REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION
DE LINEAR-ALKYL-BENZENE <
CT-EPC/017/SH/EPM/RPC-X/2023
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 1 / 61
ISSUE 2
INSTRUMENT GENERAL SPECIFICATION
2
1
0
22/Aug/2024
IFD – Issued for Design
G. Somaiya
P. Gaikwad
E. Magadeev
23/Jul/2024
IOC - Implementation of Comments
G. Somaiya
P. Gaikwad
E. Magadeev
07/May/2024
IFA - Issued for Approval
G. Somaiya
P. Gaikwad
E. Magadeev
Issue
Date
Reason for Issue – Revision Description
Prepared
Checked
Approved
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INSTRUMENT GENERAL SPECIFICATION
CONTENTS3
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
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ISSUE 2
1
PURPOSE … 4
1.1 1.2
PROJECT DESCRIPTION … 4 DEFINITIONS … 9
2 REFERENCE DOCUMENTS … 9
2.1 2.2 2.3
CODES AND STANDARDS, LAWS & REGULATIONS … 9 PROJECT DOCUMENTS … 15 ORDER OF PRECEDENCE … 15
3 ABBREVIATIONS … 16
4 GENERAL … 18
4.1 4.2 4.3 4.4 4.5
P&ID SYMBOLS AND INSTRUMENT IDENTIFICATIONS (TAG NUMBERS) … 18 UNITS OF MEASUREMENT … 18 ENVIRONMENTAL CONDITIONS … 18 INSTRUMENT INDEX … 19 PACKAGE UNITS … 19
5 DESIGN REQUIREMENTS … 19
GENERAL… 19 5.1 TEMPERATURE INSTRUMENTS … 24 5.2 FLOW INSTRUMENTS … 26 5.3 LIQUID LEVEL INSTRUMENTS … 29 5.4 PRESSURE INSTRUMENTS (INCLUDING NON-FLOW DIFFERENTIAL PRESSURE) … 33 5.5 AUTOMATIC CONTROLLERS … 34 5.6 MISCELLANEOUS … 35 5.7 MEASURING UNITS AND INSTRUMENT SCALES… 35 5.8 TRANSMISSION SYSTEMS … 35 5.9 5.10 CONTROL VALVES … 37 5.11 ON/OFF VALVES … 41 5.12 PRESSURE RELIEVING DEVICES … 47 5.13 ANALYSERS … 49 5.14 FIRE AND GAS SYSTEM (F&G) … 49 5.15 TANK GAUGING SYSTEM (TGS) … 50
6
INSTALLATION … 51
6.1 6.2 6.3 6.4 6.5
CONNECTIONS FOR INSTRUMENTS ON VESSELS AND PIPING … 51 INSTRUMENT AIR SUPPLY AND ELECTRICAL POWER DISTRIBUTION … 53 INSTRUMENTATION INSTALLATION AND INTERCONNECTION … 54 TRACING … 59 GROUNDING … 59
7
8
INSPECTION … 60
FIELD TESTING AND CALIBRATION … 60
9 MARKING … 60
9.1 9.2 9.3 9.4
MANUFACTURER NAMEPLATE … 60 JUNCTION BOXES … 60 CABINETS AND PANELS … 61 CABLES … 61
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
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ISSUE 2
9.5 9.6 9.7
LABELLING SYSTEM … 61 TERMINAL … 61 COLORS OF THE CABLES … 61
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INSTRUMENT GENERAL SPECIFICATION
1
PURPOSE
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 4 / 61
ISSUE 2
This document establishes the instrument general specification for the execution of the EPC phase of
the project “REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-
BENZENE <
1.1 Project Description
In order to fulfil its domestic needs in Linear-Alkyl-Benzene (LAB) used for the production of detergents and possibly export the excess to the international market, Sonatrach plans to build a new LAB production complex in Skikda (Algeria). The new complex will produce 100,000 tons of LAB per year and will be installed in the existing industrial zone of Skikda. Skikda is a coastal town located 350 km east of Algeri, Algeria.
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 5 / 61
ISSUE 2
Figure 1 – Satellite view of plant location
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
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Figure 2 – Satellite view Skikda industrial area
The LAB project includes the following installations located on four different sites:
• New LAB complex (DEV1 area):
The new LAB complex will include the following three process units for the production of N- Paraffins:
(U-100) Prefractionation of Kerosene feedstock, (U-200) Kerosene Hydrotreating to remove sulfur, nitrogen and aromatics contaminants, (U-300) Molex unit to extract N-paraffins through adsorption.
LAB is then produced from N-Paraffins in the following four units:
(U-400) Pacol unit carrying out the dehydrogenation of n-paraffins to n-olefins, (U-500) Define unit carrying out the selective hydrogenation of di-olefins to n-olefins, (U-600) PEP unit removing the aromatics from the Pacol outlet stream, (U-700) Detal-Plus unit making alkylation of benzene with linear olefins to produce linear- alkyl-benzene LAB and separating the HAB by-product.
Utilities units consists of the following:
U 805 – Power Plant U 810 - Natural Gas and Fuel Gas U 820 – Plant and Instrument Air
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 7 / 61
ISSUE 2
U 830 - Nitrogen U 835 – Hydrogen Production Unit U 840 – Industrial Water U 850 – Demineralized Water system U 860 – BFW, steam and condensate U 870 – Cooling Water system U 880 – Potable Water system U 890 – Hot Oil system.
Offsites units consists of the following:
U 910 – Feedstock Kerosene and Benzene storage U 920 – Intermediate and recycled products storage U 930 – Final product storage U 940 – Chemical storage facilities U 950 – Flare system U 960 – Closed Drainage system U 965 – Sour Water treatment system U 970 – Waste Water system U 980 – Fire Water system
Figure 3 – Identification of main units of DEV1 area (from FEED)
• Skikda refinery RA1K:
The project will include all the necessary facilities:
To export from the RA1K refinery, Kerosene and Benzene to the new LAB complex To receive the by-products generated by the LAB complex
• Skikda industrial area (DRIK):
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
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ISSUE 2
The project will cover the interconnecting lines for raw materials, by-products, finished LAB product to the port and utilities.
• Port of Skikda:
The project will include all the facilities necessary to load finished LAB product on ships.
Project references:
Client Project Location Official name of each site
SONATRACH LAB – EPC phase Skikda, Algeria LAB Complex (Zone DEV1) RA1K Refinery DRIK (Direction Régionale Industrielle de Skikda) Port (Zone Portuaire)
Figure 4 - Layout of Skikda industrial area showing sites
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 9 / 61
ISSUE 2
Figure 5 - DEV1 area reserved for erection of LAB complex
1.2 Definitions
CA / COMPANY / Maitre de l’Ouvrage SONATRACH DC-EPM
CONTRACTOR / Entrepreneur
TECNIMONT SPA
TECHNOLOGY LICENSOR
HONEYWELL UOP
PROJECT
REALISATION EN EPC D’INSTALLATIONS DE
PRODUCTION DE LINEAR-ALKYL-BENZENE <
SKIKDA ALGERIE
2
REFERENCE DOCUMENTS
2.1 Codes and standards, laws & regulations
In general, the new LAB complex facilities will be designed in accordance with internationally recognized codes and standards. The complete list of codes, standards and norms applicable to the EPC phase of LAB project and the associated utilities are listed in INDEX OF PROJECT REGULATIONS, CODES AND APPLICABLE STANDARDS 4439-YZ-PC-000000018.
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
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Number
Title
2014/34/UE
ATEX directive
Cast Iron Pipe Flanges and Flanged Fittings ASME B16.1 ASME/ANSI B16.5 Steel pipe flanges, flanged valves and fittings ASME/ANSI B16.34 Valves Flanged, Threaded and Welding End ASME/ANSI B16.36 Orifice flanges ASME B31.1 ASME B31.3 API 520
Power piping Process Piping Part I&II Recommended practice for the design and installation of pressure relieving systems Guide for Pressure Relief and Depressurizing Systems Pressure Safety Valves Seat Tightness of Pressure Relief Valves Part I Manual of installation of control system (superseded-only for reference) Process Measurement Instrumentation Transmission Systems Refinery Control Valves Process Instrumentation and Control Process Analyzers Inspection of Pressure Relieving Devices Valve Inspection and Testing Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries Corrosion-Resistant, Bolted Bonnet Gate Valves – Flanged and Butt- Welding Ends Fire Test for Soft-Seated Quarter Turn Valves Metal Ball Valves – Flanged and Butt-Welding Ends Butterfly Valves: Double Flanged, Lug- and Wafer-Type Machinery Protection Systems Specification for Pipeline Valves Specification for Fire Test for Valves Fire Test for Valve with Automatic Backseats Venting Atmospheric and Low-Pressure Storage Tanks Manual of Petroleum Measurement Standards – Chapter 5 – Metering – Section 1 – General Consideration for Measurement by Meters Manual of Petroleum Measurement Standards – Chapter 5 – Metering – Section 2 – Measurement of Liquid Hydrocarbons by Displacement Meters Manual of Petroleum Measurement Standards – Chapter 5 – Metering – Section 3 – Measurement of Liquid Hydrocarbons by Turbine Meters Manual of Petroleum Measurement Standards – Chapter 5 – Metering – Section 5 – Fidelity and Security of Flow Measurement Pulsed-Data Transmission Systems Manual of Petroleum Measurement Standards – Chapter 12 – Calculation of Petroleum Quantities – Section 2 – Calculation of Petroleum Quantities
API 521 API 526 API 527 API 550
API 551 API 552 API 553 API 554 API 555 API 576 API 598 API 600 API 603
API 607 API 608 API 609 API 670 API 6D API 6FA API 6FC API STD 2000 API MPMS 5.1
API MPMS 5.2
API MPMS 5.3
API MPMS 5.5
API MPMS 12.2
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 11 / 61
ISSUE 2
Using Dynamic Measurement Methods and Volume Correction Factors Pressure Gauges and Gauge Attachments Pipe Threads, General Purpose (Inch)
ASME B40.100 ASME B1.20.1 ASME PTC 19.3 TW Thermowells CENELEC EN50014 Electrical apparatus for potentially explosive atmospheres general
EN 837-1
ISA 5.1
ISA 5.4 ISA 5.5 ISA 7.0.01 ISA 18.1 ISA 18.2 ISA 20
ISA 51.1 ISA 71.01
ISA 71.04
ISA 84.00.01
ISA 92.0.01
ISA RP92.0.02
ISA RP 12.4 ISA RP 12.06.01
SA RP 55.1
ISA 75.1 ISA 75-02 ISA 75.08.01
ISO 10012
ISO 5167-2 (2003) ISO 10497 ISO 15848-1
requirements Pressure gauges. Bourdon tube pressure gauges. Dimensions, metrology, requirements and testing Instrumentation symbols and identification (since 2009 ISA standards 5.2 and 5.3 have been included in this document) Instrument Loop Diagrams Graphic Symbols for Process Displays Quality Standard for Instrument Air Annunciator Sequences and Specifications Management of Alarm Systems for the Process Industries Specification forms for Process Measurement and Control Instruments, Primary elements, Control Valves Process Instrumentation Terminology Environmental Conditions for Process Measurement and Control Systems: Temperature and Humidity Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants Part I Functional Safety: Safety Instrumented Systems for the Process Industry Sector – Part 1: Framework, Definitions, System, Hardware and Software Requirements Part I Performance Requirements for Toxic Gas-Detection Instruments: Hydrogen Sulfide Part II Installation, Operation, And Maintenance Of Toxic Gas-detection Instruments: Hydrogen Sulfide Pressurized Enclosures Recommended Practice for Wiring Methods for Hazardous (Classified) Locations Instrumentation Part 1: Intrinsic Safety Hardware Testing of Digital Process Computers (superseded; only for reference) Flow equations for sizing control valves Control Valve Capacity Test Procedure Face to face dimensions for integral flanged globe style control valve bodies Measurement management systems Requirements for measurement processes and measuring equipment Measurement of fluid by means of orifice plates and nozzles testing of valves - fire type-testing requirements Industrial valves — Measurement, test and qualification procedures for fugitive emissions — Part 1: Classification system and qualification procedures for type testing of valves
