

½” NPT

Contact Seal: [ √ ]

Hermetical

Doc. No. 2429.1-00-IC-DAB-001

Page 30 of 49


13.3

Level Transmitters Type: [ M ]

Differential Pressure Type

[ M ]

Displacer Type

[ √ ]

Radar Type

[ √ ]

Ultrasonic Type


SS316 or better

Process Connection: [ M ]

½” NPT Differential Pressure Type LT

[ M ]

2” Flanged RF for Displacer Type LT

[ M ]

3” Flanged RF for Radar Type LT

[ M]

2” NPT for Ultrasonic type LT

Mounting: [ D ] i)

Direct (Side or Top mounted as per requirement) For liquid-liquid interface level measurements, displacer type level transmitters shall be used. For higher interface level measurement, displacer type shall not be preferred.

ii)

For corrosive, fouling and services where purging is required, differential pressure type level measurements shall be used.

iii)

For viscous fluid and solid services, radar type level measurement shall be used. Also for solid services ultrasonic level measurement shall also be used.

iv)

For Ultrasonic and Radar type level measurement, the range of the transmitter shall be such as to cover the complete level span of the vessel taking care of blocking distance and frequency attenuation due to obstructions.

Doc. No. 2429.1-00-IC-DAB-001

Page 31 of 49


14

Pressure Measurement

14.1

General i)

Pressure measurements installation items such as diaphragm seal, pulsation dampener, siphon and manifolds shall be provided as applicable

ii)

All pressure gauges with maximum operating pressure exceeding 60 kg/cm²(g) and gauges in toxic service shall be solid front type.

14.2

Pressure Gauges Sensing Element: [ √ ]

Bourdon tube

[ √ ]

Diaphragm

Measurement Type: [ √ ]

Gauge

[ √ ]

Compound

Sensor Material: [ √ ]

Stainless Steel

Dial Size: [ √ ]

6”

Front Glass: [ √ ]

Shatter Proof

Case Material: [ √ ]

Stainless Steel

Process Connection: [ √ ]

½” NPT

Accuracy: [ √ ]

+/- 1% of full scale

Enclosure: [ √ ]


Doc. No. 2429.1-00-IC-DAB-001

Page 32 of 49


14.3

Pressure Switches Sensing Element: [ √ ]

Diaphragm

[ √ ]

Bellows


Gauge

Sensor Material : [ √ ]

SS316 or better

Indication Type: [ √ ]

Indicating/Non-Indicating (Blind)

Enclosure: [ √ ]



Hermetically sealed

Electric Signal Cable Entry: [ √ ]

½” NPT


½” NPT

Contact Rating: [ √ ]

14.4

2 SPDT rated 5A at 120 V AC, 60 Hz and 1 A (maximum) at 24 V DC

Pressure Transmitters Sensing Element: [ √ ]

Piezoresistive


Gauge/Differential

Doc. No. 2429.1-00-IC-DAB-001

Page 33 of 49


Sensor Material: [ √ ]

SS 316 or better

Enclosure: [ √ ]



½” NPT

[ D ]

2” Flanged RF for Diaphragm Seal Type

Doc. No. 2429.1-00-IC-DAB-001

Page 34 of 49


15

Temperature Measurement

15.1

Temperature Gauges Sensing Element: [ √ ]

Bi-metallic

Dial Size: [ √ ]

6’’

Case Material: [ √ ]

SS316 or better

Accuracy: [ √ ]

15.2

+/-1% of full scale

Resistance Temperature Detector (RTD) Sensing Element: [ √ ]

Platinum 100, 3 wire (Duplex)

Sheath Material: [ √ ]

SS316 or better

Accuracy: [ √ ]

+/- 0.25% or better

Thermowell Connection: [ √ ]

½” NPT

Enclosure: [ √ ]

Weather proof IP-65 or better 0

0

RTD shall be used within a temperature range of -200 C to 650 C.

Doc. No. 2429.1-00-IC-DAB-001

Page 35 of 49


15.3

Thermocouple Type: [ D ]

Duplex J,K ,E,T (as applicable)

Enclosure: [ √ ]


Thermowell connection: [ D ]

½” NPT

For higher temperature measurement, Thermocouple shall be preferred.

15.4

Thermowells Type: [ √ ]

Tapered Bar stock (for immersion length up to 500mm)

[ √ ]

Built up Type (for immersion length more than 500mm)

Thermowell Material: [ √ ]

SS 316 or better

Process Connection: [ D ]

1 ½” Flanged RF

Immersion length (for nozzle length of 200 mm): [ √ ]

280 mm (for pipe line size upto 6”)

[ √ ]

320 mm (for pipe line size above 8”)

[ √ ]

400 mm (for all columns/vessels)

Any pipe line size less than 4" nominal bore shall be blown to 4" size to install thermowell.

