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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specifics tion Number


0 75-JH-7903
General Instruments
Specification Number Rev Date Sheet

0 KOC Engineering Group


Specjfica&n 01 5-JH-1903 1 15-9-94 2 of 163

I CONTENTS

I1 1.0

2.0
SCOPE ...............................................
STANDARD SPECIFICATIONS ...............................
6

3.0 SERVICE CONDITIONS . . . . . . . . . . . . . . . . .................... 7


3.1 External Conditions . . . . . . . . . . . . . . .................... 7
3.2 Sulphide Stress Cracking Considerations .................... 8

4.0 BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8


4.1 Hazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Explosive Hazard Protection Methods . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Protection from the Environment . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Measurements and Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Connection Sizes and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.7 Instrument Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8 Limitations o n Selection and Approved Manufacturers List . . . . . . . . 12
4.9 Line Break Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 . 1 0 Use of Barrier Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 1 Shop Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 2 Painting and Protective Finishing . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 . 1 3 Packing, Marking and Documentation . . . . . . . . . . . . . . . . . . . . . . 14
4 . 1 4 Spare Parts and Maintenance Requirements . . . . . . . . . . . . . . . . . 15

5.0 CONTROLVALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Scope o f Control Valve Selection . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Valve Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Valve Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Trim Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.6 Valve Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7 Actuator Selection and Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.8 Actuator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.9 Noise, Flashing and Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.10 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 1 Installation Notes. Bypass and Handwheel Philosophy . . . . . . . . . . . 35
5 . 1 2 Accessories and Ancillary Items . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.13 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 4 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.0 RELIEF AND SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


6.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Scope of Relief Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.3 Relief Applications and Selection . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5 Design. Materials and Construction . . . . . . . . . . . . . . . . . . . . . . . 52
6.6 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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6.7 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


6.8 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.9 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.0 FLOW MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


7.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.2 Scope of Flow Measurement Section . . . . . . . . . . . . . . . . . . . . . . 58
7.3 Flow Instrument Types and Selection . . . . . . . . . . . . . . . . . . . . . . 58
7.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.0 PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72


8.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2 Scope o f Pressure Measurement Section . . . . . . . . . . . . . . . . . . . . 72
8.3 Pressure Instruments Type and Selection . . . . . . . . . . . . . . . . . . . 73
8.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5 Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9.0 TEMPERATURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83


9.1 Applicable Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2 Scope of Temperature Measurement Section . . . . . . . . . . . . . . . . . 83
9.3 Temperature Instrument Types and Selection . . . . . . . . . . . . . . . . 83
9.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10.0 LEVEL MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93


10.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.2 Scope of Level Measurement Section . . . . . . . . . . . . . . . . . . . . . . 93
1 0 . 3 Level Instrument Type and Selection . . . . . . . . . . . . . . . . . . . . . . 93
10.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1 0 . 6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 0 . 7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

11.0 TANK METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108


11.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
11.2 Scope of Tank Metering Section . . . . . . . . . . . . . . . . . . . . . . . . 108
11.3 Tank Metering Instruments Type and Selection . . . . . . . . . . . . . . 109
11.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 110
1 1.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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1 1 . 6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112


11.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1 1.8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

12.0 LOCAL PNEUMATIC CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . 115


12.1 Scope of Local Controller Specification . . . . . . . . . . . . . . . . . . . . 115
12.2 Pneumatic Controller Types and Selection . . . . . . . . . . . . . . . . . . 115
1 2 . 3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 117
12.4 Design and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
12.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
12.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
12.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

13.0 SPEED MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119


13.1 Scope of Speed Measurement Section . . . . . . . . . . . . . . . . . . . . 119
13.2 Speed Measurement Instruments Type and Selection . . . . . . . . . . 119
13.3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . 120
1 3 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
13.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 3 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
13.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

14.0 VIBRATION SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122


14.1 Scope of Vibration Sensing Section . . . . . . . . . . . . . . . . . . . . . . 122
1 4 . 2 Vibration Sensing Instruments Type and Selection . . . . . . . . . . . . 122
1 4 . 3 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 123
1 4 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
14.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
14.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1 4 . 7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

15.0 SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124


15.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
15.2 Scope of Solenoid Valve Section . . . . . . . . . . . . . . . . . . . . . . . . 124
1 5 . 3 Solenoid Valves Types and Selection . . . . . . . . . . . . . . . . . . . . . 125
15.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 126
15.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
15.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
15.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1 5 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

16.0 SIGNAL CONVERTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129


16.1 Scope of Signal Converter Section . . . . . . . . . . . . . . . . . . . . . . . 129
1 6 . 2 Signal Converters Type and Selection . . . . . . . . . . . . . . . . . . . . . 129
16.3 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 6 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
16.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
16.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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17.0 POSITION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133


17.1 Scope of Position Switches Section . . . . . . . . . . . . . . . . . . . . . . 133
17.2 Position Switches Type and Selection . . . . . . . . . . . . . . . . . . . . . 133
1 7 . 3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
17.4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
17.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 7 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
17.7 N a m e ~ l a t eData . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

18.0 FLAME DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135


1 8 . 1 Scope of Flame Detection System . . . . . . . . . . . . . . . . . . . . . . . 135
18.2 Flame Detection Types and Selection . . . . . . . . . . . . . . . . . . . . . 135
18.3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1 8 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1 8 . 5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
18.6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
18.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

19.0 MISCELLANEOUS INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139


19.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
19.2 Scope of Miscellaneous Instrument Section . . . . . . . . . . . . . . . . . 139
19.3 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1 9 . 4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 140
19.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
19.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
19.7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1 9 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

20.0ANALYSERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
20.1 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
20.2 Scope of Analysers Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2 0 . 3 Analyzer Types and Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 142
20.4 Sizing and Ranging Requirements . . . . . . . . . . . . . . . . . . . . . . . . 143
20.5 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
20.6 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 0 . 7 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 0 . 8 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

21.0 LOCAL PANELS AND GAUGE BOARDS . . . . . . . . . . . . . . . . . . . . . . . . 157


21.1 Scope of Local Panel and Gauge Board Selection . . . . . . . . . . . . . 157
21.2 Local Panels and Gauge Boards Type and Selection . . . . . . . . . . . 157
21.3 Sizing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 1 . 4 Construction Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
21.5 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2 1 . 6 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
21.7 Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
OKOC
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Specificakm

1.0 SCOPE

1.1 This specification details the design, manufacture, inspection, testing and
supply of plant instrumentation for installation at the Facility in Kuwait.

1.2 The plant instrumentation shall fully comply with all relevant contractual
requirements specified in the Scope of Work and Technical Specification of
the Contract.

1.3 The provisions of this specification shall apply t o all major and ancillary
plant, proprietary equipment and "packaged units" unless otherwise agreed
t o in writing by the Company.

2.0 STANDARD SPECIFICATIONS

2.1 Instruments, systems and equipment shall conform in design, materials and
performance, except where otherwise specified, w i t h the current issue and
amendments of the applicable codes and standards prevailing on the
effective date of the Contract:

2.1.1 International Standards

NACE MR0175 Material Requirements - Sulphide Stress


Cracking Resistant Material for Oilfield
Equipment

2.1.2 British Standards

BS 5 3 4 5 Code of Practice for the Selection, Installation


and Maintenance of Electrical Equipment for
Use in Potentially Explosive Atmospheres

BS 5 4 9 0 Specification for Classification of Degrees of


Protection provided by Enclosures

BS 5 5 0 1 Electrical Apparatus for Potentially Explosive


Atmospheres (Also CENELEC Std En50.014-
0 2 0 and 0 2 9 )

2.1.3 Engineering Group Specifications

All equipment and accessories covered by this specification shall


comply with all relevant Engineering Group specifications o f which
the following are specifically referenced in this specification:

0 1 5-AH-1001 Basic Design Criteria

0 1 5-AH-1 0 0 2 International Codes and Standards


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Specjficatkm 01 5-JH-1903

0 1 5-JH-1901 Instrument Engineering Basic Data

01 5-JH-1902 Instrument Design

01 5-JH-1905 Emergency Shutdown Panel

0 1 5-JH-I 907 Motor-Operated Valves

0 1 5-JH-1908 Instrument Installation

0 1 5-JH-1909 Instrumentation for Package Equipment

0 1 5-KH-1902 Spare Parts and Maintenance Requirements

01 5-NH-1104 PlantiEquiprnent Noise Control

01 5-PH-1901 Electrical Design, Installation and Testing

0 1 5-XH-1005 Shop and Field Painting

0 1 5-UH-1001 Packing, Marking and Documentation

A non-inclusive listing of applicable codes and standards shall be found in


the Engineering Group Specification entitled "lnstrument Engineering Basic
Data" (Number 01 5-JH-1901).

Specifically applicable codes are found at the beginning of each section of


this specification.

Compliance w i t h this specification shall not relieve the Contractor of its


responsibility t o supply equipment suited t o meet the specified service
conditions and applicable regulations.

Where conflicts exist between this specification and other Drawings,


standards, codes and specifications, the most stringent shall be applied.

3.0 SERVICE CONDITIONS

3.1 External Conditions

3.1.1 The equipment shall be suitable for continuous operation at a


desert location under high ambient temperatures and humidity. The
atmosphere at the Facility is generally dusty and corrosive and may
contain traces o f hydrogen sulphide.

3.1.2 Plant instrumentation shall in all respects be suitable for continuous


operation in the service conditions stated in the Engineering Group
Specification entitled "Basic Design Criteria" (Number 0 1 5-AH-
1001).
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Sp&cation

3.2 S u l ~ h i d eStress Crackina Considerations

The f l o w sheet for materials selection guidance issued with the


Contract documents shall indicate where the level o f H2S present
in the process fluid can be above the partial pressure level indicated
as critical within NACE MR0175. Where such conditions are
indicated, the Contractor shall supply equipment using materials,
manufacturing methods and testing within the NACE specification.

The requirements shall apply t o all components that can come into
contact with the process fluid, including remote mounted
instruments and impulse lines.

When any part of the plant falls within the requirement for
materials t o be specified and fabricated in accordance with the
NACE code, it is deemed that the H,S content in the general
atmosphere over the whole plant precludes the use of brass and
copper for pressure parts such as lnstrument air tube and fittings.
In this case, stainless steel grade 3 1 6 tube and double-ferrule
fittings shall be used throughout.

4.0 BASIC ENGINEERING INFORMATION

Hazardous Area

General information on allocation of hazardous area divisions and


responsibilities are stated in the Engineering Group Specification entitled
"Instrument Engineering Basic Data" (Number 0 1 5-JH-1901). Contractor
shall be responsible for confirmation o f suitable selections of hazardous area
and o f protective execution methods t o ensure the safety of the complete
Facility.

E x ~ l o s i v eHazard Protection Methods

4.2.1 All field instruments having electrical or electronic connections shall


be suitable for installation in the defined hazardous area. The
general methods of protection are as follows:

I Zone 0 Areas I Zone 1 Areas Zone 2 Areas


Ex'i'a Ex'i' a or b Ex'i'a or b
Ex'd' Ex'd'
Ex'e' (Junction boxes) Ex'e' (junction
Ex's' boxes)
Ex's'

4.2.2 Alternative systems such as Ex'p' (pressurization) or Ex 's' (special


certification) shall be subject t o written Company approval.
OKOC Engineering Group
Specificathion
Specification Number

01 ~ - J H - I ~ o ~
Rev

1
Date

15-9-94
Sheet

9 01 163

The preferred priority for the protection methods are given in the
Engineering Group Specification entitled "lnstrument Design"
(Number 0 1 5-JH-1902).

All e a. u i. ~ m e n t shall be certified for the a . ~, ~ r. o ~ r i aarea


te
classification, gas group and temperature class b y a recognized
European testing authority t o BS 5 5 0 1 (CENELEC Standard
En50.014-020 and 0391, or equivalent.

Components of systems protected b y control room-mounted


intrinsically safe (IS)isolators shall be certified individually and shall
be checked by the Contractor as a system including the field
instrument, the cable and the isolator.

Field instruments protected by an IS isolator do not require a


certificate provided that a documented statement from the
Approved Manufacturer is included t o confirm that the instrument
may be used as "simple apparatus" in an IS circuit in accordance
w i t h BS 5345.

Protection from the Environment

4.3.1 The minimum acceptable standard o f protection against water or


dust ingress is t o BS 5 4 9 0 (IEC 529) degree of protection IP 65.

4.3.2 Electronic parts shall be environmentally sealed or designed t o


operate without change of atmosphere (breathing).

4.3.3 Sun shields are required for all instruments for protection from the
direct sun. Additional cooling may be required t o maintain the
instrument below 70°C ( 165°F) or the maximum instrument design
temperature, whichever is the lower. The Contractor is responsible
for providing such cooling either within the instrument design or as
a design feature included in the installation of the instrument.

Utilities

The available utilities and their process conditions are detailed in the
Engineering Group Specification entitled "Instrument Engineering Basic Data"
(Number 0 1 5-JH-1901).

Measurements and Scales

The selected units for calculations and scales are listed in the Engineering
Group Specification entitled "Instrument Engineering Basic Data" (Number
015-JH-1901).
Specification Number Rev

OKOC
Date Sheet
Engineering Group
01 5-JH-1903 1 15-9~94 10 of 163
Sprnc~fbn

4.6 Connection Sizes and Tvoe

4.6.1 Electrical

All electrical entries shall be I S 0 metric threaded. The preferred


size is M 2 0 x 1.5 mm.

4.6.2 Process

Where connection details are given, it is not acceptable for an


adaptor t o be provided t o meet this requirement, except by
individual Company agreement.

Process connections for impulse tubing shall be 112-in NPT


female.

Process pipeline connections for thermowells shall be:

1. For pipelines 1-112-in. flanged, rated at 3 0 0 lbs.(minimum).

2. For vessels 2-in.(minimum) flanged, rated 300


Ibs.(minimum).

The flange rating shall increase t o match the pipelvessel rating


as necessary. The connection size may be increased if
thermowell stresslvortex-shedding calculations dictate. The
gasket type and face finish shall match the line specification.

Atmospheric pressure and cooling water applications may use


NPT screwed thermowells.

Pneumatic (instrument air) connections shall be 114-in. NPT


unless air flow requirements dictate a larger size. lnstrument air
tubing/connections supplied as part of the instrument items
shall conform t o the "instrument air hook-up" details given in
the Engineering Group Specification entitled "lnstrument
Installation" (Number 0 1 5-JH-1908).

Level instrument chambers shall be flanged, minimum rating


3 0 0 lbs. The flange rating shall be increased t o match the
vessel rating as necessary. The gasket type and face finish
shall match the line specification. Connections may be direct
t o the vessel for each instrument, but stand pipes shall be used
t o avoid unnecessary vessel penetrations when their use does
not impede o n access, walkway clearance etc. Ranges of
instruments shall not be compromised t o suit installation on
stand pipes. Shutdown instruments shall have dedicated vessel
nozzles.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 1 of 163
Specificahn

e. Control valves shall be flanged and faced according t o the


piping line classification, w i t h a minimum rating of 300 lbs. For
fully welded lines, individual proposals shall be submitted t o
the Company for approval.

f. Where possible, analysis instruments shall use connections as


for other instruments. Exceptions shall be submitted t o the
Company for approval.

g. Where multiple shutdown instruments are installed for 2 out of


3 voting, each shall have a dedicated tapping into the process
piping or vessel.

4.7 Instrument Identification

All instrument items shall be permanently and clearly marked for the
following categories:

4.7.1 Nameplate

Each item shall be identified w i t h a permanently fastened stainless


steel or rust-resistant material nameplate comprising:

a. Manufacturers name.

b. Model number.

c. Serial number

d. Temperature and Pressure Rating Of Wetted Parts.

e. * Voltage and Switch Rating

f. Set Point, RangelCalibration and Other Relevant Data.

g. Instrument Tag No. (Separate Tag Plate Preferred)

* = where applicable)

4.7.2 Certification Plate (For Certified Items)

Each certified instrument shall have a certification plate giving as


a minimum:

a. Type of approval and mark of certifying body.

b. Certifying authority name

c. Licenselcertificate number and date.


Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9~94 12 of 163
Spec57icatbn

!1 4.7.3
d. Area classification, gas group, temperature rating

Tag Plate
I
Each instrument having a tag number on the P&ID shall be provided
w i t h a stainless steel tag plate with the full alphanumeric tag
number hard metal stamped or deep engraved. The minimum
dimensions shall be 4 0 m m x 25 m m x 1.5 m m ( 1 % in. x 1 in. x
1/16 in.) with a 2-mm (1110-in.) hole drilled in one corner. The tag
shall be fastened t o the instrument with stainless steel wire of
minimum I.O-mm (1120-in.) diameter.

Note: A tag plate integral with the Approved Manufacturer's


nameplate is acceptable provided the tagging is large, clear
and easily read in the final installed position.

4.7.4 Equipment and Site Number Tag Plate

Each instrument shall be allocated b y the Company an Equipment


Identification Number (EIN) and a Site Number (SN). The Contractor
shall manufacture and fit tag plates bearing the allocated numbers
t o each instrument. The minimum dimensions shall be as those
above.

4.8 Limitations o n Selection and A ~ o r o v e dManufacturers List

4.8.1 All instruments and instrument items shall be of heavy duty


industrial type and be suitable for use in the stated environment.

4.8.2 Tried and tested equipment shall be used. Equipment approaching


obsolescence shall be avoided.

4.8.3 Aluminium and aluminium alloys are not permitted except w i t h


Company approval. Where use o f such alloys cannot be avoided,
they shall be of a type suitable for use w i t h electrical instruments
situated in a hazardous area, and be fully protected against the
environment.

4.8.4 Manufacturers shall be selected from the Approved Manufacturer's


list. Where a suitable manufacturer is not included o n the list, full
details of the proposed manufacturer and the instrument or system
together w i t h reasons for its inclusion shall be submitted t o the
Company for approval.

4.9 Line Break Detection

Line break resistors are required for all contact-type field switches. These
shall be fitted in the instrument head where this does not infringe on the
certification. Where this is not possible, they may be installed at the nearest
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 13 of 1 6 3
Specjficatkw

available junction point t o the instrument. The type and value of the resistor
shall be agreed t o w i t h the Distributed Control System (DCS) supplier.

4.10 Use o f Barrier Glands

4.10.1 Barrier glands shall be avoided whenever possible.

4.10.2 Barrier glands with epoxy putty filling shall be used where a failure
within an instrument could allow a flammable process medium t o
be at pressure within the terminal enclosure.

4.10.3 The Contractor shall as a preferred option try t o ensure that the
instrument design is such that failure of the element or capsule
shall not cause the above condition, thus avoiding the need for
Barrier Glands.

4.1 1 Shoo lnsoection and Testing

The Contractor shall be responsible for all inspection and testing o f materials
and equipment prior t o delivery. No equipment or materials shall be delivered
until all applicable tests have been completed and all defects rectified and
re-tested successfully. Documentary evidenceshall be available for Company
review if requested.

4.1 1.1 Quality Assurance and Quality Control

a. All items are t o be designed, manufactured, inspected and


tested under the control o f a documented QA/QC system.
General and specific requirements are provided in the Contract.

b. Special reference t o inspectionitest actions within the detailed


sections of this specification are additional t o and shall not
replace or reduce the OAiQC requirements provided for in the
Contract.

c. Approved Manufacturer specific data and model numbers


shown o n data sheets approved b y the Company in no way
relieve the Contractor o f its responsibility t o provide equipment
t o satisfy the service conditions stated on the specifications
and data sheets. It is the Contractor's responsibility t o notify
the Company of any conflict w i t h model numbers, materials or
designs specified.

d. The Company shall be permitted t o witness Approved


Manufacturer's QAiQC systems operating on all instruments
during design, fabrication, assembly and testing.
Specification Number Rev Date Sheet
wing Group
01 5-JH-1903 1 15-9-94 14 of 163
;pea;fication

e. The Contractor shall submit for Company approval minimum


inspection requirements summaries for each item prior to
purchase of the equipment.

4.1 1.2 Shop Testing

Company reserves the right t o witness testing or t o request


additional testing according t o its requirements. Such witnessing
shall include all control valves, relief valves, composite systems,
control systems etc. The detailed requirement shall be noted by the
Company o n the Contractor's submitted Quality (Test and
Inspection) Plan.

4.12 Paintinq and Protective Finishinq

All items shall be fully protected against the environmental


conditions, the effects of the process fluids, normal wear and the
handling normally expected during installation, erection and
commissioning.

Where an item cannot be rendered suitable for the conditions by


selection of material, a paint finish shall be applied in accordance
w i t h the Engineering Group Specification entitled "Shop and Field
Painting" (Number 01 5-XH-1005). Where the Engineering Group
Specification calls for Approved Manufacturers standard, an epoxy
paint finish t o a recognized offshore standard shall be the minimum
method o f protection used.

Cadmium plating is not acceptable as a final finish.

All Company-approved aluminium items shall be fully coated on all


exposed surfaces.

Mounting boards, brackets and small moving parts not suitable for
painting shall be manufactured from stainless steel.

Fasteners shall be stainless steel.

4.13 Packinq, Markinq and Documentation

4.13.1 General

For all relevant requirements, refer t o the Engineering Group


Specification entitled "Packing, Marking and Documentation"
(Number 0 1 5-UH-1001).
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 15 of 163
spea'fication

4.13.2 Packing for Shipment

Immediate Packaging

All items shall be packed in the Approved Manufacturer's


standard packaging in such a w a y that unpacking will not be
necessary until each item is required for erection. All necessary
protection and desiccants shall be included. Equipment shall be
capable of withstanding transport and storage without
affecting subsequent satisfactory operation.

Delivery Packaging

Delivery packaging is covered by the Engineering Group


Specification entitled "Packing, Marking and Documentation"
(Number 01 5-UH-1001).

4.14 S ~ a r eParts and Maintenance Reauirements

For all relevant requirements, refer t o the Engineering Group Specification


entitled "Spare Parts and Maintenance Requirements" (Number 015-KH-
1902).

5.0 CONTROL VALVES

5.1 Applicable Standards

ANSI 816.5 Steel Pipe Flanges and Flanged Fittings

ANSl B l 6 . 1 0 Face-to-Face and End-to-End Dimensions for Valves

ANSl B16.34 Valves - Flanged, Threaded and Weld Ended

ANSl 81 6.37 Hydrostatic Testing of Control Valves

ANSl B 16.104 Control Valve Seat Leakage

API RP 550 Manual on Installation of Refinery Instruments and Control


Part 1 Systems, Process Instrumentation and Control

BS 1655 Specification for Flanged Automatic Control Valves for the


Process Industry

BS 5793 Industrial Process Control Valves


(IEC 534)
OKOC Engineering Group
Specjficahkm
Specification Number

01 5-JH-1903
Rev

1
Date

15-9-94
Sheet

1 6 of 163

5.2 S c o ~ eof Control Valve Selection

A "control valve" shall mean any valve which has a process control function
o n the plant, normally denoted by having a tag number allocated on the
P&ID. The following additional items also shall be considered in this section:

Actuated shutoff or emergency shutdown (ESD) valves shall be


treated as control valves for the purpose of this specification,
except where a topic discussed in the specification specifically
states "control valve," and the context identifies that the topic is
relevant t o modulating control valves only.

Bypass valves shall be considered in the control valve analysis


where the maximum or minimum f l o w allowable through the
bypass could be critical for plant safety, or where noise or an
unusual process consideration may apply.

Electric motor-operated valves (MOVs) for modulating duty are


covered by this section of this specification.

Electric MOVs for onloff and ESD service are covered by the
Engineering Group Specification entitled "Motor-Operated Valves"
(Number 0 1 5-JH-1907).

5.3 Valve T v ~ e s

5.3.1 Standard Selection

a. Control valves for normal service shall generally be:

Plug-type globe valves.

Top and bottom guided (1-in. valves may be top guided


only).

Single seated or balanced trim w i t h flow-under plug.

Flanged t o ANSI B16.5 w i t h face-to-face dimensions in


accordance w i t h BS 1655lANSI B16.10.

Pneumatically actuated, spring return diaphragm type.

Fitted with pneumatic positioner.

Positioners for valves w i t h actuators of 0.2 t o 1.0 barg ( 3


t o 1 5 psig) spring range shall be fitted w i t h positioner
bypasses, except valves in split range service.
Specification Number Rev Date Sheet

@ KOC Engineering Group


Spe&icatiOn 01 5-JH-1903 1 15-9-94 17 of 1 6 3

b. Other trim and guidance types may be used if it can be shown


that there are advantages in the particular service, e.g., cage
guided, l o w dB trim, characterized ball etc.

c. Skirt-guided trim shall be avoided except for sizes 1-112 in.


and less in l o w DP service.

5.3.2 Self-Acting Regulators

Valves shall normally be controlled from an external signal from the


DCS or ESD system or from a local controller. Self-acting
regulators may be accepted for some services if i t can be shown
that the failure characteristic will not lead t o dangerous process
situations occurring. Where self-acting regulators are used,
consideration shall be given t o the use of line-tapped signals in lieu
of integral bleeds.

5.3.3 Valve Sizes

a. The minimum valve body size is 1 in., unless approved


otherwise, in writing, b y the Company. If smaller sizes are
approved, top guided only types may be used.

b. Valves shall be selected from standard pipe line sizes:

1 in., 1-112 in., 2 in., 3 in., 4 in., 6 in., 8 in., 1 0 in., 12 in., 1 4
in., 1 6 in. etc.

c. Unusual valve sizes, e.g., 1-114 in., 2-112 in., 5 in. etc. shall
not be used.

d. Valves in flashing service may, subject t o Company approval,


have larger outlet size than inlet size.

5.3.4 Body Pressure Rating

The minimum pressure rating for control valves shall be 3 0 0 lbs for
sizes up t o and including 8-in. nominal bore (NB). Larger valves
shall be line rated. Subject t o Company approval, shutoff valves of
quarter-turn type may be accepted as split-body type and may be
at line class rating (if the line is rated less than 3 0 0 lbs) in cases
where the piping system specifies identical manual valves and
advantages for spares stocking can be shown.

5.3.5 Screwed Valves

Screwed-end valves for screwed piping classifications or welded-in


valves for extreme service conditions may be allowed subject t o
specific approval by the Company.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 8 of 163
Specificab;on

Tight Shutoff

a. Valves shall not be used for dual purposes (control and shut-
down) when leakage cannot be tolerated. If necessary, an
additional tight shutoff (TSO) valve shall be added for process
interrupt service in cases where leakage would lead t o a
shutdown. Valves used for control shall not be specified as
TSO.

b. Quarter-turn ball valves may be used for onioff service on


clean process media. Valves for shutoff service on dirty media
shall be specially selected for self cleaning properties, e.g.,
cutting or shearing action o n closing. Techniques such as seat
flushing or purging shall be adopted as necessary t o ensure a
correct seating of the trim.

Butterfly Valves

Butterfly valves may be used o n high-capacity service where low-


pressure losses are essential and the operating differential pressure
is small. The minimum allowed body size is 2 in. wafer-type valves
are acceptable provided alignment kits are part of the scope of
supply.

Ball Valves for Control

Characterized ball valves of size 1-112 in. and upwards may be


used where the available pressure drop precludes the use of a
globe valve. If the valve design is o f flangeless body type, the
valve shall be purchased with flange studs t o line class and an
alignment kit.

Rotary Plug Valves

Low-void, self-flushing valves o f rotary-plug type may be used for


particulate service where process conditions allow.

Angle Valves

Angle valves w i t h top-guided plug may be used w i t h Company


approval.

Three-Way Valves

Three-way valves may be used for mixing or f l o w splitting service,


and may be top guided only.
Specification Number Rev Date Sheet
Engineering Group
1 15-9-94 19 of 163
Spc%?cd&n 01 5-JH-1903

5.3.12 Soft Seats

Globe valves for tight shutoff service in clean process fluids may
be fitted w i t h soft seats for services up t o the soft insert allowable
operating temperature. Lapped seats, Stellited as necessary, shall
be used for higher process temperatures.

5.3.13 Failure Action

The valve failure position indicated on the P&ID shall be achieved


in the valvelactuator design. Fail locked systems shall have a
defined drift position. If a drift position is not acceptable, double-
acting actuators with appropriate reservoir and trip systems shall
be used, as for ESD valves, refer t o section 5.7 of this
specification.

5.3.1 4 Special Applications

Solutions for special applications or conditions not covered by this


specification shall be submitted t o the Company for approval.

5.4 Valve Sizincl Reauirements

Control of Design Data

Valves shall be sized o n the basis of defined issues o f the process


data sheets, P&ID, equipment and piping data. A document control
system shall be maintained t o ensure that the valves are built t o a
calculation based o n the final issue of data. Data sheets shall state
the process data revision number, and calculations the data sheet
revision number.

Limiting Case

The valve purchase data sheet shall specify the applicable


upstream and downstream pressures (or pressure difference) for all
cases given. Where the process conditions are such that varying
combinations of different process fluids can be present, andlor the
maximum or minimum flow can occur at varying pressure,
sufficient calculations shall be performed t o ensure that the limiting
case is selected as the design case.

Calculation Required

Valve sizing calculations shall be performed in accordance w i t h BS


5 7 9 3 (IEC 5 3 4 ) . Valve size calculations shall be produced at least
for the minimum, design and over-design process conditions.
Additional calculations, as necessary, shall be performed t o
establish the correct trim form. Valve calculations shall also be
Specification Number Rev Sheet

OKOC
Date
Engineering Group
01 5-JH~1903 1 15-9-94 20 of 163
SpedficdMn

performed for onioff valves (except full-bore ball valves) t o confirm


adverse process conditions are not occurring. The differential
pressure for a globe valve shall n o t be less than 0.7 bar (10 psi) at
design flow. For DP less than 0 . 7 bar ( 1 0 psi), alternative valve
types shall be selected.

Overdesign Margin

The valve trim shall be calculated so that the design f l o w is


between 7 0 and 8 0 % of the fully open valve capacity, except that
where an over-design figure is also t o be allowed for within the
valve design, this shall occur at not greater than 90% of the valve
capacity.

Turndown

The minimum flow shall be attainable within the turndown ratio of


the selected valve/controller combination. The maximum turndown
for standard valves shall not exceed 3 0 t o 1. For valves with CV
less than 1, this shall reduce t o 1 0 t o 1. Special valves with high
turndown characteristics may be offered t o the Company for
approval t o suit special process conditions.

Valve Stroke

The stroke of the valve shall be within the band 1 0 % t o 9 0 % for


all the above criteria.

Effect o n Relief System

The calculation shall show the f l o w at design and over-design


pressure when the valve is fully open. The resulting over design on
f l o w shall be confirmed against operating conditions and relief
arrangements t o confirm plant safety. Where the flow through the
valve is critical t o the sizing o f a relief or other safety system, the
bypass valve (if fitted) shall also be fully specified w i t h an identical
valve characteristic (CV) or maximum f l o w limit t o prevent
maloperation under bypass control.

Trim Capacity

The selected valve shall be capable of accepting t w o trim changes


up and d o w n from the finally calculated size t o allow for process
design changes. This may be varied, subject t o Company
agreement, when:

a. The calculated valve body is less than 1 in


Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 2 1 o i 163
specification

b. The calculated valve body is t w o or more sizes below line size.


A body one size smaller than the line shall be used with
reduced trim.

Leakage Rate

The shutoff flow (leakage rate) shall be calculated at the shutoff


design pressure, and the figure stated o n the calculation sheet and
checked against operating conditions t o confirm plant safety, and
t o confirm trip conditions will n o t arise during process interrupt.
Additional TSO valves shall be added as necessary.

Minimum Stop

Where a minimum stop is specified (based o n flow), the appropriate


valve opening shall be calculated.

Back Flow

Where back f l o w protection is required, the valve shall be checked


t o confirm that the correct type of valve and adequate actuator
force has been selected.

Three-Way Valves

For essential safety reasons, three-way valves shall be clearly


identified as t o service, i.e., flow-splitting or flow-mixing or flow-
diversion, and all operating combinations identified before making
the calculation.