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 12 / 61
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BS EN-60874-1
BS EN-61073-1
BS EN-61274-1
EIA-RS 232
EIA-RS 485
EN 10204-2.1
EN 10204-2.2 EN 10204-3.1 EN 45544
EN 50288-7
EN 50290-2-22
EN 50290-2-29
IEC 60068-2-6 IEC 60068-2-27
IEC 60068-2-64
IEC 60079-0 IEC 60079-1
IEC 60079-2
IEC 60079-20-1
IEC 60079-5
EC 60079-6
IEC 60079-7
IEC 60079-11
IEC 60331-11
IEC 60331-21
Fibre optic interconnecting devices and passive components - Connectors for optical fibres and cables - Part 1: Generic specification Fibre optic interconnecting devices and passive components - Mechanical splices and fusion splice protectors for optical fibres and cables - Part 1: Generic specification Fibre optic interconnecting devices and passive components - Adaptors for fibre optic connectors Part 1: Generic specification Electronic Industries Association – Serial Interface for Data Communication Electronic Industries Association – Serial Interface for Data Communication Metallic products — Types of inspection documents. Declaration of compliance with the order Metallic products — Types of inspection documents. Test report Metallic products — Types of inspection documents. Inspection certificate Workplace Atmospheres – Electrical Apparatus Used for the Direct Detection and Direct Concentration Measurement of Toxic Gases and Vapours Multi-element metallic cables used in analogue and digital communication and control. Sectional specification for instrumentation and control cables Communication cables - Part 2-22: Common design rules and construction
- PVC sheathing compounds Communication cables - Part 2-29: Common design rules and construction
- Cross-linked PE insulation compounds Environmental testing – Part 2: Tests – Test Fc: Vibration (sinusoidal) Basic environmental testing procedures – Part 2: Tests – Test Ea and guidance: Shock Environmental testing – Part 2-64: Tests – Test Fh: Vibration, broadband random and guidance Explosive atmospheres – Part 0: Equipment – General requirements. Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures “d” Explosive atmospheres – Part 2: Equipment protection by pressurized enclosure “p” Electrical Apparatus for Explosive Gas Atmospheres Part 4: Method of Test for Ignition Temperature (ex 60079-4) Explosive atmospheres - Part 5: Equipment protection by powder filling “q”
- Edition 4.0 Explosive atmospheres – Part 6: Equipment protection by liquid immersion “o” - Edition 4.0 Explosive atmospheres - Part 7: Equipment protection by increased safety “e” - Edition 5.0IEC 60228 Conductors of insulated cables Explosive atmospheres - Part 11: Equipment protection by intrinsic safety ""i"" Tests for electric cables under fire conditions – circuit integrity – part 11: apparatus – fire alone at a flame temperature of at least 750 degrees C
Tests for electric cables under fire conditions – circuit integrity –
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 13 / 61
ISSUE 2
IEC 60331-25
IEC 60332-1-2
IEC 60332-3-22
IEC 60502-1
IEC 60529 IEC 60534-8-3
IEC 60534-8-4
IEC 60668
IEC 60751
IEC 60770-1
IEC 60793-2-10
IEC 60793-2-50
IEC 60794-1-1 IEC 60794-1-2
IEC 60794-2 IEC 60794-3 IEC 61000 IEC 61115
IEC 61131-2 IEC 61285 IEC 61300
IEC 61326
IEC 61326-3-1
procedures and requirements – cables of rated voltage up to and including 0,6/1,0 KV Tests for Electric Cables under Fire Conditions - Circuit Integrity - Part 25: Procedures and Requirements - Optical Fibre Cables Tests on electric and optical fibre cables under fire conditions – Part 1-2: Test for vertical flame propagation for a single insulated wire or cable – Procedure for 1 kW pre-mixed flame Tests on electric and optical fiber cables under fire conditions – part 3-22: test for vertical flame spread of vertically-mounted bunched wires or cables – category AIEC 60534-2-1 Industrial-process control valves – Part 2-1: Flow capacity – Sizing equations for fluid flow under installed conditions Power cables with extruded insulation and their accessories for rated voltages from 1 Kv up to 30 Kv Part 1 cables for rated voltage of 1Kv and 3 Kv Classification of degree of protection provided by enclosures Industrial-process control valves – Part 8-3: Noise considerations – Control valve aerodynamic noise prediction method Industrial-process control valves – Part 8-4: Noise considerations – Prediction of noise generated by hydrodynamic flow Dimensions of panel areas and cut-outs for panel and rack-mounted industrial-process measurement and control instruments Industrial platinum resistance thermometers and platinum temperature sensors Transmitters for use in industrial-process control systems – Part 1: Methods for performance evaluation Optical fibres – Part 2-10: Product specifications – Sectional specification for category A1 multimode fibres Optical fibres – Part 2-50: Product specifications – Sectional specification for class B single-mode fibres Optical fibre cables – Part 1-1: Generic specification – General Optical fibre cables – Part 1-2: Generic specification – Basic optical cable test procedures Optical fibre cables Part 2: Indoor cables Sectional specification Optical fibre cables – Part 3: Outdoor cables – Sectional specification Electromagnetic Compatibility (EMC) – All parts Expression of performance of sample handling systems for process analyzers Programmable controllers – Part 2: Equipment requirements and tests Industrial-process control – Safety of analyser houses Fibre optic interconnecting devices and passive components – Basic test and measurement procedures Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 1: General requirements Electrical Equipment for Measurement, Control and Laboratory Use – Part 3-1 Immunity requirements for Safety Related Systems and for Equipment intended to perform Safety Related Functions
IEC 61508
Functional safety of electrical/electronic/programmable electronic safety-
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 14 / 61
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IEC 61511 SER IEC 61515 IEC 61779
IEC 61931 IEC 62337
IEC 62381
IEC 62382
IEEE C37.90.1
DIN 43760 FCI 70-2 NACE MR0175/ISO 15156 NACE MR01.03
ITU-T G-651
ITU-T G-652
ITU-T G-653
ITU-T G-654
ITU-T G-655
ITU-T G-656
OIML R 117-1 OIML R 85
API 2350
related systems.- All parts Functional safety – Safety Instrumented Systems.- All parts Mineral insulated thermocouple cables and thermocouples Electrical apparatus for the detection and measurement of flammable gases Fibre Optic - Terminology Commissioning of electrical, instrumentation and control systems in the process industry – Specific phases and milestones Automation systems in the process industry – Factory acceptance test (FAT), site acceptance test (SAT), and site integration test (SIT) Control systems in the process industry – Electrical and instrumentation loop check Standard Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus Characteristics of 100 ohm Pt RTD Control Valve Seat Leakage Petroleum and natural gas industries—Materials for use in H2S-containing environments in oil and gas production Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments Characteristics of a 50/125 μm multimode graded index optical fibre cable for the optical access network Characteristic of a Single Mode Optical Fibre and Cable (ITU-T Recommendation) Characteristics of a dispersion-shifted, single-mode optical fibre and cable (ITU-T Recommendation) Characteristics of a cut-off shifted single-mode optical fibre and cable (ITU-T Recommendation) Characteristics of a NON ZERO dispersion-shifted, single-mode optical fibre and cable (ITU-T Recommendation) Characteristics of a fibre and cable with non-zero dispersion for wideband optical transport (ITU-T Recommendation) Dynamic measuring systems for liquids other than water Automatic level gauges for measuring the level of liquid in fixed storage tanks Overfill Protection for Storage Tanks in Petroleum Facilities
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INSTRUMENT GENERAL SPECIFICATION
2.2 Project Documents
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
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TCM IDENTIFICATION CODE
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SHEET 15 / 61
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Number
4439-KA-SE-032001001 4439-KF-SG-000000001 4439-KP-SG-000000001 4439-KT-SG-000000001 4439-KK-SE-066001001 4439-KK-SE-067001001 4439-KK-SE-352001001
4439-KK-SE-362001001 4439-YZ-SG-000000001 4439-YZ-PC-000000101 4439-YZ-PC-000000111 4439-YZ-PC-000000018 4439-SZ-SG-000000004 4439-SK-SG-000000001
4439-SZ-PM-000000005 4439-VW-SG-000000001 4439-JK-DQ-00000000101
4439-JK-GS-00000000101 4439-JK-SE-010001001 4439-JK-SE-020001001 4439-JK-SE-050001001 4439-JK-SE-00000000101 4439-JK-SE-040001001 4439-JK-SE-130001001 4439-JK-SE-00000000601
Title Data Sheet for Analyzer system Fire & Gas General Specification Instrument general specification for packages Telecom General Specification Data Sheet for Metering skid Data Sheet for Tank Gauging System Data Sheet for Signal/Special/Fiber Optic Instrumentation Cable Data Sheet for Junction Box Basic engineering design data Document numbering procedure Tag numbering procedure Index of project regulations, codes and applicable standards Hazardous Area Classification General Specification Fire and Gas Detection and Alarm System General Specification ARH dossiers requirements for suppliers Painting General Specification Overall Integrated Control and Safety System Architecture (ICSS) Basic Plant Control and Safety Philosophy Distributed Control System (DCS) Technical Specification Emergency Shutdown System (ESD) Technical Specification Fire and Gas Alarm System (F&G) Technical Specification Serial Interface Implementation Guidelines Machine Conditioning and Monitoring System (MCMS) Programmable Logic Control (PLC) Technical Specification Control and Instrumentation Cabinets Specification
Above specifications shall be considered including any reference documents and standards.