15.5

Temperature Transmitter Mounting: [ √ ]

Remote Mounted

Temperature Transmitters shall have a built-in linearising function to produce an output linear to temperature range. Doc. No. 2429.1-00-IC-DAB-001

Page 36 of 49


16

Analytical Instruments Analyser Type: [ M]

pH

[ M]

Conductivity

[ M]

Gas

Accuracy: [ M]

+/- 0.01 pH for pH analyser

[ M]

+/-1% of full scale for conductivity analyser

[ M]

+/-2% of measured value for Gas analysers

Enclosure: [√ ]


Sample Tubing Material: [√ ]

SS316 or better

Doc. No. 2429.1-00-IC-DAB-001

Page 37 of 49


17

Weighing Instruments Load Cell Type: [√ ]

Bending

[√ ]

Shear (Beam)

[√ ]

Compression

Sensing Element: [√ ]

Strain Gauge

Sensor Material: [√ ]

Stainless Steel or better

Sensor Excitation Voltage: [D ]

5-15 V DC (as applicable)

Accuracy: [ M]

+/- 0.05%

Enclosure: [√ ]


Doc. No. 2429.1-00-IC-DAB-001

Page 38 of 49


18

Valves

18.1

General The action of valves on failure (Fail open (FO), Fail Close (FC)) in operating medium shall be determined by process requirement with regard to safe operation and emergency shutdown requirements.

18.2

On/Off Valves Type: [ M ]

Ball/Plug/Globe (as applicable)

Body Material: [ √ ]

According to piping specification and process conditions

Leakage Class: [ M ]

Class V (as applicable)


Flanged/Wafer (as applicable)

Actuator Type: [ M ]

18.3

Pneumatically operated

Control Valve Type: [ M ]

Globe (as applicable)


According to piping specification and process conditions

Leakage Class: [ M ]

Class V (as applicable)


Flanged

Actuator Type: [ √ ]

Pneumatically operated

Air Filter Regulator: [ √ ]

Required

Doc. No. 2429.1-00-IC-DAB-001

Page 39 of 49


18.4

Solenoid Valves Type: [D ]

Universal/NO/NC

[D ]

Direct/Pilot Acting


SS316 or better

Enclosure: [ √ ]


Insulation Class: [ √ ]

Class ‘H’

Solenoid valve shall not be used for process service applications.

18.5

Limit Switches Type: [ √ ]

Proximity

Enclosure: [ D ]



Hermetically sealed

Doc. No. 2429.1-00-IC-DAB-001

Page 40 of 49


19

Cables

19.1

Cable Type Signal and Power Cables: [ √ ]

As per IEC/SASO

Separation: [ √ ]

300 mm between Power & Instrument/Control cable 2

For Instrumentation Signals (1.5mm ) - Analog and Digital: [ √ ]

Single Pair for individual signals

[ √ ]

Multi pair for multiple signals 2

For RTD Cables (1.5mm ): [ √ ]

Single Triad for individual signal

For Thermocouple Cables (20 AWG): [ √ ]

Thermocouple Extension cable

For Power Supply (2.5mm2): [ √ ]

3 core 2

For Control Cables (1.5mm ):

19.2

[ √ ]

2 core for individual signal

[ √ ]

Multi-core for multiple signals

Cable Specification Fire Protection: [ √ ]

Flame Retardant Low Smoke Zero Halogen

Shielding (for single/multi pair cable): [ √ ]

Overall shielding only for Digital Signals

[ √ ]

Individual as well as overall shielding for Analog Signals

Outer Sheath: [ √ ]

PVC Insulated

Doc. No. 2429.1-00-IC-DAB-001

Page 41 of 49


Core Material: [ √ ]

Copper

Conductor Insulation: [ √ ]

UV-resistant Cross Linked Polyethylene (XLPE)

Screen: [ √ ]

Aluminium Mylar tape

Inner Sheath: [ √ ]

Polyethylene

Armour: [ √ ]

19.3

Round Galvanized Steel

Cable Glands Type: [ M]

Stainless Steel

Threading: [ √ ]

19.4

½ “ NPT

Cabling Philosophy i)

For all analog and digital signals to/from DCS, instrumentation pair cable shall be used.

ii)

For local push button signals (Electrical Signals), control cable shall be used.

Doc. No. 2429.1-00-IC-DAB-001

Page 42 of 49


20

Junction Box Material : [ √ ]

Die-cast Aluminium alloys

[ √ ]

Stainless Steel

Mounting: [ √ ]

Column

[ √ ]

Wall

Enclosure: [ √ ] i)

Weather proof IP 65 or better Separate junction boxes shall be used for the following type of signals: •

Intrinsically Safe Analog Inputs/Outputs (4-20 mA)

•

Non Intrinsically Safe Analog Inputs/Outputs (4-20 mA)

•

Intrinsically Safe Digital Inputs/Outputs

•

Non Intrinsically Safe Digital Inputs/Outputs 2

2

ii)

Terminal size in junction box shall be suitable for 0.5 mm to 2.5 mm cables.

iii)

Drain port shall be provided with nozzle & valve assembly for all junction boxes.