Two-Phase Flow

Suitable calculation methods shall be used for two-phase and


flashing flow t o ensure the gas phase CV is properly considered.

5.5 Trim Selection

5.5.1 Characterized Positioners

Wherever possible, the trim characteristic shall be specified so as


t o obtain a linear installed valve characteristic over the operating
range. Characterized positioners are only accepted where the
correct inherent trim types are not possible.

5.5.2 Selection of Characteristic

The inherent trim characteristic (or characterization in the case of


non-globe types) shall be carefully selected for each application t o
provide the best control compromise. The following table (table 1)
Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 22 of 163
Spedfication

can be used t o assist the selection. The Contractor is responsible


for ensuring that the final trim selection provides control within
specification.

Small Pressure Drops

Systems shall be individually assessed when the pressure drop


across the control valve is less than 25% of the total dynamic
pressure loss at design f l o w rate.

Standard cases

I f detailed process analysis is not available, the trim shall be


selected as linear where 50% or more of the dynamic system
pressure drop a t design f l o w is across t h e valve, and equal percent
for other applications.

TABLE 1: SELECTION ( VALVE CHARACTERIS ICS


Equal Percentage Linear Quick Opening 1
Level 1 If full load DP is less than If pressure drop is When DP
20% o f no-load DP. constant. increases w i t h
load at a rate

Flow I f no guide lines are


available f l o w range
changes less than 10:l
but system rangeability
above 20:1, i.e., desired
For f l o w range greater
than 10:1, except
w h e n measuring
element has no
square root extractor
I
greater than 2: 1

f l o w rate relatively and control valve is


constant but valve DP diverting f l o w from
varies widely due t o load the measuring
changes. When valve is elements.
in bypass and controller
does not have square
root extractor.
Pressure For liquid service. For Compressible fluids if
compressible fluids if downstream system
downstream line is capacity is large.
shorter than 30 m ( 100
ft.) if DP varies more
than 5 : l . If process
demand varies more than
General If operating conditions Where control can
are unpredictable. be obtained by
on-off action.
When maximum
valve capacity
must be obtained
rapidly. When
liquid temp. may
be controlled by
mixing liquid
streams.

5.6 Valve Desian Reauirements

Valve Positioning

All control valves shall be supplied w i t h a positioner. Some process


shutdown valves may require a positioner in unusual cases if the
service demands precisely controlled rates of opening or closing,
these shall be indicated o n the P&ID if required. For all services
where 0 . 2 t o 1 . 0 barg ( 3 t o 1 5 psig) actuators are provided, or
where any vibration is present, pneumatic positioners w i t h a
separate signal convertor shall be used. Other services may use
direct electro-pneumatic (EIP) positioners subject t o Company
approval.

Failure Action

The action of valves o n failure o f the operating medium shall be


determined b y process requirements w i t h regard t o safe operation
and emergency shutdown and shall be noted on the P&ID. The
failure action shall be the same for signal loss, air power loss and
actuator failure. Field accessories shall be provided as necessary t o
achieve the actions.

High- and Low-Temperature Service

Where the temperature of the controlled fluid exceeds 230" C


(450" F), an extension neck or bonnet shall be used. The Approved
valve Manufacturer's recommendations shall be followed for valves
in cryogenic service.

Bellows Seals

For specified duties as agreed t o by the Company, e.g., toxic fluids


or penetrating liquids, the valve stems shall be double bellows
sealed w i t h the outer bellows gland sealed t o the stem. An
appropriate system shall be fitted t o monitor t h e enclosed space t o
detect inner bellows leakage. Where indicated o n the P&ID, purging
of the interspace and a purge f l o w alarm shall be used.

Replacement of Trim

The valve trim (plug and seat, ball and seat etc.) shall be
removable. Access t o the trim for globe-type valves shall be from
the top of the valve. If a bottom flange is fitted t o the body for
access t o the seat, this shall not be drilled and tapped for drainage
or pulling.

Opening and Closing Times and Valve Response

a. All data sheets shall specify the maximum allowed opening and
closing times based o n the process conditions and equipment
being operated. Valves in compressor anti-surge control shall
have a stroke time not exceeding 5 seconds.

b. The response time shall also be stated, based on the time for
the valve t o complete its movement when the signal t o the
positioner undergoes a 10% step change.

Minimum and Maximum Stops

Minimum stops shall not be used except w i t h Company approval.


Minimum f l o w shall be achieved b y providing piping and valve
bypasses w i t h an orifice restriction. Maximum stops shall only be
fitted if valve over-design cannot be tolerated safely. In all cases
the stops shall be based on the calculated stem position for given
f l o w and pressure conditions. The stops shall as a minimum be
double nut locked and shall be permanently secured, preferably by
welding, after proving during commissioning. The stop mechanism
shall be picked out in a contrasting colour t o the valve and
actuator.

Seat Leakage

Valve data sheets shall state the seat leakage t o be tolerated.


Generally, valves in depressurising, shutoff and emergency shut-
d o w n shall be specified class V and for process shutoff shall be
specified t o class IV of ANSI 81 6.104. Bubble-tight valves shall be
specified for shutdown of flammable fluids for supply t o end users
such as the fuel supply t o a fired heater, and for all total ESD
applications.

Gland Packing

a. For normal service on clean fluids, a bolted bonnet w i t h gasket


and retaining recess shall be fitted, packed with interlocking
self-lubricating packing of the Teflon or Grafoil type. Lantern
Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 25 of 163
Spea7ication

ring and spring followers shall be used For highertemperatures,


2 0 5 t o 540°C ( 4 0 0 t o 100O0F), solid graphite packing shall be
provided, with braided packing where solids may be deposited
o n the stem. Finned bonnets, cooling rings and thermal
isolation techniaues shall be used.

b. For higher temperatures, 205 t o 540°C ( 4 0 0 t o 100O0F), solid


graphite packing shall be provided, w i t h braided packing where
solids may be deposited o n the stem. Finned bonnets, cooling
rings and thermal isolation techniques shall be used as
necessary.

c. Packing for valves above 540°C (1000°F) shall be the subject


of individual agreement w i t h the Company.

d. Low-temperature service, minus 5 5 t o 0°C (minus 67 t o 32°F)


shall use solid teflon V-rings w i t h an extended bonnet and
thermal isolation suitable for the service.

e. Packing shall be accessed through adequately sized bolted


stuffing boxes.

f. The Approved Manufacturer's installations instructions, e.g.,


bonnet over or under body, side-mounting restrictions etc. shall
be strictly followed t o prevent damage occurring t o the
packing.

g. Other packing materials and methods may be offered for


Company approval by submitting full details, accompanied by
the Approved Manufacturer's statement of the advantages
offered.

I 5.6.1 0 Gland Lubrication

All glands shall be drilled and tapped for lubrication units even
where packing is self-lubricated. Lubricators shall only be fitted as
necessary. Un-used tappings shall be plugged. The plug material
shall be compatible w i t h the bonnet material. Lubricators for high-
pressure valves (greater than 1 5 barg, i.e., 2 2 0 psig ) shall have an
isolating valve fitted between the lubricator and the stuffing box.

I 5.6.1 1 Direction of Flow

The direction o f flow through the valve shall be clearly and indelibly
marked on the body, preferably b y a cast on arrow or stamped
plate.

__1
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 2 6 of 163
Sp&icat;on

5.7 Actuator Selection and Sizing

5.7.1 Selection

The actuator shall be purchased together w i t h the valve as an


integrated package. Where the actuator manufacturer is not on
the Approved Manufacturer's list, the selection is subject t o
Company approval.

Actuators shall normally be pneumatic-diaphragm type for


globe valves, plug valves and butterfly valves and pneumatic
spring return piston actuators o f scotch yoke or geared type for
onioff quarter-turn valves.

Piston actuators of air or hydraulic type may be used with


Company approval when it can be shown that long strokes,
high forces, speeds etc. are essential.

Motor-operated modulating valves, piston-operated pneumatic


actuators, airloil systems or other special actuation methods
may be used in special circumstances subject t o Company
approval.

For control valves the normal pneumatic actuator spring range


shall be 0.2 t o 1 . 0 barg ( 3 t o 1 5 psig), t o enable positioner
bypasses t o be fitted. If i t can be shown that a bypass is not
necessary or undesirable, or if circumstances demand a higher
force or a higher speed than is available from 1.0 barg (14.5
psig), an alternative spring rate may be used, subject t o
approval by the Company. Under no circumstances shall the
spring rate exceed 4 . 0 barg ( 6 0 psig). The actuator shall be
able t o withstand a mechanical design air pressure of 11.3
barg ( 16 4 psig).

Pneumatic piston actuators are t o be sized t o supply the full


specified force at an air pressure no greater than 4 . 0 barg ( 6 0
psig).

5.7.2 Actuator Sizing Criteria, Control Valves

a. The actuator shall be able t o overcome a minimum of 1 2 5 % of


the worst predictable process and mechanical forces within the
valve, inclusive of fluid shutoff pressures, coking or solids,
gland compression, stiction and friction and all other expected
or possible forces. As a minimum, the process force shall be
taken as the upstream process design pressure (or the piping
mechanical design pressure if the actuator size resulting from
this is economic) and an atmospheric downstream pressure.
Where this calculation results in an uneconomic actuator, or
Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 27 of 163'
SpecMcatkm

one which is too large t o provide a n adequate speed of


response, the overall solution shall be subject t o Company
approval.

b. If back-flow protection is parr of the valve service, the actuator


shall be capable of the necessary forces t o achieve the
operation.

c. Sizing criteria for actuators for three-way valves shall be


chosen t o enable the valve t o operate against the worst
maximum design differential pressure across a single port. All
the operating scenario shall be reviewed t o confirm that the
worst case has been foreseen.

d. The selected actuator sizing criteria shall be clearly stated on


the data sheet. For pneumatic actuators, full details of the
minimum, maximum and spring design air pressures shall be
noted.

e. The actuator shall be sufficiently powerful that bench setting


for achievement o f specified leakage rate is not required.

5.7.3 Actuator Sizing Criteria, Emergency Shutdown Valves

a. Calculation Requirements

1. This section applies t o all valves controlled directly from


the ESD logic, including vent valves and de-pressurizing
valves.

2. As shutdown valves spend long periods without cycling,


particular care shall be taken t o ensure that the actuators
deliver sufficient force t o fully openiclose the valves at the
extremities of operation when called upon t o do so. Due
regard shall be paid t o the possibility of sticking and
gummy deposits o n valves which are stationary for long
periods.

3. The torque 1 linear force delivered b y the actuator at the


minimum air design pressure shall be at least double the
calculated force for the most arduous of the following
conditions or combination of conditions, and any other
restrictions applicable in the particular application:

a. Breakaway force.

b. Running force.

c. Re-seat force.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 28 of 163
Spedficafibn

d. Gland or packing forces.

e. Coking, dirt, rust or gumming clearance forces,


internal and external.

f. Safety factors o n all the figures.

g. Positive tolerances on all measured figures.

4. The design check shall ensure that the other mechanical


components of the valve are specified with sufficient
strength t o utilize the forces of the oversized actuator.

b. Actuator Selection

1. Actuators shall normally be diaphragm type when globe


valves have been specified for shutdown duty, and spring
return piston actuators operating through a scotch yoke or
gearbox for quarter-turn type. Where a pneumatically
powered shutdown valve is in a service where the
standard spring return system is n o t suitable due t o return
force or closing speed restriction, a double-acting or
spring-assisted system shall be used.

2. The requirement and method of operating double-acting


actuators shall be indicated on the P&ID, w i t h the speed
Parameters stated.

c. Actuating Method

1. Generally, the actuation method for ESD, vent and de-


pressurizing valves shall be selected from t w o types:

a. Direct Pneumatic Type

The actuator shall operate directly on air supplied from


a dedicated reservoir.

b. Indirect Hydraulic Type

These valves shall be operated by an air-driven


hydraulic package. The air shall be supplied from a
dedicated reservoir.

2. For both types, the air reservoir shall be supplied with


sufficient reserve capacity t o enable three complete valve
operation cycles. The reservoir shall be sized for 3-full
strokes of the valve with a 50% safety factor. The
reservoir may be dedicated t o a single valve, or t o a group
o f valves when the service of these valves is strictly
related and controlled by the same ESD logic sequence,
and the valves are positioned within a 5 - m pipe run from
the reservoir.

3. The reservoir shall be charged at the normal Facility


instrument air pressure. The supply t o the reservoir shall
incorporate filters and check valves t o ensure that the air
supply for the ESD valve is retained during loss o f general
air pressure. The design pressure for reservoir sizing
purposes shall be the same as the actuator sizing design
pressure, which shall not exceed 4.0 barg (60 psig).

d. Trip Action

The trip action shall be initiated in all cases by the de-


energisation of a solenoid valve(s) powered from the
Facility ESD system, for all situations including reset, ESD
trip or controlled vent action and any air failure actuation
resulting from the reservoir low-low pressure switch signal.

For the l o w air pressure alarm and safety actions,


electronic pressure switches shall be fitted t o the reservoir
t o detect when the air reservoir pressure is at 15% ( l o w
alarm) and at 5 % (low-low trip) above the reservoir sizing
pressure. The l o w pressure switch shall bring up DCS
alarm t o warn of a possible problem o n the air supply, the
low-low pressure switch signal passes t o the ESD system,
which will institute the necessary action o n the logic
svstem as follows:

a. Single-Acting (Spring Return) Actuators

Unless otherwise specified, the low-low pressure switch


input will prevent further use of air toward the "plant
unsafe" (run) condition but allow manual selection of a trip
t o the "plant safe" condition. The valve will thus stay in
the "Run" condition until the air pressure drops below the
spring-return force, the spring will then drive the valve
toward the "safe" position.

b. Double-Acting Actuators

Unless otherwise specified, the low-low signal shall cause


a trip of the valve t o the safe position while there is still
sufficient air t o ensure that the valve can be moved t o the
safe position.
A t Company option, alternative strategies may be adopted.
The Contractor shall submit full details of the philosophy,
the hook-up and proposed field and control room-mounted
instrument and operator interface for Company approval.

The ESD logic shall not be self-resetting. The solenoid


valve shall be of mechanically self-resetting type, but shall
require electrical reset b y operation of a local pushbutton
openlclose station interfacing w i t h the ESD system,
operable when the logic has been enabled b y the control
room operator. Details are provided in the Engineering
Group Specification entitled "Emergency Shutdown Panel"
(Number 0 1 5-JH-1095).

Where an ESD valve is also used t o perform a process


interrupt function, an additional solenoid valve shall be
supplied. This shall be operated from the control logic and
shall be so positioned and piped that the ESD function
shall overrule the control function in the case of an ESD
trip.

5.7.4 Actuators for Motor-Operated Valves (MOVs)

MOV actuators fall into t w o service categories:

a. Direct motorlgearbox drives for direct application t o the valve


stem in onloff application (no modulation) are covered by the
Engineering Group Specification entitled "Motor-Operated
Valves" (Number 0 1 5-JH-1907).

b. Electric MOVs for modulating service: actuators in this


category shall only be used when stipulated or authorized by
the Company. The actuator, electrical control card and power
control gear shall all be purchased as a fully integrated
matched set. The actuators can be used in closed-loop service,
or open loop w i t h valve position feed back b y precision
potentiometer. The actuator shall be fitted w i t h torque and end
of travel switches that shall override the control signals.

The actuators must be certified for use within the hazardous


area classification o f the Facilitv.

5.8 Actuator Construction

5.8.1 Diaphragm Actuators

a. The pneumatic diaphragm actuator shall be of totally enclosed


spring-return type.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 31 of 1 6 3
SpeaZication

The actuator shall be direct or reverse acting according t o the


required process failure action. Within this constraint, direct
acting (spring up) actuators are preferred in the sandy
environment due t o the avoidance o f a shaft seal and wiper.

The spring shall be of linear characteristic over the stem travel


range, and be corrosion resistant.

A spring screw and locknut shall be readily placed for


adjustment.

The yoke shall be of cast steel or ductile iron, adequately


painted or plated against the environment in accordance with
the Engineering Group Specification entitled "Shop and Field
Painting" (Number 0 1 5-XH-1005). A valve position indicator
shall be fitted, synchronized and scaled t o match the actual
valve stroke. The connection t o the valve stem shall be a
threaded split clamp with clamping bolt.

The diaphragm case shall be o f bolted pressed steel


construction.

The diaphragm shall be of nylon reinforced neoprene or Buna


N. the maximum allowable deviation from the rated effective
area shall not exceed plus 1 5 % and minus 0 % through the
entire travel.

5.8.2 Quarter-Turn, Piston- and Cylinder-Type Pneumatic Actuators

a. Only heavy industrial types shall be accepted. The actuator


shall preferably be of steel w i t h a chrome-plated bore, or
stainless steel. High-grade aluminium with a suitable coating
system may be used, subject t o Company approval.

b. The flow sheet for materials selection guidance issued with the
Contract documents shall indicate where the level of H,S
present in the process fluid can be above the partial pressure
level indicated as critical within the NACE MR0175. When any
part of the plant falls within the requirement for materials and
fabrication t o be in accordance w i t h the NACE code, it is
deemed that the H2S content of the general atmosphere over
the whole Facility requires the use of solid stainless steel
actuators, also in these circumstances, chrome plating is not
permitted.

c. The mechanism, shafts etc. shall be adequately protected


against dust ingress. If bellows are used, the design shall
protect against dust being drawn in due t o air change during
operation. Exposed shafts shall be stainless steel. Tie rods and
other exposed fastenings shall be stainless steel.
Specification Number Rev Date Sheet
Engineering Group
015-JH-1903 1 15-9-94 32 of 1 6 3
SpeiHcatEon
1
d. Ports shall be a minimum size 114-in. NPT. Smaller ports with
adapters are not acceptable. Ports o f at least 114 in. of other
thread forms shall be accepted provided they are fitted with
permanent NPT thread form adapters. Exhaust ports shall be
fitted with a silencerhand screen.

e. A n external position indicator and inductive type certified limit


switches (in a protective box) shall be fitted.

5.8.3 Hydraulic and Special-Purpose Actuators

A detailed specification and analysis o f all proposed actuators shall


be presented t o the Company for approval.

5.9 Noise. Flashinq and Cavitation

5.9.1 Noise

a. The Company shall be informed of all cases where the


predicted noise level o f a control valve or its bypass valve
approaches t o within 3 Db o f the maximum permitted noise
level of 8 5 dB A, or any lower figure stated in the Engineering
Group Specification entitled "PlantiEquipment Noise Control"
(Number 015-NH-1104). In all cases where it is necessary t o
use special control valves, silencers or other devices, they shall
be subject t o the prior approval of the Company.

b. Where the outlet pressure is less than half the inlet pressure in
the design case, valve noise will probably occur at normal duty.
noise-reducing trim shall be specified as standard for these
valves.

c. Control valve noise shall wherever possible be stopped at the


source. The preferred design priorities are:

1. Re-appraisal of the process design or arrangement t o avoid


the root noise cause.

2. Selection of a suitable valve and t r i m type

3. Lo-dB plates downstream of the valve.

4. Insulation of the valve and downstream piping.

5. Geographical relocation of the equipment items and piping


t o enable external screening t o be considered, or valves t o
be away from personnel areas. This approach can only be
used when the valve noise contribution does not cause the
global plant noise t o exceed the Company stated limits.
5.9.2 Potential Flashing andlor Potential Cavitating Service

a. Valves shall be selected that are specially designed for these


services. Valves of l o w recovery type, using frictional paths,
multiple port cages, vortex f l o w or other methods of velocity
and anti-cavitation control shall be specified.

b. Potential blockage of the trim shall be carefully considered


when selecting l o w recovery valves. Design appraisal shall be
conducted t o confirm that any particulates or sludging present
in the process will not block the passages. Normally, drillings
less than 3-mm (118-in.) diameter shall be avoided.

5.10 Construction Requirements

5.10.1 Pressure E n v e l o ~ e

The pressure envelope is defined as all parts of the valve


which, if a failure occurred, would allow process fluids to be
released t o the atmosphere. This includes the body, bonnet,
flanges, plugs and seal plates and any other part retaining the
pressure.

The pressure-part materials shall be equal t o the line


specification for piping class valves in the same service. The
Approved valve Manufacturer shall, however, confirm that the
material is fit for the service and the mechanical design criteria
stated o n the data sheet.

In the interests of standardization, a higher grade of material


may be offered t o cover a number of services; however, the
metallurgy shall be individually verified b y the Contractor as
suitable for the applicable service conditions.

Forged materials shall be used throughout except with


Company approval for alternatives.

5.10.2 Valve Trim

a. The valve trim is that part of the valve which controls the flow
o f fluids. This includes the valve seat and plug, ball etc., the
stem, the cage and any other renewable parts separate from
the body.

b. The materials for the valve internals shall be selected for the
individual service, w i t h a minimum requirement of 316
stainless steel. For special services, the Approved
Manufacturer's recommendation shall be offered for approval
b y the Company.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15~9-94 34 163
Sp&icaMn of

c. The addition of stellite coatings (or solid stellite parts for small
valves and special services) and special hardening treatments
shall be performed as necessary.

d. Chrome plating of trim parts is not permitted.

e. Table 2 indicates the minimum selection requirements for


various services:

TABLE 2: TRIM MATERIALS AND APPLICATION

service. valve Valve size P Limit T e m p Limit Tlirn M n t e l i a i r


P
TI= i n BarlPSIl -c PFI

General Throffling Globe sizes fa 2 in. 0 - 1 4 12001 3 0 0 16001 Plug - 3 1 6 Stainless Steel
Services. including Valves 3 in. o r larger 0 - 7 11 W l 3 0 0 16001 Seat Rings - 3 1 6 S t a ~ n l e s rSteel
gases and vapours. Stem - 3 1 6 Stainless S i e e l
neutral water. Guide
hydrocarbon liquids, o f Bushings - H a r d e n e d 4 4 0 C or 17-4PH
chemicals compatible
w i t h t r i m mstsria1r

smam Globe A l l sizes 2 I". mu9 3 1 6 Stainless Steel


General Same service Valves 3 in. o r larger Steliite Faced
as above e x c e p t seating s u r f a c e s
application requires Seet Rings 3 1 6 Stainless Steel
frequent a h m ~ o f f - Sfellife Faced
A l l sizes seating S u r f a c e r
Fleshing liquids Stem - 3 1 6 Stainless Steel
Guide
Burhingr - Hardened 4 4 0 C or 1 7 - 4 PH -
4 4 0 C not used i n acidic boiler
feed.

steam Globe A l l Sizes Plug 3 1 6 S t s i n i e r r Sfeei


GeneralbSame Services Valves - Stellite Faced
a s above except All Sizes Seailng Surfacer and Guide
frequent h h u t ~ o f f Pasts
A i l sizes Seat Rings - 3 1 6 Stainless Steel
Flashing Liquids - Stelllte Faced
Seating Surfaces and Guide
Ports
Stem - 3 1 6 Stainless Steel
Guide
Bushings - 3 1 6 Stainless Steel
Stellite Faced Core
or 1 7 - 4 or Hardened.

General - Same service A l l sizes Greater t h a n Plug 3 1 6 Stainless Steel


a s above except 2513501 A l l surfaces Sfellite
application requires e x c e p t b e t w e e n D.P. piugs and
frequent s h u t - o f f All sizes Greater t h a n b e t w e e n plugs and guide post
2513501 tearing surfaces not required.
Seat Rings 3 1 6 Stainless Steel
- stei1ite Sheath
Stem - Hard Chrome Finish
Guide
Bushings Stainless Steel
- Stellite Faced Care.

Chlorine and Fluorine Globe A l l sizes A11 t r i m p a n s o f M o n e l


Gases and Compounds Valves or
Spacer
Type

For all Services Globe All Sires 100114401 1 9 0 14001 Plug Hardened 1 7 - 4 PH
Valves or b o d y Trim 4 1 6 or 4 4 0 C
with rating i f variation* Cage Hardened 1 7 - 4 PH.
cage Trim less Stem - 3 1 6 Stainless Steel
10091 OOE

10821 *2 1

awes

1002
01 OZ 1-1
6 L 01 66-

UO!lSP
Ueluuooa~
A~ol'aj p e l q IOU OBJ!nlOS

IAI 3.
1w!1 dual anls,,
az!~ WPA seawas
5.1 1.2 Control Valve Accessibility

Control valves, whether electrically, pneumatically or


hydraulically operated shall be installed so that they are readily
accessible from grade or a fixed platform for ease of
maintenance and hand operation.

Control valves shall be installed so that the stem is truly


vertical. Where this is not possible, valves can be installed in
other orientations, provided that:

1. The Approved valve Manufacturer approves the


valve/actuator combination being installed in the
alternative orientation especially w i t h respect t o the
overhung weight of the actuator being carried by the
yokelseal assembly and the effect caused t o the gland
packing.

2. Agreement of the Company is obtained.

Notwithstanding the above, actuators for butterfly valves shall


always be installed with the actuator shaft vertical and easily
accessible from grade or fixed platform.

Clearance shall be provided above and below control valves so


that the bottom flange and plug can be removed w i t h the valve
body in the pipeline. Where this is not possible, subject t o
agreement w i t h the Company, the valve body may be swung
around a single flange bolt for maintenance work. In this case,
there shall still be allowed sufficient access t o the valve to
enable inspection of the valve trim without removing any
flange bolting.

5.1 1.3 Bypass and Handwheel Philosophy

a. The Contract-specific P&ID shall s h o w all bypasses required for


startup and for the maximum availability of the plant during
breakdown, upset conditions and maintenance operations
without affecting safety.

b. In certain instances, full bypassing of a control valve, using


block and bypass valves will n o t be possible. In these
circumstances, a valve actuator override by use of a
handwheel shall be indicated on the P&ID, enabling control t o
be manually executed while maintenance of the control and
actuating elements of the loop is conducted.
Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 3 7 of 163
SpecYi7cation

c. When fitted, block and bypass systems shall as a minimum


conform t o the following:

1. Sizes shall not be smaller than API RP550, Part I, section


6, Table 6.1.

2. Pipeline stresses shall not transfer t o the bypass line when


the main valve is removed for maintenance.

3. When the control valve is mounted in a pre-stressed line,


the bypass shall be anchored or located separately t o the
main line, with sufficient flexibility t o prevent stressing
forces affecting the bypass line. The piping either side of
the control valve shall have provision for safe location
while the valve is out of line.

4. Where blockvalves are provided, a valve or valves shall be


fitted so that when the block valves are closed, pressure
may be relieved and the control valve drained. Such drain
and vent valves shall be of roddable type.

d. As a general guideline, though possibly overruled b y process


considerations or safety considerations, Contract-specific or
Company instructions, the following shall apply:

1. Cases where block and bypass shall normally apply.

(a) Where a valve controls a service common t o a number


of users.

( b ) Where a valve is in continuous operation and there is


not sufficient assurance of reliability over the
anticipated period between plant overhauls, e.g., on
corrosive or erosive service or where the temperature
is below 0°C (32°F) or above 180°C (365°F). The
shutdown cost of the appropriate sections of the plant
de-commissioned due t o a failure shall be taken into
account.

( c ) Where failure of the valve would necessitate


continuous operator action t o maintain the process
control, e.g., the fuel supply t o a fired heater.

( d ) In the case that block and bypasses are n o t initially


specified, but the service is safe t o have them, the
piping layout shall allow for the future addition of the
facility.

-
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15-9-94 38 of 1 6 3
Specification

( e l Where conditions (a), (b), or ( c ) are met and a


handwheel is indicated on the P&ID, but the cost of a
handwheel is greater than a block and bypass, then
the block and by-pass shall be installed.

2. Cases where valve handwheel shall normally apply:

(a) Where conditions are met where it would be safe t o


provide a bypass, but a block and bypass system is
not selected, a permanent side-mounted handwheel
shall be fitted. (See also "Cases where block and
bypass shall normally apply," 1 above).

3. Cases where a by-pass or handwheel shall not be fitted:

(a) Bypasses shall not be fitted o n valves for process


shutdown or ESD service.

I (b) Bypasses shall not be fitted for hydrogen service

I (c) Bypasses shall not be provided on three-way valves.

(d) Bypasses shall not be fitted around self-acting steam


pressure regulators.

I 5.1 2 Accessories and Ancillary Items

I 5.1 2.1 Mounting

a. Where accessories are required w i t h the valve, they shall be


purchased by the Contractor as a fully mounted and tested
assembly. The mechanical installation arrangements for the
valve shall be carefully reviewed before designing the
accessory mounts t o ensure that the completed system is
accessible for operation and for maintenance and bypassing
arrangements in the installed position.

I b. As a general rule:

I 1. Pneumatic or EIP positioner shall be fully mounted.

I 2. Solenoid valves shall be fully mounted.

3. Limit switch sets, position transmitters, etc., shall be fully


mounted.

4. Handwheel sets shall be fully mounted (except for butterfly


valves).

5. Lock-up kits shall be fully mounted.


-
N12-0056
Specification Number Rev Date Sheet
Engineerhg Group
01 ~ - J H - I ~ o ~ 1 15-9-94 39 of 163
Sp&cat.-6n

6. Supply air sets and backup reservoir and fail-safe kits shall
normally be tested with the valve but supplied loose for
mounting adjacent t o the valve. In the case of large valves,
the air set may be mounted on the valve.

7. All piping and fittings o n the valve and accessories shall be


in accordance w i t h the Engineering Group Specification
entitled "Instrument installation" (Number 0 1 5-JH-1908)
and be of stainless steel or copperlbrass material in
accordance with the H,S considerations. The size shall be
318-in.OD for power air and 114-in. OD for signals. T w i n
ferrule stainless steel fittings shall be used when stainless
piping is fitted.

5.1 2 . 2 Pneumatic Positioners

a. Pneumatic positioners shall be of the force or motion balanced


type, suitable for 0.2 t o 1 .O barg ( 3 t o 15 psi) input signals.
They shall be fitted w i t h 50-mm (2-in.) dial pressure gauges
indicating the signal input pressure and the output pressure t o
the valve actuator. The air connection size shall be 114 NPT.

b. The cases shall be resistant t o the environmental conditions


and the bleed port protected from windblown dust and sand.

c. All mechanical linkages, fastenings etc. shall be suitable for


operation in the sandy environment and shall be of stainless
steel material.

d. The positioner shall be reversible in the field, and shall be fully


adjustable for span.

e. The positioner shall be side mounted on globe valves, and be


t o p mounted o n quarter-turn piston actuated valves.

f. The output will normally be within the range 0 . 2 t o 1 . 0 barg ( 3


t o 15 psig). If a higher output range is required the maximum
pressure shall be 4 . 0 barg ( 6 0 psig), b u t the positioner shall
withstand 8 . 0 barg ( 12 0 psig) without mechanical damage.

g. A pneumatic bypass shall be fitted t o all positioners for 0 . 2 t o


1.0 barg (3 t o 15 psig) actuators unless the application is
inappropriate, and shall be defined o n the data sheet.
5.1 2.3 Electro-Pneumatic Positionel

Subject t o Company agreement, valves o n control service


where a pneumatic bypass is not appropriate, and where
vibration and other undesirable service conditions are not
present, electro-pneumatic positioners (EIP) may be used in
place of the pneumatic positioner and associated signal
convertor.

The operating signal shall be 4 - 2 0 m A . The specification shall


be the same as for the pneumatic positioner, w i t h only one 50-
m m (2-in.) gauge displaying the output t o the actuator only.

The positioner shall be certified for use in the defined


hazardous area, in accordance w i t h the Company-selected
execution code.

5.1 2.4 Split Range Control

a. Unless an exception is approved b y the Company, split range


control shall be accomplished b y using t w o outputs from the
DCS system. Each output shall be scaled t o 0 - 1 0 0 % at the
DCS. Each valve shall have an individual positioner scaled 0 . 2
t o 1 .O barg ( 3 t o 1 5 psig) or 4 - 2 0 mA, according t o type, for
full valve travel.

b. Pneumatic bypasses shall not be installed o n positioners for


split range service.