2.3 Order of Precedence
In case of conflict among the requirement of this specification and the documents listed herein, the decreasing order of precedence shall be the following:
• Algerian Law, Decrees and regulations including Algerian Statutory requirements • Purchase Order document, Purchase General and Special Conditions including amendments • Material requisition • Supply specifications and data sheets
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 16 / 61
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• General specifications (& UOP standards for licensed and/or PEQ items) • International/industry codes and standards
All Codes and Standards shall be those current at Enquiry Requisition issue date unless otherwise specified. Any conflicts or ambiguities among the referenced Codes, Standards, etc. and this Specification shall be immediately referred to CONTRACTOR by VENDOR in writing for resolution. VENDOR shall be solely responsible for requesting instructions or interpretations and shall be solely liable for any costs and expenses arising from its failure to do so. The acceptance of any material or items of equipment by any authorized representative of the CONTRACTOR in no way releases the VENDOR from providing all equipment fully in accordance with the intent of this project equipment specification. Determinations, instructions, and clarifications of CONTRACTOR shall not constitute a change to the CONTRACT. VENDOR shall not be entitled to claim for a change as a result of any determination, instruction or clarification of CONTRACTOR
3
ABBREVIATIONS
AC APl ARH
ASCll ASME ATEX AWG BDV CCTV CCS DC DCS DDE DP DO EDP EIV ESDV EMl EPC ESD F&G FAT FEED HFT FO FOC
Alternating Current American Petroleum lnstitute L’Agence Nationale de Contrôle et de Régulation des Activités dans le domaine des Hydrocarbures (Agency for Regulation of Hydrocarbons) American Standard Code for lnformation lnterchange American Society of Mechanical Engineers Atmosphères Explosives American Wire Gauge Blowdown Valves Closed Circuit Television Compressor Control System Direct Current Distributed Control System Dynamic Data Exchange Differential Pressure Digital Output Emergency De-pressurization Valve Emergency Isolation Valve Emergency Shutdown Valve Electromagnetic interference Engineering Procurement & Construction Emergency Shut-Down Fire and Gas System Factory Acceptance Test Front End Engineering Design Hardware Fault Tolerance Failure Open Fiber Optic Cable
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 17 / 61
ISSUE 2
FC HART HMl HPU HP l/O ID lEC lEEE lER lP lS LCD MAC MCC MMS MOV MP NAMUR
NPT NO NC OD OPC ONML OSBL OWS P&lD PAGA PC PES PEQ PLC PSV PST PSU PTFE PVC RTD RTJ SAT SPDT SOV SIT SlL
Failure Close Highway Addressable Remote Transducer Human Machine lnterface Hydraulic Power Unit High Pressure lnput / Output Inside Diameter lnternational Electro technical Commission lnstitute of Electrical & Electronic Engineers lnstrument Equipment Room lngress Protection lntrinsically Safe Liquid Crystal Display Manual Alarm Call point Motor Control Center Machine Monitoring System Motor Operated Valve Medium Pressure Standardization Association for Measurement & Control in Chemical Pharmaceutical industries National Pipe Thread Normally Open Normally Closed Outside Diameter Open Platform Communications (OPC) Organization National de Metrologie Legale Outside Battery Limit Operator Workstation Piping & lnstrument Diagram Public Address & General Alarm Personal Computer Programmable Electronic System Proprietary equipment Programmable Logic Controller Pressure Safety Valves Partial Stroke Testing Power Supply Unit PolyTetraFluoroEthylene Polyvinyl chloride Resistance Temperature Detector Ring Type Joint Site Acceptance Test Single Pole Double Throw Solenoid-Operated Valve Site Integration Test Safety lntegrity Level
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INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
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SlF SS TSO TÜV UCP UPS
Safety lnstrumented Functions Stainless Steel Tight Shutoff Technischer Überwachungs-Verein Unit Control Panel Uninterrupted Power Supply
4
GENERAL
4.1 P&ID symbols and instrument identifications (tag numbers)
P&IDs symbols and identification (tag numbers) for instruments and controls shall be in accordance with P&IDs symbols: 4439-VZ-DM-0000-0001 to 4439-VZ-DM-0000-0012
4.2 Units of measurement
Refer to document ‘’BASIC ENGINEERING DESIGN DATA’’ № 4439-YZ-SG-000000001.
4.3 Environmental conditions
The most severe climatic data are defined below and shall be used to define the common design basis for LAB’s Plant Units. Refer also to document 4439-YZ-SG-000000001 “BASIC ENGINEERING DESIGN DATA”
Environmental Conditions
Temperature: Highest maximum on record Lowest temperature – Minimum Design Metal Temperature Max Design Temperature for instrumentation (outdoor) Relative humidity: Annual average mean Average min (%) Average max (%) Design value for air fans, compressors and gas turbines (%)
Value
47 °C 1 °C 50 °C
72 69 (July) 79 (March) 72
Notes
1 2 3, 4, 5
Notes:
- This is the maximum shade air temperature that the equipment and systems must be physically
designed for. Equipment must also be able to operate continuously at this temperature.
- This is the minimum shade air temperature that the equipment and systems must be designed
for. Equipment must also be able to operate continuously at this temperature.
-
Electrical/electronic equipment located outdoors shall be rated for an ambient temperature of 50°C. Electrical equipment (i.e. panels, etc.) to be located indoors and all cables shall be rated for continuous operation in an ambient temperature of 40°C.
-
Electrical/electronic equipment and cables shall be located away from direct sunlight wherever possible. Equipment located outside shall be provided with sunshades or shields to protect the equipment from solar heat gain.
-
All electronic devices in direct sunlight should be designed to withstand and operate with a surface temperature of 85°C. If this is not possible the Supplier shall design adequate sun shading and inform CONTRACTORs Engineer of requirements.
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4.3.1 Tropical Environment
All equipment shall be tropicalized to eliminate mildew, fungi, and other detrimental effects of a tropical environment. Packaging shall be suitable for shipment and storage under tropical conditions.
4.3.2 Marine Environment
All field equipment shall be suitable for operation in a corrosive, salt laden, marine atmosphere.
4.3.3 Desert Environment
All equipment shall be suitable for operation in a dusty environment subject to frequent sand storms.
4.4
Instrument index
An Instrument Index listing all instruments for the project shall be furnished. The Instrument Index shall be developed starting from a standard template (Excel format) made available also to the package unit Vendors for their own use to guarantee the complete consistency. The instrument index of the package units shall be supplied by the relevant Vendor.
4.5 Package units
a. The instrumentation requirements, when packaged or licensed units are specified, shall conform to this specification. Additional details and clarifications are given in the specification 4439-KP-SG-000000001. Any deviations shall be submitted for agreement by CONTRACTOR. b. For complete list of Package control system type (Plant Control system DCS/ESD or PLC) refer
to Basic Plant Control and Safety philosophy 4439-JK-GS-00000000101
c. The panel with the instrumentation therein and the relevant equipment shall be tested as a unit
wherever possible.
5
DESIGN REQUIREMENTS
5.1 General
5.1.1 Nameplates
a. An identification nameplate shall be attached to each piece of instrumentation equipment. b. These nameplates shall be fabricated from 316 SS and shall be permanently and securely
c.
fastened to the instrument by either stainless steel wire or drive screws. Instrument nameplates shall have the following information:
- Equipment identification/tag number, which shall be supplied by purchaser.
- Manufacturer’s name, model, and serial number.
In addition, each instrument shall be provided with a stainless-steel tag plate which shall be fixed to the instrument with a stainless-steel wire. This plate shall be marked with the instrument tag number.
5.1.2 Painting
Manufacturer’s standard painting and colors shall be used for all project instrumentation, including visible portions of instruments mounted on the control panel, unless otherwise specified in the specification: 4439-VW-SG-000000001.
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5.1.3 Electrical Equipment and Enclosures
a. All electrical instrument equipment and enclosures for all field mounted or local panel mounted electrical or electronic instruments (or instruments having electrical connections or power) shall be suitable for electrical area classification and environment where installed.
b. When installed outdoor the minimum degree of protection shall be IP65 minimum according to IEC 60529 standard. External surfaces must be suitably treated to ensure a protection against aggressive marine atmosphere.
c. Where not otherwise specified field electronic instrumentation, to be installed in hazardous
area, shall be as follows:
EQUIPMENT
4-20 mA Electronic Transmitters Switches Lamp/horns Solenoid valves Thermocouples heads Resistance Element heads Junction boxes Local Panels
IEC ZONE 1/2 (IEC/EN 60079) Ex-i (*) Ex-i Ex-d Ex-d Ex-i Ex-i Ex-i / Ex-e Ex-e
(*) Ex-d (explosion proof) protection method shall be avoided and used only in special cases, when intrinsically safe execution is not available/suitable.
With respect to electrical hazardous area certifications, all field instruments shall be certified to ATEX and suitable for Zone 2, Gas Group IIB +H2, T3, as minimum. Exception is made for Fire & Gas detection devices that shall be certified to ATEX and suitable for Zone 1, Gas Group IIB +H2, T3 regardless of the area in which they are installed.
d. All the electrical equipment shall demonstrate the conformity with the international and local Codes, if any, concerning the Hazardous area installation (IEC 60079) and electromagnetic compatibility (IEC 61000). Instruments without this conformity will not be accepted.
5.1.4
Instrumentation General Requirements
a. Electronic transmitters are strongly preferred over switches for control, supervision and safety applications. Switches may be considered only for clean process services (e.g., lube oil, nitrogen, air) and where relay-based or electronic logic is employed. Use of switches shall be approved by CONTRACTOR engineer. Instrumentation will be 4-20 mA, 2 wires 24 V DC with HART Protocol. 4 wires (24VDC/230VAC external power supply) or 3 wires standards will be used when 2 wire technology is not available. Field instrumentation with fieldbus communication protocols will not be used. Exceptions could be made for instrumentation connected to tank gauging systems.
b. All parts, such as Bourdon tubes, diaphragms, ball and tubular floats, displacers, and bellows, exposed to process fluids shall resist and compliant with the corrosive properties of the process fluid.
c. Where applicable instruments and valves shall be supplied with manufacturer’s calibration
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certificates and material certificates as per EN 10204-3.1 for all main pressure components and EN 10204-2.1/2.2 for all other components.
d. All instrumentation in H2S service shall meet NACE MR 0103 requirements. e. Post Weld Heat Treatment (PWHT) shall be executed on welds subject to stress due to
corrosion, such as on amine and caustic services.
f. All instruments, valves, instrument components and accessories shall be asbestos free. g. Instruments belonging to Fiscal Metering Systems shall be designed according to specification:
4439-KK-SE-066001001 Metering skid specification.
h. NAMUR devices, typically limit switches, with suitable associated I.S barriers installed in
termination room, shall be used only if approved byCONTRACTOR’s Engineer.
i. Positive Material Identification (PMI) on in-line instruments installed on stainless steel and alloy steel piping and equipment is required for all pressure retaining parts of instrumentation components, including, but not limited to: a. flow nozzles b. flow meter runs c. control valves d. PSVs bodies e. orifice plates f. orifice flanges g. thermowells h. Welds.
j. Positive Material Identification (PMI) is NOT required for:
a. internal non-pressure retaining components, unless specifically required by Material Requisition, drawings or other documents; b. components where alloy material is not required by Material Requisition since it is not necessary to withstand corrosion attack but has been specified for product purity reason or as a Vendor Standard; c. stainless steel and alloy steel pressure retaining components of in-line instruments installed on carbon steel piping and equipment; d. external attachments non pressure retaining; e. welds non pressure retaining; f. gaskets (except RTJ gaskets and camprofile); g. instrument components not part of piping system; h. instrument piping, covered by instrument piping specs; i. instrument tubing.
k. Signals for control loop purposes and for trip actuation will not be taken from the same sensing device (field transmitter). Separate transmitters with separate sensing elements will be generally installed for trip services. Flow measurement is an exception: in case of common flow measurement for both control and ESD trip application, a separate transmitter including manifold, isolation valves and impulse lines shall be installed and connected to the second pair of tapings on the common orifice flanges (no separate orifice plates). This philosophy might not be applied in case of particular Licensor requirements.
l. Solenoid Valves will be low-consumption type, enabling the use of 24VDC as supply voltage; m. Field devices belonging to ESD safety loops shall be preferably specified according to IEC 61511 “proven in use” criteria, to be discussed with CONTRACTOR; nevertheless, all instrumentation that is part of a SIF shall be required with SIL certification and with minimum SIL level as required from SIL classification study.
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n. Trip pushbuttons shall be red mushroom type, push to stop, turn and pull to release. The pushbuttons shall be installed with a protective cover to avoid misoperations. The pushbuttons shall have at least 3 individual NC contacts (open for trip) to ensure trip command in a voted 2oo3 logic.
o. Where required by SIL study for specified safety functions and in order to extend the test intervals to meet planned shut-down intervals, final elements (typically ON-OFF valves) shall be provided with on-line test facilities such as partial stroke testing devices.
p. Test and maintenance facilities shall be provided for proof testing and maintenance of the
system to avoid interruption of the process operation.