Doc. No. 2429.1-00-IC-DAB-001

Page 43 of 49


21

Control and Automation System Type: [ √ ]

DCS Based System

Operator Interface: [ √ ]

Workstation based Console

Power Supply: [ √ ]

Redundant UPS

Process Interlock Logic: [ √ ]

Built in DCS

Redundancy: [ √ ]

Controller level

[ √ ]

I/O Card level (for critical signals)

[ √ ]

Power Supply level

[ √ ]

Communication level

[ √ ]

Client-Server level

Interfacing with Field: [ √ ]

Serial Communication / Hard wired

Functional Requirements: [ √ ]

Control Algorithm (P, PI, PID, Adaptive, Ratio, Gain control, etc.)

[ √ ]

Arithmetic and Logic Function

[ √ ]

Linearisation (Square root Extraction, Flow Computation, Polynomial etc.)

[ √ ]

Data Acquisition

[ √ ]

Interlock Logics

[ √ ]

Alarm Management

[ √ ]

Historian trending

[ √ ]

Dynamic Graphics

Doc. No. 2429.1-00-IC-DAB-001

Page 44 of 49


[ √ ]

Logging & Report Generation

Controller Response Time: [ D ]

100 ms (for critical signals)

[ D ]

250 ms

Control Processor Loading: [ √ ]

Less than 60%

i)

Failure of any one redundant part shall not interrupt other system functions; A failure can be a hardware failure, software failure, power supply failure or the loss of one AC feeder in a dual feeder system.

ii)

The switch-over time from primary to back up controller and vice-versa shall be of the order of one second in case of failure of primary controller.

iii)

All controllers shall have facility for bumpless auto-manual and manual-auto transfer and set point adjustment.

iv)

Flow, pressure and level controller shall be provided with proportional plus integral action, while temperature controller with proportional plus integral plus derivative action.

Doc. No. 2429.1-00-IC-DAB-001

Page 45 of 49


22

Cabinet and Enclosures i)

The control system cabinets located inside air-conditioned control rooms shall have appropriate IP rating, totally enclosed, free standing type with a 3mm (minimum), LM5/LM-6 material and dimensions measuring 2200mm (H) x 1200mm (W) x 800mm (D). Dimension indicated are subjected to change during detailed engineering.

ii)

The cabinets shall have full height front and rear double leaf doors with louvers and filters, suitable gland plates for top/bottom cable entry, isolated system and electronic shield earthing buses, eye bolts and lifting hooks, etc.

iii)

The panel surfaces shall be painted with appropriate colour and adequate paint film thickness.

Doc. No. 2429.1-00-IC-DAB-001

Page 46 of 49


23

Cable Trays [ D ]

SS 316/ Mild Steel Ladder Cable Tray

[ D ]

Cable trays may be Hot Dipped Galvanised

[ D ]

Galvanized pipe Conduit if required for underground cabling

i)

Cable shall be run through cable tray, duct and trench as applicable during detailed engineering.

ii)

Instrument and control cables shall not be grouped with power cables particularly where there is already a possibility of induced pick-up affecting the signal.

iii)

All cable routes shall be fully co-ordinated with the relevant disciplines to preclude interference of services and structures and ensure that routes do not obstruct correct and safe access to mechanical equipment for maintenance and repair purposes.

iv)

Cable in hot areas shall have proper heat protection. Flexible conduits shall be provided wherever necessary.

v)

Cable tray shall run in a two-tier arrangement and the top tier shall be covered.

vi)

Ladder Cable tray shall be most commonly used, perforated cable tray shall only be considered for branch trays.

vii)

For intrinsically and non-intrinsically safe instrument cable separate cable tray shall be envisaged. Blue colour tape shall be provided with intrinsically safe cable tray.

Doc. No. 2429.1-00-IC-DAB-001

Page 47 of 49


24

Installation

24.1

Instrument Installation i)

The flow meter pipe shall be fully supported in both in the vertical and horizontal orientations and not cause any strain on the flowmeter.

ii)

For electromagnetic type flowmeter, the pipelines must be completely filled.

iii)

Installation of electromagnetic type flow meters shall be avoided close to large conducting surfaces such as metal supports. The metal objects may interface with the magnetic field of the flow meter and hence influence its accuracy and its behaviour.

iv)

For pressure instruments installations, siphons shall be used for steam high temperature applications.

v)

All gauges and switches for pipelines and vessels shall be installed in separate wells.

vi)

Control valve actuating systems and cabling shall not be located in close proximity to high temperature sources.

vii)

24.2

The control valves shall be installed after the orifice plate in the direction of flow.

Cabinet Installation i)

All controls, instruments and devices mounted on the front of the control cabinets shall be flush mounted.

ii)

All panels, cabinets shall be welded or bolted to floor channels, also before installation of cabinets and desks, the necessary openings and inserts required shall made on the floor as applicable.

Doc. No. 2429.1-00-IC-DAB-001

Page 48 of 49

instrumentation design basis

Recommend Documents