5.1 2 . 5 Air Lock-Up Kits

For valves having a fail locked requirement on air failure, and


a defined drift direction, an air lock-up kit shall be provided,
mounted and piped on the valve. The pneumatic snap action
lock-up relay shall detect l o w pressure downstream of the air
set and lock-in the air contained in the actuator. The system
shall normally be self-resetting o n a differential basis.

Careful design correlation shall be conducted for all the


pressure levels chosen for the elements of the system as
follows in ascending order:

1. Setting of air regulator.

2. Reset pressure.

3. Lock-up pressure.

4. Spring rate pressure


Specification Number Rev Date Sheet
Engineethg Gmup
01 5-JH-1903 1 15-9-94 41 of 1 6 3
SpedficaMn

c. In the event that a "drift" action is not desirable, the valve shall
employ a double acting actuator and positioner, and the lock-
up kit shall act o n both sides o f the actuator.

5.12.6 Fail Locked Action for OnIOff Valves

Where a fail locked action is specified for onloff valves, the valve
shall stay in its last position in all failure cases, including electrical
and air pressure failure. The electrical failure action shall normally
be accomplished by the provision of a double-acting actuator using
separate solenoids for each travel direction and a neutral mid-
position. Single press or "inching" operation shall be appropriately
actioned by the logic arrangement. The air failure action shall be
accomplished by use o f a lock-up kit acting on both sides of the
actuator. Alternative suitable systems may be offered t o the
Company for approval.

5.1 2.7 Handwheels

a. Handwheels for globe, butterfly and three-way valves shall be


side mounted, lockable and de-clutchable and linked in such a
manner that the actuator can be removed when the handwheel
is engaged.

b. The operational force required shall not exceed 2 3 kgs ( 5 0 lbs)


at the rim.

c. Quarter-turn valves using linear diaphragm or piston actuators


may utilize handwheels as specified for globe valves, or
alternative arrangements giving equal facilities. The handwheel
may be detachable where permanent fitting is impractical or
undesirable. A suitably designed parking place shall be
assigned t o the removed unit.

d. Low-powered electric actuators up t o 1 1 3 Newton Metre


( 1 0 0 0 inch pounds) torque may be hand-positioned directly
through the gearbox shaft b y use of a wrench on a square-
ended shaft. Higher powered types require a handwheel geared
d o w n t o a reasonable torque and a declutchable or
withdrawable device t o prevent rotation when the motor is
operating.

5.12.8 Solenoid Valves

a. Solenoid valves shall be direct acting, spring return and of


robust design for heavy industrial use. The coil and spring
power shall be selected t o provide ample operational force t o
position the solenoid correctly under all applicable service
conditions and air pressures up t o 11.3 barg ( 164 psig).
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15~9-94 42 of 163
Sp&c8ti0n

The operating voltage shall be stated in the Engineering Group


Specification entitled "Instrument Design" (Number 0 1 5-JH-
1902).

The solenoid shall generally be factory mounted t o the valve,


and where this is not possible shall be tested w i t h the valve,
hooked up in a way that closely approximates the final installed
situation.

Solenoids for fast action ESD service shall be mounted as close


t o the actuator port as possible, quick exhaust valves shall be
added if necessary t o achieve the specified closing time.

Solenoid valves shall not be installed in signal lines unless they


are for control services, e.g., injection of a pre-set signal.

Solenoid valves shall not be used directly in process lines


without Company approval. Approval shall not be given in the
case of shutdown applications. These services require the use
of a valve w i t h limit switches installed t o prove valve status.
For cases where a solenoid valve may be suitable (e.g.,
tightness testing systems in clean gases which are non-
corrosive and non-gumming t o the valve or its seals). The
Contractor shall submit full details for Company approval of the
proposed application.

Solenoids shall be certified for use in the applicable hazardous


area.

5.1 2.9 Limit Switches

a. Where valve limit switches are required, they shall be of the


inductive proximity type unless modified b y the Contract
documents.

b. They shall be supplied mounted in an enclosure sealed t o IP


65. The switch box, complete w i t h internally adjustable switch
actuators shall be mounted o n the valve yoke and be driven by
stainless steel linkages and shafts properly sealed for use in the
sandy environment.

c. The switches shall be terminated within the enclosure, which


shall have overall hazardous area certification in accordance
w i t h the applicable Contract-specified execution method.

5.12.1 0 Air Filter Regulator Sets

a. Each valve or individual instrument air user on the valve shall


be fitted w i t h an air set. This shall consist of an air regulator
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 43 of 163
Specjficatim

w i t h suitable spring range, an integral filter and drain b o w l and


a 50-mm (2-in.) output air gauge.

b. The airset shall generally be of downstream relieving type.


Spring adjustment shall be by hexagon stainless steel screw
and locknut. The port size shall be 114-in. NPT.

5.13 Performance Reauirements

5.13.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states the


minimum requirements directly related t o control valves and
shall not in any way replace or reduce the general QAIQC
requirements.

b. The inspection and test plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality o f the product:

A check of all materials of construction by cross-


comparing the goods, the material test certificates and the
data sheets and Drawings.

A check o f the dimensions of the finished valves against


the drawings supplied for the Contract and approved by
the Company.

A check of the completed valve and all accessories against


the data sheet and specification requirements.

A check of the valve position and failure arrangements


against the data sheet.

A check of the valve plug travel against the approved


Drawings.

A check that the valve packing and gasketting is in


accordance w i t h the data sheets and s ~ e c i f i c a t i o n s .

A check o n the valve nameplate data in accordance w i t h


this specification and the data sheets and Drawings.

Full testing of the valve in accordance w i t h this


specification, the Approved Manufacturer's additional QA
procedures and the approved test and inspection plan.
Specification Number Rev Date Sheet
" ~mup
, Specr%icatbn 0 1 5-JH-1903 1 15-9-94 44 of 163

9. A check o n the valve and accessories painting and


protection and general suitability for the environment.

10. A check o n the tagging being in accordance w i t h this


specification and the data sheets.

5.1 3.2 Valve Testing

a. Non-destructive testing (NDT) frequencies, types and methods


shall be specified by the Approved Manufacturer in accordance
w i t h the Contract QAIQC specifications. All tests shall be listed
in the inspection and test plan and submitted t o the Company
for approval.

b. The following standard performance tests shall be performed:

Valve hydrostatic pressure test, conducted according to


ANSI B 16.34 and B 16.37.

Seat leakage test for valves class IV and above, in


conformity t o ANSI B1 6-104. Air and de-mineralized water
shall be used as the respective phase fluids. Valves of
lower sealing ratings shall only be checked t o confirm the
actuator can operate against the design fluid pressure.

Prove that the actuator will open against the design fluid
pressure in the case of f l o w over plug and quarter-turn
valves.

Confirm valve speed of travel over the full stroke is in


accordance w i t h the data sheet. Also check stroke
linearity w i t h increasing and decreasing input signal.

Perform hysteresis check. Sensitivity shall be based on a


proven or observed valve movement when the signal is
changed b y 0 . 0 2 barg ( 0 . 3 psig). The test shall be
conducted in 2 0 % steps from 10% t o 90% of valve travel,
i n b o t h directions.

Perform response check. When the signal is changed by


l o % , the valve shall start t o move without perceptible
delay. Total signal response times in excess of 4 seconds
for the 10% change are t o be submitted t o the Company
for approval for the specific application. The test will not
apply at the fully open and fully closed positions.

5.1 3.3 Actuator Testing

a. The actuator shall be tested in conjunction w i t h the valve.


Specification Number Rev Date Sheet

@ KOC Engineering Group


Speo%mtbn 01 ~ ~ J H - 1 9 0 3 1 15~9-94 45 of 1 6 3

b. The diaphragm case shall be tested for leakages. The test shall
be conducted at 3 barg (45 psig), or at the higher level at
which the actuator is specified t o operate. The test shall be
successful if n o leakage is detected over a 3-minute period
around the diaphragm case bolts, periphery of the diaphragm
and at the breathing side of the diaphragm.

c. For push-up actuators with packing at the shaft seal, the


leakage test shall be additionally applied around the shaft at
several positions of stroke.

I 5.1 3.4 Certification

All the certification for each valve or group of valves shall be


collated in a Valve Data Book which shall be available at final
inspection. The book shall include as a minimum:

I a. Completed test and inspection plan.

I b. Material certificates and component test certificates

I c. NDT certificates.

I d. Weld procedures and qualifications.

I e. Pressure test certificate.

I f.

g.
Leakage test certificate.

Valve and actuator performance test certificate. Actual


recorded figures t o be added during the test.

I h. Hazardous area certificates.

I i. As-built Drawings as necessary.

I 5.14 N a r n e ~ l a t eData

General information for production of the nameplate data is given in section


4.7 of this specification, Instrument Identification. Additionally, for valves,
the following information is required:

I a. Valve serial number.

b. Valve model or catalogue number.

c. Body material.

d. Body rating and size.

N12-0056
e. Trim material or specification number.

f. Trim size.

g. Trim CV rating.

h. Trim characteristic.

I. Stem travel in mm.

j. Action "air t o close" or "air t o open."

6.0 RELIEF AND SAFETY VALVES

6.1 Applicable Standards

ANSl B 1 6 . 5 Steel Pipe Flanges and Flanged Fittings

ANSl B 1.20.1 Pipe Threads

API RP 5 2 0 Sizing, Selection and Installation of Pressure Relieving


Devices in Refineries

API RP 5 2 1 Guide for Pressure Relieving and Depressurising Systems

API Std 526 Flanged Steel Safety Relief Valves

API Std 527 Commercial Seat Tightness for Safety Relief Valves with
Metal-to-Metal Seats

6.2 Scope of Relief Valve Section

6.2.1 Cases

a. This specification covers all systems o f pressure relief for the


following relief cases:

1. Maloperation

Control failure resulting in excessive pressure build-up due


t o malfunction in temperature or fluid control into or out of
a vessel or protected system.

2. Fire Case

Overheating of a vessel or piping system due t o an


external fire or source of heat.
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15-9-94 47 of 163
SpeaZcabion

3. Thermal Overload

Liquid relief of pressure build up in a system that is


blocked in due t o receiving heat input from the surrounding
ambient conditions or from equipment in the line.

b . The most severe of the applicable cases shall be taken for


design purposes. The cases shall not be additive.

Relief Devices

This specification covers mechanical devices such as relief and


safety valves, thermal relief valves and bursting discs. Other
devices may be necessary for special process conditions, e.g., U-
type blow-out w e t legs. The use of any such device shall be
approved by the Company before adoption.

Redundancy

a. T w i n or multiple safety valve systems shall be supplied if


required b y vessel codes, the P&ID or detailed analysis of the
process system.

b. All pressure relief valves o n critical service (excluding thermal


relief) shall be supplied w i t h an installed spare equally sized
relief valve.

Isolating Valves

a. Where relief valves are 1 0 0 % spared, the inlet and outlet lines
will be provided w i t h interlocked isolation valves t o ensure one
valve is on-line w h e n the other is off-line. The interlocking
isolation valves shall have the ability t o be padlocked t o
prevent unauthorised operation. The off-line relief valve shall be
able t o be removed for servicing.

b. Isolation valves where fitted for other relief valves shall be full-
bore roddable type and fitted w i t h a "locked open" facility.

6.3 Relief Aoolications and Selection

6.3.1 Normal Case

a. The selected relief valve for the standard application shall be:

1. Full lift, snap action w i t h enclosed spring.

2. Flanged connections, minimum 3 0 0 LB rated on the inlet


side.

2-0056
3. Bolted bonnet.

4. Screwed cap.

5. Full one-piece nozzle.

Liquid relief valves for service o n systems such as pump


outlets, where snap-action valves are inadvisable, shall be
proportional types.

Liquid thermal relief valves (size 314-in.x I - i n . ) shall be of


screwed construction (except when required for NACE service)
w i t h semi-nozzle.

Large relief valves (6-in. and above) may use inlet flanges rated
at 1 5 0 LB when the process conditions allow.

The relief valves shall be sized t o API RP 520, designed and


constructed in accordance w i t h API RP 5 2 6 and be tested t o
API RP 5 2 1 . They shall be furnished w i t h type approval testing
conforming t o the vessel design code, and where the applicable
vessel is supplied w i t h a code stamp, then relief valves shall
also be code stamped.

High Temperatures

High-temperature valves shall use exposed springs. The Approved


Manufacturer recommendations for the valve design and packing
shall be followed.

Back Pressure Applications

a. Valves of balanced bellows design shall be used for the


following applications:

1. Where the built-up back pressure due t o downstream


piping, silencers and fittings exceeds 10% of the valve set
Dressure.

2. For a constant back-pressure application where the sum of


the valve and piping accumulation and the constant back
pressure would result in an over-pressure o f the vessel.

3. Where an imposed back pressure is not constant and the


variations can exceed 5 % of the valve set Dressure.

4. Where savings in the downstream disposal piping can be


made because of the increased allowable piping
accumulation and back-pressure.
Specification Number Rev Date Sheet
Engineedng Group
01 5 ~ J H ~ 1 9 0 3 1 15-9-94 49 of 163
Specificatbn

Pilot-Operated Systems

a. Pilot-operated systems shall be considered for the following


applications:

Where automatic de-pressurisation is required in addition


t o over-pressure protection.

Where "valve simmer" could be a problem, t o enable short


relieving periods w i t h small differentials and tight shutoff.

Where set pressure is within 10% of operating pressure.

Installations requiring the valve t o be tested when installed


and under pressure.

High-volume relief.

Economic considerations for larger valves, 4-in.x 6-in. and


above.

Other applications which are difficult or impractical w i t h


conventional relief valves.

b. All pilot-operated systems shall be provided w i t h dual pilots


arranged so that either pilot can be maintained and tested
while the other is in service.

Bellows Seals

Where the service requires absolute security o f the seal between


the relief disc shaft and the bonnet, bellows seals shall be fitted.
Applications include corrosive, hazardous and lethal substances
which have special relief disposal conditions.

R u ~ t u r eDiscs

a. Rupture discs as a sole protection for plant safety shall only be


used w i t h Company approval.

b. Rupture discs may be fitted upstream of a relief valve in


corrosive or particulate service or where the valve operation
could be affected adversely b y contact w i t h the process. The
following considerations shall apply:

1. Nozzle flushing, if required for particulate service, shall use


fluids compatible w i t h the line fluids. The flushing system
shall be independently protected against over-pressure.
2. Disc fracture detection shall be installed for each
application. This shall be independent of the relief valve
actuation. When IS techniques are being used, the method
for non-conductive fluids is b y use of an electrical contact
which breaks t o alarm at the DCS when a frangible
element o n the downstream disc surface is broken as the
disc ruptures. When non-IS systems are specified or the
fluid is conductive, a bleed shall be installed o n the space
between the disc and the relief valve. This shall be routed
t o the relief system downstream of the relief valve. The
bleed piping shall incorporate a restriction orifice sized at
3.00 m m ( ' I , in.) and an excess flow check valve as
necessary. The bleed shall be monitored by a pressure
gauge and pressure switch on the high pressure side of the
restriction, t o detect and alarm t o the DCS any fracture of
the disc.

c. All rupture discs shall be manufactured in batches using the


same plate material. A t least three discs shall be pressure
ruptured t o confirm the calibration. Each fitted disc shall be
supplied with t w o spares from the same batch.

Sizina Reauirements

6.4.1 Control of Design Data

Valves shall be sized on the basis of defined issues of the process


data sheets, P&ID, equipment and piping data. A document control
shall be maintained t o ensure that the valves are built t o the latest
case evaluation and calculation, based on the final data. Data
sheets shall state the process data revision number, and
calculations the data sheet revision number.

6.4.2 Limiting Case

a. The valve data sheet shall specify the selected case, all
applicable vessel and process conditions, the constant, variable
and built-up downstream pressures and the allowable noise
level.

b. Silencing where necessary shall be purchased with the valve,


and the back-pressure caused shall be included in the
calculation.

c. Where a number of process conditions and/or choices of


applicable case exist, sufficient calculations shall be performed
t o ensure that the limiting case and conditions are selected as
the design case.
Specification Number Rev Date Sheet
Engjneerfng Group
01 5-JH-1903 1 15-9-94 5 1 of 1 6 3
Spedficatbn

d. Regardless of the accumulation value, the relief valve setting


shall not be greater than the vessel design pressure.

6.4.3 Calculation Required

a. The calculation shall be conducted in accordance with API RP


520 or t o the code dictated b y the vessel design code and shall
be submitted t o Company for approval before purchase.

b. The calculation shall tabulate:

1. Valve tag number.

2. System and equipment protected.

3. Cases applicable and the selected case.

4. Relief loads for each of the applicable cases.

5. Blowdown restrictions and calculated figure.

6. Type of valve, e.g., proportional, balanced bellows etc

7. Body and inlet and outlet flange sizes and ratings.

8. Pipelvessel line specification, line number and sizes.

9. Back-pressure force at full relief.

10. Operating setting and the cold setting, both at the


Approved Manufacturer's test facility and the Company
and the Contractor's Site workshops. The calculations
shall take into account the different ambient pressures and
temperatures.

11. Valve capacity at relieving conditions.

6.4.4 Blowdown

a. The blowdown for spring operated valves shall be as follows:

1. Valves of set pressure 7.0 barg ( 1 0 0 psig) and less: valve


shall re-seat at not less than 0.14 barg ( 2 psig) below the
set pressure, lower limit set b y process requirement
(normally 5 % below set pressure).

2. Valves of set pressure over 7 . 0 barg ( 1 0 0 psig): valve shall


re-seat at not less than 2% or more than 7 % below the
set pressure.
-
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 5 2 of 163
speaifcab;on

b. Pilot-operated valves shall conform t o the above criteria 01


have defined limits set according t o the process conditions.

6.4.5 Limits on Valve Selection

The minimum size shall be I - i n . x 2-in. except for thermal relief


valves (TSV).

The area of discharge of flanged valves operating at set


pressures over 1 9 barg ( 2 7 6 psig) shall be n o t less than four
times the area of the nozzle. The area of discharge shall apply
t o any point in the valve downstream of the nozzle, including
the discharge flange opening.

The selected orifice size shall exceed the calculated area only
b y an amount as limited by standard orifices available.

The valve shall be selected at such a size that a larger orifice


may be fitted at a later date t o accommodate process changes.
A n allowance of 1 0 % increase of f l o w shall be possible
without increasing the overall accumulation.

A minimum number of valves shall be used in multiple safety


valve applications. Mixed orifice sizes are not acceptable.

6.5 Desiqn, Materials and Construction

6.5.1 Lifting Levers

Lifting levers shall be installed only on air, nitrogen or low-pressure


steam service or where dictated b y the vessel design code.

6.5.2 ShippingiTest Gags

Gags shall be fitted t o all valves except thermal relief valves.

6.5.3 Code Requirements

a. The relief valves shall be designed and constructed within the


applicable vessel design code.

b. Where a code is not stipulated, the valves shall conform t o the


ASME code for Section VIII, Div I.

c. This requirement shall not apply t o thermal relief valves for


pipingiequipment service only.

-
--

6.5.4 Connections

Bodies shall be flanged (except thermal relief valves) t o ANSl


B16.5, rated and faced in accordance with the vessellpiping
specifications.

The flanges shall be forged integrally w i t h the body. Welded-on


flanges are not acceptable.

Welded in safety valves are not allowed. Where valves shall be


installed o n fully welded systems, the Contractor shall submit
an alternative flange system, suitable for the process
conditions, for Company approval.

Screwed valves (314-in. x 1-in.) for thermal relief shall have


threads formed in accordance w i t h ANSl €31.20.1.

6.5.5 Body and Flange Ratings and Material

The normal materials shall be carbonsteel bodies w i t h stainless


steel trim. The trim shall include:

1. The nozzle.

2. The disc and disc holder.

3. The stem and guide.

4. The blowdown ring, ring pin and bushing.

5. All other parts contacting the inlet side process fluid.

The body may be cast or forged.

The bonnet shall be of the same material as the body.

All the trim components shall be renewable.

The nozzle and disc shall be of forged material.

All materials shall be upgraded as necessary t o suit the actual


service rating.

Valves of "lightweight" pattern are not permitted. The inlet


side of all relief valves (flange, nozzle, disc and seat) shall be
rated equal t o the pressure temperature rating of the inlet
flange. The outlet side of all relief valves (flange, body, bonnet,
packing etc.) shall be equal t o the pressure temperature rating
of the piping class flange.
h. The body and flanges shall be of the same material as the
applicable connecting pipework. This can be varied only under
the following conditions:

1. In the interests of providing a common body for a number


o f applications, a single material may be specified provided
that it can be shown t o be equal or superior t o the pipe
class material in each of the applications.

2. In order t o enable the body t o be rated equally t o the


piping class flanges, the body may be o f a superior
material.

Nozzle and Seat

a. Safety relief valves shall be of "full nozzle" design. Thermal


relief valves may be of "semi-nozzle" design. Valves w i t h seat
material integral w i t h the body are not acceptable.

b. Nozzles shall have integral seats of sufficient proportions t o


permit several lapping operations.

c. Soft seats shall be fitted on air, water and nitrogen service up


t o the soft seat allowable temperature. Hard-faced seats and
disks shall be used on abrasive service and all steam valves.

Cold Setting

The Contractor shall calculate the "cold setting" pressures based


o n the "service setting" figures specified according t o the selected
case. The "cold setting" shall also be noted o n the data sheets.

Valve Springs

a. Valve springs shall be coated for corrosion resistance and be


of materials suitable for the operating temperature t o enable
the setting t o be held between bench tests. The material shall
normally be an alloy steel for valves in services between minus
20" C (minus 68°F) t o + 230" C ( + 4 4 6 ° F ) . Springs of other
materials shall be selected according t o the process and
surrounding conditions. Springs for valves in NACE service
shall be of lnconel X 750.

b. Safety /relief valves for set pressures o f 2 0 barg ( 2 9 0 psig) or


less shall have springs suitable for a range of adjustment of
plus or minus 1 0 % . Valves set at above 2 0 barg ( 2 9 0 psig)
shall have spring ranges suitable for a range of adjustment of
plus or minus 5 % of the set pressure.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 159-94 5 5 of 163
Specificalion

6.5.9 Bellows

Where the service requires bellows seals t o be fitted, the minimum


material requirement is stainless steel.

6.5.10 In-Line Testing

The stem shall be suitably extended and threaded t o allow the


installation of in-line, on stream testing machinery.

Noise
The noise emitted b y a single relief valve at maximum operation shall not
exceed 105 dB A or any lower figure stated in the Engineering Group
Specification entitled "Plant/Equipment Noise Control" (Number 0 1 5-NH-
1104). The Contractor shall state the predicted noise spectrum on the data
sheets submitted for approval t o the Company.

Installation Notes

Each relief valve shall be installed, w i t h the spring vertical, in a


position accessible for inspection and maintenance, but shall be
clear o f walkways where relief noise could be a hazard t o operating
personnel.

The piping and supporting shall be designed t o withstand the valve


back pressure forces at full relief. The valve shall not be used t o
support the downstream piping (except abbreviated vent legs) or
silencers.

Vent legs shall be positioned so as not t o cause any hazard t o


personnel or equipment while the valve is relieving.

Vertical vent legs shall be provided w i t h a drain hole t o prevent


water build-up in the leg. Heat tracing shall be fitted as necessary
in sub-zero service conditions t o avoid icing in the discharge piping.

For large relief valves, a permanent lifting facility shall be installed


for servicing and removal of the valve.

Performance Reauirements

6.8.1 Quality Control (QC)

a. OC shall be as detailed in the Contract. This section states the


minimum additional requirements related t o relief valves only
and shall not in any way replace or reduce the general OAIOC
requirements.
b. The inspection and test plan shall include the following checks
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check o f all materials of construction b y cross-


comparing the goods, the material test certificates and the
data sheets and Drawings.

2. A check of the dimensions of the finished valves against


the Drawings supplied for the Contract and approved by
the Company.

3. A check of the completed valve and all accessories against


the data sheet and specification requirements.

4. A check o n the valve nameplate data in accordance with


this specification and the data sheets and Drawings.

5. Full testing of the valve in accordance with this


specification, the Approved Manufacturer's additional
QAIQC procedures and the approved test and inspection
plan.

6. A check o n the valve and accessories painting and


protection and general suitability for the environment.

7. A check on the tagging being in accordance with this


specification and the data sheets.

Casting Quality

Castings shall be true t o form and free from shrinkage defects,


strains, scales, lumps, sand holes, or other defects.

Testing

a. The nozzle and body shall be hydrostatically tested before


assembly at 1.5 times the respective ratings of the inlet and
outlet flanges.

b. The valve shall be calibrated b y popping pneumatically at the


cold differential test pressure calculated for the conditions
prevailing at the testing workshop.

c. The valve shall be pressure tested as an assembly at no greater


than 1.5 times the rating of the outlet flange, but this figure
shall be reduced if there is a design restriction o n back pressure
on the outlet side of the nozzle.
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spea%ication 01 5-JH-1903 1 15-9-94 57 of 163

d. The valve shall be tested for leakage across the seat by a


procedure in accordance with API RP-527. Tests to
"commercial" standard are acceptable for non-hazardous
service. Valves for hydrocarbons and corrosive substances
shall be bubble tight.

6.8.4 Documentation

All the certification for each valve or group of valves shall be


collated in a Valve Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed test and inspection plan.

b. Material certificates and component certificates.

c. NDT certificates.

d. Weld procedures and qualifications.

e. Pressure test certificates.

f. Leakage test certificates.

g. Relief set pressure certificate.

h. As-built Drawings as necessary.

6.9 Nameolate Data

General information for production of the nameplate data is given in section


4.7 of this specification, Instrument Identification. Additionally, for relief
valves, the following information is required:

a. Body material .
b. Trim material.

c. Rating of inlet and outlet flange (nozzle and body).

d. Nozzle size or number.

e. Set pressure.

f. Cold set pressure.

9. Spring number and spring range.


Specification Number Rev Date Sheet

@ KOC Engineering Group


SpWcation 01 5-JH-1903 1 15~9~94 58 of 163

7.0 FLOW MEASUREMENT

A ~ o l i c a b l eStandards

API RP550 Manual o n Installation of Refinery Instruments and Control


Part 1 Systems, Process Instrumentation and Control

ISA RP3.2 Flanged-Mounted, Sharp-Edged Orifice Plates for Flow


Measurement

I S 0 51 6 7 Measurement of Fluid Flow b y Means of Orifice Plates, Nozzles


and Venturi Tubes Inserted in Circular Cross-Section Conduits
Running Full

S c o ~ eo f Flow Measurement Section

This section covers the requirements for the measurement of f l o w variables


in the Facility for local indication, local control, remote control, remote
signalling or transmission.

Flow Instrument Tvpes and Selection

7.3.1 Accuracy Requirement Evaluation

Flow measurement equipment shall be classified depending on


the purpose o f its application.

1. Fiscal or commercial use.

2. Plant mass balance, long-term storage and reporting


computer or calculated set-point control.

3. Feedback control and operator information.

Fiscal or commercial applications shall be indicated o n the P&ID


and require the use of highly accurate instruments such as
turbine and positive displacement type and special provisions
for checking and verifying the measurements. Each fiscal
application shall be the subject of individual proposal,
evaluation and Company approval and is not covered b y this
specification except in a general sense.

Instruments for mass balance calculations and long-term


storage and reporting computer input are t o be specified with
no relaxation on any of the design factors affecting accuracy.
These include the physical restraints such as straight lengths
and other tappings etc., but also cover requirements for
density and temperature corrections and other physical
variables.
Specification Number Rev Date Sheet
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01 5-JH~1903 1 15~9~94 5 9 of 163
SpecjfiCdtEon

d. Instruments used on feedback control are required t o give a


repeatable and correctly characterized signal throughout the
range, o f sufficient accuracy t o control the plant and provide
a proper level of equipment performance information t o the
operator. Certain relaxations on the accuracy conditions can be
submitted for Company review and comment.

7.3.2 Instrument Type

For all applications other than fiscal, the standard selection of


instrument wherever process conditions allow shall be the
square-edged, concentric-orifice plate w i t h flange taps and a
differential pressure transmitter.

Corner taps and other entrance forms shall be used to


overcome high viscosity, l o w DP, high Reynolds numbers etc.
within the calculation requirements of I S 0 5 1 6 7 .

Pipe taps shall be used where back-flushed chemical seals are


required, for services such as viscous, corrosive or particulate
service.

Conical entrance or quarter-circle orifice plates shall be used t o


measure high-velocity liquids or slurries.

Segmental or eccentric-orifice plates shall be used on liquids


containing large amounts of solids.

Critical f l o w orifices w i t h upstream pressure gauge shall be


used t o measure stripping steam flow. The upstream pressure
must be greater than twice the downstream pressure
throughout the range. The pressure gauge shall be scaled in
flow units.

Fabricated metering runs shall be used for line sizes 2 in. and
below. Sizes smaller than 2 in. shall only be used if it can be
shown that swaging up t o 2 in, is not viable. Vent and drain
holes shall not be used on orifice plates fitted into metering
runs.

Where l o w pressure loss is essential, venturi or f l o w tube (Dall)


type meters shall be used.

Where no appreciable pressure loss can be tolerated, pitot and


annubar tubes shall be used o n clean service only. These shall
be o f the retractable under pressure type unless the line can be
isolated without local or complete shutdown. These
instruments shall not be used on lines subject t o scraping.
Specification Number Rev Date Sheet
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01 5-JH-1903 1 15-9-94 60 of 163
spea;ficBt&n

For small rates of flow such as samples for analysers, variable


area meters shall be used. For purging flow, variable area
meters with a constant f l o w regulator and a low-flow alarm
shall be used.

Sight glasses shall only be used at atmospheric pressure, on oil


and water flows t o machinery, where the lack of a f l o w will
cause an alarm from another measurement before any injurious
result could arise.

Totalizing shall be performed in the DCS or long-term storage


and reporting computer systems. Should the Company
specifically require local totalizing instruments, these shall be
positive displacement, w i t h or without local temperature
compensation according t o the process conditions.

Except where the Company has specified a particular type of


instrument, a written application for each unusual case shall be
made t o the Company justifying the selection of such other
devices as:

1. Vortex flow.

2. Turbine meters.

3. Electromagnetic flowmeters

4. Ultrasonic flowmeters.

5. Positive displacement flowmeters.

6. Target-type flowmeters.

7. Thermal-type flowmeters.

8. Coriolis-type mass flowmeters.

9. Insertion meters (of any type).

Flow elements which may endanger downstream equipment


due t o possible loss of mechanical components upon failure
shall not be offered, e.g., insertion turbine meter in a
comDressor inlet.

Integral orifice instruments shall be avoided unless this type is


specifically identified on the P&ID as the Company
requirement.
OKOC
Specification Number Rev Date Sheet
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01 5-JH-1903 1 15-9-94 61 of 163
specjfication

7.3.3 Local lndication of Flow

a. Local f l o w indication for gases, liquids and steam shall be by


use o f an orifice plate, a pneumatic or electronic differential
pressure transmitter and a receiving pressure gauge or series
connected electronic indicator. When the electronic transmitter
also serves a DCS indicator or is part of a control loop, a re-
transmitted signal from the DCS shall be used instead of a
series connection in the field.

b. Variable area, positive displacement and other instrument types


may be used within the limitations stated in the preceding
sections.

7.3.4 Flow Measurement for Remote Control or lndication

a. Remote transmission shall be b y use o f an orifice plate and an


electronic differential Dressure transmitter.

b. All transmitters shall have an integral signal indicator with a


scale characteristic the same as the output.

c. Turbine meters shall be considered where high accuracy or high


turndown is required, subject t o Company approval.

d. Other instrument selections may be made within the limitations


stated above.