5.1.5 Transmitters
a. In general, transmitters shall be of the force balance type or other negligible displacement type (i.e. capacitive or piezoresistive), except where such devices are not available for a specific measurement.
b. Electronic transmitter shall be:
• All transmitters shall be SMART type with HART protocol. The latest version shall be used for the HART maintenance. • 4-20 mA HART protocol for use with DCS, Emergency Shutdown System (ESD) and Fire & Gas System (F&G). • Electrical transmitters utilizing two wire 24 volt DC power supplies shall be designed to operate with 12 volt DC at 20 mA to ensure enough available loop voltage loss for lengthy input wiring. • Provided with LCD indicator.
c. SIL certified electronic transmitters with 4-20 mA HART protocol shall be used for SIF (Safety Instrumented Functions – i.e. initiators to ESD/F&G). Instruments shall be SIL 2 certified for use on single initiator SIF (HFT=0) and certified for use on SIL 3 applications (with HFT>0). These transmitters shall have the capability of write protection to prevent unauthorized configuration changes via HART. e.g. re-ranging.
d. Use of non-SIL certified instruments, or of instruments with ‘Prior in use’ approach, for ESD SIL
rated applications, shall be agreed with CONTRACTOR.
e. If any, all pneumatic transmitters shall be equipped with an air input gauge as a part of the air
supply filter regulators.
f. Process variable indication shall be provided for each transmitter via direct reading of its output. For transmitters and receivers, the lowest value of the rated signals shall correspond to 0 percent of range and the highest value shall correspond to 100 percent of range. Where a local indication is required, this shall be either from an integral indicator showing the value in custom engineering units (preferred) or by external field signal-loop powered indicator(s) wired in such a way that a malfunction/removal of the indicator(s) will not affect the integrity of the loop (i.e. with a diode shunt).
g. Transmitters shall have adjustable damping delays, set as default to 0 sec. h. In process streams containing hydrogen (piping and equipment in hydrogen service), the use
of gold-plated diaphragms shall be considered.
5.1.6 Transmission System
a. No process fluids of any type shall be piped into the control/instrument rooms. b. Transmission of the process variable shall be by means of electronic, electric, pneumatic, or
thermocouple type instruments.
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INSTRUMENT GENERAL SPECIFICATION
5.1.7
Instrumentation Performance
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a. Transmitters, recorders, indicators, controllers, and transducers shall meet the following
performance requirements: • Hysteresis shall not exceed ±0.3 percent of span. • Dead band shall not exceed 0.25 percent of span. • Output change caused by 56°C ambient shift shall not exceed 1% of upper range limit. • Transmitter shall have an accuracy of 0.075% of the scale
b. For local instrumentation such as dial thermometers and pressure gauges, accuracy shall be
1% of the scale.
5.1.8 Transmitters Failure Mode Configuration
a. 4-20mA transmitters shall be designed to drive output signals slightly greater than the 4 to 20mA “Base” signal as per NAMUR NE43. The intention is to set analog alarm thresholds (A) recognizably beyond the normal operating 4 to 20 mA range (M), to indicate measurement out of range, and to set further alarm thresholds to indicate a fault condition.
b. The choice of the diagnostic failure output (High or Low) of the transmitter is subject to the
application requirements.
c. Based on that, control and protection systems continuously check the status of the transmitters
with alarm set-points internally configured to detect failure info.
d. Below the general failure mode configuration criteria to be applied to the project.
1oo1 Trip Transmitters (Fail Action Approach) Transmitter failure mode has to be configured towards the trip:
- If the logic trips on HIGH → Transmitter drives output HIGH
- If the logic trips on LOW → Transmitter drives output LOW
Voted 1oo2/2oo3 Trip Transmitters Transmitter failure mode has to be configured towards the trip:
- If the logic trips on HIGH → Transmitter drives output HIGH
- If the logic trips on LOW → Transmitter drives output LOW
e. the ruleset for determining failure modes shall be defined in EPC when the control systems and
transmitters are selected. Other specific failure modes or degradation modes shall be further discussed and agreed with CONTRACTOR together with HSE Specialist.
Wire Break In addition to the transmitter diagnostic type failures above the logic shall be designed to
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respond in a similar way to a transmitter wire break / loss of power. For a 1oo1 the logic solver should consider that a wire break is a trip condition, e.g. if the signal fails to less than 3.65mA in less than 500ms this does create a trip condition. For a 2oo3 voting configuration the logic solver should consider a wire break is a trip condition. e.g. if the signal fails to less than 3.65mA in less than 500ms this does create a single trip condition. The discrepancy alarm shall be activated. Where fail no action approaches shall be applied the above criteria shall be modified accordingly.
Non-Trip Transmitters For transmitters NOT involved in trip logics (indication, control), failure mode has to be configured as a hard fail (wire break).
f. Transmitters can experience both “hard” and “soft” faults. Selection and setting of the values at which a transmitter is faulty (i.e., Bad) - and not simply process-saturated - is complicated, but critical to the avoidance of nuisance “Bad Value” Alarms and actions.
5.2 Temperature instruments
a. Thermoelements will be connected with Temperature transmitters to DCS and ESD Systems.
For the temperature range −20°C to +1090°C, the preferred thermocouple material is chromel- alumel (Type K, per API RP 551). Thermocouple extension wire, if required, connected to Type K thermocouples shall be Type KX. For the temperature range −195°C to +95°C, the preferred thermocouple material is copper- constantan (Type T). Thermocouple extension wire, if required, connected to Type T thermocouples shall be Type TX. Where required by application (for accuracy/ repeatability reason and in the range 0°C to 200°C), a resistance temperature element (RTD) may be used connected to relevant temperature transmitter. RTDs shall industrial 100-ohm platinum, three- or four-wire type and shall conform to IEC 60751.
b. Temperature transmitters shall be head mounted type, provided that the operating process temperature does not affect the correct operation of the instrument. Otherwise temperature transmitters shall be remotely installed, in dedicated weather proof housings if required by environment conditions, and wired to the relevant temperature element. In case if head mounted transmitter is not suitable based on process temperature, accessibility and transmitter vendor recommendations, remote mounted transmitter will be considered.
c. Local temperature controllers having a temperature range span of 200°C or less may use filled system transmitters, limited to a maximum operating temperature of 650°C, provided the direction the instrument is driven in the event of capillary failure does not create a hazardous situation. The use of local temperature controls shall be avoided if possible.
d. Thermocouple instruments shall drive to a safe configuration on thermocouple failure (see also
para. 5.1.8).
e. Where not otherwise specified, thermocouples shall be of K type as per ASTM E230/E230 M-
- Ungrounded thermocouple hot junction shall be used.
f. Process Temperature measurement shall be by means of temperature elements installed in
thermowells.
g. The standard thermowell, except pipe type wells, shall be fabricated of Type 316L stainless steel. Where the nature of the fluid is such as to require other material, the thermowell material shall be suitable for the service.
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h. Thermowell material shall be selected considering mechanical performance on each process condition. Where required, SS type/grade and rating shall be upgraded to match the required process / piping classes design conditions.
i. Thermowell thread for element connection shall have 2” (50 mm) lagging extension when used
with insulation for high temperature.
j. Thermowell lengths shall be as shown on applicable Material Requisition. Typically thermowell immersion length shall be 1/2 of pipe nominal ID up to 20” pipe, while of 250 mm min above 20” pipe.
k. Thermowells shall be purchased with the relevant temperature element to assure proper fit (i.e
Thermocouple/RTD assemblies).
l. For cryogenic measurements the typical range shall be -200ºC to 50ºC. m. Thermowell connections into piping and equipment shall be in accordance with Section 6.1 of
this specification.
n. Flanged thermowells shall have flanges and weld filler metal of the same material as specified for the thermowell in order to build an assembly of the same material. Weld shall be of full penetration type. Where piping specifications permit a carbon steel flange, the weld filler metal to be used for welding of carbon steel flange to stainless steel thermowell shall be selected according to applicable job specification for welding.
o. With the exception of wells for bulb type elements, protection wells and test wells shall be 6.6
mm bore to receive bimetallic or sheathed thermocouple type primary elements. All thermowells shall be drilled from barstock (no built-up type wells) except pipe type wells. p. Pipe type thermocouple wells with welded ends shall be furnished for gas temperature measurement at fired heaters, boilers, furnaces, flues, stacks, and large vessels. This also includes those wells used for multiple element thermocouple assemblies in reactors, etc. Well material shall be suitable for the process conditions.
q. Velocity and pressure rating calculations of a thermowell will be performed and compared to the service conditions in those services judged to be critical by the CONTRACTOR Engineer. Vibrations induced by a Von Karman vortex may occur in pipes with high velocity. Thermowell wake frequency calculation shall be executed for thermowells where fluid velocity is greater than 8 m/s. ASME PTC 19.3 code “Performance test code on temperature measurement” shall be followed. When wake frequency calculation results require well standard tapered design modification, the first choice is to shorten the well length, provided that the relevant immersion portion is enough long to detect the fluid temperature. The installation of a collar could be another solution; where used, these collars, integral with the thermowell, shall be installed in a machined nozzle where the annular space between the ID of the nozzle and the OD of the thermowell collar is an interference fit. Alternative well helical strake design can be considered (i.e. well helical strake design instead of well dimension modification or collar installation).
r. Thermocouples shall be furnished with terminal blocks enclosed in a corrosion resistant metallic weatherproof head having a female threaded, gasketed cover. Thermocouple elements shall be in accordance with ASTM E230/E230 M-12. Mineral insulated metal sheathed (normally Type 304 stainless steel) thermocouples shall be used and shall be 6.4 mm O.D. For general service, the nominal thermocouple wire size shall be 18 AWG but within the temperature limits as recommended by the manufacturer.
s. Dial thermometers bi-metallic, every angle stem type, furnished with well as complete
assemblies, shall be used for local temperature indication. Minimum dial size shall be 100mm.
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Where stem lengths exceeding 610 mm are required, or where service conditions dictate, thermometers of the filled capillary type may be used. For cryogenic service nitrogen filled capillary type thermometers with at least 2 meters of capillary tubing shall be used. Extensive facilities including a nitrogen dewar flask will be required in the instrument maintenance workshop for calibrating these thermometers.
t. Thermowells in Cryogenic services for local thermometers and Pt100 RTDs shall be installed on horizontal piping at 5º angle below the pipe centre line and sloping down towards the head to prevent condensate from collecting inside the well.
u. Local temperature multiplexers or Remote I/Os can be used when a high number of temperature measurements shall be connected to control system for monitoring purpose only (i.e Reactor multipoint thermocouples or Boiler case thermocouples). Such multiplexers shall be connected to instrument equipment room by means of suitable communication cables according to multiplexer manufacturer specification (typically Modbus RS 485 or Modbus TCP/IP). However, use of above devices is subject to CONTRACTOR approval.
5.3 Flow instruments
a. The following paragraphs covers the design and selection of flow meters and associated
equipment for standard process applications.
b. Any system of flow measurement to be used for custody transfer applications is covered by
specification: 4439-KK-SE-066001001 In case of flow element placed on vessel liquid outlet, provide sufficient static head to prevent
c. vaporization across the orifice.
5.3.1 Primary Elements
a. Concentric square-edged orifice plates shall generally be used as primary elements for flow instruments. In general 316L stainless steel orifice plates shall be provided. Where the nature of the fluid in such as to require other material, it shall be suitable for the service. Material shall be selected considering mechanical performance on each process condition. Where required, SS type/grade and rating shall be upgraded to match the required process / piping classes design conditions.
b. Orifice plates shall be in accordance with ISO EN 5167-2 and shall conform to the requirements of API RP 551. The minimum orifice flange size shall be 2” (50 mm). Where the process line size is less than 2”, then the line size shall be increased for the length of the metering run. If this is not possible, one of the devices specified at para. 5.3.2.a shall be used.
c. Orifice plate thickness shall be min 3 mm. The thickness value shall be in accordance ISO EN 5167-2 par 5.1.5. API Manual of Petroleum Measurement Standards Chapter 14.3 and vendor recommendations shall also be considered.
d. All primary element calculations shall be in accordance with ISO 5167 standard. Other
calculation methods shall be applied for special elements upon project requirements.
e. Orifices shall be sized so that normal flow rate falls between 70 and 80 percent of the full-scale flow with the following provision. The anticipated minimum and maximum flow rates shall be between 33 and 95 percent of the full scale flow, and the accuracy of the transmitter shall be at least 0.25 percent of the calibrated span. Orifice meter differential range shall be selected for a d/D ratio of 0.7 maximum, and 0.25 minimum. With 2” pipe and 50mb of differential range, d/D ratios smaller than 0.25 may be used. In any case, actual orifice diameter shall not be less than 6.4 mm. A differential range of 250 mb, dry calibration, shall normally be used for all liquid flow meters, 125 mb range may be used. Anyway orifice meter differential range shall not exceed
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500mb.
f. Special conditions may dictate the use of devices such as the following:
(1) Eccentric or segmental orifice plates shall be used to measure the flow of liquids which contain solids. (2) Venturi tubes or similar types of flow elements may be used to measure the flow of low pressure gases or liquids where loss of pressure is an important consideration.. Venturi tubes shall preferably be installed in horizontal piping and shall be designed in accordance with the standard piping classification for the line in which the element will be installed. (3) Pitot tubes or averaging Pitot tubes such as Annubar may be used to measure flow in certain applications and shall be so indicated on the P&IDs (i.e. large size piping, or very low pressure services and air ducts). (4) Where the pipe Reynolds Number (RD) is less than 10000, the use of a quadrant edge orifice, conical entrance orifice, or wedge meter shall be considered.
g. Orifice plates shall be installed between orifice flanges having flange taps and a minimum rating of 300# RF. Orifice flange taps shall be 1/2” NPT. Flanges shall be in accordance with ANSI B16.36 standard.
h. Where the requirements for traditional orifice plates installation are not fulfilled, conditioning orifices combining a flow conditioner with an orifice plate into a highly accurate primary element can be adopted to improve accuracy while reducing the requirements of straight pipe run upstream and downstream from a flow disturbance. Refer to ISO 5167 for the applicable upstream and downstream diameters.
i. Pressure retaining parts of in-line flow instruments (such as turbine meters and Venturi meters) and associated devices (such as strainers and de-aerators) shall be fabricated with full penetration welds. These shall be in accordance with the requirements of ASME B16.5 and ASME B31.3.
j. Vent and Drain holes shall be provided in orifice plates, wherever necessary.
5.3.2 Meter Runs
Metering orifices shall not normally be installed in lines less than 2”. If the line is less than 2”, one of the following devices shall be used: (1) Swaged (2”) meter run (2) Certified meter run with corner taps (line material shall be 316SS or better) (3) Rotameter (4) Integral orifice. Although variable area meters are preferred for pipe sizes of 1” and below for fluids up to a maximum flow of 250 l/hr, integral orifice transmitters may be used an alternative. Because the calibrated orifice is 6.4 mm dia or less, they should be confined to clean liquids and gases.
5.3.3 Flow Instruments
a. Force-balance or other negligible displacement type (i.e. capacitive or piezoresistive) flow measuring instruments shall, where possible, be selected for all pneumatic or electronic transmitter services.
b. For Local measurements differential pressure force balance transmitters with local receiver instruments shall be used. Bellows type manometers shall be used for local differential pressure type indicating instruments if an air supply is not readily available in the area.
c. Differential pressure instruments shall withstand differential pressure equal to full line pressure without zero or calibration changes. Body materials shall be consistent with the instrument
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piping material specification and process conditions (stainless steel as minimum).
d. Rotameter type flow instruments may be used for the following:
(1) In pipe sizes 1 ½” and smaller. (2) Where an operating flow range exceeds the ratio of 3 or 1 (maximum to minimum). Normal rotameter rangeability is 10 to 1 and the meter shall be selected so that the normal flow falls at to 60% of maximum range. (3) Where low meter accuracies are allowed up to 2%.
Vortex meters When wide rangeabilities, higher than those covered by differential pressure instruments are required, Vortex meters should be considered for all clean liquid, gas and vapour duties for line sizes up to and including 8” (unless otherwise stated by the P&IDs), where the Reynolds number is greater than 20000 and the temperature of the fluid is below 280°C. Special vortex meters may be considered for higher temperature applications. For use in cryogenic service the meters should have a proven record. Vortex meters can be located in pipeline which may run in any direction from horizontal to vertical. Preferred flow direction in a vertical arrangement is upward. If the meter is located in a non accessible place (non desirable), a remote transmitter shall be provided. Where dictated by maintenance reasons, retractable type vortex meters can be specified.
Electromagnetic flowmeters E.M.F. meters may be used for metering dirty liquids and slurries. Only electrically conducting materials (greater than 0.5 micro siemens) can be monitored. Fluid velocity shall be minimum 0.5 m/s. To eliminate the possibility of gas entrainment in the fluid the preferred mounting arrangement is in a vertical line with the flow upwards. Horizontal mounting is allowed, piping design to ensure that the flow meter shall always run completely full. Stressing of the meter must be avoided, and therefore, supporting of associated piping is essential.
Turbine meters Turbine meters shall be used for clean gas and liquid services where a measurement high accuracy and high rangeability is required. They are typically used for custody transfer and in- line blending applications. Design, construction, installation and calibration of turbine meters shall be in accordance with ISA RP31.1 or API MPMS 5.3 (for liquid hydrocarbons). When installed inside hazardous areas all equipment and cables shall meet the appropriate electrical classification. Turbine meters shall have flanged connections; body material shall be in accordance with line piping specification, with as minimum stainless steel internals, unless the application requires other materials. On non-lubricating services (such as LNG) the turbine meter bearings shall be tungsten carbide. Turbine meters for custody transfer shall have two pick up coils for use with an electronic pulse integrity input circuit in the read out system. The security of any electronic pulse transmission shall, as a minimum, meet Level B of the API MPMS 5.5. All turbine meters shall have signal amplifiers mounted close to the meter. Flow straighteners may be used with turbine meters.
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NOTE Electronic packages for custody transfer metering systems shall perform all measurement calculations as defined by API MPMS 12.2 or equivalent (refer also to 4439-KK-SE- 066001001).
Positive displacement meters P.D. meters shall be used where a high degree of accuracy of volume measurement is required, specially in liquids with high viscosity and liquid hydrocarbons without solid particles. Design, construction, installation and calibration of positive displacement meters shall be in accordance with the API MPMS 5.2. P.D. meters shall be used for batching and dosing applications. For improved accuracy and performance, the use of strainers, air releases, thermal compensators and two stage shut-off features should be considered. P.D. meters used on toxic or highly dangerous process applications shall have magnetic couplings to counters etc.
Mass flow meters Coriolis meters shall be used for true liquid mass flow measurement, independent of changes in fluid pressure, temperature, density or viscosity. Coriolis meters shall be installed on duties where high accuracy and rangeability are required.
V-cone meters V-cone meters can be used instead of standard orifice plates because of unavailability of upstream and downstream straight diameters required by ISO 5167-5 standard.
Ultrasonic flow meters Theses meters can be used where the pipe walls and the fluid flowing in the pipe are acoustically transmissive, such us flow to the flare. These meters may be considered in place of Turbine Meters if local regulations allow.
5.4 Liquid level instruments
5.4.1 Basic Design
a. Pressure/temperature rating of level instruments, switches, and gauges shall be equal to or
greater than the pressure/temperature rating of the vessel to which they are connected.
b. Materials of construction shall be compatible with the service conditions. c. Pressure retaining welds on all instruments shall be full penetration welds and shall be in
compliance with the requirements of ASME B31.3.
d. Variation in fluid properties during start-up, shutdown, and special operations shall be considered and fully addressed during instrument selection. If the shift in properties is too great to be covered by a single technology, diversity shall be employed to cover the full range of operation.
e. Level measurement range shall cover all level functions. Low alarms shall be equal to or greater than 5 percent of measurement range and high alarms shall be equal to or less than 95 percent of range.
f. All electronic level transmitters shall have an integral indicator calibrated in percent level. g. Level Transmitters and level gauges shall be piped so that they can be independently isolated
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for maintenance.
5.4.2 Differential Type Level Measurement
a. External differential pressure type level instruments can be used for pressure vessels. b. Flange mounted differential type instruments may be used where process conditions or accessibility make these preferable regardless of range. Flange mounted differential type shall have manufacturer’s standard size flanges; flange ratings shall be in accordance with the vessel specifications.
c. The preferred type of level measurement for cryogenic applications is differential pressure, with the transmitter mounted above the top tapping point. For addition installation requirements in cryogenic service refer to para. 6.1 of this specification.
d. A suppression or elevation adjustment shall be supplied for differential type instruments in level service. Suppression or elevation shall be adjustable when the instrument is in service and under pressure. Adjustment of the elevated-zero and suppressed-zero range shall be at least 100 percent of the maximum transmitter upper range value.
e. If differential pressure type transmitters with remote seals are specified, their capillaries shall be as short as possible and equal in length. The capillaries may also require insulation or insulation and heat tracing to counteract the effects of ambient temperature changes. Remote seals may also require flushing to avoid fouling the seal diaphragm chamber and connecting piping.
5.4.3 Guided Wave Radar Level Transmitters
a. Guided Wave Radar Level Transmitters (GWR) are state of art level instruments, based on TDR (Time Domain Reflectometry) technology, alternative to traditional displacer type meters. Guided Wave Radar Level Transmitters (GWR) shall be the first choice for level measurement. b. External cage mounted Guided Wave Radar Level transmitters shall be used for level and level interface measurements in a wide range of applications, including high temperature services up to 400°C and saturated steam (i.e. steam drum liquid level measurement) when fluid dielectric constant is within a range of 1.4 to 100. For interface applications it is required that the upper liquid has a dielectric constant between 1.4 and 5, and the lower liquid has a dielectric constant greater than 15.
c. The liquid level range shall be from a minimum of 356 mm up to about 3000 mm. For higher ranges the cost of the instrument shall be compared to the one of a differential pressure based level transmitter, including its impulse line material and installation.
d. Flange connection shall be 4‘’ 300lbs min (the GWR probe must not touch the wall of the chamber or the bottom of the chamber). Its connections to the vessel shall generally be side to side 2” flanged 300lbs mini, material and rating shall be in accordance with the piping specifications. Refer also to para. 6.1 of this specification.
5.4.4 Displacer Type Instruments
a. External displacement type level transmitters may be furnished for pressure vessels in level ranges equal to or less than 2000 mm. Instrument cases shall be rotable with respect to vessel connections and external displacer instrument chambers (where present) shall be provided with tapped ¾” (20 mm) vent and/or drain connections as appropriate for the connection orientation specified. Connections on the instruments shall generally be 4” flanged, in accordance with the piping specifications. Refer also to para. 6.1 of this specification. External displacement type level transmitters can be used when interface measurement is required.
b. Internal type displacement or ball float type level instruments can be used for open sumps and
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tanks. They may also be used on pressure vessels under special conditions of extreme temperature, high viscosity, liquids which could boil in an external cage, corrosion, or where other similar process conditions dictate their use. The design selected shall permit removal of the instrument without the need for entering the vessel for prior dismantling. The minimum mounting flange diameter shall be 4”. Stilling wells shall be used where the liquid being measured is subject to turbulence.
c. Displacer, float, and differential pressure type level instruments shall have cages and/or bodies and trim material suitable for the process fluid, the temperature and pressure conditions.