7.3.5 Alarms and Trips

Alarms

Intermediate and pre-alarms shall be generated in the DCS from


the transmitter signal that is used for control and indication.
Magnetic or proximity switches o n variable area ( V A ) meters
shall only be used on non-hazardous service and require
Company approval. In-line f l o w switches shall not be used
except where specifically required or approved by the
Company.

Trips

For applications where the detection of high-high or low-low


trip is required for general or local shutdown, a separate
transmitter is required, with a high integrity control room
mounted trip amplifier t o provide the switching action. High
and l o w trip may be generated from the same transmitter
provided it is in range.
c. In the case of orifice meters, the same orifice plate and flange
set shall be used for all transmitters, but each instrument shall
have its o w n isolation valve.

7.3.6 Local Flow Control

a. Where local f l o w control is specified, generally an orifice


plate and pneumatic differential pressure transmitter w i t h
local receiver controller shall be used. Other forms of DP
primary element may be used within the limitations stated in
this specification.

b. V A meters fitted w i t h constant flow regulators may only be


used for fixed rate flows such as flushing and purging. A
f l o w alarm shall alwavs be fitted.

7.4 Sizina and Ranclincl Reauirements

7.4.1 Differential Pressure Instruments

Orifice plates used o n differential pressure f l o w


measurement installations shall be sized t o I S 0 5167.
Computer input and output data is required for Company
review. Sizes below 50 m m (2in.) not covered by I S 0 5167
shall be calculated in accordance with the Approved
Manufacturer's proven system. Corner taps are required on
small lines.

Meter maximum used in f l o w calculations shall be taken as


20% above maximum design f l o w rate.

For feedback control, flow rate turndown for an orifice plate


fitted w i t h a single conventional electronic transmitter shall
not be greater than 3:l. The transmitter span shall be
selected so that the turndown is within the capsule range
limits (normally 6:l). Smart transmitters may be used t o the
Approved Manufacturer's recommended turndown, but not
greater than 10:l.Range increases b y change of orifice plate
shall only be allowed when specifically requested b y the
Company, and only when seniorljunior type fittings are used.

For flow rates up t o (but not exceeding) 10:l t w o


conventional (i.e., non-smart) transmitters may be used. The
first transmitter shall be ranged t o approximately 35% of
range (to the nearest sensible unit) and the second shall be
ranged 100%. Transfer shall be bumpless.

For mass balance and long-term storage and reporting


computer purposes, due regard shall be paid t o the ranging
Specification Number Rev Date Sheet
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1 15~9~94 6 3 of 163
SpecNcdtion 01 5-JH-1903

of the primary element as well as the transmitter capability


before choosing overall acceptable ranges within the
accuracy required.

f. Mass f l o w measurement shall be based o n differential


pressure or volumetric measurement supplemented b y other
measurement corrections (e.g., pressure and temperature).
Temperature, pressure or density correction shall be used as
specifiedlagreed t o with the Company.

g. Where a transmitter is in a low-low or high-high detection


service only, i t may be ranged at 5 0 % of the range of the
control transmitter.

h. Corrections shall not normally be applied t o trip instruments


unless they are essential for safe detection of the out-of-limit
condition.

i. Differential pressure transmitters shall be ranged for a full


scale differential of 2 5 0 mbar ( 1 0 0 ins WGI where ever
possible. Alternative ranges may be selected from the table
below:

5 0 mbar 1 ( 2 0 ins WG)


1 0 0 mbar 1 (40 ins WG)
I
1 5 0 0 mbar 1 ( 2 0 0 ins WG) I
j. Other ranges may be used subject t o Company approval

k. The following rules shall be followed:

1. The minimum orifice size shall be 8 m m (113 in.), ( 3 m m


(118 in.) for restriction orifices) unless approved
otherwise b y the Company.

2. The calculated d/D ratio (Beta ratio) for square-edged


orifice plates shall be within the range 0.4 t o 0 . 7 0 for
n e w equipment. For plant modification or exceptional
cases, both subject t o approval b y the Company, ratios
between 0 . 2 5 and 0.75 are acceptable. If the initially
calculated beta ratio exceeds 0 . 7 for a 5 0 0 mbar ( 2 0 0
ins WG) DP transmitter range, the line shall be swaged
up for the metering length as necessary.

3. The beta ratio for conical entrance plates shall not


exceed 0.3, and for quarter circle shall not exceed 0 . 6 .
Specification Number Rev Date Sheet
Engineering Gmup
01 ~ - J H - I ~ o ~ 1 15-9~94 64 of 163
Sp&icatbn

7.4.2 VA Meters

V A meters shall be sized w i t h sufficient capacity t o absorb line


fluctuations such as opening of manual valves etc. Internal
spring buffers and other protection as necessary shall be fitted
t o prevent damage t o the operating element.

7.4.3 Turbine, Positive Displacement (PD) and Other Specific Types of


Meter

Turbine and PD meters shall be sized according t o the Approved


Manufacturer's recommendations and ranges shall be dependant
o n flow rates and service conditions.

7.5 Construction Reauirements

7.5.1 General

All flowmeters shall have a positive means of identifying the


direction o f flow.

7.5.2 Orifice Plates

a. Orifice plates shall be manufactured in accordance with the


dimensions and tolerances given in ISA RP 3.2, "Flange-
Mounted Sharp-Edged Orifice Plates for Flow Measurement"
or API RP 550, Part I.

b. The standard orifice plate material shall be 3 1 6 stainless


steel. This selection shall be varied when process conditions
require an alternative material. Brackish water may require
monel; high-velocity steam service may require specially
selected materials w i t h Stellite overlay.

7.5.3 Flanges and Metering Runs

a. Orifice plates shall be installed in straight lengths of process


pipework in accordance with I S 0 5167. The half length
alternatives given in section 1 . I may be submitted for
approval b y the Company for use w i t h instruments used only
in feedback control or operator aid services. Any other
variations are subject t o approval by the Company.

b. In general, orifice plates shall be installed between orifice


flanges rated at 3 0 0 lbs minimum and bored t o the pipe size
used in service and in the calculation. Pipe connections shall
be weld neck. Process tappings shall be 112-in. NPT. Unused
tappings shall be plugged for the correct pressure rating with
a compatible material.
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The flange material, facing and type of gasket shall be as the


line s~ecification.

Where RTJ gaskets are specified, flange or corner taps shall


not be used. Alternatives such as pipe taps ( D and D l 2 or
2.5D and 8D), orifice carriers or alternative instruments shall
be considered. For difficult cases, fabricated spool inserts
w i t h integrally machined orifice may be offered for approval
by the Company.

Where it is necessary t o change orifice plates without major


plant disruption, retractable plate adaptors or carriers may be
used.

Fabricated metering sections ( 5 0 m m ( 2 in.) and below) shall


normally be supplied complete w i t h all fittings including
flange bolting, isolation valves and orifice plate w i t h gaskets.
All items shall be t o line specification except where it has
been agreed t o use a higher specification, e.g., 31 6 stainless
steel, for standardization. The metallurgy o f the weld t o the
main pipework shall be checked before such material is
accepted.

The length of the metering run shall be in accordance, as a


minimum, with the dimensions given in I S 0 5 1 6 7 (pro-rata
against dimensions for larger pipes) over which the
roundness and dimensional accuracy o f the piping shall be
ensured.

7.5.4 Differential Pressure Transmitters

a. Electronic transmitters shall be o f the strain gauge, piezo


resistive or capacitive type. Other elements may be used
provided that accuracy, stability and reliability criteria meet
operational requirements.

b. Differential pressure transmitters shall have a minimum 1 0 0


bar ( 1 4 5 0 psi) rated stainless steel body. All wetted parts
shall be 316 stainless steel as minimum w i t h superior
alternative materials t o suit service conditions.

c. Transmitters shall be capable of withstanding over-range


pressure on either side of the capsule at least equal t o the
body rating.

d. Transmitters shall be installed w i t h a local output indicator.


This may be an integral part o f the transmitter body,
provided it can be clearly read in the finally installed position.
Otherwise, it shall be a loop-powered or re-transmitted
output of the measured signal.
Specification Number Rev Date Sheet

0 KOC Engineering Gmup


Specificahion 01 5-JH-1903 1 15-9~94 6 6 of 163

e. If the output is used t o assist the local operation of a control


valve with handwheel or valved bypass, a local indicator
scaled in physical units shall be visible from the control
valve.
f. Process connections shall be 112-in. NPT female.

g. Electrical entry shall be M 2 0 x 1.5 ISO.

h. Pneumatic transmitters shall have a 50-mm (2-in.) gauge


fitted showing the output, w i t h a square root scale. Air
connections shall be 114 in. NPT.

i. Electronic transmitters shall be suitable for two-wire 4 - 2 0


mA, nominal 24-VDC transmission and be of "smart" type.

j. Pneumatic transmitters shall be o f the force balance type


and have an output between 0 . 2 and 1 . 0 barg (3 t o 15
psig), w i t h a 1.4 barg ( 2 0 psig) air supply.

k. Mounting shall be b y means of 2-in. pipe clamp, or by direct


mounting from the process manifold.

7.5.5 Turbine Meters and PD Meters

The use of turbine meters or PD meters for any


measurement shall be approved b y the Company.

Turbine meters shall be supplied w i t h stainless steel bodies


and wetted parts as a minimum. The body rating shall be
suitable for the service conditions. The connection flanges
shall be ANSI 3 0 0 lb minimum.

PD meter bodies may be of forged steel when the service


conditions permit, and the flange rating may be t o line
specification for l o w pressure duties.

Pulse outputs from transmitting PD and turbine meters shall


be integrated via the main control room interface or DCS
digital t o analogue input cards, performance details of which
should be specified b y the Approved Manufacturer.

Where transmission distances exceed the limits of the self-


powered instrument, head-mounted pre-amplifiers shall be
provided.

Automatic flow limiting devices shall be installed where


process conditions could cause meters t o operate above the
maximum f l o w rate specified b y the Approved meter
Manufacturer. Alternatively, a high-flow alarm may be
supplied subject t o the agreement o f the Company.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15~s-94 67 o f 163
Spedfication

g. Where fluid properties can have an adverse effect on meter


mechanical performance, turbine meters w i t h tungsten
carbide or similar bearings are required. I n adverse fluid
conditions including fluids w i t h poor lubricating qualities, in
particular LPG products, consideration shall be given t o force
fed lubrication.

h. Dual-head turbine meter systems shall be provided w i t h


discrepancy alarms. In the case o f fiscal metering, the t w o
turbine meter outputs shall be run in separate cables.

i. The connection between the moving and indicating parts


shall be by glandless magnetic coupling.

j. Conversion of the volume measurement t o mass f l o w by


correction for temperature or density shall be a DCS
function. Field automatic temperature compensation is
subject t o Company approval. Instruments in such service
shall have an additional dial for uncompensated flow. Ranges
of temperature elements for automatic temperature
compensators for heated oil PD metering installations shall
be such as t o cater for all temperatures which can be
expected under operational and static conditions. The effects
o f line and tank heating variations shall be taken into
account.

7.5.6 V A Flowmeters

V A meters o f the tapered tube and float type shall be used


where appropriate.

V A meters shall have a metal metering tube as standard. The


connection t o the piping system shall be ANSl flanged, 3 0 0
Ib minimum. The tube and flanges shall be 3 1 6 stainless
steel as a minimum, facings and gaskets etc. shall be in
accordance w i t h the piping class. The connection between
the moving and indicating parts shall be b y glandless
magnetic coupling.

Glass tube meters o f mechanically protected type may be


used on tubes up t o 2 0 - m m (314-in.) diameter in non-
hazardous services, w i t h temperatures up t o 130" C (266"F),
on fluids always above freezing, and may be flanged t o ANSl
1 5 0 LB or have NPT screwed connections.

The tube and float shall be renewable without recalibration


being required.
e. Filtering requirements shall be supplied, similar t o PD meter
philosophy.

7.5.7 Diaphragm Seals

The tappings for all instruments used for handling viscous or


corrosive fluids or slurries shall be sealed. Seals may be the
liquid type employing seal pots or the chemical type
(diaphragm seal) utilizing a diaphragm w i t h silicon oil (or
other fluid) between the diaphragm and the pressure element
of the instrument.

Diaphragm seals are the preferred method for these


applications within the temperature limitations for this type
o f seal. The transmitters shall be supplied with the capillary
tubes fitted and tested as a unit. The l o w and high pressure
transmitter chambers shall be of equal volume when these
seals are fitted.

The seals may need t o be used in conjunction w i t h a flushing


system in some circumstances, e.g., some slurries. The
flushing fluid shall be compatible w i t h the process fluid and
be supplied via a constant flow regulator and low-flow
alarm.

Connecting capillary tubing shall be 3 m m (118 in.) stainless


w i t h spiral-wound stainless steel armour.

7.5.8 Other Flow Meters

Design and construction of other types of f l o w meters shall be


t o the Approved Manufacturer's standard, provided that the
materials and pressure design is suitable for the applicable
service conditions. Welded in equipment is subject t o individual
Company approval.

Installation Notes

7.6.1 Differential Pressure Installations

a. Piping isolation block valves shall be supplied for all


differential pressure installations. Transmitters may share
isolation valves (e.g., in the case of high turndown
applications where t w o transmitters are used) but
instruments o n shutdown service shall have individual locked
oDen block valves.

b. A five-valve manifold shall be provided for all differential


pressure transmitters.
Specification Number Rev Date Sheet
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01 5-JH-1903 1 15-9-94 6 9 of 163
Sp&icBtion

Three-valve process manifolds may be used on low-pressure


installations.

The manifold shall be mounted o n the instrument support,


the transmitter shall be supported from the manifold.

lnstruments on shutdown service shall have their manifold


valve handles removed.

lnstruments o n toxic, high-pressure or flammable service


shall have their manifold vents and drains piped t o a closed
header.

Process line tappings shall be fitted w i t h line class isolating


valves of roddable type. lnstruments shall be close coupled
whenever possible. The use of condensate pots and vent
chambers shall be minimised b y use of respective elevations
of the tappings and the instrument, t o provide self-draining
for dry gases and self-ventinglwet leg filling for liquids and
condensates.

Tappings for immiscible fluids shall be horizontal t o minimise


separation.

Horizontal metering runs are preferred for liquid flow, and are
mandatory for eccentric orifices. Vertical runs may be used
w i t h downward f l o w for steam and condensates, and
upward f l o w for liquids close t o their boiling (vaporization)
point.

M i n i m u m straight metering lengths upstream and


downstream of the orifice plate or other primary element
shall be selected from the relevant tables in I S 0 5167. The
sections of the pipe in which the orifices are mounted shall
be cylindrical, smooth and free from splatters, burns and
scale. Mill finish internally is satisfactory within the above
conditions. The welded joint between the pipe and orifice
flange shall be square, concentric, free from undercut and all
excessive metal projection shall be removed by grinding after
the flanges are installed.

For accurate determination of the operating conditions at the


location of the f l o w measurement, a test thermowell shall be
provided, unless there is a temperature tapping already fitted
for another purpose. For gas or steam service, a pressure
tapping shall also be fitted. The tappings shall be outside the
required straight run.
Specification Number Rev Date Sheet
Engineering Group
015-JH-1903 1 15-9-94 7 0 of 163
Sp&cation

7.6.2 PD and Turbine Meters

a. If servicing of the instrument is required without shutting


d o w n the line, block and bypass valves are required. These
shall be in accordance w i t h the line specification i.e., dual
with bleed o n hazardous services. If the line is t o be shut
d o w n for service, at least one isolating valve of the block
and bleed type shall be provided in each meter path.

b. Strainers shall be installed upstream of metering installations.


The mesh of the strainer shall be selected t o cause minimal
pressure drop and shall be that recommended by the
Approved meter Manufacturer.

c. A n indicating device (e.g., differential pressure instrument)


shall be installed across the strainers t o measure any
increase in differential pressure caused by imminent
blockage, and shall be arranged t o activate a remote high
differential alarm at the DCS.

d. Turbine and PD meters shall be mounted in lines that are


always full of the fluid t o be measured

e. Airlvapour separators shall be provided where there is a


possibility of entrained gases in the fluids routed t o the
metering system. These devices shall be combined with the
filters where possible. The vapours must be routed t o a safe
disposal system or returned t o a lower pressure system.
Small quantities can be vented b y manual means, large
quantities require a fully automatic separation system
(outside the scope of this specification).

7.6.3 V A Meters

a. Fluids which may contain solids shall be adequately filtered


upstream of the V A meters.

b. V A meters shall be installed truly vertical and be located


w i t h sufficient clearance t o permit tube and float removal
without removing the meter body from the line.

c. I f the flow must not be interrupted during plant operations,


line size block and bypass valves shall be provided. The
meter shall normally be fitted in the bypass leg t o avoid line
stresses being imposed on the meter.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 7 1 of 163
Sp&iicab;on

7.7 Performance Reauirements

7.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o flow
instruments only and shall not in any w a y replace or reduce
the general QAIQC requirements.

b. The Inspection and Test Plan shall include the following


checks in addition t o those found necessary by the Approved
Manufacturer t o ensure the quality of the product:

A check o f all materials of construction by cross-


comparing the goods, the material test certificates and
the data sheets and Drawings.

A check o f the dimensions of the finished instruments


against the drawings supplied for the Contract and
approved b y the Company.

A check of the completed instruments and all


accessories against the data sheet and specification
requirements.

A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

Full testing of the instrument in accordance this


specification, the Approved Manufacturer's additional
QAIQC procedures and the approved Test and
Inspection Plan.

A check o n the instrument and accessories painting and


protection and general suitability for the environment.

A check on the tagging in accordance this specification


and the data sheets.

7.7.2 Testing

a. Forged items or items which are formed b y welding into a


pressure enclosure shall be hydrostatically tested at 1.5
times the rating of the flanges.

b. Transmitter instruments shall be factory calibrated t o the


range noted o n the data sheets.
Specification Number Rev Date Sheet
Engineerhg Group
01 5-JH-1903 1 15-9-94 7 2 of 163
SpecHmtbn

7.7.3 Documentation

All the certification for each instrument or group of instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed Test and Inspection Plan.

b. Material certificates and component certificates.

c. NDT certificates.

d. Weld procedures and qualifications.

e. Pressure test certificates.

f. Calibration certificates.

g. As-built Drawings as necessary.

7.8 N a r n e ~ l a t eData

General information for production of the nameplate data is given in


section 4.7 of this specification, lnstrument Identification. Additionally,
for orifice plates, the following information is required t o be stamped o n
the projecting tag of the orifice plate:

On The Upstream Face:

a. lnstrument tag number.

b. Line rating.

c. Plate material and thickness.

d. Plate bore size and pipe internal diameter (ID).

f. Process fluid and temperature.

8.0 PRESSURE MEASUREMENT

8.1 A ~ o l i c a b l eStandards

BS 1780 Specification for Bourdon Tube Pressure and Vacuum


Gauges

8.2 S c o ~ eof Pressure Measurement Section

This section covers the measurement of all process pressure variables in


Specification Number Rev Date Sheet

@ KOC Engineerhg Group


Sp&cation 01 5-JH-1903 1 15-9-94 7 3 of 163

the plant, for the purposes of local indication, local control, remote
signalling or transmission.

8.3 and Selection


Pressure Instruments T v ~ e

8.3.1 Local lndication o f Pressure or Differential Pressure

a. Local indicators shall be installed for monitoring purposes


wherever there is a pressure change of the process caused
b y the action of a control element of the system. They shall
also be installed for the following purposes:

1. Where a vessel code requires a gauge t o be fitted

2. Where a filter or other piece o f equipment is subject t o


change of pressure drop o n a "life" or "maintenance
period" basis.

3. Wherever there is a transmitter or s w i t c h detecting a


pressure variable.

4. A t positions o n the plant where the process designer


deems that pressure monitoring is desirable.

b. Local indicators shall be of the following types:

1. 1 5 0 - m m (6-in.) dial-size field mounted absolute, gauge


or differential pressure gauges.

I 2. 100-rnm (4-in.) board mounted gauges.

I 3. Strip-type draught gauges

I 8.3.2 Pressure Measurement For Remote Control or lndication

a. Electronic transmitters shall be used in all cases where a


continuous transmission of a pressure measurement is
required in the control room for use in a control loop, or for
indication or data acquisition.

b. Transmitters shall be installed w i t h a local output indicator.


This may be an integral part o f the transmitter body,
provided it can be clearly read in the finally installed position.
Otherwise, it shall be a loop powered or re-transmitted
output of the measured signal.

c. If the output is used t o assist the local operation of a control


valve w i t h handwheel or valved bypass, a local indicator
scaled in physical units shall be visible from the control valve.
-
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specjfication 01 5-JH-1903 1 15-9-94 7 4 of 163

d. If a transmitter is o n shutdown service, the measurement


shall be duplicated by a locally mounted direct reading
pressure gauge, having its o w n process tapping. Local
output indicators are not acceptable for this duplicate
measurement.

8.3.3 Alarms and Trips

a. Alarms

1. Intermediate alarms and pre-alarms shall be generated in


the DCS from a transmitter signal that is also used for
control and/or indication.

2. Pressure gauges with a switch contact may be used only


for alarms o n non-hazardous service such as HVAC. The
application of such switches is subject t o approval b y
the Company. Where used, these switches shall be of a
type that maintains the signal for the whole range
respectively above or below the set-point (not
momentary); otherwise the Contractor shall provide
latchldelatch logic.

b. Trips

For applications where the detection of high-high and/or low-


l o w pressure is used for general or local shutdown, a
dedicated process pressure switch is required.

8.3.4 Local Pneumatic Pressure Control

a. Where local pressure control is specified, a pneumatic


pressure transmitter shall be used, feeding into a local
receiving controller.

b. For suitable services approved b y the Company, the pressure


element may be incorporated as an integral part of a local
controller. The design of the instrument shall be t o the
Approved Manufacturer's standard practice. The local
controller shall be in accordance t o section 1 2 . 2 . 2 of this
specification.

8.3.5 Viscous, Corrosive or Particulate Service

Special methods for prevention of nozzle blockage shall be


adopted, such as diaphragm seals andlor flushing systems, t o
ensure the integrity and availability of instruments installed in
adverse process conditions.
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8.4 Sizina and Ranainq Reauirernents

The pressure applied t o the instrument shall be corrected t o


allow for static pressure heads from tall vessels etc.

Instruments for vacuum service shall have under-range


~ r o t e c t i o nof full vacuum.

Pressure Gauges

Pressure gauges shall be ranged so that the normal pressure


shall be in the middle third of the w a n .

For large turndown requirements, the normal pressure can be


read at a maximum of 7 5 % of scale provided that the
maximum pressure is not above 9 0 % of scale. Additional
gauges shall be added as necessary t o ensure that the
process range is adequately covered.

Ranges shall be selected from the standard list in BS 1780,


Part 2.

The gauge shall be able t o withstand, without affect on the


zero or calibration range, the safety relief pressure of the
system in which it is installed. If this cannot be
accomplished within the design over-range of the instrument
(which shall not be less than 1 . 4 x range for standard
gauges), other provisions such as over-range protection shall
be installed.

Pressure Transmitters (Electronic and Pneumatic)

a. Where possible, pressure transmitters shall use the same


range selection as pressure gauges. However, the range of a
transmitter shall always be within the range of the local
gauge used t o monitor its output.

b. The normal pressure shall not be read at greater than 7 5 %


o f the transmitter calibrated range for instruments reading
steady pressure. For fluctuating service, the normal pressure
shall be not more than 60% o f the range. Suppressed ranges
can be used for control loops or large ranged indications t o
improve accuracy and clarity of the readout.

c. The calibrated range of the transmitter shall preferably utilize


between 6 0 % and 8 0 % of the capsule span. Under no
circumstances shall the unit be calibrated outside the
Approved Manufacturer's recommendations for span and
turndown rating.
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01 5-JH-1903 1 15-9-94 7 6 of 1 6 3
Spec17icabion

8.4.5 Pressure Switches

The pressure switch span shall be selected t o cover the


requirements of :

1. The required range.

2. The switch reset hysteresis.

3. Be within the range of the monitoring pressure gauge.

The proof pressure shall be within the system relief pressure.


"Gauge minders" are not permitted o n shutdown
instruments.

Particular attention shall be paid t o ensure that the switch


reset can occur without completely venting lines, stopping
pumps etc.

8.5 Desian and Construction

Instruments measuring absolute pressure shall have compensation for


barometric pressure changes.

8.5.1 Pressure Gauges

a. Casing and Dial

Gauges o f 150-mm (6-in.) diameter shall be standard.


100-mm (4-in.) gauges shall only be used for panel-
mounted applications where a number of gauges are
installed together. Draught gauges of strip type shall be
mounted on a local panel w i t h illumination or may
employ a quadrant edgewise illuminator.

The connection shall be at the bottom and shall be 112-


in. NPT male for process gauges and 114-in. NPT male
for receiver gauges. Diaphragm sealed gauges shall use
the Approved Manufacturer's standard connection
(normally 1-in. flange t o line pipe rating).

Gauges shall be moisture and dust resistant w i t h n o


change of atmosphere.

Dials shall be white w i t h black numerals.

Gauges shall be fitted with shatterproof safety glass.


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The casing shall be of Phenolic material or 3 1 6 stainless


steel.

Circular gauges below 2 5 barg ( 3 6 3 psig) scaling shall


have a safety blow-out disc in the back. Gauges for
higher pressures shall have a solid front and blow-out
rear. Gauges for services above 4 0 barg ( 5 8 0 psig) shall
be the full safety pattern type.

The gauge shall be filled w i t h glycerine as standard,


gauges in vibration or pulsation duty shall be fitted w i t h
gauge snubbers (pulsation dampers) t o the same
material specification as the element.

The dial shall be marked as follows:

(a) Unit title.

(b) Manufacturers full name.

( c ) Manufacturers full model number.

(d) Element material spec. and grade.

(e) Other key details, e.g., "To NACE MR01075" etc.

b. Measuring Element and Movement

For general use, the gauge shall use a bourdon tube


measuring element. The accuracy shall be 1 % or better.
The movement shall be either rotary geared stainless
steel or cam and roller type. There shall be an external
zeroing device.

Slack diaphragm elements can be used for l o w pressure


applications (less than 0 . 8 barg, i.e., 1 2 psig).

Bellows or diaphragm elements shall be used for


differential pressure gauges.

Dual element gauges shall only be used when the


differential pressure exceeds 10% o f the available static
Dressure.

The element material for process gauges shall be 3 1 6


stainless steel as a standard, and t o a superior
specification when the service demands.
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01 5-JH-1903 1 15-9-94 7 8 of 1 6 3
Speaiccafion

6. Receiver gauges shall have bronze extra-wide bourdon


tubes w i t h brass socket and tip.

8.5.2 Electronic Transmitters

a. Electronic transmitters shall be of the strain gauge, piezo-


resistive or capacitance type. Other elements may be used
provided that accuracy, stability and reliability criteria meet
operational requirements.

b. For low-pressure ranges, minus 1 barg t o plus 2 barg (minus


1 5 t o + 3 0 psig), differential pressure instruments shall be
used for gauge pressure service, w i t h the low-pressure
connection open t o the atmosphere or connected t o a
reference zero.

c. Electronic transmitters shall be of the two-wire type,


operating at a nominal 2 4 VDC. They shall be certified for
the hazardous area in accordance w i t h the execution code
noted in the Engineering Group Specification entitled
"Instrument Engineering Basic Data" (Number 0 1 5-JH-I 9 0 1 ) .

d. Electronic transmitters of the "smart" type shall be used.

e. Transmitters shall have a minimum 1 0 0 barg ( 1 4 5 0 psig)


rated stainless steel body. All wetted parts shall be 31 6
stainless steel as a minimum, with the specification
increased as necessary for the service.

f. Transmitters shall be capable of withstanding over range


pressure on either side of the capsule at least equal t o the
body rating.

g. Connections shall be 112-in. NPT female

h. Electrical entry shall be M 2 0 x 1.5 I S 0

i. Mounting shall be by bolting t o the mounted manifold


wherever possible, and shall be from the manifold in cases
where the vent and drains are piped or a protection box is
supplied.

8.5.3 Pressure and Differential Pressure Switches

a. Pressure switches shall be of a design where the sensing


element is remote from the switch housing. The movement
of the element shall be translated into a snap action on the
switch, with a fixed or adjustable differential.
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Switches shall be hermetically sealed single-pole double


t h r o w (SPDT). The switch contacts shall be selected
according t o the service conditions and certification stated in
the Contract requirements. Generally, this shall be:

1. For Ex'd' apparatus connected directly t o a PLC or relay


system, contacts shall be minimum I amp rated for 1 1 0
VAC.

2. For IS systems using "simple apparatus," contacts shall


be gold plated and suitable for l o w signal levels.

The set-point shall be adjustable over the whole range, with


an internally calibrated scale.

The process wetted parts of the system shall be of 3 1 6


stainless steel material as a minimum, with the specification
increased in accordance with the process requirements.

To avoid the need t o provide barrier glands for electrical


entries, pressure switches shall be of a type which provide
positive protection against process fluids entering the
electrical housing in the event of element failure, i.e., by
means of a solid barrier and a vent.

Process connection shall be 112-in. NPT female.

Electrical connection shall be M 2 0 x 1.5 ISO.

Mounting arrangements shall be the Approved


Manufacturer's standard.

8.5.4 Pneumatic Pressure Transmitters

a. Pneumatic transmitters shall be o f the motion-balanced


nozzle and flapper type.

b. The output will be from 0.2 t o I.O barg (3 t o 1 5 psig), with


a 1 . 4 barg ( 2 0 psig) supply air pressure.

c. A n output signal gauge shall be supplied.

d. Process connection size shall be 112-in. NPT female. Signal


and air supply connections shall be 114-in. NPT female.

e. Mounting will be by 2-in. pipe clamp.


Diaphragm Seals

All instruments used for handling viscous or corrosive fluids


shall be sealed. Seals may be the liquid type employing seal
pots or the chemical sealed type (diaphragm seal) utilizing a
diaphragm and a silicon oil (or other suitable fluid) filling t o
transmit the pressure signal.

Diaphragm seals are the preferred method within the


constraints of temperature limitation for the filling fluid. The
instruments shall be purchased w i t h the seals and capillary
tubes fitted and tested as a unit.

For instruments used o n differential pressure service, the


low-and high-pressure chambers shall be o f equal volume
when chemical seals are fitted.

Capillary tubing shall be stainless steel 3 - m m (118-in.) ID


protected b y spiral-wound stainless steel armour sheathing.

Flushing Systems

a. Flushing can be constant b y use of a constant f l o w regulator


and low-flow alarm, or intermittent b y manual pump. Valve
connections shall be provided o n a spool between the line
class valve and the seal where flushing is t o be performed.

b. The flushing liquid shall be compatible w i t h the process fluid.

High-Temperature Service

Process instruments connected t o high-temperature systems


shall be installed w i t h provision t o maintain the instrument
temperature below 70" C (158'F) during normal duty, venting
and bleeding etc. A condensate seal, scroll, extended capillary or
proprietary cooling extension shall be fitted.

Low-Temperature Service

Pressure instruments connected t o crude oil, w e t gas or water


service in sub-zero conditions shall have winterisation provisions.

Pulsating Service

a. Instruments connected t o equipment and services in


pulsating service shall be protected b y pressure snubbers of
an approved adjustable type. The material for the snubbers
shall be the same as that selected for the instrument wetted
parts.
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Spea'fcathn

b. The use of partially closed valves is not permitted.

8.5.10 Range Protection

a. Pressure instruments shall generally be pressure rated up t o


the setting of the system relief valve, or other maximum
pressure that can arise under fault conditions. Where this
would prevent the instrument being suitably ranged for its
process function, the correct range shall be selected and
over-range protection shall be provided.

b. Over-range protection is not permitted on emergency


shutdown pressure switches.

c. The protectors, or "gauge minders," shall be adjustable ( w i t h


lock-nut) and shall be of a material equal t o that selected for
the instrument wetted parts.

8.6 Installation Notes

A piping block valve may be shared by a transmitter and local


gauge, but a shutdown instrument shall have an individual
locked open line class block valve.