5.4.5 Level Switches
a. Switches instrument types shall be avoided in favour of transmitters, as much as possible. In
case no alternatives are possible, present paragraph shall be considered.
b. External ball float type level switches shall be flanged body type to permit access to the float
without removal of the cage from the piping. External level switches shall have side and bottom oriented flanged process connections with valved vent and drain. Top mounted level switches shall be avoided as far as possible (if used, a ≥ ND 4” flange and a stilling well shall be installed). Connections on vessels shall be in accordance with para. 6.1 of this specification. Switch contacts shall be hermetically sealed and SPDT type (Single Pole Double Throw). Contact-ratings shall be suitable for the service specified.
5.4.6 Level Gauges
a. Magnetic type or gauge glasses shall be used for local level measurement. Level gauges shall be of sufficient length to provide complete coverage of the range of the associated level instrument dedicated to remote indication, control or shutdown.
b. Magnetic type level gauges are preferred for most services but in particular for the services
listed below: • All clean services • Cryogenic services • Fluids that attack glass (e.g., strong acids, alkalis, boiler feed water) • Light ends services • Toxic services • Pressures above 34.5 barg • Temperatures above the auto-ignition point Magnetic type level gauges shall not be used where process fluid contains magnetic particles affecting the correct operation of the instrument. Magnetic type level gauges chamber material shall be stainless steel or other material compatible with the correct operations of the magnets. Magnetic type level gauges shall not be used in case of fluids specified with a wide range specific gravity.
c. Gauge glasses shall be armored reflex type for all services except the following, where armored
transparent type (without illuminations) shall be used: • Interface between liquids. • Distillates below 25 degree API Gravity and all crude residuals. • Liquids containing gum, sediment, or other solid material which may coat the flutes of a reflex glass.
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• Liquids requiring protecting shields, such as steam above 300 psig (20.6 barg) or above 15% caustic solution
d. Frost shields shall be used if the operating temperature is below 0° C. e. Transparent and reflex gauge glass units shall normally be fabricated from standard length sections having 300 mm visible length. The maximum unit length shall consist of five glasses. When grater total visibility is required, multiple gauge glass units may be installed either on the vessel or on a pipe column. Chamber connections shall normally be ¾” screwed. Gauges shall have vent and drain valves.
f. Gauge glasses for low pressure vessels containing low temperature non-flammable fluids, such as water or phosphate solutions, may be tubular glass type in lengths not exceeding 760 mm, with guards to protect glass from breakage.
g. Level gauges for steam boilers shall be in accordance with local boiler codes. h. Connections on vessels shall be in accordance with para. 6.1 of this specification. Separate valving shall be provided for the level instrument and its associated level gauge. The use of a bridle (standpipe) assembly to reduce the number of vessel connections is acceptable when approved by CONTRACTOR Engineer.
i. On non-fouling process fluids and where the service conditions fall under the cases listed below the gauge glasses shall be supplied with ball (excess flow) type check valves (Gauge Cock) at each process connection: • Light ends services. • Toxic services. • Pressure above 34.5 barg. • Temperature above the auto-ignition point.
j. Mica shields shall be provided for all services where the process fluid may corrode the glasses
(i.e boiler water, high temperature alkaline solutions)
5.4.7 Nuclear Type Level Measurement
a. Radioactive type Level Meters may be used for pressure vessels under special conditions such as high temperature, high pressure, high viscosity, vacuum conditions, abrasive, corrosion and/or to avoid pressure taps on the vessel.
b. For continuous level measurement, gamma ray technology shall be used. Gamma Ray source with scintillation detectors/transmitters at opposite side of vessel shall be used for continuous level measurement.
c. For interface detection neutron backscattering technology shall be used. The use of integrated source/detector enclosure for density measurement or interface detection shall be considered. Remote transmitter is available.
d. For level or density point detection, gamma point detectors shall be used, also if level switch is required. Density point measurement may be required for continuous level compensation. e. In case of multiple readings or redundancies, total number of Nuclear Sources shall be
minimized considering common sources for multiple receivers.
f. Preferred nuclear isotope - to be properly incapsulated in fire-proofed container - is Cesium-
5.4.8 Other Types of Level Measurement
Where process conditions dictate and where shown on the P&IDs, capacitance, ultrasonic, etc. type of instruments may be used.
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5.5 Pressure instruments (including non-flow differential pressure)
a. Pressure gauge measuring elements shall be the C-type seamless Bourdon tube-type and in accordance with ASME B40.100 or EN837-1. Where range requirements cannot be satisfied by Bourdon tube gauges, other standard applicable elements shall be used. Accuracy shall be Grade 2A.
b. Pressure measuring elements shall, in general, be Type 316L stainless steel except:
-
Where the nature of the fluid is such as to require other metal, the primary element material shall be suitable for the service (i.e. Monel element is typically required in sea water service).
-
On receiver gauges and diaphragm sealed gauges, where bronze elements may be
substituted.
- On very low pressure ranges, such as for draft gauges or barometrically compensated
elements for absolute pressure where alloy steel elements are not available.
c.
In general, standard pressure instruments and gauges shall be furnished with full scale pressure ranges having the lower limit of the range equal to zero gauge pressure. Suppressed range pressure instruments may be furnished where required for measurement sensitivity. Ranges shall be selected such that the operating pressure falls in the second third of the full- scale range. Locally mounted pressure gauges shall be 150 mm size.
d. Local electronic receiver gauge scales shall be 65 mm minimum. Panel mounted pneumatic receiver gauges shall be 100 mm, except those mounted within the graphic section which may be smaller.
e. Direct connected pressure gauges shall be provided with blowout backs or discs. Solid front
gauges shall be used on all services.
f. For pressure gauges, a mechanical stop that prevents the pointer from moving past the 6 o’clock position is required. This can be a visible stop pin located at the 6 o’clock position on the gauge front or an internal mechanism.
g. Where seal elements are used, they shall be of the continuous duty type, shall be directly connected to the pressure element, and furnished as an integral part. The process connection on the seal shall normally be ¾” NPT.
h. Standard gauge stem size shall be ½” NPT, except receiver gauges shall be ¼” NPT. i. A ½” pipe siphon shall be installed adjacent to pressure instruments on steam and other high temperature services when the instrument is close coupled and/or mounted above the tapping point.
j. Pulsation dampeners shall be furnished for all pressure instruments and gauges on the discharge of reciprocating pumps, and on the suction and discharge of reciprocating compressors and other pulsating services.
k. Pressure instruments shall be located so that the head of liquid between the instruments and the point of measurement does not exceed the manufacturer’s limit of impressed static head. l. Connection in piping or equipment for pressure and differential pressure instruments shall be
in accordance with para. 6.1 of this specification.
m. The measuring element shall withstand over-ranging to a pressure 1.3 times the maximum scale reading without a permanent set that affects gauge calibration and without shifting calibration more than 1% of the scale reading. Specific overrange protections to the maximum operating pressure shall be applied to all elements where the normal high pressure range is likely to be exceeded. Pressure elements on vacuum service shall have underrange protection at full vacuum.
n. Fill fluids used in liquid-filled gauges shall be selected carefully based on the applications, and
account for both process and ambient temperature limits.
o. Pressure Switches shall be supplied with hermetically sealed SPDT contacts (contact-ratings
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suitable for the service specified), with fixed (adjustable where needed) differential and Ex-d enclosure.
p. All pressure instruments on vacuum duty shall have scales marked in millibars, or mm H20. q. Scales and displays (local or remote) shall read in engineering units. r. Bourdon tubes shall be welded to socket and tip and stress relieved as required. s. Sensing element and movement for all gauges shall be stainless steel SS316 or anodized
aluminum and nylon (if the required process / piping classes design conditions).
t. Cases shall be vapor tight and weatherproof. u. Dials shall be white with black numerals and markings. v. w. Shatterproof glass to be provided for pressure, receiver or draft gauges.
All gauges shall be equipped with screw driver slot type adjustment for calibration purposes.
5.6 Automatic controllers
Use of Local controllers shall be avoided; their use is subject to CONTRACTOR approval and accepted only where no exceptions are feasible.
a. Control modes for other than self-acting regulator type local controllers shall normally be on the
following basis:
- Single Mode (Proportional Band)
(1) Local level controllers (2) Local pressure controllers
- Two Mode (Proportional Band Plus Reset)
(1) All panel mounted controllers except temperature (2) Local flow controllers (3) Local temperature controllers
- Three Mode (Proportional Band Plus Reset Plus Derivative)
(1) All panel mounted temperature controllers
b. Controllers used for intermittent services such as minimum flow by-passes shall be furnished
with anti-reset windup where necessary.
c. Where 4 pipe systems are supplied, the control modes shall be the same as for a panel
mounted controller for the same variable.
d. Bumpless transfer switching shall be provided between automatic and manual on all controllers.
Controllers shall have provision for adjusting the manual output.
e. Controllers that receive setpoint signal from an external source shall come equipped with a
local/remote setpoint switch, and permit bumpless transfer between setpoint sources.
f. Control function settings, such as setpoint and manual output, manual-automatic transfer
switch, etc., shall be located on the front of all panel mounted controllers.
g. Setpoint, process variable, deviation, and continuous controller output indications shall be from
the front panel of all panel mounted controllers.
h. Receiver controllers shall be either the indicating process type with a separate or integral recorder, where a recorder controller is specified, or shall be the indicating deviation type. i. Panel mounted controllers shall preferably be of the self-contained type with removable
chassis.
j. Panel mounted instruments shall be provided with tag number identification on both front and
rear.
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5.7 Miscellaneous
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a. Pressure seals should be used on highly corrosive or toxic services. The Teflon coating is
preferred. Seals are not permitted on deep vacuum service.
b. When purged lines are required for a field instrument, they shall be connected directly to the manifold (use 5 valve manifold). Any alternative approaches that could be found on Licensors Standards shall be evaluated and discussed with CONTRACTOR.
c. Saddle type seals (flanged directly to the pipe) may be required for very viscous or corrosive
fluids.
5.8 Measuring units and instrument scales
a. Measuring units and local instrument scales shall be according to para. 4.2. b. Local instrument scale shall be as per the following:
VARIABLE
SCALES
Temperature Pressure Level Flow Analyzers
Direct Reading Direct Reading 0-100% linear Direct Reading (*) Direct Reading
NOTE: (*) Square root extraction to be implemented by the system.
5.9 Transmission systems
5.9.1 Pneumatic Transmission
a. Each air consuming device (i.e. control valve positioners) shall be provided with its own filter
regulator air set.
b. Instrument air connections shall be ¼” NPT. c. Pneumatic connections for field instruments and control valves shall be typically 1/4” OD and 0.035’’ thickness SS. tubing with SS. double ferrule compression fittings. 1/2” OD X 0.049” thickness or higher sizes can be adopted if specifically required by the applications and upon approval of CONTRACTOR’s Engineer (i.e. on fast response circuits).
d. Open vent ports on pneumatic components (e.g., solenoid vents, I/Ps, Positioners) shall be provided with screens (bug screens) to prevent blockage, and installed to prevent the buildup of ice on the screened ports. Screens shall be manufactured from corrosion resistant material consistent with normal plant atmospheric conditions and shall be of a design (e.g., screw-fit) to prevent blow out when the solenoid vents. This provision applies also for avoiding any obstruction of the pneumatic component vent, e.g., by insulation, labeling, etc.
5.9.2 Electronic Transmission
a. Regulatory Codes
(1) Unless otherwise specified, all electrical instrument facilities shall comply with the applicable
requirements of the latest edition of the IEC Codes and applicable local codes.
(2) Where applicable, the design and installation of the materials shall be guided by
recommended practices of the ISA standards and API RP 551.
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b. General
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(1) Electronic panel instruments shall generally be compatible with each other, with field instruments and other devices used on the project, without the use of signal converters. (2) Signal ranges for electronic process control instruments shall be in accordance with para.
5.1.8.
(3) Where possible, all field mounted electronic instruments shall employ a true two-wire transmission system. Where not feasible, reliable power sources (i.e. from UPS) shall locally feed the instruments at the voltage level specified by the Instrument manufacturers. (4) Instruments that are mounted in classified areas shall be in accordance with the requirements stated at para. 5.1.3 of this specification: However, instruments that are not readily available in a certified “ex” construction, such as some analysers, will be considered acceptable when totally enclosed and purged with instrument air. With loss of purge, an alarm circuit will be actuated per IEC/EN 60079-2 or ISA 12.04.01 Type X, and, for equipments located in zone 0 and 1, the instrument will be de-energized.
(5) Purging system design shall meet the requirements of IEC/EN 60079-2, ISA STD 12.04.01
or NFPA 496 depending on the applicable local code.
(6) Where specified as an intrinsically safe installation, all control room instrumentation and associated field transmitters shall be solid state, intrinsically safe, electronic type. All equipment, material, and installation procedure shall be certified as complying with the requirements of IEC/EN 60079-11 and 60079-25 (or ISA RP 12.06.01 and NFPA 70), and of the particular vendor’s approved design. Approval and/or certification of intrinsically safe process control equipment must come from a nationally recognized laboratory. For each loop a certification shall be provided proving that loop schematics and wiring diagrams meet the vendor’s system design requirements. All instrument installations shall satisfy any existing local codes. I.S. Calculation reports per IEC/EN 60079-25 shall be produced. (7) Electro-pneumatic transducers shall be furnished for control valves which are operated by
electronic signals.
(8) Instruments shall be suitable for operation from a central power supply, either AC or DC as
required.
(9) Thermocouple and voltage signal receivers shall have an input impedance of more than 100 times the impedance in the rest of the circuit. This includes the wiring and the output impedance of the signal source.
(10) Controllers, recorders, indicators, computer, inputs, alarm relays, etc., shall operate on voltage signal measured across vendor-specified calibrated resistors or other electronic devices.
c. Power Supply for Panel Mounted Instruments
(1) Panel mounted electronic instruments may be provided with or without integral power supply. Power supply for panel mounted instruments and field mounted transmitters shall be located in the control room/RIB. When integral power supply modules and their own accessories (i.e. diode assemblies) are foreseen, they shall have 0V grounded on DC circuits.
(2) Instrument power transforming and stabilization system shall be provided, as required. (3) Power supply back-up system will not be provided except where specifically defined in the
Proposal or Job Specifications.
(4) Instrument power supply systems shall be designed in accordance with the instrument
vendor’s recommendations.
(5) In general, DC power is derived from AC power by rectifying and filtering. The out-put of this power supply shall be regulated for AC line variations in accordance with instrument vendor’s specifications.
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5.10 Control valves
5.10.1 General
a. Wherever practical, all control valves shall be of the spring and diaphragm pneumatically actuated type. Consideration of piston type actuators, with or without helper springs and/or fail- safe capacity tanks, shall be given for special applications if their failure cannot jeopardize plant safety. Control valve trim and body style shall be determined by the application.
b. Depending on application, control valves shall be globe type, with single or double seated plug type trim; otherwise flanged rotary plug type shall be used. Butterfly type control valves shall be used on large pipe lines with small pressure drop, while ball valves shall be used where a high rangeability is required. Double-seated globe type control valves shall be top and bottom guided. Single-seated globe type control valves may be top, top and bottom, or cage guided. c. Control valve sizing shall be in accordance with ISA 75.01.01 or IEC 60534-2-1. Control valves shall usually be sized for a normal operating flow at no more than 70% of the capacity of the valve. Butterfly valves shall be sized for a maximum flow at 60 degree angular opening, except for a characterized vane valve (such as the “fishtail”) which may be sized at 90 degree angular opening. Three-way valves shall be sized to pass maximum flow through either port with minimum available pressure drop through the same port.
d. Requirements for noise control shall be developed by CONTRACTOR during EPC phase. e. Diaphragm actuators normally shall be the fully enclosed spring type. Springs shall be corrosion resistant and shall have a readily accessible adjusting nut. Stem position indicators shall be provided.
f. The valve actuator shall be sized to fully stroke the valve against the unbalanced forces acting on the valve plug and stem when the differential pressure across the valve is equal to upstream design pressure or the maximum differential pressure that can be experienced in the field (e.g., maximum torque requirement of a butterfly valve; shutoff pressure of a pump during start-up with the receiver at atmospheric pressure or vacuum), whichever is greater. In addition to these forces, allowance shall be made for hysteresis in the movement of the valve components and weight of the moving parts. Loading relays shall not be used to increase stem force in lieu of larger size topwork. Any combination of loading relay and topwork requires approval of CONTRACTOR engineer. The valve vendor’s standard method of actuator sizing may be used. The cold bench set of the valve spring shall not vary be more than 10% from the spring range requirements for operating pressure.
g. The minimum size for control valves shall normally be 1” in line sizes 1” and larger.
In lines smaller than 1” a line size valve will be provided. For line sizes larger than 1”, the valve size shall not be less than two inlet line reductions (i.e inlet line size 8”- valve size 4”; inlet line size 3”- valve size 1 ½”). Body sizes of 11/4 in., 21/2 in., and 5 in. NPS (32 mm, 65 mm, and 125 mm) shall not be used. Reduced trim shall be specified when the required valve capacity is below these sizes.
h. Normally, all control valves shall be flanged, except valves such as butterfly that may be wafer or lug type designed to fit between companion flanges. As general rule, the flange shall be 300 lbs as minimum. The use of flangeless (wafer) or lug-type control valves shall be restricted as follows:
- Flangeless or lug-type valves shall not be used where the design temperature is above
315°C.
- Flangeless valves shall not be used where the design temperature is below 315°C and the
service conditions meet the “dangerous” criteria defined below: i) Toxic materials such as phenol, hydrogen sulfide, chlorine. ii) Highly corrosive materials such as acids, caustic, and similar materials. iii) Flammable materials (including light hydrocarbons lighter than 68 degrees API).
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iv) Boiler feedwater and steam, in systems requiring ANSI Class 300 and higher flange ratings. v) Oxygen in concentrations greater than 35 percent.
- For design temperatures above 205°C body material shall have the same nominal coefficient of thermal expansion as the bolting material and adjacent flanges.
- Flangeless valves installations shall consider the possibility to removal of the valve avoiding any damage to valve internal parts. All flanged control valves shall have face-to-face dimensions in accordance with ISA applicable standards wherever practicable.
i. Control valves in process services shall have steel bodies unless the piping specifications require alloy. In water, air or low pressure steam lines where the piping specifications permit, control valve bodies may be cast iron.
j. The pressure-temperature
rating, dimensions,
tolerances, materials, nondestructive examination requirements, testing and marking for cast, forged, fabricated steel flanged, threaded, and buttwelding end valves shall be per ASME B16.34. Flanged-end and flangeless valves shall match the applicable piping class rating, but never less than 300 lbs min.
k. Control valve trim materials shall be in accordance with the piping class for the specified service
conditions.
l. Hardened stainless steel or stellite facing shall be furnished for valve plugs, seat rings, guide posts and bushings in severe services as below specified. Under these conditions, rotary plug valves shall not be used. Use of special trim (i.e. cage type) could be considered where phenomena due to high speed occur. Trim selection shall be preformed according to IEC 60534. The following additional prescriptions shall be applied:
- Exposure to wet H2S service. Trim material shall be limited to stainless steel type 316 and
Hardfacing Alloy 6 (stellite).
-
Nitrided valve components should be avoided where sulfidation due to H2S is a concern due to experience with fouling and sticking of control valves. Stellite-lined internals should be satisfactory where surface hardening is required.
-
Hardened trim, such as hardened stainless steel 440C or 17-4PH, are required for the
following severe services:
i) Steam pressure reduction where the pressure drop may exceed 7 barg. ii) Condensate from boiler where the pressure drop may exceed 7 barg. iii) Where more than 3 percent of the inlet fluid by weight may vaporize in the valve together with a pressure drop exceeding 10 barg (flashing service). An angle valve with flow down direction shall be selected. iv) Any pressure reduction greater than 17 barg. v) For fluids containing solids, and services above 315⁰C, unless higher grade materials
are required for process conditions.
- For other severe services such as catalyst slurry service and all others that are not listed
above, the trim material shall be approved by the CONTRACTOR’s Engineer.
m. Control valves shall be furnished with packing glands and teflon packing for operating temperatures below 232°C. For 232°C and above graphite compounds packing shall be furnished. Selected vendor’s recommended packing for this service may supersede this paragraph. Double packing or low emission type packing shall be used on toxic services. Where Zero leakage to atmosphere shall be certified, packing meeting EN ISO 15848-1 or TA-Luft requirements shall be supplied. Asbestos packing is prohibited.
n. Radiation fins or extended bonnets shall be provided for operating temperatures above 232°C and for operating temperatures of 0°C or lower, unless specifically designed bonnets or packing
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does not require them. Selected vendor’s recommendations may supersede this paragraph. o. Acceptable control valve seat leakage shall be defined on the basis of FCI 70.2 standard. Where the Process Engineer requests “Tight Shut-Off”, and on ESD on-off service Class V metal to metal single seat valve shall be specified. Where “TSO” is not required, Class IV or the manufacturers standard shall be provided. Special applications requiring Class VI soft seats, or permitting “swing through butterfly leakage” shall be defined and examined individually.
p. Two-way control valves shall have equal percentage characteristics, except as indicated below:
-
Valves used in pairs, as three-way valves, including rotary actuated valves such as ball or butterfly types, shall have linear characteristics. Where characterized positioners are used to meet this requirement, valve Manufacturer shall perform calibration for the required characterization.
-
Gas compressor recycle control valves shall have linear characteristics.
-
Valves in pressure reducing service shall have linear characteristics.
-
Valves in level control service shall have linear characteristics.
q. Normally positioners shall be of electropneumatic SMART type (HART protocol) and certified
as intrinsically safe.
r. Pneumatic valve positioner shall have 3 pressure gauges (2 for electropneumatic). s. Where required, valve movement (open/close) shall be indicated by using, as a minimum, single pole double throw (SPDT) hermetically sealed proximity type position switches. Magnetic, inductive, or capacitive type switches with valve position indication are preferred. NAMUR (DIN 19234) proximity switches requiring an isolating amplifier shall be subject to CONTRACTOR Engineer’s approval. Continuous movement, where specified, shall be remotely indicated by means of 4-20 mA position transmitters.
t. Control valves with diameter up to 6” shall be installed with block and bypass, the control valves above 6” shall be supplied with side mounted handwheel. Top mounted handwheels shall be avoided and limited to those case where space is not a constraint for block and valve piping arrangement. Control valves above 6” will be installed with bypass on critical services, erosive or corrosive. Are considered critical the valves with pressure drop above 10 bars.
u. Screwed or socket welds control valves should not be used. v. A ¾” drain consisting or pipe nipple and gate valve shall be provided immediately upstream for
each control valve.
w. Hand control valves shall have the same characteristics as pneumatically actuated valves except for the handwheel and fine-threaded stem. Valve position indicators mounted on the actuator yoke shall be furnished.
x. Self-actuated regulators may be used for services where a variation of 10% above or below the
set point is not objectionable. Special sizing is required to maintain these allowances.
y. The direction of the flow shall be permanently marked on the valve body. z. RTJ ball valves used in 900# services shall be designed with top entry joint to allow the valve
internals to be removed without having to remove the valve body from the pipe.