Where an instrument is mounted at a distance exceeding 2.5 m


( 8 ft.) from the primary block valve, an additional block valve
shall be installed adjacent t o the instrument. The block valve and
connecting piping shall be line class.

Each direct pressure instrument shall have an individual t w o -


valve manifold. A five-valve manifold shall be used for DP
application. Low-pressure DP may use a three-valve manifold.
Shutdown manifolds shall be labelled as such and valve handles
removed.

Manifold vents and drains shall be piped t o a safe place or


disposal system except for instruments in non-hazardous service
such as low-pressure non-toxic and non-flammable fluids.

Pressure instruments shall be installed in orientations in


accordance with the Approved Manufacturer's instructions and
shall not be mounted directly o n machinery.

Gauges up t o 150-mm (6-in.) diameter may be supported direct


from the process pipe work in suitable cases.

Pulsation and gauge minders when required shall be mounted as


close t o the instrument as possible.
8.6.8 Pressure instruments o n LPG or high-pressure steam service shall
be fitted w i t h a restriction orifice of 1.44-mm (1116-in.) diameter
downstream of the piping class block valve t o prevent excess
flow in the event of a fracture o f the measuring element.

8.6.9 The transmitter air signal output piping from pneumatic


transmitters shall incorporate a tee w i t h valve and plug for
connection o f a calibration gauge.

8.7 Performance Reauirernents

8.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o pressure
instruments only and shall not in any w a y replace or reduce
the general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality o f the product:

A check of the instrument and all accessories in


accordance with this specification and the data sheets
and Drawings.

Full works calibration and issue o f test and calibration


certificate.

A check on the nameplate data in accordance with this


specification and the data sheets and Drawings.

A check o n the painting and protection and general


suitability for the environment.

A check o n the tagging in accordance w i t h this


specification and the data sheets.

8.7.2 Documentation

The following data shall be available at final inspection:

a. Completed test and inspection plan.

b. Material certificates and NACE certificates where required by


the Contract.

c. Instrument test and calibration certificate.

d. Hazardous area certificates.


8.8 Nameolate Data

General information for production of the nameplate data is given in


section 4 . 7 of this specification.

9.0 TEMPERATURE MEASUREMENT

9.1 A ~ ~ l i c a b Codes
le

BS 1 8 4 3 Colour Code for Twin Compensating Cable for


Thermocouples

BS 1 9 0 4 Specification for Industrial Platinum Thermometer Sensors

BS 4 9 3 7 International Thermocouple Reference Tables

9.2 S c o ~ eof Tern~eratureMeasurement Section

This section covers the requirements for the measurement of temperature


variables in the plant for local indication, local control, remote control,
remote signalling and transmission.

9.3 Temoerature Instrument Tvoes and Selection

9.3.1 Local Indication of Temperature

a. Local indication of temperature shall generally be by bi-


metallic, gas-or liquid-filled dial thermometers.

b. Mercury in steel thermometers for local indication, recording


or control is not permitted.

c. Bi-metallic thermometers shall only be used where errors in


indication in excess of 1 % of span are acceptable.

d. Local temperature indication o n cryogenic service shall utilize


a galvanometer-type indicator in conjunction w i t h a pad-type
thermocouple. These indicators shall be direct reading in "C,
w i t h "F equivalents.

9.3.2 Temperature Measurement for Remote Control or Indication

a. Thermocouples or resistance thermometer detectors with


local millivolt or resistance t o current converters are the
chosen method of temperature measurement and signal
transmission for centralized control, multi-point indication
and recording.

b. The choice between resistance thermometers and


thermocouples shall be made, taking the following points
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Spedficatbn

into consideration:

1. Where accuracy of measurement greater than that


obtainable w i t h a thermocouple is required, a resistance
thermometer shall be used.

2. Resistance thermometers shall not be used where high


frequency vibration is present, e.g., in high-velocity
steam or gas streams, or at temperatures greater than
750°C ( 1380°F).

c. Resistance Temperature Detectors (RTDs) shall be used in


the following specific applications:

1. Temperature compensation in f l o w measurement.

2. Remote indication of temperature span less than 5 0 "C


(122°F) or where the span of temperature t o be
measured includes 0" C (32°F).

3. Where a temperature measurement is t o be used t o


prove a plant's performance (mass balance).

d. Thermocouples and RTDs shall be provided w i t h field


mounted 4 - 2 0 mA, two-wire "smart" transmitters certified
for the electrical area classification.

Wherever possible, a local temperature indicator shall be fitted at


the same process position as the transmitting element.

Alarms and Trips

a. Alarms

1. Intermediate alarms and trips shall be generated in the


DCS software from the transmitter signal that is also
used for control and indication.

2. Dial thermometers with integral switches shall not be


used as field-mounted temperature switches.

For applications where the detection of high-high or low-low


temperature trips are required for general or local shutdown,
dedicated temperature-measuring points w i t h dedicated
transmitters and trip amplifiers shall be specified. High-high
and low-low trip may be generated from the same
transmitter (and trip amplifier) provided it is in range.
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specjfi~ahn

c. Thermocouples or resistance thermometers used in


conjunction w i t h interlocks or ESD systems shall not be
connected t o any other instrument.

9.3.4 Local Temperature Control

Where local temperature control is required, thermal liquid or


gas-filled type indicating transmitters shall be used, with the
pneumatic output feeding a receiving controller. Details of
pneumatic controllers are given in a section 12.2.5 of this
specification.

Combined transmitterlcontrollers of the liquid-or gas-filled


type may be offered for Company approval for simple
services such as tank heating up t o 300" C (572°F) range.

Pneumatic instruments shall have an output o f 0.2-1.0 barg


( 3 t o 1 5 psig) w i t h a supply pressure of 1 . 4 barg ( 2 0 psig).
A n output gauge shall be provided.

The transmitter element shall be a bulb type, 12-mm (112-


in.) diameter preferred, with a bendable neck and armoured
PVC-sheathed capillary connection t o the transmitter.

The normal ranges shall be 5 O ( l 2 2 ) , l O O ( 2 l 2 ) and 2 0 0 ( 3 9 2 )


"C ( O F ) .

When local temperature transmitters are fitted, a check dial


thermometer shall be fitted in the same process position.

9.4 Sizinq and Ranqina Requirements

9.4.1 The use of RTDs shall be limited t o the range : -200" C t o + 7 5 0


"C (-328°F t o + 1380°F).

9.4.2 Thermocouples shall be ranged according t o the temperature


limitations of the couple materials or limitations imposed by the
specific application and are as follows:
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Spec&ahn

1 1
T ,v. ~ e Material I Nominal Temperature
( Range "C (" F).
I I

l B l Platinum - 3 0 % Rhodium
/Platinum - 6 % Rhodium
0 to 1820
(32 to 3300)
E Nick - Chromium -270 to 1000
/Copper - Nickel (-450 t o 1 8 3 0 )
J IronICopper - Nickel -210 to 760
(-340 to 1400)
K Nickel - Chronium -270 to 1372
/Nickel - Aluminium ( - 4 5 0 t o 2500)

Platinum - 1 3 % Rhodium
/Platinum 1 -50 to 1768
( - 6 0 t o 32201
S Platinum - 1 0 % Rhodium -50 to 1768
/Platinum -(60 to 3220)
T CopperICopper - Nickel -270 to 440
(-450 to 750)

Type J and K thermocouples are the preferred types; other types


may be used for specific applications subject t o Company
approval.

Local indicators (dial thermometers) shall have the following


preferred standard ranges:

The range of any temperature measuring instrument shall be the


Approved Manufacturer's shortest standard span appropriate t o
the application.

9.5 Construction Recluirements

9.5.1 Temperature Gauges

a. Gauges or dial thermometers shall be bi-metallic, gas-or


liquid-filled type w i t h a 150-mm ( 6 -in.) dial calibrated in "C
and "F equivalent. A n extension capillary shall be specified t o
facilitate ease o f reading; where a capillary extension is
used, the capillary tube shall be supported along its length.
b. Capillaries shall be stainless steel armoured and PVC
covered.

c. Bi-metallic dial thermometers shall be hermetically sealed,


every angle, 9.5-mm (318-in.) stem, with external pointer
adjustment.

d. The connection of the head t o the well shall be by 112-in.


NPT adjustable union.

9.5.2 Resistance Temperature Detectors (RTDs)

a. RTD elements shall comply w i t h BS 1 9 0 4 and shall be


Platinum type PT 100, i.e., 1 0 0 ohms @ 0°C. and
Fundamental Interval (FI) o f 38.5 ohms. They shall be of the
grade of accuracy appropriate t o the application.

b. RTDs shall be connected t o measuring instruments by either


a three- or four-wire system. Three wire systems are
preferred for normal process measurement applications.

c. All applications shall use duplex element RTDs even if only


one signal is required.

9.5.3 Thermocouoles

a. Thermocouples shall comply w i t h BS 4 9 3 7 .

b. Thermocouples shall be mineral insulated spring-loaded type,


sheathed t o 6-mm (114-in.) diameter w i t h the hot junction
insulated from or bonded t o the sheath. Larger diameter
sheaths may be used for special applications.

c. Thermocouple sheaths shall be constructed from seamless


tube material of minimum 1 - m m (3164-in.) wall thickness
selected t o suit temperatures and specific conditions. (See
section 9 . 4 for details.)

d. The minimum sheathing material grade is 3 1 6 stainless steel.


lncolloy shall be used for all services above 1000" C
( 1832°F)

e. Thermocouples for use above 1 2 0 0 " C (2192°F) may be


constructed from bare wire w i t h ceramic insulators for
applications where the element may be prone t o binding in
the well.

f. All applications shall use duplex thermocouple elements,


even if only one signal is required.
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SpeiMcabion 01 5-JH-1903 1 15-9-94 8 8 of 163

Thermocouple head terminals shall be marked w i t h positive


and negative symbols. When the thermocouple has wired
terminations, these should preferably be colour coded t o BS
1843. Alternatively, they shall be sleeved and identified as
positive and negative.

On cryogenic process pipework, pad-type thermocouples


shall be used wherever possible. Thermowells shall only be
used where absolutely necessary for accuracy or sensitivity.

Skin thermocouples shall be specified in certain special


applications, e.g., furnace tube skin temperature
measurement; the hot junction shall be permanently secured
t o the tube or pipe. The protection tube or pad shall be
shaped t o match, and welded t o the furnace tube or pipe.
External insulation shall be fitted over the protection tube
where it is e x ~ o s e dt o the burner flame.

Care shall be taken in the selection of the protection tube


material and pad t o ensure the correct metallurgy of the
weld t o the parent pipe.

Terminal Head

Thermocouples and RTDs shall be o f the duplex type, i.e.,


t w o elements mounted in the same thermowell or sheath
with all connections taken t o a head-mounted terminal block.
The elements shall be connected d o w n t o an intermediate
junction box mounted adjacent t o the transmitter and
containing sufficient terminals t o connect both elements. For
thermocouples, the cable shall be the correct-extension type
and the terminals shall be manufactured from the correct-
extension material.

One element shall be connected from the intermediate


junction box t o the field mounted transmitterlconverter. For
thermocouples, the correct extension cable shall be used.
The second element shall terminate at the intermediate
junction box terminals, enabling the element t o be changed
over at the junction box in case of failure of the first
element.

Head-mounted terminal enclosures and the intermediate box


shall be weatherproof t o IP65 as a minimum and certified for
the electrical area classification.

When t w o or more thermocouples or resistance detectors are


located in the same thermowell, they shall be individually
and permanently identified regarding function, e.g.,
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SpeiHcaLkm

temperature-indicating controller (TIC) or temperature


indicator (TI).

e. The head shall be connected t o the well b y a galvanised


extension complete w i t h a union coupling. The connection
thread in the well shall be 112-in. NPT.

9.5.5 Temperature Switches

a. Temperature switches may only be used in specific


circumstances w i t h specific Company approval such as
"package vendor" equipment of standard design, or where
indicated o n the approved P&IDs.

b. Temperature switches shall be SPDT, weatherproof t o IP65


minimum and must be certified for the electrical area
classification. Switches can be of the liquid-filled type with
stainless steel bulb, capillary and armour and shall include
union connection. Alternatively, switches may be of the bi-
metallic type. Temperature setting and differential
adjustment shall be external t o the switch housing.
Indicating-type switches are preferred.

c. Electrical entry size shall be 20 mm, threaded t o I S 0 1.5.

9.5.6 Temperature Transmitters

a. Electro-motive force (EMF) or resistance t o current


converters shall be used for all remote transmission of
temperature signals.

b. Converters shall be field mounted at the nearest accessible


point adjacent t o the measuring point, and be of "smart"
type. Converters shall be weatherproof t o IP 6 5 as a
minimum and shall be certified for the electrical area
classification.

c. Dial thermometers shall be provided as a "check gauge" for


temperature measuring points where indicated on the P&IDs.

d. Transmitters shall be specified suitable for the installed


thermocouples and the installed three- or four-wire RTD
configurations and shall have upscale burnout in the event of
loss o f input from either RTDs or TICS. They shall
incorporate linearisation circuits in accordance w i t h the
connected element. Outputs linear t o input signal are not
acceptable. Linearisation in the auxiliary room interface
cabinet or the DCS 110 is acceptable as an alternative.

-
Rev Date Sheet

OKOC
Specification Number
Engineering Group
01 5-JH-1903 1 15-9-94 90 of 163
SpecMcation

e. Electrical entry shall be 20 m m (314 in.) 1.5 ISO.

9.5.7 Thermowells

a. Thermowells shall be specified for all temperature detecting


elements, with the exception of detectors on skin point and
cryogenic service, and shall enable the element t o be
removed during plant operations.

b. 40-mm (1.5-in.) flanged thermowells shall be used for all


normal duties o n pipework and 5 0 m m ( 2 in.) for vessels,
unless otherwise stated. Thermowells shall be solid drilled
and tapered, the flange shall be attached b y fillet welding for
3 0 0 lbs rated flanges and full-penetration welding for higher
ratings.

c. Flange ratings shall be 3 0 0 lbs. minimum or a higher rating


t o suit the relevant vessel or piping specification. The flange-
face type and finish shall be in accordance with the relevant
piping specification.

d. Thermowell material shall be 3 1 6 stainless steel minimum or


alternative materials t o suit process conditions.

e. Screwed thermowells, size 314-in. NPT, shall only be used


on cooling water or atmospheric vessel applications.

f. The ID of thermowells for duplex thermocouples and


resistance thermorneters shall be t o suit 6 m m (114 in.)
elements. Larger diameter elements may be used for special
applications.

g. The surface of the well shall be smooth and free from burrs
and notches. The transition at diameter changes and
connection t o the flange shall be a smooth radius t o
minimise stress amplification.

h. Where thermowells are installed in gas or vapour lines or in


lines subjected t o high-liquid velocities, combined stress and
vibration calculations shall be carried out t o a proven
method.

i. All thermowells shall be manufactured of certified materials


and shall be pressure tested. Welding shall be conducted in
accordance with ASME IX.

j. Proprietary thermowells supplied w i t h instruments shall meet


the requirements of this specification.
Specification Number Rev Date Sheet
Engineering Group
01 5 . ~ ~ ~ 1 9 0 3 1 15~9~94 91 of 163
SpMcation

9.6 Installation Notes

9.6.1 Thermowells shall not be installed in line sizes less than 1 0 0 m m


(4 in). In smaller lines where temperature measurement is
required, the line shall be swaged up t o 1 0 0 m m (4 in) or, for 3-
in. lines and above, the thermowell shall be mounted in an
elbow.
9.6.2 Temperature instruments, i.e., dial thermometers, transmitters
etc shall be installed such that they are readable and accessible
from ladders and platforms.

9.6.3 All wells shall be installed in positions such that the element and
head can be withdrawn without removing other equipment.

9.7 Performance Reauirements

9.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o temperature
instruments only and shall not in any w a y replace or reduce
the general QAIQC requirements.

b. The inspection and test plan shall include the following


checks in addition t o those found necessary by the Approved
Manufacturer t o ensure the quality of the product:

A check of all materials of construction by cross-


comparing the goods, the material test certificates and
the data sheets and Drawings.

A check of the dimensions of the finished instruments


against the Drawings supplied for the Contract and
approved b y the Company.

A check o f the completed instruments and all


accessories against the data sheet and specification
requirements.

A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

Full testing of the instrument in accordance this


specification, Approved Manufacturer's additional
QAIQC procedures and the approved test and inspection
plan.

A check on the instrument and accessories painting and


protection and general suitability for the environment.
7. A check o n the tagging in accordance this specification
and the data sheets.

Testing

a. Forged items or items which are formed b y welding into a


pressure enclosure shall be hydrostatically tested at 1.5
times the rating of the flanges, or 1.5 times the line rating,
whichever is higher.

b. Transmitter instruments shall be factory calibrated t o the


range noted on the data sheets.

Documentation

All the certification for each instrument or group of instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed Test and Inspection Plan.

b. Material certificates and component certificates for


thermowells.

c. NDT certificates (minimum dye penetrant test of all welds).

d. Weld procedures and qualifications.

e. Pressure test certificates.

f. Calibration certificates.

9.8 Nameolate Data

General information for production of the nameplate data is given in


section 4.7 of this specification, lnstrument Identification. Additionally,
for thermowells, the following information is required t o be stamped on
the flange rim or lagging extension:

a. Instrument tag number.

b Temperature Range.

c. Flange rating and size.

d. Test pressure.

e. Material
Specification Number Rev Date Sheet

, SpeMcatr;on 01 5-JH-1903 1 15-9-94 93 of 163

f. Bore (element) size.

10.0 LEVEL MEASUREMENT

10.1 Aoolicable Standards

BS 3 4 6 3 Specification for Observation and Gauge Glasses for


Pressure Vessels

10.2 Scooe of Level Measurement Section

This section details the measurement of all process level variables on the
plant, for the purposes of local indication or remote signalling or
transmission.

10.3 Level Instrument Tvoe and Selection

10.3.1 General

a. Level instruments shall be selected t o provide the required


accuracy and integrity w i t h the emphasis o n simplicity of
installation and maintenance.

b. Level instruments shall be placed in chambers external t o the


vessel and not mounted internally except w i t h the approval
of the Company.

c. Level instruments shall be mounted o n stand pipes (bridles)


t o avoid excessive numbers of individual vessel nozzles,
provided that:

1. Construction requirements o f the pipinglvessel


fabrication code can be met without compromising the
required ranges.

2. Access for operational readings and maintenance is not


impaired.

3. Walkway clear space is not impeded.

d. Where a safety trip function is required, a separate


instrument shall be supplied. Shutdown instruments shall not
share connections or standpipes w i t h control instruments.

e. I f level instrument requirements are included in the


fabrication code for the vessel, these shall be followed
during the selection and the specification o f level
instruments.
Specification Number Rev Date Sheet
Engineen'ng Gmup
0 1 5-JH-1903 1 15-9-94 94 of 163
SpeiHCdtion

f. Some liquids which in their service condition may be of


suitable consistency for float or displacer measurement
methods may form coagulants when exposed t o reduced
temperatures in external chambers. In these cases, methods
shall be considered t o prevent this formation, e.g., by trace
heating, or an alternative instrument system selection.

10.3.2 Local Gauges

All vessels, columns and tanks which have level instruments


such as transmitters, controllers or switches shall be
provided w i t h local visual liquid gauges. Other vessels shall
have gauges when observation of level is important t o
operation or safety.

The gauge shall cover the complete operating range of any


other level instrument installed o n the same vessel section.

For local indication o f level, direct vision gauges of


transparent or reflex type shall be applied, unless process
conditions, physical dimensions or required accuracy mean
that other types of instruments offer technical or commercial
advantages without loss o f performance or integrity.

Glass tube gauges shall not be used. Gauges for caustic


service shall have protective sleeving or mica shielding.

Reflex gauges shall be used o n all clean services except


liquid level interface.

Transparent gauges shall be used on acid, caustics, dirty


fluids, coloured liquids and liquid interface where the
interface is visually discernible.

For high-pressure, high-temperature, toxic or hazardous


duties the use of magnetic follower gauges shall be
considered. DP type, self-acting mechanical level indicators
(Yarway type) may be used for the back-up gauge o n steam
drum applications.

For large vessels and tanks, a number of overlapping gauges


shall be used. The overlap of the visible length shall not be
less than 2 5 m m ( 1 in.). For total ranges exceeding 2.2 m
(7ft.) on atmospheric or low-pressure systems, DP
measurement and transmission t o a local gauge, or the
requirements indicated in section 11, Tank Metering, of this
specification shall be considered.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 95 of 163
Specir7cdthn

i. For cold services, glass-type gauges can be obscured by


frost or condensation. "Non-frosting" gauges shall be
specified. For applications where heating o f level gauges is
required, the heating element(s) shall be external. Where
other conditions are favourable, a float-operated magnetic
coupled level indicator shall be considered for those
applications which would otherwise require a heated gauge.

j. Local level indicators for open storage tanks shall be float


type w i t h internal guides and w i t h a gauge board. Approval
shall be obtained from the Company for all internally
mounted installations.

10.3.3 Level Transmitters

Displacer-type instruments are preferred for transmitted


measurement of level when the range does not exceed 1.5
m ( 5 f t 0 in.), or 2.5 m (8 f t 0 in.) for static vessels and
separators. Lengths up t o 3 m ( 1 0 f t 0 in.) can be offered for
Company approval in special cases when the vessel has no
agitation.

Internally mounted displacers may be accepted, subject t o


Company approval, for simple applications such as for non-
corrosive atmospheric service and for storage tanks. Any
such proposal shall cover positive means of retaining,
retrieving and guiding the displacer.

DP transmitters shall be used for longer spans and where the


liquid is viscous, corrosive or particulate or where flashing,
agitation or vibration may occur. DP transmitters may be
used for non-critical applications such as water and fuel
tanks when the span is greater than 1 . 5 m ( 5 f t 0 in).

When materials are liable t o separate, solidify or deposit in


impulse lines the connections shall be purged andlor, if the
temperature permits, diaphragm seals shall be used.

Differential systems shall use a w e t reference leg except in


dry gas service when a dry or gas purged reference leg shall
be used.

Mechanical ball float level transmitterlcontrollers shall not be


used on process vessels.

Bubble-type systems may be used on atmospheric and


constant l o w pressure tanks of the blanketed type where the
accuracy is not of prime importance.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 96 of 163
SpMcatbn

h. Other types of measurement, e.g., capacitance or ultrasonic


may be offered t o the Company for approval. The use o f
radioactive instruments shall only be considered after
consultation w i t h the Company.

10.3.4 lnterface Service

The upper connection of all interface installations shall


always be submerged in the less dense liquid. Additional
connections t o the vessel may be installed as necessary t o
drain back separated fluids. The additional connections shall
be o f an equal size and standard as the main connections.
All proposed systems for interface measurement are subject
t o Company approval.

Gauging shall be b y through-vision gauge glasses where


practical. Float-type instruments with magnetic followers
may be used for suitable services.

lnterface transmitters shall normally be o f displacer type.


Where the specific gravity difference is 0 . 1 or less,
capacitance-type instruments shall be considered.

10.3.5 Alarms and Trips

a. Alarms

Intermediate alarms and pre-alarms shall be generated in the


DCS from a transmitter signal that is also used for control
and/or indication. The use of magnetic switches mounted
outside float-type level gauges t o generate alarms shall only
be used o n non-hazardous service and with Company
approval.

b. Trips

For applications where the detection of high-high and/or low-


l o w level is used for general or local shutdown, dedicated
instruments shall be used and they shall be direct-mounted
process switches. Float-type switches shall normally be
used. Displacer operated switches shall only be used where
the exact switching point cannot be determined at the
design stage.

c. If for mechanical reasons and if agreed t o b y the Company,


level switches have t o be internally installed, they shall only
be o n vessels which can be emptied and depressurised
during plant operation.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 9 7 of 163
Spea%icathn

d. Where appreciable changes in liquid density occur across the


plant operating range, including startup conditions,
calculations shall be performed, for Company approval, t o
confirm that the measurement system chosen for the
application is not rendered unsafe at any condition.

e. Corrections shall only be made t o transmitted signals used


for shutdown purposes when it can be shown that failure of
the correction signal in either direction cannot reduce the
shutdown integrity.

10.3.6 Tank Metering

Where accurate assessment of tank contents on a mass basis


are required t o be measured, the equipment is covered in section
1 1 . 0 of this specification.

10.3.7 Local Level Control

a. Where local level control is specified, a pneumatic


transmitter (displacer or differential pressure as appropriate)
shall be used, feeding into a receiver controller.

b. Combined transmitterlcontroller systems may be offered for


Company approval when the service conditions are suitable.

c. The local controller shall be in accordance w i t h section


12.2.4 of this specification.

10.4 Sizina and Ranains Reauirements

10.4.1 Range Criteria

a. The calculation of level instrument range depends o n the


physical dimensions of the installation. The operating levels
in the vessels can depend o n complex process calculations,
particularly when exposed surface areas are important, or
when dip tubes, overflow separation or similar vessel
internals are fitted. The selection of ranges should be
determined in association w i t h the Contractor's process
engineers t o achieve the required monitoring and control
while retaining a practical and economic installation.

b. The design of the system shall take into account the


avoidance wherever possible of trapped fluids when an
instrument is isolated and drained. This problem is more
common on small vessels. Changes of the preferred nozzle
locations are acceptable when there are improvements t o the
self-drainage or valve drainage systems.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 98 of 163
Specl7caiion

10.4.2 Level Coordination Sketches

Prior t o level connections being finalized on any vessel, tank


etc., detailed level coordination sketches shall be submitted t o
Company for review. These shall detail all pertinent factors,
dimensionally related t o the tangent line or inside-shell of the
vessel, such as:

Key dimensions o f vessels.

Instrument type and rating.

Connection centres type and rating.

Span or visible length.

Calibrated range.

Elevation for DP instruments.

Process level at normal, alarm and ESD levels.

Reference t o codes (e.g., steam drums) where applicable.

10.4.3 Visible Range

a. The visible length or display of the level gauge shall exceed


the range of the transmitter b y the greater of 5 % or 5 0 m m
( 2 in.) on both l o w and high level. The normal, alarm and trip
levels and the transmitter 0 % and 1 0 0 % points shall be
marked on the gauge body.

b. The range of the transmitter shall place normal level at the


5 0 % position unless modified by process restraints, shall
extend beyond the highest and lowest levels by the greater
of 5% of the range or 5 0 m m (2 in.), and shall encompass
any trip switches b y the same margin. If alarms are
generated b y the control transmitter, they shall be
sufficiently separated from the trip levels t o enable operator
intervention t o prevent a trip following an alarm. Such a
separation shall be the greater of 1 0 % o f the instrument
range or 5 0 m m ( 2 in.), or a calculated figure based o n the
rate o f change of level caused b y flow in or out of the
vessel, t o give the operator several minutes t o act.

10.4.4 Code Requirements

Where the vessel is designed t o special codes, e.g.,team drums,


and the code requirements conflict w i t h the general

2-0056
Specification Number Rev Date Sheet
Engineetfng Group
01 5-JH-1903 1 15-9-94 99 of 163
Spe&cBtion

considerations stated, the code requirements shall be complied


with.

DP Instruments

For DP applications, zero elevation/suppression calculations shall


be performed for each case. Where vessel level measurement is
severely modified b y temperature (density) changes, correction
shall be applied. Where the upper vapour density can vary
greatly because o f temperaturelpressure range, correction shall
be applied. The DP transmitter specification shall be attached t o
the calculation and submitted t o the Company for approval.

Direct Action

For transmitted signals (control or shutdown), an increase in


level shall give an increase in measurement unless otherwise
agreed t o with the Company for safe operation.

Interface Service

For liquid-liquid interface service, special attention shall be given


t o the displacer or float diameter t o enable satisfactory
sensitivity, especially when the difference in densities is small.

Standard Manufacture

Centre-to-centre dimensions, ranges and visible lengths of all


level instruments shall be t o the Approved Manufacturer's
standards. Specially designed instruments shall be used only in
exceptional instances with Company approval.

10.5 Construction Reauirernents

10.5.1 Connection Type, Size and Rating

a. Connections t o the vessel shall be in accordance with the


vessel specification for size (2-in. nozzles shall be used as a
minimum), flange rating ( 3 0 0 lb shall be used as a minimurn)
and flange facinglgasket type.

b. The connection t o the instrument shall be (refer t o table


below) 2-in. NB or I - i n . NB via a reducing nozzle or reducing
spool, 3 0 0 lb (minimum rating) and a line class isolating
valve.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 100 of 163
SpecHmtbn

The instrument connections and positions are as follows:

INST. TYPE CONN. POSN. INST. CONNECTION


I I
I Gauae Glass I side-side I 1 in.-300 lb min. I
Magnetic Gauge side-side 1 in.-300 lb min.
Displacement Tx side-bottom 2 in.-300 lb min.
Level Switch side-bottom 1 in.-300 lb min.
DP TX mnfr. std. 112 in.-NPT (5-valve
1 manifold)

Special connections and other sizes and types shall be


subject t o approval b y Company.

All instruments shall be fitted w i t h full bore roddable 112 in.


drain and vent valves. These shall be plugged for standard
services and piped t o a safe location for hazardous services.
Piped system disposal arrangements shall include a safe
visual means of checking that effluent f l o w has stopped,
e.g., tun dish or sight f l o w tube.

10.5.2 Stand Pipes (Vessel Bridles)

a. Where stand pipes are used they shall be constructed using


the same fittings, materials, codes, production techniques
and inspection procedures as the vessel trim. They shall be
4-in. NB but may be 2 in. or 3 in. w i t h Company approval.
They shall be connected t o the vessel b y isolating valves t o
line specification (minimum 3 0 0 lb rated) and be adequately
supported. Each instrument shall be individually served by
full-bore type roddable isolating valves of 1-in. NB 3 0 0 lb
minimum rating (2-in. NB for displacement transmitters). The
stand pipe isolating valves shall be capable of being locked in
the open position.

b. All stand pipes shall be fitted w i t h full bore roddable 314-in.


drain valves and 1-in. vent valves. These shall be plugged for
standard services and piped t o a safe location for hazardous
services. Piped system disposal arrangements shall include a
safe visual means of checking that effluent f l o w has
stopped, e.g., tun dish or sight f l o w tube.

c. The stand pipe shall be insulated t o at least the same


standard as the vessel. Since the temperature of the fluid in
the stand pipe will vary from the bulk fluid temperature,
calculations shall be performed t o ensure that:
Specification Number Rev Date Sheet
Engineering Group
1 15-9-94 101 of 163
Spedfic~fhn 01 5-JH-1903

1. Mechanical integrity is not affected b y differential


expansion between the nozzle centres. The weight of
the stand pipe and all the attached instruments shall also
be taken into account.

2. Fluid density changes do not cause measurement errors


outside acceptable limits for the application.

10.5.3 Materials and Fabrication

All instrument wetted pressure parts shall be constructed


using materials equal t o the vessel design specifications,
w i t h welding, heat treatment, NDT, certification and hydro-
testing all conducted t o the same standard as the vessel.

NACE, impact testing and any other special Project or


service requirements shall be noted o n the data sheets and
shall be supplied.

Operating parts o f the instruments shall be constructed of


materials suitable for the service w i t h a minimum
requirement o f 3 1 6 stainless steel.

If the float of float-type instruments cannot be pressure


tested at the vessel test pressure, this shall be clearly
labelled on the outside of the instrument.

Where the measured liquid contains particles or material


which would accumulate in the chamber or connecting
piping, the nozzle(s) shall be purged w i t h a compatible fluid.
The fluid shall be monitored b y a constant f l o w regulator and
alarm.

1 0 . 5 . 4 Visual Gauges (Glass and Magnetic Coupled Types)

a. General Requirements

1. All fittings and valves for gauges shall be of steel unless


the service requires different materials.

2. All gauges shall be stamped w i t h the maximum working


pressure and temperature.

3. Gauges o n vaporising service shall be manufactured with


oversized chambers.

4. Expansion and contraction of gauges used o n hot or cold


liquids shall be compensated w i t h piping expansion loops
supplied with the instruments.
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15-9-94 102 of 1 6 3
s~ecjfi~atkm

5. In addition t o the line class valve, all gauges shall be


supplied w i t h shutoff valves o n the top and bottom
connections and 112-in. full-bore roddable-type drain and
vent valves. Shutoff valves shall be 112-in. NPT nipple
connected of the handwheel-operated quick action
offset screw-down type, w i t h bolted bonnets and safety
velocity ball checks.

6. For special services using exotic materials, the shutoff


valve may be replaced w i t h a 112-in. line class valve or
omitted completely subject t o Company approval.

b. Glass Type Gauges

Glass tube gauges shall not be used.

Gauges on coded vessels shall be code stamped. All


gauges shall have approval b y Lloyds or an equal body.

Gauges shall comply generally w i t h the requirements of


BS 3463.

Gauges for caustic service shall be fitted w i t h caustic


resistant inserts.

Gauges for cold service shall have frost protection.

Double-plate and reflex gauges shall have forged steel


columns and toughened Borosilicate glass. Allowance
shall be made t o take up expansion without undue stress
on the instrument or nozzles.

Transparent gauges shall be backlit w i t h an illuminator


suitably certified for the hazardous area. A foot switch
shall be supplied, connected t o the electrical system in
such a w a y that the light remains on for an adjustable
period after depression of the switch. The specification
of the electrical items shall be in accordance with the
Engineering Group Specification entitled "Electrical
Design, Installation and Testing" (Number 0 1 5-PH-
1901).

Extended gauge glasses shall not be o f more than four


sections long.

c. Magnetic Coupled Gauges

1. T w o types are acceptable:


Specification Number Rev Date Sheet

@ KOC Engineering Group


SpeaiCicBtbn 01 5-JH-1903 1 15-9-94 103 of 163

a. Parallel-tube types having a density balanced float in


a parallel chamber magnetically coupled t o the float
in the process fluid.

b. Magnetic-indicator types where magnetised flaps or


balls w i t h contrasting paint colour on each side roll
over as the float magnet passes them.

2. The chamber material shall be 31 6 stainless steel unless


the service demands a higher specification.

10.5.5 Displacer Instruments

a. The top and bottom of the chamber shall be full-sized


flanged t o enable withdrawal of the displacer and cleaning.

b. The head shall be rotatable on the flanges t o enable


orientation.

c. The required handing shall be noted o n the data sheet

d. Electronic transmitters shall have an output of 4 - 2 0 mA for a


24-VDC supply and be certified in accordance with the
hazardous area and execution code stated in the Engineering
Group Specification entitled "Instrument Engineering Basic
Data" (Number 0 1 5-JH-1901). A n output indicator shall be
provided.

e. Pneumatic instruments shall have an output o f 0 . 2 - 1 . 0 barg


( 3 t o 1 5 psig) with a supply pressure o f 1 . 4 barg ( 2 0 psig).
An output gauge shall be provided.

f. Displacer instruments shall be glandless.

g. Standard materials are:

1. Displacer: 3 1 6 stainless steel.

2. Torque tube: Inconel.

h. Internal displacers may be used where an external


arrangement is not possible (e.g., sumps). In this case,
facilities shall be provided t o allow testing and routine
maintenance. All such displacers shall be shielded and
guided, and a means shall be provided t o retain and recover
dislodged displacers. The mounting flange for top-mounted
instruments is 4 in. unless a larger size is required.
i. Instruments for high- or low-temperature service conditions
shall employ finned torque tube extensions as necessary t o
maintain the temperature between the operational limits.

j. Displacer chambers connected t o hydrocarbon vessels


employing steam as a stripping medium shall be provided
w i t h a gas purge of the vapour connection.

10.5.6 DP Instruments

DP measurements shall normally employ a filled reference leg


connected above the vessel liquid phase, w i t h a reversed
transmitter output. Filling of the leg shall be b y condensation
method where possible. Where filling of the legs b y gravity
feed from sloping impulse piping cannot be guaranteed,
constant head chambers shall be installed.

Where it is difficult t o maintain a filled reference leg, e.g., in


vacuum systems, a dry or purged leg shall be used. A dry leg
is defined as a service where the vessel is always below the
temperature at which the contained liquids would evaporate
at ambient pressure.

Purged legs are liquid filled at startup and maintained b y the


purging system. The purge fluid may be liquid, gas or steam.
The leg shall be initially filled w i t h the purge fluid for liquid
purge, and w i t h water for the steam-purged system.

Gas-purged legs shall be filled w i t h a suitable non-vaporising


liquid.

Connections shall be provided t o fill the legs at startup.

Where materials are liable t o separate, solidify or deposit in


impulse lines, the lines shall be purged or direct-mounting,
liquid-filled diaphragm systems shall be used o n the 2-in.
vessel connection. Where deposition is serious, purging of
the nozzle can be used in addition t o the diaphragm seal. All
materials used shall be suitable for the service conditions.

Extended diaphragm systems passing into the nozzle, flush


with the vessel wall may be used with 4-in. or 6-in. vessel
nozzle sizes. Extended diaphragms shall not be used on
vessels requiring periodic mechanical cleaning.

Transmitters for closed vessels shall have range suppression


or elevation facilities as required. Range suppression shall
take account of the differences in density of the leg fillings,
including the gas phase for high-pressure applications.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 105 of 163
Speaicicafion

i. Electronic transmitters shall provide a 4 - 2 0 mA signal using


a 24-VDC supply, and be certified in accordance with the
hazardous area and execution code stated in the Engineering
Group Specification entitled "Instrument Engineering Basic
Data" (Number 015-JH-1901). A n output indicator shall be
fitted.

j. Pneumatic transmitters shall provide a 0.2-1.0 barg ( 3 t o 15


psig) signal w i t h a 1 . 4 barg ( 2 0 psig) supply and be fitted
w i t h an output gauge.

10.5.7 Level Switches

Direct-acting level switches shall be external-float type with


magnetically operated (glandless) transmission of float
movement t o the switching element. The coupling shall be
shielded against accumulation o f magnetic particles and
provide high integrity partitioning between process and
electronics.

The float shall be of 3 1 6 stainless steel as a minimum and


shall withstand the vessel test pressure. Applications where
the float is suitable for the service but cannot safely
withstand the test pressure shall be referred t o the Company
for approval.

Integral float stops shall be provided t o limit the angle of


float travel, and shall be fitted as close t o the float as
possible. Floats shall be restrained in cages (or alternative) t o
restrain the float from blocking nozzles in the event of
becoming detached. Oversize floats shall be fitted in
housings with oversized flanges so that the instrument can
be fittedlwithdrawn with the float in position (applicable for
vessel-mounted switches where these have been allowed by
the Company).

Switches shall be environmentally sealed. Contacts shall be


SPDT and shall be rated at 1 amp at 2 4 VDC for Ex'd'
certified equipment and shall be gold plated for IS (simple
apparatus) applications. They shall be certified for the
hazardous area noted in the Contract documents.

Where the process conditions are such that the float will be
subjected t o turbulence, provision shall be made by
shielding, guiding or other means t o eliminate the effects of
turbulence on the float shaft and bearing assembly.
Specification Number Rev Date Sheet
Engineering Group
0 1 5-JH-1903 1 15-9-94 106 of 163
Speo5cation

10.6 Installation Notes

Access for Maintenance

Each level instrument shall be capable o f individual removal


without shutting downldraining the vessel. As well as ensuring
that adequate isolation valves are located in accessible positions,
installations shall be checked t o confirm that sufficient headroom
and removal space is allowed for the removal of the instruments,
and for internals such as displacers without removal of the
instruments.

Access for Operation

Gauges shall wherever possible be readable throughout their


range from grade or from a single platform. If other levels have
t o be accessed t o read the gauge, the stairway must be
immediately accessible. Gauges t o be read from fixed ladders
require Company approval.

Mounting of Chambers

Chambers shall be mounted truly vertical.

Vents and Drains

The complete installation o f instruments, chambers,


connecting legs, impulse tubing etc. shall be completely
drainable at a full shutdown. Installations which involve
connecting legs below the vessel base are subject to
Company approval, but where these are approved, shall have
additional lockedlclosed drain valves t o drain the leg.

Vent and drain piping for coagulating or condensing service


o n corrosives or hydrocarbons require preheating or other
precautions t o ensure that materials are not left in the line
after use. Steam purging may be considered if steam is
available.

Flow t o the drain shall be visible in a safe manner


commensurate with the materials being handled.

Low-point traps on drain and vent piping are not acceptable.

10.7 Performance Reauirernents

10.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states

2-0056
Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 107 of 163
Sp&ca&n

the minimum additional requirements related t o level


instruments only and shall not in any w a y replace or reduce
the general QAIOC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality o f the product:

A check o f all materials o f construction b y cross-


comparing the goods, the material test certificates and
the data sheets and Drawings.

A check of the dimensions o f the finished instruments


against the Drawings supplied for the Contract and
approved b y the Company.

A check of the instrument and all accessories in


accordance with this specification and the data sheets
and Drawings.

Full testing of the instrument in accordance this


specification, Approved Manufacturer's additional
QAIQC procedures and the approved Test and
Inspection Plan.

A check o n the nameplate data in accordance w i t h this


specification and the data sheets and Drawings.

A check o n the painting and protection and general


suitability for the environment.

A check on the tagging in accordance w i t h this


specification and the data sheets.

1 0 . 7 . 2 Testing

a. The pressure enclosures shall be hydrostatically tested


before assembly at 1.5 times the rating of the flanges.

b. The instrument shall be calibrated w i t h a fluid having the


same properties as the process fluid.

c. The Instrument shall be pressure tested as an assembly at no


greater than 1.5 times the rating of the flanges, but this
figure shall be reduced if there is a design restriction on
pressure o n any component. If such restrictions exist, this
fact shall be clearly marked o n the instrument in English and
Arabic languages.
Specification Number Rev Date Sheet
Engineering Gmup
SpMication 01 5-JH-1903 1 15-9-94 108 of 1 6 3

10.7.3 Documentation

All the certification for each instrument or group of instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed test and inspection plan.

b. Material certificates and component certificates.

c. NDT certificates.

d. Weld procedures and qualifications.

e. Pressure test certificates.

f. Test and calibration certificates.

g. Hazardous area certificates.

h. As-built Drawings as necessary.

10.8 N a m e ~ l a t eData

10.8.1 General information for production o f the nameplate data is


given in section 4.7 o f this specification.

10.8.2 For level instruments the following additional information is


required:

a. Body material .
b. lnternals material.

c. Rating of inlet and outlet flange .


d. Test pressure of complete instrument.

11.0 TANK METERING

1 1. I A o ~ l i c a b l eStandards

API Manual of Petroleum Measurement Standards - Chapter 3 - Tank


Gauging

11.2 S c o ~ eof Tank Meterina Section

11.2.1 This section details process measurements on tank and storage


vessels where the selection criteria for instruments stated in the
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 109 of 163
Sp&catiiOn

"level instruments " section of this specification cannot generally


be applied due t o span restrictions.

11.2.2 This specification applies t o storage tanks only. For process


vessels o n which conventional process level variables are
required t o be measured, for the purposes o f local indication or
remote signal transmission, the requirements are covered by
section 10.0 of this specification, Level Measurement.

11.3 Tank Metering Instruments Tyoe and Selection

11.3.1 Use of Conventional Instruments

Where conventional instruments are applied t o tank level


measurements, e.g., level switches, direct DP measurement,
displacer instruments, etc., the requirements of section 1 0 . 0 of
this specification shall be followed. Dedicated level switches
shall be used for the high and l o w trip detection. They shall be
displacer type for low-level detection and float type for high
level.

11.3.2 Measurement of Large Spans

The method of measuring the full span of the tank shall be


indicated on the P&ID issued for the Project, or if not indicated
shall be agreed t o w i t h the Company during design definition.
The selection shall be from the following instrument types:

Inferred level measurement, using DP measurement by a DP


transmitter. The local readout can be a direct reflection of
the calibration o f the transmitter, or a re-transmitted signal
from the DCS (including any specified corrections applied).

Float-operated mechanically linked indicator w i t h position


transmitter.

Servo-motor-operated float or displacer-type surface-seeking


systems. These shall be specified w i t h rnicro-processor-
based calculation modules.

Radar-type tank level gauges.

Servo-motor operated surface-seeking capacitive tank level


gauges.

Sonic and ultrasonic tank level gauges

Inductive tank level gauges.


h. Resistive tank gauges.

i. Various systems available such as by use of radio frequency


signals and others in development.

1 1 . 3 . 3 Tank Gauging Systems

a. Where measurement of level is combined with other


variables (such as density measurements, temperature
correction and extrapolated vessel volumes) t o enable the
vessel contents t o be calculated, the system shall be
deemed t o be a tank gauging system. All tank gauging
systems shall have a local level indicator ( w i t h alarm points
marked) and remote transmission of the level, contents
evaluation data, and alarm sensing. Tank gauging systems
shall comply w i t h the requirements o f the API manual of
Petroleum Measurement Standards, Chapter 3, Tank
Gauging. Where statements in that specification are
preceded w i t h the adjective "should," this shall be read as
"shall."

b. Unless otherwise specified b y the Company, tank gauging


applications on the Facility shall utilize a standard Approved
Manufacturer's DP level measurement, w i t h separate
transmission of the tank temperature and other variables.
The DCS system shall calculate and display the tank level,
liquid density and temperature and compute and display the
mass and volume of the contents.

1 1.3.4 Pre-Alarm Switching

The tank metering measurement shall be used t o derive the


alarm high and l o w levels and t o start and stop pumps and other
control devices. Separate devices shall b e used for the high-high
and low-low trip point detection.

11.3.5 Shutdown Switching

Shutdown inputs t o the ESD system shall be derived from


dedicated high-high and low-low switches installed in external
chambers o n the side of the tank.

11.4 Sizina and Ranclina Reauirements

1 1.4.1 Requirements Applicable t o All Systems

a. The calibrated range of the tank level measurement


instrument shall cover the full range of tank levels, including
alarm and trip points.
Specification Number Rev Date Sheet
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01 5-JH-1903 1 15~9-94 1 1 1 of 1 6 3
Specificab;on

For DP-based systems o n tanks w i t h liquid interface control,


the calibrated range shall commence above the highest
interface level.

Level coordination sketches showing all pertinent information


shall be produced b y the Contractor for all applications.
These shall be approved b y the Company and verified by the
Approved Manufacturer before order placement.

Scales shall be as follows unless requested otherwise by the


Company:

1. Local and remote level indication: 0-100%.

2. Liquid volume: cubic metres (m3)

3. Mass: kilogram (kg).

4. Density: kilogram per cubic metre (kg/m3)

Facilities shall be installed o n the tank adjacent t o the


gauging system t o enable manual gauging b y dip rod. The
complete system shall be field calibrated in accordance with
all recommendations in the API code previously noted.

Requirements for Hydrostatic Tank Gauging System

The hydrostatic tank gauging (HTG) system shall be ranged in


accordance w i t h the API Manual of Petroleum Measurement,
Chapter 3.

Temperature Measurement

The temperature measurement shall be b y use o f an RTD. The


RTD shall be mounted in a thermowell mounted adjacent t o the
lower transmitter tapping and penetrating at least 1 m into the
process fluid. The readout shall be ranged t o cover from zero t o
the maximum possible process temperature, allowing for any
increase due t o ambient effects.

OilIWater Interface Measurement

The oillwater interface detection shall be b y use of an externally


mounted displacement transmitter, a capacitance probe, or by
another Company-approved method. The range of the instrument
shall cover all possible movement o f the interface level, up t o
and including the upper process fluid outlet level.
Specification Number Rev Date Sheet

01 5-JH~1903 1 15-9-94 l 1 2 o f 163


I Soecjficaan

11.5 Construction Reauirements

11.5.1 Requirements for All Systems

The instruments used in tank metering systems shall be


selected t o provide the required accuracy and integrity with
emphasis o n simplicity o f installation, operation and
maintenance. Where the instrument items forming parts of
the system are of the types described in the other sections
of this specification (pressure measurement, temperature
measurement etc.,), the requirements of those sections shall
be followed.

The systems proposed shall be fully proven and the


compatibility w i t h the selected DCS system shall be ensured,
both for the required process parameter updates and for
system diagnostic and integrity checks.

Where field power supplies are required or servo motors are


used, they shall be operable at the UPS power supplies
available, 24-VDC or 110-VAC 5 0 Hz. Exceptions require
Company approval.

The system shall be capable of field calibration without shut-


d o w n or isolation o f equipment. Special equipment for
calibration shall be part of the package.

When the service requires special considerations such as the


use of diaphragm seals etc., the approach shall be as
specified in section 1 0 . 0 of this specification.

The minimum material requirement for transmitter bodies and


all wetted parts shall be 3 1 6 stainless steel. The material
shall be upgraded t o suit the process conditions and any
specified requirements such as corrosion resistance t o the
NACE code etc.

All field items shall be certified for use in the hazardous area
and weatherproof t o IP65 minimum.

11.6 Installation Notes

11.6.1 All internally mounted devices such as floats and displacers shall
be installed in stilling wells and shall be removable without
draining the tank. Retention and retrieval devices shall be
installed in case of detachment of the float or displacer.

11.6.2 The minimum flange size o n the tanks shall be 2-in. 3001b rated.
Larger flanges and higher ratings shall be installed as necessary
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for the process conditions and equipment loads. Flange finish


and gaskets shall be in accordance w i t h the tank specification.

11.6.3 The system shall be installed in accordance with the


requirements o f the Engineering Group Specification entitled
"Instrument Installation" (Number 0 1 5-JH-I 9 0 8 ) and any
applicable special notes contained in the "Level Measurement "
section 1 0 . 0 of this specification. All instruments shall be
provided with isolation valves t o enable removal for maintenance
without tank drainage.

1 1 . 6 . 4 The measurement sensors shall be placed clear of all incoming


and outgoing process f l o w penetrations, mixers or distributors
and any possible eddy currents in the fluid etc.

11.6.5 The Contractor shall provide at each tank a junction box with a
telephone jack connection for a portable telephone handset.
These shall connect into the control room telephone exchange
system.

11.7 Performance Reauirements

1 1.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o tank gauging
systems only and shall not in any w a y replace or reduce the
general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality o f the product:

1. A check of all materials o f construction by cross-


comparing the goods, the material test certificates and
the data sheets and Drawings.

2. A check o f the dimensions o f the finished instruments


against the Drawings supplied for the Contract and
approved by the Company.

3. A check of the instrument and all accessories in


accordance with this specification and the data sheets
and Drawings.

4. Full testing of the instrument in accordance this


specification, Approved Manufacturer's additional
QAIQC procedures and the approved test and inspection
plan.
Specification Number Rev Date Sheet
Engineehg Group
01 5-JH-1903 1 15-9-94 1 1 4 o f 163
Specjfica&n

5. A check on the nameplate data in accordance w i t h this


specification and the data sheets and Drawings.

6. A check o n the painting and protection and general


suitability for the environment.

7. A check o n the tagging in accordance with this


specification and the data sheets.

11.7.2 Testing

a. The pressure enclosures shall be hydrostatically tested


before assembly at 1.5 times the rating of the flanges.

b. The instrument shall be calibrated w i t h a fluid having the


same properties as the process fluid.

c. The instrument shall be pressure tested as an assembly at no


greater than 1.5 times the rating of the flanges, but this
figure shall be reduced if there is a design restriction on
pressure on any component. If such restrictions exist, this
fact shall be clearly marked o n the instrument in the English
and Arabic languages.

11.7.3 Documentation

All the certification for each instrument or group of instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed Test and Inspection Plan.

b. Material certificates and component certificates

c. NDT certificates.

d. Weld procedures and qualifications.

e. Pressure test certificates.

f. Test and calibration certificates.

g. Hazardous area certificates.

h. As-built Drawings as necessary.


11.8.1 General information for production of the nameplate data is
given in section 4.7 of this specification.

11.8.2 For level instruments the following additional information is


required:

a. Body material .
b. lnternals material.

c. Rating of connecting flanges

d. Test pressure of complete instrument.

12.0 LOCAL PNEUMATIC CONTROLLERS

12.1 Scooe of Local Controller S ~ e c i f i c a t i o n

This specification details the requirements for pneumatic controllers used


for direct control of process variables o n the Facility.

12.2 Pneumatic Controller T v ~ e sand Selection

1 2.2.1 General

Local controllers shall normally be o f the pneumatic receiver


type. They shall be capable of controlling a process variable via a
valve or other final element, by providing a 0 . 2 t o 1.0 barg (3 t o
1 5 psig) output lor some other range as determined by the
requirement of the final element). The output shall be related t o
the comparison between the received process variable
measurement 1 a signal of 0 . 2 t o 1 . 0 barg ( 3 t o 1 5 psig), usually
from a local transmitter) and the controller set point. The set
point may be applied locally at the instrument, or when required
b y the P&ID by use of an autoiremote switch, as a 0 . 2 t o 1 . 0
barg 13 t o 1 5 psig) signal from a remote source.

12.2.2 Local Pressure Controllers

a. Pressure controllers shall be specified as follows:

1. T w o term, proportional and integral.

2. Proportional band 0 t o 2 5 0 % for gas, 0 t o 5 0 0 % for


liquid control.
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spec&atbn

3. External auto-manual station w i t h bumpless transfer


facility.

4. Reset wind-up prevention.

b. Combined transmitter/controller systems may be offered for


Company approval when the service conditions are suitable
for standard capsules.

12.2.3 Local Flow Controllers

a. Flow controllers shall be soecified as follows:

1. T w o term, proportional and integral.

2. Proportional band 0 t o 500%.

3. External auto-manual station w i t h bumpless transfer


facility.

4. Reset wind-up prevention.

12.2.4 Local Level Controllers

a. Level controllers shall be specified as follows:

1. T w o term, proportional and integral (integral not


normally used).

2. Proportional band 0-100%.

3. External auto-manual station with bumpless transfer


facility.

4. Reset wind-up prevention.

b. Combined transmitter/controller systems may be offered for


Company approval when the service such as tank heating
upto 300" C (572" F) range.

12.2.5 Local Temperature Controllers

a. Temperature controllers shall be specified as follows:

1. Three term, proportional, integral and derivative.

2. Proportional band 0 t o 2 5 0 %
Specification Number Rev Date Sheet
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Spmmtion 01 5-JH-1903

3. External auto-manual station w i t h bumpless transfer


facility.

4. Reset wind-up prevention

b. Combined transmitter/controllers of the liquid or gas filled


type may be offered for Company approval for simple
services such as tank heating up t o 300°C (572°F) range.

12.3 Sizina and Ranaina Reauirements

12.3.1 The calibrated range of the controller shall be the same as the
range selected for the associated transmitter. The span shall be
selected so that the range accounts for at least 5 0 % of the
span.

12.3.2 The scale shall be graduated t o the same characteristic as the


transmitter output unless external signal conditioners are
indicated on the P&ID .

12.4 Desian and Construction

12.4.1 General

Local controllers shall be o f large case design with lockable


front. They shall be mounted o n a 2-in. instrument stand or
rear flange mounted.

The movement shall be of nozzle and flapper motion or


force- balance type, integral air supply and output gauges
shall be fitted.

Indicating scales shall be white w i t h black numerals. Units


and multiplying factors shall be marked.

Auto-manual switch shall be external. Set-point adjustment


may be external or internal according t o the application.
Auto-manual switch may be substituted for
remotelbalancelautolmanual when indicated o n the P&ID. An
indicator shall be provided for the remote signal.

The wetted parts shall be 3 1 6 stainless steel (preferred) or


bronze.

The signal output shall be 0 . 2 t o 1.0 barg ( 3 t o 15 psig).


The action shall be reversible. The supply air pressure shall
be 1 . 4 barg ( 2 0 psigl.

Air connections shall be 114-in. NPT


Specification Number Rev Date Sheet
Engineering Gmup
spmmiion 015-JH-1903 1 15-9-94 1 1 8 0 1 163

h. The controller shall indicate set point, measurement and


output.

12.4.2 Combined Pressure TransmitterIControllers

Combined systems for direct pressure control shall only be used


when the range is suitable for the Approved Manufacturer's
standard capsule. The capsule shall be direct mounted in the
controller. All wetted parts shall be stainless steel 3 1 6 as a
minimum. All other features are as "controllers."

12.4.3 Temperature Controllers (See Section 12.2.5)

a. Filled system temperature controllers shall be capillary type


with AlSl 3 1 6 stainless steel bulb, capillary and capillary
armour which shall be PVC coated.

b. Preferred capillary lengths are 3 m ( 1 0 ft.) and 1 0 m ( 3 0 ft.).

c. Capillary tubing shall be supported throughout its entire


length.

d. Thermowells shall be used for all temperature detecting


elements and shall be constructed from 3 0 4 stainless steel,
minimum w i t h other materials t o suit process requirements.

e. The thermowells shall follow the same requirements as those


specified in section 9.0 o f this specification. 2-in. flanges
may be used if necessary.

12.5 Installation Notes

12.5.1 The instruments shall be installed in accessible positions,


between 1.2 and 1.6 m (4 and 5'1, ft.1 above grade or a fixed
olatform.

11.5.2 Sun shields shall be provided.

12.6 Performance Reauirements

12.6.1 Quality Control (QCI

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o pressure
instruments only and shall not in any w a y replace or reduce
the general QAIQC requirements.
Specification Number Rev Date Sheet
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01 5 - ~ ~ ~ 1 9 0 3 1 15-9-94 119 of 163
Sp&mtbn

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check of the instrument and all accessories in


accordance with this specification and the data sheets
and Drawings.

2. Full works calibration and issue of test and calibration


certificate.

3. A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

4. A check on the painting and protection and general


suitability for the environment.

5. A check on the tagging in accordance with this


specification and the data sheets.

12.6.2 Documentation

The following data shall be available at final inspection:

a. Completed test and inspection plan.

b. Material certificates and NACE certificates where required by


Contract documents

c. Instrument test and calibration certificate.

12.7 Nameolate Data

General information for production of the nameplate data is given in


section 4.7 of this specification. Information for tagging of the
thermowell is given in section 9.0 of this specification.

13.0 SPEED MEASUREMENT

13.1 Scooe of Soeed Measurement Section

This section details the measurement of shaft rotational speed of


equipment t o be installed at the Facility in Kuwait.

13.2 Soeed Measurement Instruments Tyoe and Selection

13.2.1 Standard System

Rotational speed for indication at normal levels of accuracy shall


be measured b y a field-mounted proximity sensor or magnetic
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Specjficatbn

pick-up, arranged t o detect the presence o f one or more


indicators o n the rotating shaft. A control room-mounted
integrator, scaled in accordance with the number of indicators,
shall transmit the rotational speed as a 4 - 2 0 ma signal scaled in
RPM t o the DCS, ESD or interlock system. Display and alarm
outputs shall be developed in these downstream systems.

13.2.2 Alternative Systems

Other types of system may be offered for Company approval if


the system offers an equal standard of integrity and reliability.

13.2.3 Integration w i t h Monitoring Systems

Where rotational speed measurement is specified as part of an


overall equipment monitoring system, the Contractor shall ensure
that the selected system is compatible w i t h the equipment
installation and signal monitoring requirements.

1 3 . 2 . 4 Speed Control

Where rotational speed is detected in order t o apply a feedback


speed control t o the rotating equipment, the speed measurement
system shall be selected t o operate in conjunction with the
speed control device t o give the required level o f accuracy.

13.2.5 Vibrating Reeds

Vibrating reed sensors shall not be used

13.3 Sizina and Ranaina Reauirernents

13.3.1 The display scale shall be calculated so that the maximum


predicted running speed is between 6 0 % and 8 0 % of full scale.

13.3.2 The number of indicators o n the rotating part shall be selected


as a maximum consistent with the repeat rating o f the field
detector and the control room amplifier and integrator.

13.4 Construction Reauirements

13.4.1 Speed sensors are t o be of robust construction suitable for


service o n the specific type of rotating equipment, taking into
account vibration, temperature, lubricants etc.

13.4.2 Duplicate sensors, or systems as necessary, shall be supplied,


allowing one unit t o be serviced while the other is on-line.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15~9-94 121 of 163
Speh7cation

13.4.3 The sensor casing shall be stainless steel. Local brackets shall be
stainless steel.

13.4.4 Connecting leads shall be fully protected, as short as possible


and terminated in an approved certified enclosure.

13.4.5 The sensors shall be immune from radio frequency interference.

13.5 Installation Notes

13.5.1 Detectors shall be installed in accessible positions w i t h sufficient


protection t o enable freedom from damage during operation and
maintenance.

13.5.2 They shall not be placed where debris from ruptured couplings,
shear pins etc. can be expected t o impinge.

13.5.3 The units shall be factory installed and tested in conjunction


with the equipment performance tests and connected t o the
specified amplifierlintegrator.

13.6 Performance Reauirements

13.6.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o speed
measurement instruments only and shall n o t in any way
replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality o f the product:

1. A check of the instrument and all accessories in


accordance w i t h this specification and the data sheets
and Drawings.

2. Full works calibration and issue o f test and calibration


certificate.

3. A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

4. A check o n the painting and protection and general


suitability for the environment.

5. A check o n the tagging in accordance with this


specification and the data sheets.
Specification Number Rev Date Sheet
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1 15-9-94 1 2 2 o f 163
SpeCHcdb;on 0 1 5-JH-1903

13.6.2 Documentation

The following data shall be available at final inspection:

a. Completed Test and Inspection Plan.

b. Instrument test and calibration certificate.

c. Hazardous area certificates.

13.7 Nameolate Data

General information for production of the nameplate data is given in


section 4.7 o f this specification.

14.0 VIBRATION SENSING

14.1 S c o ~ eo f Vibration Sensins Section

This section covers the measurement o f shaft vibration sensing of


equipment t o be installed at the Facility in Kuwait.

14.2 Vibration Sensinq Instruments T v ~ e


and Selection

Standard System

Degrees of vibration shall be measured b y field-mounted eddy


current transducers or piezo-electric accelerometers mounted at
the detection points o n the X and Y axis of the rotating shaft. A
control room-mounted integrator, scaled in accordance w i t h the
limiting conditions applicable t o the specific equipment shall
transmit the vibration measurement as a 4-20 m A signal t o the
DCS, ESD or interlock system. Adjustable contact alarm outputs
shall also be available.

Alternative Systems

Other types of system may be offered for Company approval if


the system offers an equal standard of integrity and reliability.

Integration w i t h Monitoring Systems

Where vibration measurement is specified as part of an overall


equipment monitoring system. The Contractor shall ensure that
the selected system is compatible with the equipment
installation and signal monitoring requirements.
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01 5-JH-1903 1 15-9-94 123 of 163
SpecY?7ica&n

14.3 Sizinq and Ranqinq Requirements

The display scale shall be calculated so that the maximum predicted


running vibration is between 6 0 % and 8 0 % of full scale.

14.4 Construction Reauirernents

Vibration sensors shall be of robust construction suitable for


service o n the specific type of rotating equipment, taking into
account temperature, lubricants etc.

Duplicate sensors, or complete systems as necessary, shall be


supplied, allowing one unit t o be serviced while the other is on-
line.

The sensor casing and extension shall be stainless steel. Local


brackets shall be stainless steel.

Connecting leads shall be fully protected, as short as possible


and terminated in an approved certified enclosure.

The sensors shall be immune from radio frequency interference

14.5 Installation Notes

14.5.1 Detectors shall be installed in accessible positions with sufficient


protection t o enable freedom from damage during operation and
maintenance.

14.5.2 The sensors shall be positioned so that electromagnetic fields


close t o the equipment do not affect the reading.

14.5.3 They shall not be placed where debris from ruptured couplings,
shear pins etc. can be expected t o impinge.

1 4 . 5 . 4 The units shall be factory installed and tested in conjunction


w i t h the equipment performance tests and connected t o the
specified amplifierlintegrator.

14.6 Performance Reauirernents

14.6.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o vibration-
sensing instruments only and shall not in any w a y replace or
reduce the general QAIQC requirements.
Specification Number I Rev 1 Date I Sheet
I
@ KOC Engineering Gmup
Specr%ic~hn 01 5-JH-1903 I 1 1 15-9~94 1 124 of 163

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check of the instrument and all accessories in


accordance w i t h this specification and the data sheets
and Drawings.

2. Full works calibration and issue of test and calibration


certificate.

3. A check o n the nameplate data in accordance w i t h this


specification and the data sheets and Drawings.

4. A check on the painting and protection and general


suitability for the environment.

5. A check o n the tagging in accordance with this


specification and the data sheets.

14.6.2 Documentation

The following data shall be available at final inspection:

a . Completed Test and Inspection Plan.

b, Instrument test and calibration certificate.

c. Hazardous area certificates.

General information for production o f the nameplate data is given in


section 4.7 of this s~ecification.

15.0 SOLENOID VALVES

15.1 A p ~ l i c a b l eStandards

BS 2 7 5 7 Method for Determining the Thermal Classification of


Electrical Insulation

15.2 S c o ~ eo f Solenoid Valve Section

This section details the requirements fm the application of solenoid valves


in the plant when used as part of the process control or shutdown
system.
Specification Number Rev Date Sheet
Engineering Group
0 1 5-JH-1903 1 15-9-94 125 of 163
Specjfication

I 1 5 . 3 Solenoid Valves T v ~ e sand Selection

I 15.3.1 Valve Type

Solenoid valves shall be the direct-acting type. Pilot-operated


valves are not a c c e ~ t a b l e .

I 15.3.2 Application of Solenoid Valves

Solenoid valves shall normally be used in the air or hydraulic


power line acting as the actuating device operated b y the DCS,
ESD or other control system t o cause full opening or closing of
pneumatically or hydraulically powered valves.

I 15.3.3 Solenoid Valves in Process Lines

Solenoid valves shall not be used directly in process lines for


ESD service. Any other use of solenoid valves in process lines
requires Company approval. For cases where a solenoid valve
may be suitable (e.g., tightness testing or sample injection
systems using clean gases which are non-corrosive and non-
gumming t o the valve or its seals), the Contractor shall submit
full details for Company approval o f the proposed application.

I 1 5 . 3 . 4 Reset of Solenoid Valves

a. Automatically re-setting solenoid valves shall be used for all


applications except where "manual reset" is indicated on the
P&ID.

b. Data sheets shall clearly state whether the reset function


shall also action an override when the solenoid is not
energised, i.e., reset and override. Tamper-proof reset shall
be specified in all cases where an override for test purposes
cannot be tolerated for safety reasons. Where not specified,
tamper-proof valves shall be supplied.

I 15.3.5 Solenoid Valves Fitted t o Control Valves

When a solenoid valve is fitted t o a control valve with positioner,


the solenoid valve shall be fitted in the line between the
positioner and the actuator. The solenoid valve shall not be in
the signal line except where the purpose is t o inject a preset
pneumatic signal.

15.3.6 Number of Ports

Three-port solenoid valves shall be used for single-acting spring-


return actuators, five-port valves shall be used for double-acting
actuators.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 126 of 163
Specricicadion

15.3.7 Solenoid Valves for Venting Service

For venting both sides o f a double-acting actuator (e.g., t o


enable manual override), t w o three-port valves shall be used.

15.4 Sizina and Ranaina Reauirements

15.4.1 Sizing for Speed of Operation

The minimum solenoid valve size used shall have 114-in. NPT
connections and a 6-mm (114-in.) orifice. The Contractor shall
not assume that this is adequate t o achieve the required speed
of operation without verification o f each case taking into
account the completed installation o f actuated valvelconnecting
tubelsolenoid valvelexhaust arrangement.

15.4.2 Sizing for Process Service

In cases where the Company has approved the use o f a solenoid


valve for direct process duty, each application shall be sized
against the operating conditions.

15.5 Construction Reauirements

15.5.1 General

Solenoid valves shall be direct-acting, spring-return type and


shall be robustly constructed for heavy industrial use. The coil
and spring shall be selected t o provide ample operational power
t o position the valve stem correctly under all conceivable service
conditions. An external earth stud shall be provided.

15.5.2 Design Rating

The design pressures shall be as follows (minimum


requirements):

Operating Mechanical
Pneumatic 8.5 barg 1 2 . 0 barg
Service ( 1 2 5 psig) ( 1 7 5 psig)
Hydraulic (to be according t o individual requirements
Service but not less than the blocked-in pump head)
Processes (to be according t o service requirements but
Service not less than 1.5 x process design figure)
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 127 of 163
SpMcation

15.5.3 Coil Rating

Coils shall be rated for continuous operation when connected t o


the electrical supply stated in the Engineering Group
Specification entitled "Instrument Engineering Basic Data"
(Number 0 1 5-JH-1901). The temperature must not rise t o more
than 70°C ( 158"F), (or the coil service rating if lower) when used
at the ambient conditions prevalent at the Facility and with the
sun shielding and heat dissipationicooling arrangements provided
by the Contractor.

15.5.4 Coil Insulation

Coil insulation shall be Class A t o BS 2 7 5 7 (minimum), and a


surge suppression device shall be fitted within the terminal
enclosure.

15.5.5 Terminations

Integral terminals shall be provided for the termination of


cabling. Flying leads extending from the coil enclosure are not
acceotable.

15.5.6 Electrical Entry

The electrical entry shall be I S 0 metric threaded t o M 2 0 x


1.5 mm.

15.5.7 Body Materials

a. Pneumatic solenoid valves shall be constructed of brass or


stainless steel body, stainless steel trim and cast iron
enclosure. Aluminium enclosures are acceptable only if fully
epoxy painted.

b. All solenoid valves shall be stainless steel in cases where


H2S is present in any part of the process in sufficient
quantity t o warrant the need for materials t o be selected and
manufactured in accordance w i t h the NACE code MR0175.
This is t o enable the valve bodies t o resist the H2S that will
be present in the atmosphere.

c. For process service, the body and trim material shall be


suitable for the process fluid and design conditions, with
3 1 6 stainless steel as a minimum requirement.

d. The selection of seal material shall be t o the Approved


Manufacturer's recommendation for the service and
environmental conditions.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 128 of 163
spmca&n

15.5.8 Lever Reset Operators

Mechanical reset and test or tamper-proof reset shall be operable


b y lever from a convenient position accessed from grade or a
permanent platform. Pushbutton resets requiring high mechanical
forces are not acceptable.

15.6 Installation Notes

Supporting

Solenoid valves shall be supported from the body or brackets.


Supporting by the pneumatic pipework is not accepted. The
valve spindle shall be vertical.

Short P i ~ e w o r k

The valve shall be mounted as close as possible t o the port that


it controls.

Exhaust Screen

Each exhaust port shall incorporate a silencerisand screen,


placed so that it shall not be affected b y windblown dirt or sand.
Exhaust ports shall not be commoned. Unused ports shall be
screened or plugged. The use of silencers and sand screens shall
not detract from the attainment o f stipulated valve closure
speeds when in ESD service.

15.7 Performance Reauirements

15.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o solenoid
valves only and shall n o t in any w a y replace or reduce the
general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check of all materials of construction b y cross-


comparing the goods and the data sheets and Drawings.

2. A check o f the dimensions o f the finished solenoid


valves against the Drawings supplied for the Contract
and approved by the Company.
Specification Number Rev Date Sheet

OKOC Engineering Group


SpMCdtion 01 5-JH-1903 1 15-9-94 129 of 163

3. A check of the instrument and all accessories in


accordance w i t h this specification and the data sheets
and Drawings.

4. A check on the nameplate data in accordance w i t h this


specification and the data sheets and Drawings.

5. A check on the painting and protection and general


suitability for the environment.

6. A check o n the tagging in accordance w i t h this


specification and the data sheets.

15.7.2 Testing

The solenoid valves shall be tested during manufacture in


accordance with Approved Manufacturer's quality control
system.

15.7.3 Documentation

All the certification for each instrument or group o f instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:

a. Completed test and inspection plan.

b. Certificate of works test and conformitv.

c. Hazardous area certificates.

General information for production of the nameplate data is given in


section 4.7 of this specification.

16.0 SIGNAL CONVERTORS

16.1 S c o ~ eof Siqnal Converter Section

This section details the requirements of signal convertors for use in signal
transduction and manipulation of pneumatic and electronic signals used in
instrument control loops.

16.2 Siqnal Converters Type and Selection

16.2.1 Current t o Pneumatic Conversion WP)

Conversion of a control room 4 - 2 0 m A control signal t o a 0.2 t o


Specification Number Rev Date Sheet
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1 15-9-94 1 3 0 o f 163
SpeaZcahn 01 ~ ~ J H - I ~ o ~

1.0 barg ( 3 t o 1 5 psig) pneumatic signal shall normally be b y use


of a 2-wire loop powered IIP convertor. For control valve service
in non-vibrating applications, and if approved b y the Company,
EIP positioners (where the signal conversion is an integral part of
the valve positioner) may be used.

16.2.2 Pneumatic t o Current Convertors (P/I)

Conversion of a field pneumatic signal for transmission t o the


control room as an electronic signal shall be b y use of a 2-wire
loop powered PI1 convertor.

16.2.3 Miscellaneous Convertors and Conditioners

Field-mounted devices shall be used where depicted o n the P&ID


for signal processing such as square root extraction, high and
l o w selection, multiplying and delay services.

16.3 Sizina Reauirements

The pneumatic output flow rate from convertors shall be


checked against the maximum air requirement o f the user.
Pneumatic relays and boosters shall be used as necessary t o
ensure an adequate supply o f air.

Current t o pressure (IIP) and pressure t o current (Pil) convertors


shall be field adjustable and ranged so that 4 - 2 0 m A corresponds
t o 0 . 2 t o 1.0 barg ( 3 t o 1 5 psig), unless required otherwise by
the service.

Split ranges shall be accomplished b y using t w o outputs from


the DCS, each scaled at 0 - 1 0 0 %. In this case, each valve will
have an individual l i p convertor scaled 0 . 2 t o 1 .O barg ( 3 t o 15
psig).

Where split range control using one electronic output is required


eg. 0.2 t o 0 . 6 barg ( 3 t o 9 psig) and 0 . 6 t o 1 . 0 barg (9 t o 15
psig) signals t o each valve respectively, one IIP convertor shall
be used and the split ranging shall be carried out at the
positioners.

Other ranges may be specified w i t h the agreement of the


Company.

16.4 Construction Reauirements

16.4.1 IIP Convertors


Specification Number Rev Date Sheet
Engineering Group
01 ~ - J H - I ~ o ~ 1 15-9-94 131 of 163
Specification

ln~ut 4 - 2 0 m A 2 4 VDC. 1
Output 0.2 t o 1 . 0 barg ( 3 - 1 5 psig).
I
Air Supply 1 1.4 barg ( 2 0 psig)
I Electrical Connections 1 2 0 m m x 1.5 I S 0 1
Body Material Zinc die cast
I Mountina I 50-mrn (2-in.) voke 1
Painting I EPOXY
The units shall be weatherproof t o IP 6 5 minimum and certified
for the electrical area classification.

P/I Converters

Input 0.2 t o 1 .O barg (3-15 psig).


Output 4-20 m A 2 4 VDC
Air Supply 1.4 barg ( 2 0 psig)
Electrical Connections 2 0 m m x 1.5 I S 0
Body Material Zinc die cast
Mountina 5 0 m m (2-in.) voke
I Painting 1 Epoxy I
The units shall be weatherproof t o IP 65 minimum and certified
for the electrical area classification.

16.5 Installation Notes

16.5.1 I/P convertors used w i t h final control elements such as control


valves, shall be mounted away from the valve o n 50-mm (2-in.)
pipe t o avoid possible malfunction of the unit caused by
vibration.

16.5.2 All convertors shall be piped up using materials in accordance


w i t h the Engineering Group Specification entitled "Instrument
Installation" (Number 0 1 5-JH-1908).

16.5.3 Convertors shall be mounted vertically, supported from brackets


and not by the pipework. A 50-mm ( 2-in.) diameter gauge shall
be supplied w i t h all l/P convertors t o indicate the output.

1 6 . 5 . 4 Discrete pneumatic components used for field signal conditioning


and manipulation shall be assembled o n a chassis mounted in a
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 3 2 of 163
Sp&cdhn

protective box, or mounted o n a substantial plate and a cover


provided.

16.5.5 Sun shielding is required for all convertors.

16.6 Performance Reauirements

16.6.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o signal
convertors only and shall not in any w a y replace or reduce
the general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

A check of the dimensions o f the finished items against


the Drawings supplied for the Contract and approved by
the Company.

A check o f the equipment and all accessories in


accordance with this specification and the data sheets
and Drawings.

Functional testing of instruments in accordance w i t h this


specification, Approved Manufacturer's additional
QAIQC procedures and the approved test and inspection
plan.

A check on the nameplate data in accordance with this


specification and the data sheets and Drawings.

A check o n the painting and protection and general


suitability for the environment.

A check on the tagging in accordance with this


s ~ e c i f i c a t i o nand the data sheets.

1 6 . 6 . 2 Testing

Instruments shall be function tested and calibrated.

16.6.3 Documentation

All the certification for each instrument or group of instruments


shall be collated in a Data Book which shall be available at final
inspection. The book shall include as a minimum:
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 133 of 163
Sp&cab;on

a. Completed Test and Inspection Plan

b. Hazardous area certificates

16.7 Namedate Data

General information for production of the nameplate data is given in the


section 4.7 o f this specification.

17.0 POSITION SWITCHES

17.1 Scooe of Position Switches Section

17.1.I This section details the design and application o f all switches
installed t o detect the limit or intermediate position of valve
stems, dampers, safety devices or other items requiring an
electrical transmission of a fixed position. This specification shali
be applicable t o switches o n all equipment and packages t o be
installed at the Facility in Kuwait.

17.1.2 This section does not detail position transmitters used for
continuous feedback of the position of a moving part.

17.2 Position Switches Tvoe and Selection

17.2.1 Switches shall be of the inductive proximity type,


communicating with an IS amplifier mounted in the main control
block auxiliary room. The amplifier shall give volt-free contact
outputs t o the DCS and ESD equipment as necessary.

17.2.2 Conventional contact-type mechanical action limit switches shall


only be used in specific applications when approved by the
Company. When used, they shall be in mechanical fail-safe
mode, i.e., the spring action shall push the follower toward the
actuation point (inverse cam or hole etc.), so that a stuck switch
cannot be interpreted as a safe position. Such switches shall use
environmentally sealed switch contacts o f noble metal suitable
for low-energy signals.

17.2.3 Proximity switches shall be purchased as sets ready mounted


and terminated in a sealed enclosure containing the switch
adjustment and actuation system. The only exposed part shall be
the actuation shaft emerging from a sealing gland at the rear of
the box. This shall be driven b y the moving part which is t o be
position detected.

17.2.4 External proximity switches may be used when space


restrictions preclude the use of enclosed type, with approval
from the Company, and provided that they can be located in a
Specification Number Rev Date Sheet
Engineering Group
Sp&icaMn 01 ~ - J H - I ~ o ~ 1 15-9-94 134 of 163

position safe from the possibility of mechanical damage during


operation and maintenance activities. Such switches shall be of
flying lead type, terminated in an IP 65 enclosure adjacent t o the
switch. The length of the flying lead shall be minimised, and
shall be protected throughout its length.

17.2.5 The actuation element shall be an unambiguous part of or


addition t o the moving part of the valve etc., chosen t o be free
o f accidental corruption by tools etc.

17.2.6 The adjustment facilities shall be locked after setting b y drilling


and pinning.

17.3 Svstem Reauirements

The switch system consists of the field proximity device and the control
room amplifier. These items shall be selected w i t h matching
characteristics in regard t o the performance and the IS certification
requirements. The amplifying devices shall be of rack or de-mountable
rail-mounted type and shall be installed in the standard interface cabinets
in the control block auxiliary room.

17.4 Construction Reauirements

17.4.1 The switches shall be the Approved Manufacturer's standard


units, certified for use in an IS circuit. They shall be mounted in
boxes sealed t o a minimum standard IP65 constructed of
reinforced polyester, stainless steel or cast iron. Terminals within
the box shall be blue for IS circuits. Electrical entries shall be
size M 2 0 1.5 ISO.

17.4.2 All external linkages, brackets, mountings etc. shall be stainless


steel w i t h stainless steel fasteners.

17.5 Installation Notes

17.5.1 All equipment shall be positioned w i t h due regard t o access for


maintenance. Wherever possible, the switches shall be mounted
away from any vibrating equipment, the coupling system being
designed t o suppress transmission o f harmful vibrations.

1 7 . 5 . 2 Where individual externally mounted proximity switches have


been allowed, the actuating element is preferably a ferrous or
magnetic part fastened securely t o a stainless steel moving part.
Where this is not possible, the extension o f the actuating part
shall be sufficient t o ensure that accidental actuation of the
switch is not possible under all conditions, including movements
caused b y wear etc.
Specification Number Rev Date Sheet
Engineering Group
1 15-9-94 135 of 163
Spec%?c~b;on 015-JH~1903

17.6 Performance Requirements

17.6.1 Quality Control (QC)

a. Quality Control shall be as detailed in the Contract. This


section states the minimum additional requirements related
t o position switches only and shall not in any way replace or
reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check o f the switch and all accessories in accordance


with this specification and the data sheets and
Drawings.

2. A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

3. A check o n the tagging in accordance with this


specification and the data sheets.

17.6.2 Documentation

The following data shall be available at final inspection:

a. Completed Test and Inspection Plan.

b. Hazardous area certificates.

17.7 N a m e ~ l a t eData

General information for production o f the nameplate data is given in


section 4.7 of this s ~ e c i f i c a t i o n .

18.0 FLAME DETECTION

18.1 S c o ~ eof Flame Detection Svstem

This section covers the design and application of flame detection devices
used for verifying the presence of flame at the burner or pilot of fired
equipment installed at the Facility in Kuwait.

18.2 Flame Detection T v ~ e sand Selection

18.2.1 Main Burner Flame Detection

a. Ultraviolet (UV) detectors of the self-checking type shall be


Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15~9-94 136 of 163
SpecriCicatbn

used for gas flames.

b. Combined element detectors, (UV with flicker or infrared)


shall be used for all oil or dual fuel systems.

c. In cases where the fuel is of a type where the detection


signal o f the systems noted may be of insufficient strength
t o guarantee detection under all firing loads and load
combinations, additional detectors or alternative types shall
be subject t o Company approval.

d. lonisation flame rod detectors shall not be used for main


flame detection.

18.2.2 Pilot Flame Detection

a. lonisation detectors of the flame rod type shall be used for


pilot detection.

b. A n earth electrode shall be installed t o earth the flame in


case o f liftoff. This can be omitted if the design ensures that
flame liftoff cannot occur under any conditions.

18.2.3 Intermittent Pilot Service

Where the pilot is discontinued after the establishment of main


flame, the pilot flame rod may be omitted. A single UV-type
detector may be indicated on the P&ID. When this system is
used, the detector shall be so positioned that it views the pilot
and main flames at the same setting. The logic system must
prove the pilot burner valve is closed, and stays closed, after the
main flame establishment period before accepting the main flame
signal.

18.2.4 Multiple Detector Systems

a. Where particular requirements for either increased integrity


(voting 2 from 2 or 3 from 3 ) or increased availability (voting
1 from 2 or 2 from 3 ) multiple detectors are indicated on the
P&ID, w i t h details of the vote required.

b. These requirements shall not be confused w i t h the voting


systems used in cases where multiple detectors are selected
b y Contractor in applications where adequate flame signal
strength is not available at one detector sighting.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 3 7 of 163
SpecjficaliJn

18.3 Svstern Reauirements

Scope

Flame detection equipment shall comprise a flame detection


sensor and a flame detector amplifieriswitch unit.

Self-checking

Flame viewers shall be of the automatic self-checking type


having the rotating shutter interlocked w i t h the output t o
produce a continuous signal of the true flame state.

Discrimination

a. The flame sensor shall be mounted o n the burner front or


other suitable location where it is able t o v i e w the intended
flame, whilst discriminating from other flames as necessary.

b. It is a requirement that where a continuous pilot is used, the


main flame viewer shall not see the pilot flame.

c. A main burner viewer shall n o t see the flame of any other


burner or pilot.

d. A pilot viewer may see its associated main flame but no


other.

Flame Amplifier

a. The flame amplifier shall be mounted in the interface rack in


the main control block auxiliary room. The use o f systems
that require field amplification or relay stations shall require
Company approval.

b. The amplifier relay shall have t w o noble metal changeover


output contacts, one normally open and one normally closed.

c. The amplifier shall have signal output terminals suitable for


the connection of a flame strength indicator, or for
permanent or future connection t o the DCS input system for
display.

18.4 Construction Reauirements

18.4.1 Enclosure

a. The flame detector sensor shall be o f rugged, weatherproof


construction and have a flange or substantial threaded union
Specification Number Rev Date Sheet
Engineetfng Group
01 5-JH-1903 1 15-9-94 138 of 163
Sp&ca&n

mounting t o the tapping nozzle.

b. The enclosure shall be certified for use in the hazardous area


surrounding the heater location. Systems requiring
continuous air purge for certification purposes are not
permitted.

18.4.2 Mounting

a. Viewer-type sensors shall be mounted o n adjustable,


lockable swivel joints t o effect accurate alignment. This
requirement can be waived if the Company is satisfied that
the burnerlviewer arrangement is of completely standard
proven design where the fixed alignment is ensured.

b. There shall be a coolinglpurging air connection o n the nozzle.


Air shall only be connected if stipulated b y the Company.

18.4.3 Redundant Viewers

If redundant viewing-type sensors are used, the tapping nozzle


shall have a full-bore isolation valve incorporated t o enable
isolation of the tapping when the detector is removed for
cleaning.

18.5 Installation Notes

18.5.1 All detectors shall be installed w i t h sufficient cable slack t o


enable full withdrawal without disconnection.

18.5.2 Nozzle lengths shall be sufficient t o carry the viewer head clear
of the burner hot zone. Heat insulators shall be fitted as
necessary t o ensure the instrument does not rise above the
lower of its design temperature or 70" C ( 158°F).

18.6 Performance Reauirernents

18.6.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o flame
detectors only and shall not in any w a y replace or reduce the
general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check of the instrument and all accessories in


accordance with this specification and the data sheets
Specification Number Rev Date Sheet
Engineering Group
1 15-9-94 139 of 163
SpeaZcation 0 1 5-JH-1903

and Drawings.

2. Full works calibration and issue of test and calibration


certificate.

3. A check o n the nameplate data in accordance w i t h this


specification and the data sheets and Drawings.

4. A check o n the painting and protection and general


suitability for the environment.

5. A check on the tagging in accordance with this


s ~ e c i f i c a t i o nand the data sheets.

18.6.2 Documentation

The following data shall be available at final inspection:

a. Completed test and inspection plan.

b. Instrument test and calibration certificate.

c. Hazardous area certificates.

18.7 Namedate Data

General information for production of the nameplate data is given in


section 4.7 of this specification.

19.0 MISCELLANEOUS INSTRUMENTS

19.1 A ~ ~ l i c a b Standards
le

BS 5 5 0 1 Electrical Apparatus for Potentially Explosive Atmospheres

19.2 S c o ~ eof Miscellaneous Instrument Section

19.2.1 This section covers the requirements for miscellaneous


instruments t o be used on equipment t o be installed at the
Facility in Kuwait.

19.2.2 Miscellaneous instruments are defined as:

a. Field items which are identified by a tag number on the


P&ID, but are of a type not specifically covered b y the other
sections within this specification (refer t o the Contents page,
page 2).

b. Items provided by a Contractor as a standard part of a


packaged or proprietary piece of equipment which can
Specification Number Rev Date Sheet
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1 15-9-94 1 4 0 o f 163
Sp&ca&n 01 ~ - J H - I ~ o ~

reasonably be described as an instrument or control item.


This shall apply even if the item does not appear on the
P&ID and has not been allocated a tag number.

19.3 Selection

19.3.1 lnstruments classified as "Miscellaneous" under the above


description may only be supplied if alternative instruments
selected from the other sections of this specification will not
adequately perform the required function.

19.3.2 Miscellaneous instruments shall be selected in accordance with


parameters set in this specification for similar types, with
respect t o power supplies and signal levels, hazardous area
protection methods, finishing, weatherproofing and all pertinent
requirements. All miscellaneous instruments require Company
approval before selection. lnstruments not complying with the
general parameters shall be rejected.

19.4 Sizinq and Ranqinq Requirements

The display scale shall be calculated so that the maximum predicted


operating point is between 60% and 80% of full scale.

19.5 Construction Requirements

All miscellaneous instruments shall be o f robust construction


suitable for service in the stated environment and particular
service conditions. They shall be of the same standard and
quality as is required in this specification for similar items.

Items containing electrical parts shall be certified as suitable for


the hazardous area by a recognized European testing authority
and be in accordance with BS 5501.

Any coils, contacts etc. shall be environment free encapsulated


type. Contacts shall be noble metal.

Environmental protection shall be provided t o the required


standard IP 65 minimum.

Stainless steel is the preferred material o f construction. Other


materials may be used if suitable for the service, and must be
adequately protected t o withstand the environmental conditions,
an epoxy paint finish or hot dip galvanising are acceptable
systems. Cadmium plating is not accepted as a final finish.

Transparent parts shall be of shatterproof glass, mechanically


protected where possible.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9~94 141 of 163
spe&%athn

19.5.7 Electrical items shall have integral terminals. Flying leads are not
acceptable.

19.5.8 Electrical entries shall be M 2 0 x 1.5 ISO.

19.5.9 Pneumatic connections shall be 114-in. NPT.

19.5.10 Process connections shall be 3 0 0 lb flanged (minimum) or 112-in.


NPT for line-mounted and impulse-connected items respectively.

19.5.1 1 Sensors shall be immune from radio frequency interference.

Installation Notes

Installation shall be carried out in accordance with the Engineering Group


Specification entitled "Instrument Installation" (Number 015-JH-1908) as
related t o similar instruments described in this specification and the
particular requirements of the specific instrument.

Performance Reauirernents

19.7.1 Quality Control (QC)

a. QC shall be as is detailed in the Contract. This section states


the m i n i m u m additional requirements related t o
miscellaneous instruments only and shall not in any way
replace or reduce the general QAIQC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary b y the Approved
Manufacturer t o ensure the quality of the product:

1. A check of the instrument and all accessories in


accordance with this specification and the data sheets
and Drawings.

2. Full works calibration and issue of test and calibration


certificate.

3. A check o n the nameplate data in accordance with this


specification and the data sheets and Drawings.

4. A check on the painting and protection and general


suitability for the environment.

5. A check o n the tagging in accordance with this


specification and the data sheets.
6. Additional checks commensurate w i t h the type of
instrument related t o similar instruments in this
specification, e.g., welding, NDT etc.

19.7.2 Documentation

The following data shall be available at final inspection:

a. Completed Test and Inspection Plan.

b. Instrument test and calibration certificate.

c. Hazardous area certificates.

d. Other documents commensurate w i t h the type of instrument


related t o similar instruments in this specification.

19.8 Nameplate Data

General information for production of the nameplate data is given in


section 4.7 of this specification.

20.0 ANALYSERS

20.1 Applicable Standards

API 5 5 0 Manual o n installation o f Refinery lnstruments and Control


Part 2 Systems, Process Stream Analysers

20.2 Scope of Analvsers Section

This section details the requirements for lnstruments and systems t o be


used for the analysis of process fluids and effluent at the Facility in
Kuwait.

20.3 Analvzer T v ~ e sand Selection

20.3.1 Analyzer types shall be selected for their specific applications for
process requirements. Where the type has not been specified by
the Company, the Contractor shall propose a suitable system for
approval.

20.3.2 Analysers shall be installed in a ventilated analyzer house except


where the Company agrees that a particular instrument shall be
fitted in the field or in a field shelter. Exceptions t o this are
analysers w i t h an intrinsic fast loop requirement such as for the
analysis of oxygen content of furnace flue gases, power of
hydrogen (pH) analysers for alkalinitylacidity of liquids, density
and conductivity analysers. These types of analysers shall be
located close to the sample point.
Specification Number Rev Date Sheet
Engineering Group
015-JH 1 9 0 3 1 15-9-94 143 of 1 6 3
SpecWa&n
--

20.3.3 For analysers o n critical duties, e.g, on safety systems,


consideration shall be given t o redundancy techniques. Detailed
proposals shall be submitted t o the Company for approval in all
cases where an analyzer output is vital t o a safety function.

20.3.4 Analysers shall be used on single streams unless multi-stream


applications are approved by the Company.

20.4 Sizina and Ranaina Reauirements

The range selected shall cover the full scale of variation possible
o n the variable subjected t o analysis. The normal operating point
shall preferably be at the midpoint of the scale.

Indicating and control functions shall be carried out b y the plant


DCS. Wherever possible, serial data links (e.g., RS 4 2 2 etc.)
shall be used t o transmit analytical data t o the DCS; isolated 4-
2 0 m A signals shall also be made available.

Where a separate safe area interface module is an essential part


o f the system, this shall be in the unmanned auxiliary room in
the control block. All necessary outputs displayed o n the
interface unit must be presented as repeats t o the DCS.

For ease of maintenance, analysers shall have also have local


indicators wherever practicable. Local panel display facilities
shall be provided where the individual indication is not visible at
the analyzer.

For instruments requiring field operator attention, e.g., those in


the analyzer house, test displays, alarms etc. shall be located in
a readily accessible position for maintenance. Purge alarms shall
be readily visible t o the operator.

Analysers o n closed loop control through the DCS shall operate


through a cascade loop. The range o f set-point adjustment of the
slave controller shall be restricted within preset high and l o w
limits. Alarms shall be actuated (after a brief time delay) t o warn
the DCS operator if the output from the analyzer attempts t o
exceed these limits.

20.5 construction Reauirements

20.5.1 General

a. All analysers shall be microprocessor based and be provided


with self-diagnostic and calibration functions.
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15~9~94 144 of 163
S P ~ C B & ~

Analysers shall be suitable for the specified environmental


exposure.

All parts exposed t o the process shall be suitable for the


pressure and temperature and resistant t o the specified fluid,
and will be constructed of stainless steel grade 316 as a
1
minimum. Alternative materials such as Monel, Hastelloy or
lnconel shall be supplied where necessary.

All components exposed t o process fluid o n sour service


shall comply with the requirements of NACE MR0175.

Analysers shall be certified for use in hazardous areas


classified Zone 1, as a minimum. Non-certified analysers
may be installed in certain services when the analyzer is t o
be mounted in a safe area, or an analyzer house made safe
b y purging, gas detection and electrical supply isolation
procedures. Such applications are subject t o Company
approval and shall only be allowed when the composition or
amount of the sample inside the analyzer is insufficient t o
produce an explosive or ignitable mixture in the event of
component failure or leakage.

Analyzer power supplies shall be 2 4 VDC or 1 1 0 V +/-


l o % , 5 0 HZ + / - 2 % .

Sensitivity shall be +/- 112% of span, with reproducibility


+ / - 1 % or better.

Analyzer outputs shall be 4 - 2 0 m A wherever possible and


shall be linear over the specified range. Alarm or other digital
outputs shall be by volt-free contact, on segregated
terminals suitable for IS circuits.

Analysers requiring manual restart after a power failure shall


be protected from shutdown b y a power failure of 4 seconds
or less.

Routine maintenance shall be possible without disturbing the


operation or location of the analyzer, and shall not be more
frequent than once every 7 days.

Analysis times shall be as short as possible, and in all control


applications including alarm and protective systems, the
permissible analysis times shall be agreed t o by the
Company.
Specification Number Rev Date Sheet
Engineeting Group
01 5-JH-1903 1 15-9-94 145 of 163
SpecHcation

20.5.2 Sampling Systems

Sampling systems shall comprise all equipment necessary t o


provide the analyzer with a continuous sample representative
o f the process stream t o be measured. The sample shall be
retained within temperature and pressure conditions
specified for the analyzer.

The delay time between the sample being withdrawn from


the process and being made available t o the analyzer shall be
as short as possible and shall not exceed five minutes for
monitoring applications and three minutes for control
applications. Shorter periods shall be provided according to
the process requirement.

Samples shall be drawn from a point in the process where


stream conditions are such that the minimum of sample
conditioning is necessary. This requirement is subject t o
acceptable process, sampling and analysis lag.

For direct process connected analysers, fast sample loops


shall be provided. Where process conditions do not favour
self-powering, the sample shall preferably be driven by a
sample pump located close t o the sample takeoff point.
Pumps shall not be placed inside analyzer housings unless
this is demanded b y control considerations or other sampling
difficulties.

Circulating loops may be used, returning the sample t o a


lower pressure point in the same process system. These
may be used in the bypasses t o pumps, across vessels and
other process elements. Samples shall not be taken across
orifice plates used for f l o w measurement. Samples may be
taken across control valves provided the sample flow is too
small t o affect the control application, and the pressure drop
across the valve is always sufficient t o ensure an adequate
sample f l o w rate.

Restriction devices shall not be placed in the line t o cause a


pressure drop for circulating sample takeoff.

The return points of circulating and bypass samples shall be


selected so that the pressure is at least 2 bar (30 psi) above
the vapour pressure of the sample.

Secondary fast loops, where a relatively large volume fast


loop or circulating loop f l o w bypasses an analyzer and the
analyzer sample is supplied b y a fast loop from this bypass,
shall be used t o maintain transport velocity and reduce time
lag. This method shall be used for field-mounted analysers
Specification Number Rev Date Sheet
Engineeting Group
01 5-JH-1903 1 15-9~94 146 of 163
Speai7cat.h

only and care shall be taken t o ensure that the final sample
line volume is small in relation t o analyzer sample
consumption.

Secondary fast loops shall only be used in the following


cases:

1. Sample conditioning equipment causes time lags

2. To reduce the amount o f sample entering the analyzer


house.

The takeoff for a secondary fast loop shall be a restriction in


the primary fast loop, adjustable so that the DP can be
selected t o give optimum performance.

Unless a fast loop is provided, process samples shall be


drawn b y probes constructed t o API RP 550, Part 2, Figures
14-2 and 14-3. For lines below 100-mm (4-in.) diameter, the
length of the stub connection shall be increased so that the
probe insertion is not greater than one quarter of the line
diameter.

Circulating loop materials, i.e., tubing from sample point t o


main filter and from filter t o return point, shall be the same
as the line or vessel from where the sample is drawn. The
filter shall also be c o m ~ a t i b l ew i t h the line class.

Analyzer loop materials, i.e., tubing and major components


between the main filter and the analyzer, shall be minimum
stainless steel grade 3 1 6, unless the application necessitates
alternative superior materials.

Sample isolating valves shall be provided near t o the


analyzer, outside any housing and accessible from grade or
platform.

Each sample isolating valve and the ends o f each sample line
shall be clearly labelled with the stream identity and analyzer
tag number.

Sample lines shall have drains and vents as necessary.


Permanent facilities shall be provided for sample lines and
analyzer flushing when sample viscosity is greater than 5 0 0
centistokes at 50°C (122"F), and other cases as may be
specified in the Contract. Double block and bleed isolation
shall be provided if leakage o f the flushing medium would
significantly affect the measured property o f the sample.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 4 7 of 163
Sp&ca&n

Sample f l o w rate through each loop, bypass and analyzer


shall be indicated locally. Sample pressure (and temperature
if required) at the analyzer inlet shall also be indicated
locally.

Liquified gas samples shall be completely vaporized


immediately adjacent t o the process line sample probe, with
samples being kept above their d e w point.

Flue gas and other vapour samples containing a large


proportion of steam or other components which need t o be
condensed and removed before analysis shall be given
special consideration.

Lines shall not be heated or lagged (except for personnel


protection) and shall be continuously sloped downwards
from the process connection t o the condensate removal
point.

Precautions shall be taken t o prevent damage t o the analyzer


and sampling components because of abnormal plant
conditions, e.g., reverse flow or if there is a danger of cross
contamination of process streams.

Safeguards shall be provided t o protect analysers and


sampling components from high pressure, temperature or
vacuum conditions resulting from malfunction of the
sampling system. Relief valves and automatic shutoff
systems shall be considered t o protect those components
installed in a system which has a limited pressure rating,
e.g., sample conditioning vessels or glass-containing
components. Where shutoff is used, an automatic vent shall
be used t o prevent damage due t o pressure/vacuum in a
blocked in system.

Relief valves and vents shall be connected t o a vent or


drainage system as required.

A takeoff point shall be provided o n each sample stream to


enable a sample check t o be made on the analyzer. This
point shall be close t o the analyzer, shall be easily accessible
and arranged so that drawing off a sample does not impair
analyzer operation.

y. Facilities shall be provided for introducing test samples into


the analysers. Gaseous test samples, or volatile, toxic or
otherwise dangerous liquid samples shall be stored outside
the housing. Introduction o f a test sample shall not cause a
hazard.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 4 8 of 163
Sp&Cdtion

z. Provisions for introducing a test sample shall include


containers fitted with relief valves, pressure gauges, and
pressurisation facilities.

aa. Solenoid valves shall not be used directly in sample lines,


and shall only be applied for switching instrument air or
nitrogen t o pneumatically operated valves.

ab. All hazardous samples or test gases shall be automatically


disconnected by operation of these valves when a gas
emergency arises in the analyzer house.

20.5.3 Flow Rates t o Analvsers

a. The total amount of flammable fluids flowing t o the analyzer


shall be limited by an excess f l o w valve which shall be of the
self-closing type t o prevent exceeding the limits mentioned
below.

b. Maximum f l o w rate of flammable gases shall not exceed 2 0


normal litreslhour.

c. Liquid flow rate shall not exceed the maximum required, as


specified by the Approved Manufacturer of the analyzer
concerned.

d. Flow rates exceeding the above limits require the approval of


the Company.

20.5.4 Sample Disposal Systems

a. Samples shall be returned back into the process stream


wherever possible.

b. Hydrocarbon gases or vapours which cannot be returned t o


the process shall be discharged t o a flare system or an
atmospheric vent at a safe height which shall be
independent o f any process vent; due regard shall be given
t o the vent's influence o n the surrounding electrical area
classification.

c. Hydrocarbon liquids which cannot be returned t o the process


shall be discharged into a plant hydrocarbon recovery system
or hydrocarbon liquid drain pit.

20.5.5 Sample Conditioning

a. The removal of entrainments in liauids shall be as follows:

-
Specification Number Rev Date Sheet
Engineehg Gmup
01 5-JH-1903 1 15-9-94 149 of 163
Spe&ca&n

Entrained gases shall be separated b y passing the


sample through an expansion pot w i t h a l o w level liquid
takeoff.

Liquid entrainments (i.e., oil in water) shall be coalesced


and separated by specific gravity differences.

The sample point shall be carefully chosen t o eliminate


as much as possible solid entrainment. Further
entrainment shall be eliminated using cyclone filters,
coalescing of liquid droplets or by filtration o f solids.

Chemical means and drying shall be used t o remove


gases or water vapour which are either not required or
could affect the accuracy o f the analyzer. These
methods shall include :

(a) Liquid or solid chemicals.

(b) Desiccants (silica gel etc.).

(c) Molecular sieves,

(d) Caustic pellets.

(e) Concentrated sulphuric acid

The treating medium shall in no w a y affect or influence


the critical properties of the fluid stream t o be analysed.

20.5.6 Field Mounting o f Analysers

a. Field mounting of analysers shall only be considered under


the following conditions:

1. When the cost o f an analyzer house is disproportionate


t o the advantages gained. If this is the case, the
requirements of the analyzer shall be re-evaluated.

2. The location of the analyzer away from the tapping


would result in an unacceptable time lag.

3. The construction and installation of the analyzer is such


that repair and routine maintenance can only be safely
effected in the workshops.

b. When the analyzer is t o be field mounted, the construction


and mounting shall be fully suitable for the environmental
conditions and be fully protected against rain, sandstorms
Specification Number Rev Date Sheet
Enginewing Group
01 5 - J H ~ 1 9 0 3 1 15-9-94 1 5 0 o f 163
Spmi'i~aikm

and possible vibration from neighbouring equipment. The


black body temperature under the direct sun exceeds 8 0 " C
(176" F). Sun shielding shall be provided so that the
instrument does not rise above the lower of the instrument
design temperature or 7 0 " C (158°F).

Field-mounted analysers shall be installed individually or in


groups close t o their sample points and protected by simple
shelters and sun shields. Where an analyzer sample contains
a possible source o f toxic vapours, the analyzer shall be
located in a separate freely ventilated shelter.

Shelters shall be weatherproof and constructed of either


metal sheet on a steel frame or flame-retardant glass fibre.
Each shelter shall be fitted w i t h the following:

Electric lighting.

Windows

Concrete base sloped w i t h a fall of 1 in 3 0 t o a drain


located at least 2 m (6 ft.) from the shelter.

Exit points at both ends sized for the removal of all


equipment. Doors, where fitted, shall be outward
opening and provided w i t h windows.

The lower edge o f all shelter walls shall be at least 1 8


in. aboveground w i t h ventilation provided along the
uppermost part o f the shelter roof t o ensure free
circulation of air within the building.

T w o or more analysers may be housed in a single shelter.


This arrangement is subject t o the restrictions for allowable
transport time, taking into account the distance t o sample
taps.

Analysers or shelters shall not be located under pipe racks,


air coolers or other items o f process equipment.

All power supplies t o analysers shall have a field-mounted


isolating switch.

The analyzer, power supply isolating switch, sample takeoff


and return points and sampling system components shall be
readily accessible from grade or fixed platforms.

Approximate sizes and locations o f all analysers 1 shelters


shall be shown o n the plot plan when this is submitted for
approval.
Specification Number Rev Date Sheet
Engineeting Group
0 1 5-JH-1903 1 15-9-94 151 of 163
Spea%at&n

20.5.7 Analvsers in Hazardous Areas

Wherever possible, analysers shall be selected having all


components certified for use in the hazardous area. Where
this is not possible, and with Company approval, the
analyzer can be mounted in a purged analyzer house and be
connected t o a safety system such that all power t o the
analyzer is cut o f f in the event of a failure o f the purge
system or a gas emergency. Where an analyzer house is not
provided, or the instrument is in a service that requires
continuous operation, the use o f an individually purged and
pressurized enclosure shall be offered for Company approval.
The purge control unit shall be certified, b y a recognized
European Testing Authority, and the complete enclosure and
its fitted analyzer and components supplied as a system by
the purge unit Approved Manufacturer.

Analysers which handle flammable products within non-


explosion-proof housings shall n o t only be pressurized but
shall also be purged b y a continuous f l o w of dilution air t o
prevent the buildup of explosive concentrations in the event
of a seal failure.

If inert gas is used, pressurisation only is required if i t is at a


higher pressure than the sample.

Depending o n the area classification, the following purge


systems shall be considered. In all cases, the purge systems
shall be those of a specialist proprietary Approved
Manufacturer and shall be supplied complete with
interlocking system, timers, alarms etc. and be fully certified
for the electrical area classification, and be approved b y the
Company before detailed design commences.

1. Overpressure only - shall be 5-25-mm W G ('/,-I in. WG)


with at least ten volume changes per hour.

2. Overpressure with alarm.

3. Overpressure with interlock.

4. Overpressure with l o w f l o w rate interlock.

The f l o w rate shall be related t o the maximum f l o w rate of


the sample system t o cover the possibility of seal failure. A
purge flow rate o f four times the maximum sample flow rate
shall be regarded as a safe figure. This figure may be
reduced depending o n the concentration of the flammable
gas necessary t o remain below the lower explosive limit.
Specification Number Rev Date Sheet
Engineering Gmup
01 5-JH-1903 1 15-9-94 1 5 2 o f 163
Sp&catlon

The purge medium shall in general be dry instrument air.


Nitrogen shall be used when the lower explosive limit is
difficult t o reach or the location is remote and there is no
instrument air supply.

Purge systems shall be interlocked w i t h all analyzer power


points so that on failure of the purge, the power points are
switched off.

Purge systems shall be alarmed for l o w pressures in all


cases. High-purge pressure alarm and low-pressure
shutdown shall be considered per installation.

In the event of a shutdown of the analyzer system due t o


purge failure, the system shall be interlocked such that the
analysers cannot be switched on until at least five volume
changes have taken place.

20.5.8 Analyzer House

A n analyzer house shall be provided where i t is feasible t o install


several analysers in one location, and where sampling stream lag
time is n o t a major consideration or can be accommodated. The
type o f analyzer house required shall be indicated in the Contract
documents:

a. Masonry Construction

The analyzer house shall be of solidly constructed design


able t o withstand blast forces from inside or outside.
Internal blast relief provisions shall be included in the
design. The house shall be equipped with self-closing
doors w i t h closure alarm switches.

The analyzer house shall be fitted w i t h a dual ( 1 0 0 %


redundant) air purging /cooling system t o maintain the
temperature between 1 5 and 30°C ( 5 9 and 86"F),
lighting at 2 5 0 lux minimum, Ex'd' power sockets and
power distribution and all facilities and safety equipment
normal for an operator w o r k area. Sinks and sluices shall
be provided.

The house shall be fitted w i t h fire and flammable gas


detectors connected t o the plant-wide system.

The space allocation shall be at least l - m (3-ft.) wall


space and 2.5 m3 (88 ft3) volume for each analyzer, with
3 0 % spare allocation for future expansion.
Specification Number Rev Date Sheet
Engineering Group
0 1 5-JH-1903 1 15-9-94 153 of 163
Spei%%ation

Wherever possible, an analyzer house shall be located in


a non-hazardous area or if this is not feasible, at worst
in a Zone 2 area.

Construction Drawings and materials specifications for


the analyzer house shall be approved b y the Company.
The Drawings shall show the locations of analysers,
sample conditioning systems, laboratory sample points,
calibration sample containers, gas cylinders and drains.

Note : The sample lines and the sample conditioning


system will probably create a Zone 2 area around the
analyzer house.

All test sample bottles and conditioning equipment


wherever possible shall be mounted in racks outside the
analyzer house in a covered, vented gallery. All
hazardous sample and test lines into the building shall
have an automatic and a manual isolation valve outside
the building.

The location of the analyzer house shall be as close as


practicable t o the sample takeoff points of the relevant
analysers, in order t o minimise sample transport time lag
and cooling of the sample t o l o w ambient temperature.
The location shall also be free from spillage of water and
process liquids.

The analyzer house shall be ventilated w i t h air t o keep


out flammable and toxic gases, and any leakage of
flammable gases andlor vapours that may occur inside
the house shall be diluted t o a safe level.

The f l o w o f air shall be sufficient to:

(a). Dilute escaping vapours resulting from the failure of


any sample line t o less than 2 0 % of the LEL.

(b). Maintain the pressure inside the analyzer house at


0 . 2 5 mbarg (1110-in.WG) above that of the outside
atmosphere, t o prevent ingress of that atmosphere.

11. The ventilation system shall be capable of at least 1 2


volume changes per hour t o ensure adequate dilution of
the internal atmosphere.

12. The required air flow rate shall be calculated for each
analyzer house based o n the above conditions and shall
be submitted t o the Company for approval.
Specification Number Rev Date Sheet
Engineering Gmup
1 15-9-94 1 5 4 o f 163
Specificatbn 01 ~ - J H - I ~ o ~

13. Air intake t o the ventilation system shall be taken


through a stack provided w i t h a rain hood and, wherever
necessary, a sand filter.

14. The air shall be drawn from a non-hazardous area, and


the intake duct and diameter should be sized so as t o
limit the air velocity inside the ducting t o a maximum of
8 misecond ( 2 6 ftisecond).

1 5 . Gas detectors shall be provided within the ventilation


ducts t o detect the presence o f any airborne flammable
gases.

16. Should the analyzer house ventilation system fail or be


shut d o w n due t o gas detected in the inlet duct,
protective measures shall be taken against the
potentially hazardous atmosphere caused by possible
leakages both inside and outside the house. All analysers
which cannot be switched o f f in such circumstances
shall be engineered for operation in a Zone 1
environment.

17. Upon failure of the ventilation system or failure of a door


t o close within a preset time, an audible and visual alarm
shall be initiated in the analyzer building and in the
control room.

18. When flammable gas is detected in the ventilation air


inlet ducts, the ventilation system shall be switched off
and isolated.

19. When flammable gas is detected inside the analyzer


house but not at the inlet, the ventilation system shall
be left running, but all non-certified equipment shall be
switched off and isolated.

20. After a failure of the ventilation system, non-explosion


proof equipment can only be switched o n when:

(a). The gas detected in the house is below 2 0 % of the


L.E.L

( b ) . The ventilation system has been running for a


sufficient length of time for at least five air volume
changes.
Specification Number Rev Date Sheet
Engineering Group
O I ~ - J H - ~ ~ O ~ 1 15-9-94 1 5 5 of 163
SpMcation

b. Steel Framed Building with Cladding

Enclosed analyzer houses constructed of steel framing and


having insulated metal cladding shall incorporate all the
features of the masonry-built houses, including the
provisions for air-conditioning, purging, pressurisation and
gas detection.

c. Glass-Reinforced Polyester (GRP) Construction

Enclosed analyzer houses of GRP or similar lightweight


materials may be used for a limited number of analysers.
The houses shall be installed o n a tiled concrete base
and shall include all the features o f the masonry analyzer
house including the provisions for air conditioning,
purging, pressurisation and gas detection.

The construction shall not be rated as blast resistant.


Windows may be installed as for the ventilated field
analyzer shelters.

Sinks and sluices may be omitted if not required for the


installed analysers. A sloping floor piped t o an external
drain shall be installed.

The analysers shall be installed o n floor-mounted frames


and shall not be supported from the analyzer house
walls.

A sun shield shall be installed t o protect the GRP from


direct exposure t o the sun.

20.6 Installation Notes

Analysers and related equipment shall be installed in accordance with the


Engineering Group Specification entitled "Instrument Installation" (Number
0 1 5-JH-1908), as modified for the special requirements o f process
analysis equipment.

20.7 Performance Reauirernents

20.7.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o analysis
instruments only and shall not in any w a y replace or reduce
the general QA/OC requirements.
Specification Number Rev Date Sheet
Engineering Group
01 5 ~ J H ~ 1 9 0 3 1 15-9-94 156 of 163
SpeiHcahbn

b. The test and inspection plan shall include the following items
in addition t o those found necessary by the Approved
Manufacturer t o ensure the quality of the product:

1. A check of the instrument and all accessories in


accordance w i t h this specification and the data sheets
and Drawings.

2. Full works calibration and issue of test and calibration


certificate.

3. A check on the nameplate data in accordance with this


specification and the data sheets and Drawings.

4. A check o n the painting and protection and general


suitability for the environment.

5. A check o n the tagging in accordance with this


s ~ e c i f i c a t i o nand the data sheets.

6. Additional checks commensurate w i t h the type of


instrument related t o similar instruments in this
specification, e.g., welding, NDT etc.

20.7.2 Documentation

The following data shall be available at final inspection:

a. Completed test and inspection plan.

b. Instrument test and calibration certificate.

c. Hazardous area certificates.

d. Other documents commensurate w i t h the type o f instrument


related t o similar instruments in this specification.

20.8 Namedate Data

20.8.1 General information for production of the nameplate data is


given in section 4.7 of this specification.

20.8.2 In addition, the analyzer systems as a whole shall be fitted with


clear, dual-language labels at all isolation valves, test points,
indicators, test panels, flammable gas detector test points etc.
Labels outside shall be stainless steel. Inside the analyzer house,
laminate or similar labels, white w i t h black legends shall be used,
provided adequate allowance is made for differential expansion
between the label and panel materials t o prevent cracking in
service.
-
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 159-94 157 of 163
Speaiccation

21.0 LOCAL PANELS AND GAUGE BOARDS

21.1 S c o ~ eof Local Panel and Gauae Board Selection

This section covers the design and application of all local panels and
gauge boards used for assisting field operational control.

21.2 Local Panels and Gauae Boards T v ~ e


and Selection

21.2.1 Centralized Control

Control and monitoring shall wherever possible be via the control


room DCS and its operator. The use o f local panels shall be
minimised within the constraints of safe, economical control of
the Facility.

21.2.2 Local Panels

Where an equipment package requires t o be startedistopped in


the field andlor t o have important operating statusldata relayed
t o the field from the ESDIDCS systems, a local panel shall be
installed adjacent t o the equipment, readily accessible from
grade or a fixed platform. Such panels shall not contain logic or
any components other than terminals, lamps and pushbuttons.

21.2.3 Special Panels

By agreement with the Company, special-purpose local panels


can be supplied. Examples are:

a. Where the field repeat and control interface is complex, a


field hardened VDU operator station may be supplied, with a
redundant data link t o the main DCS system. The station
shall in all respects comply w i t h the requirements for the
hazardous area certification and ingress protection, and be
mounted in a room maintained under environmental
conditions suitable for the equipment contained.

b. Where a standard piece of equipment o f proven design and


performance is proposed, subject t o Company approval,
discrete electronic components may be contained within the
certified enclosure. Such equipment shall only be accepted
when its use is intermittent and maintenance can be
conducted without plant shutdown.

21.2.4 Gauge Boards

Where a number of gauges are in related service, they shall be


collected together o n a clearly labelled gauge board t o assist the
easy, unambiguous reading of the process variables.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 5 8 of 1 6 3
Speai7cab;on

21.2.5 Field Enclosures

Where conditions dictate that the amplifier or transducer for a


particular piece o f equipment requires t o be field mounted close
t o the tapping points, the Approved Manufacturer shall provide a
local enclosure. It is the Contractor's responsibility t o specify the
equipment directly suitable for the environment and hazardous
area, or t o provide such additional protection as is necessary.

21.2.6 Miscellaneous Panels

Panels and boards shall also be provided t o assist in clarifying


plant areas for maintenance purposes, e.g., sample points
collected together, gas injection points for detector testing,
solenoid valve reset groupings for related services in tight
locations etc.

21.3 Sizina Reauirements

21.3.1 Layout for Operator Access

Local panels shall be the minimum size commensurate with clear


and adequate spacing of the instruments and associated bi-
lingual labelling (English and Arabic). Instruments t o be viewed
b y the operator shall be between 1.4 and 1 . 6 m (4'1, and 5'1,
ft.) from grade or a fixed platform. Pushbuttons shall be between
1 . 0 and 1.5 m ( 3 and 5 ft.) from the same levels.

21.3.2 Terminations

a. Items requiring termination, maintenance etc. such as


solenoid valves shall be not less than 3 0 0 m m ( 12 in.) and
not more than 1.8 m ( 6 ft.) above the standing surface.

b. Terminal boxes shall be placed w i t h the bottom entry gland


at least 3 0 0 m m ( 1 2 in.) above the platform level, or a
sufficient distance above grade t o manipulate lead-sheathed
multicore cables.

21.4 Construction Reauirements

21.4.1 General

a. Local panels shall be constructed as free-standing, pre-wired


assemblies. They shall consist of one or more certified
junction boxes with certified lamps and pushbuttons installed
in the front face. They shall be complete w i t h certified
junction box for connection of main plant cabling. The lamps
and pushbuttons shall be labelled externally w i t h full tag
number and service, in English and Arabic and internally with
Specification Number Rev Date Sheet

@ KOC Engineering Group


SpeMcafhn 01 ~ - J H - I ~ o ~ 1 15-9-94 1 5 9 0 f 163

tag number only. For Zone 1 or 2 use, the junction boxes


shall be Ex'e', the pushbuttons Ex'i' and the lamps Ex'd' or
Ex's'.

b. The junction boxes shall conform t o the details given in the


Engineering Group Specification entitled "Instrument
Installation" (Number 01 5-JH-1908).

c. Panels having a large number of lamps/buttons may use a


fabricated carcase w i t h the junction boxes mounted inside
and connected by flying lead t o certified lamplpushbutton
units o n the front face. The hazardous area within the
enclosure shall be rated one zone higher than the
surrounding area, unless adequate ventilation can be
ensured.

Gauge Boards

Gauge boards shall be constructed as free standing. The front


facing shall be 5-mm (3116-in.) plate, suitably plated or painted
for the service conditions. The gauges and isolating valves shall
be pre-assembled and piped t o bulkhead or termination fittings.
The method of mounting gauges shall not infringe upon the
blow-out integrity. The gauges shall be labelled w i t h full tag
number and the service, in English and Arabic. All installation
materials, including tray work, shall be as specified in the
Engineering Group Specification entitled "Instrument Installation"
(Number 01 5-JH-19081.

Field Enclosures

Local transducerlamplifying stations will normally be supplied as


certified weatherproof enclosures b y the Approved Manufacturer
and installed by the Contractor onto a panel constructed similar
t o a gauge board. Where the equipment is n o t t o protection
standard IP65 or better, a secondary enclosure may be provided;
however, since the hazardous area classification will increase t o
the next zone, the Contractor shall ensure that the equipment
certification is suitable. Other techniques, such as purged and
pressurized panels, may be adopted subject t o Company
approval.

Framework

The supporting framework shall be provided w i t h drilled base


feet of ample proportions t o support the weight and wind forces,
without causing trip points o n the grade or platform area where
the panel or board is installed. Lifting points shall be provided as
necessary. Where removable lifting points are provided, blanking
bolts and washers shall be fitted after installation. The
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 6 0 0 f 163
SpetMcathn

framework shall be manufactured of robust angles and sections


welded together, galvanised after manufacture and after drilling
of all holes.

21.4.5 Visibility and Sun Screens

Measures shall be adopted t o ensure that the panel lamps,


indicators etc. can be easily read under any expected light
conditions. In most external locations, side enclosures and
overhead deflectors will be required in addition t o mounting the
panels in advantageous positions. Care shall be taken t o ensure
that the use o f such enclosing does not increase the hazardous
area classification above the rating of the equipment.

21.4.6 Lamp Test

All panels having lamps shall also include a lamp test push-
button which shall communicate w i t h the logic system and thus
activate all unlit lamps when depressed.

21.4.7 Fabrication and Finishing

a. Fabricated cubicles, side panels etc. shall be of minimum 2-


m m (313241-1.) plate with folded edges and welded
construction. They shall be painted in accordance w i t h the
Engineering Group Specification entitled "Shop and Field
Painting" (Number 0 1 5-XH-1005). Ventilated panels shall
have high level louvres w i t h mesh screens. Opening doors
shall be supplied w i t h robust stainless steel hinges and T-key
door fastening system. Door locks shall be fitted only where
agreed t o as specifically required b y the Company.

b. All entries shall be from the bottom, preferably direct into


the junction boxes via an open bottom so that free
ventilation is possible. For grade-mounted panels, a closed
bottom is required t o prevent ingress o f wind blown
materials. In this case, the cable shall enter the panel via a
cable stopper gland (without stripping of the cable sheath)
mounted in the base gland plate and then be terminated in
the junction box. In these cases, an adequate ventilation
system is required t o prevent an increase in the hazardous
area classification.

21.4.8 Local Indicators

Local electronic indicators shall be digital IS type when the


clarity of the reading can be ensured under the sunlight
conditions. Indicating dial type may be used subject t o Company
approval.
Specification Number Rev Date Sheet
Engineering Gmup
1 15-9-94 1 6 1 of 163
spedfi~atbn 0 1 5-JH-1903

21.4.9 Terminations

Terminations, wiring etc. within the junction boxes shall be in


accordance w i t h the Engineering Group Specification entitled
"Instrument Installation" (Number 0 1 5-JH-1908), including
glanding, numbering, earthing etc. The minimum cable core size
shall be 1.5 mm2.

21.4.1 0 Earthing

All panels/cubicles shall have a fully wired earthing system


connecting all metal components via greenlyellow earth
conductors (of minimum 6 mm2) back t o one main plant earth
boss, with 10-mm (318-in.) brass earth stud, 3 0 - m m (13116-in.)
projection and t w o brass nuts and washers.

21.4.1 1 Sunshield

All panels and gauge boards require an overhead sun shield of


such proportions and materials that the temperature of the panel
does not rise above 70°C ( 158°F) due t o direct sun effects or re-
radiation.

11.5 Installation Notes

Visibility

Control panels shall be installed in the truly vertical position.


They shall be installed in the best position t o make use of
ambient light while minimising the effect of glare, and shall be
adequately lit for night use b y general or specific illuminators.
The panel instruments, lights and annunciators shall be clearly
visible t o the operator under all possible lighting conditions. The
Contractor shall make whatever provisions are necessary t o
achieve this condition t o Company satisfaction.

Choice of Location

Panels shall be mounted as far as possible from sources of


harmful matter and vibration.

Access

The space in front of the panel shall be an unobstructed


passageway of at least 1 5 0 0 m m (5 ft.) A minimum distance of
1 0 0 0 m m (3'1, ft.) shall be provided for rear access when
required. All visual instruments shall be within the range 1.4 t o
1.6 m (4'1, t o 5'1, ft.) and operator accessible instruments 1.0
m t o 1.5 m ( 3 t o 5 f t . ) from the standing platform level.
Specification Number Rev Date Sheet
Engineering Group
01 5-JH-1903 1 15-9-94 1 6 2 o f 163
specmation

21.6 Performance Reauirements

21.6.1 Quality Control (QC)

a. QC shall be as detailed in the Contract. This section states


the minimum additional requirements related t o local panels
and gauge boards only and shall not in any w a y replace or
reduce the general QAIOC requirements.

b. The test and inspection plan shall include the following items
in addition t o those found necessary by the Approved
Manufacturer t o ensure the quality of the product:

A check of the dimensions o f the finished items against


the Drawings supplied for the Contract and approved by
the Company.

A check o f the panellcubicle and all accessories in


accordance with this specification and the data sheets
and Drawings.

Full point-to-point, functional and earth resistance


testing of the panellcubicle in accordance this
specification, the Approved Manufacturer's additional
QA/QC procedures and the approved test and inspection
plan.

A check on the nameplate data in accordance with this


specification and the data sheets and Drawings.

A check o n the painting and protection and general


suitability for the environment.

A check o n the tagging in accordance w i t h this


specification and the data sheets.

21.6.2 Testing

a. LampiPushbutton panels shall be tested b y applying


simulated signals and loads at the junction box terminals.

b. Gauge boards shall be tested w i t h instrument quality air up


t o the rating of the instrument or the air line, whichever is
lower. A soap and water or bubble chamber test shall
confirm the tightness of the joints.

c. Cubicles containing the Approved Manufacturer's amplifying


equipment shall be tested in simulated conditions with the
sensor and receiving equipment connected.
Specification Number Rev Date Sheet
Engineering Group
Speaiccation 01 5-JH-1903 1 15-9-94 163 01 163

21.6.3 Documentation

All the certification for each cubiclelpanel shall be collated in a


Data Book which shall be available at final inspection. The book
shall include as a minimum:

a. Completed test and inspection plan.

b. Weld procedures for structural welds.

c. Leak test certificates.

d. Hazardous area certificates.

e. As-built Drawings as necessary.

21.7 N a m e ~ l a t eData

21.7.1 General information for production o f the nameplate data is


given in section 4.7 of this specification.

21.7.2 The proposed title for "Service" of panel front instruments shall
be submitted t o the Company for approval.

21.7.3 Front-of-panel labels shall be engraved and infilled stainless


steel. The labels shall be fastened with stainless steel screws.
Adhesive jointing paste shall be used o n the rear of the label so
that moisture cannot penetrate behind and cause rust marks at
the screw holes.