Control Valves design criteria
a. Restricted trim should be used to allow for expected future capacity. However, the basis for the valve calculations is the full size control valve (a note on the P&ID shall be added in case the control valve failure is the sizing case for the relief valve protecting the system).
b. Cavitation and flashing at the valve should be minimized or eliminated. The control valve
Vendor should be consulted when calculations indicate cavitation and/or flashing.
c. Pressure drop should be minimized where an increase in pressure must be provided
downstream.
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d. Control valves and the associated manifold valves shall be installed such that they are easily accessible from grade (preferred) or from permanent platforms or walkways and installed such that instruments indicating the controlled variable are preferably visible from the control valve location.
e. Sufficient clearance shall be provided above and below control valves so that maintenance on valve (internals) and/or actuator can be performed without removing the valve body. Side clearance shall be provided to allow maintenance on positioners and other accessories. Piping around control valves shall not induce excessive stresses on the control valve body and shall be self-supporting or permanently supported with the control valve either installed or when temporarily removed from the manifold.
f.
g. Backup air system will be identified on the P&ID’s to ensure that critical control valves can operate after a failure of instrument air to accomplish a controlled and safe plant shutdown. To achieve this, adequate volumes of air are needed to be stored in air buffer bottles (reservoirs). This air supply enables the critical control valves, or straight on-off type valves, to be operated a limited number of times during the shutdown process.
ACCESSORIES
The following accessories, if required, shall be installed on the valve or on a stainless-steel mounting plate on the valve:
• Solenoid valve • Limit switches (if any) • Electropositionner (Smart, HART protocol) • Lock-up valve • Air Filter regulator with drain • Filter
Accessories with flying leads shall not be used (e.g. solenoid valves). Tubing and fittings: All accessories on valves shall be piped and tubed onto the control valve, by the manufacturer /supplier, with 316 SS tubing and 316 SS double compression fittings.
VALVE IDENTIFICATION
The control valve shall be provided with a permanently attached stainless steel identification plate. At minimum the following information shall be clearly stamped on the plate:
• Valve tag number • End connection size / rating • Manufacturer’s name or trade mark; • Manufacturer’s model/type number (valve and actuator); • Manufacturer’s serial number; • Body pressure rating; • Size (body and trim); • Material (body and trim); • Type of plug (characteristic); • • Bench setting/spring range; • Action on air supply and/or signal failure; and
Installed Cv value;
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• Limit stop setting in % travel and between brackets, the related Cv value.
In addition, each control valve shall be provided with a stainless-steel tag plate which shall be fixed to the control valve with a stainless-steel wire. This plate shall be marked with the control valve tag number.
5.11 On/off valves
The following valve types are considered: • EMERGENCY SHUTDOWN VALVES (ESDV) • EMERGENCY ISOLATION VALVES (EIV) • GENERIC MOTOR OPERATED VALVES (MOV) • EMERGENCY DE-PRESSURIZATION VALVES (EDP)
5.11.1 Emergency Shutdown Valves (ESDV)
a. Emergency Shutdown Valves (ESDVs) are directly actuated by the ESD system in order to protect the process units and the equipment from upsets outside operating limits and from dangerous conditions.
b. Typically ESDVs have a fail safe position (failure open or close valves). c. Emergency shutdown valves shall be fitted with single acting diaphragm/piston type spring return actuators; the valves operation will be accomplished by de-energizing solenoid valve(s), bringing them in their fail safe status.
d. The actuator shall be equipped with double vent valve/orifice to minimize air stuck probability
during trip demands.
5.11.2 Emergency Isolation Valves (EIVs)
a. The Emergency Isolation Valves (EIVs) are directly actuated by the ESD system in order to limit the quantity of hazardous substances released following an emergency situation (loss of containment).
b. They are typically installed in the suction and discharge lines to isolate equipment such as
c.
compressors and in the pump suction line. In certain high risk applications, to enable a large inventory to be rapidly isolated from a fire which has resulted from a failure of connected piping or equipment, an Emergency Isolation Valve is required in each normally open line connected below the normal liquid level.
d. EIVs can be both manually actuated and power actuated. Manually operated EIVs are not
covered by this specification.
e. Power actuated EIVs will be preferably Motor Actuated. In case valve failure position shown on
relevant P&ID is FO or FC, pneumatic actuation can be considered.
5.11.3 Generic Motor Operated Valves (MOV)
a. Motor Operated Valves (MOV) should be installed as dictated by maintenance or operational
requirements in order to ease the field operators’ activities.
b. MOVs can be typically used on tank farms for remote operation of oil movement or when large
size valves require an actuator for their easier operation.
c. MOVs are normally failure stationary (they cannot be operated in case of power failure). d. MOVs are not intended for activation during an emergency situation.
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5.11.4 Emergency De-pressurization Valves (EDP)
a. The Emergency Depressurization Valves (EDPs) – also called BDV, Blowdown Valves, are directly actuated by the ESD system in order to to reduce pressure by voluntary, rapid removal of fluids from the pressure equipment to prevent the occurrence of stress rupture in case of fire (hot depressuring) or to mitigate the consequences of leakages (cold depressuring).
b. EDP valves shall be automatically pneumatic actuated valves, full-bore, Tightshut off (TSO) with Failure Open position. Actuation shall foresee redundant solenoid valves; actuation principle shall follow a energize-to-trip design, in order to reduce the spurius-trips that would result in undesired release to flaring systems.
c. EDP Valve design shall be reviewed according to applicable SIL assessment relevant to the
Unit where the valve is installed.
5.11.5 General Requirements
a. P&IDs show the ESDVs, EIVs, EDPs and MOVs to be supplied. b. Unless otherwise specified, automated ON/OFF valve type shall follow the type of piping valve
defined in the applicable piping specification.
c. According to the application, valve shall be of ball, globe, plug or butterfly type. d. Automated ON/OFF valves shall be operated, according to service and the valve type, using a
piston type actuator, a diaphragm type actuator or a motor.
e. ON/OFF valve pressure rating shall conform to the piping specifications. f. ON/OFF valves shall be line size. g. All automated ON-OFF valves shall be flanged. The use of flangeless or lug type valves shall be subject to CONTRACTOR Engineer’s approval and any case subject to the restrictions indicated to par 5.10.h of this Specification.
h. RTJ ball valves used in 900# services shall be designed with top entry joint to allow the valve
internals to be removed without having to remove the valve body from the pipe.
5.11.6 Additional Requirements For ESDVs
a. ESDVs shall not have handwheels. b. ESDVs shall be single-seated globe, ball, or butterfly valves with metal-to-metal seat contact
and shall meet the following requirements: • Valves shall be designed and installed such that flow through the valve shall tend to force
the valve in the required failure direction (flow tending to close or open).
• PTFE packing shall be used at packing box temperatures up to 230 ⁰C. Graphite packing
shall be used at temperatures above 230 ⁰C.
• Tight-shut off characteristics according to API 598 will have to be specified is required by
Process on relevant Valves datasheets.
• Where the ESDV is also required to be fire safe, the valve shall be fire tested according to EN ISO 10497 or API 607. For fire safe valves, a graphite packing system is required. Where soft seated valves are used in fire safe service, the valve shall be of fire safe approved design which forces metal-to-metal backup seating upon loss of the soft seat. If the same requirement applies to actuators they shall be supplied with fire resistant protection housings or coated with intumescent epoxy paintings, meeting IEC60331-11 requirements (an “IEC60331-11 fire” is a rapid rise fire that reaches 1093°C within the first 5 minutes of the fire exposure test)
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• The differential pressure across the valve shall be limited to the minimum. ESDV body shall
be line size. Reduced trims shall be avoided.
• When ball valves are specified, trunnion supported ball shall be used for valve size over 6”
(150 mm) and for all sizes for rating over 300 lbs.
• ESDVs shall normally be actuated by means of instrument air via Solenoid Valve(s). All electrical solenoid valve coils shall be encapsulated type to protect them from ambient conditions. Class shall be F according to NEMA. Solenoid valves shall be certified for the applicable hazardous area. Coil voltage level shall be 24 VDC +/- 10%. A surge suppression diode in the solenoid valve coil (especially if not low powered) shall be provided to minimize or reduce voltage spikes and coil current “stagnation” during de-energise phase. Solenoid will be of the low powered type.
c. Where required by the application, ESDVs shall remain in their protective state after a trip or loss of power source (e.g., electrical, air, or hydraulic) until manually reset, even if any trip initiators return to their normal operating positions. In such a case ESD system final elements require manual reset at the final element. Manual reset can be accomplished by an electrical switch installed for this specific ESDVs purpose or solenoid valve with integral reset can be supplied. The pneumatic circuit shall be supplied with an air volume booster, useful for improving actuator speed performances, also in case of large dimension or long tubing arrangements.
d. Voting redundancy for solenoid valves used in fail-action ESD systems can be specified for critical systems, typically considering a 2oo2 voting arrangement. 2oo2 solenoids, used to minimize spurious trips, can be obtained using two separated solenoid valves, one downwards the outlet of the other one (see schematic drawing hereunder), properly connected or with a double coil solenoid valve. Where single coil testing facility is specified only two separate solenoid valves shall be used. Solenoid valves shall be SIL certified, minimum SIL 2 rated, according to IEC 61508.
e. Pneumatic connections on ESDVs shall be in SS (SS tubing and SS compression fittings). f. Valve actuators shall be designed to fully open or close the protective system valve against a pressure drop equal to the maximum upstream design pressure, with minimum operating instrument air pressure at the valve and, for fail-close valves, to meet the required shut off requirements (normally Class V leakage rate). Actuator sizing shall include an oversize, or safety factor over and above these design factors. Minimum value of the safety factor shall be 1.25 – 1.5 for valves. Safety factor shall be reviewed with the valve Vendor to ensure that the
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actuator force will not damage the valve stem or seat.
g. Typically, in unmanned scenarios, the valves shall be equipped with their own air accumulator, engineered as per ASME Sec. VIII, taking into consideration the instrument air design pressure, duly sized to perform at least 3 full strokes. The air accumulator shall feed the valve actuator. It shall be equipped with a pressure relief valve, a drain valve and a pressure transmitter for monitoring purposes.
h. In case of instrument air absence or evident heavy duty process or piping conditions the actuating media will be turned to oil feeding the valve actuator from a hydraulic power unit. The same shall be equipped with a MP or HP (depending on needs) pump, under redundant UPS supply, handling at least 3 valve full strokes in case of pump malfunction, operating anytime the Hydraulic Power Unit (HPU) oil accumulator pressure gets lower than a defined threshold. An extra pressure transmitter shall be provided for potential ESD actions. The HPU shall be equipped with a Partial Stroke Test (PST) facility (se clause m below). The PST dedicated solenoid valve shall be NO type (energize to drain).
i. Metal components of actuators (e.g., mounting bracket spring, spring barrel, diaphragm case, diaphragm plate) on ESDVs shall be fabricated of steel and shall be suitable for the application environment including ambient temperature extremes, ambient H2S concentrations, and salt environment (offshore, near shore).
j. ESDVs shall be equipped with at least one position switch, proximity type, indicating the valve reached the actuated position, that is corresponding to their fail safe status. The requirement of having open/close position switches and a position feedback is highly needed in conjunction with partial stroke test facility. Three cams position switches shall be avoided. As a general rule, facilities to allow on-stream periodic testing of the ESDVs, should be provided. Facilities allowing this on stream testing will be identified case by case during P&IDs and HAZOP reviews.
k.
l. When required, each ESD valve shall be delivered with a local control panel, IP65 (or NEMA4X), installed nearby and suitable for the involved hazardous, connected to ESD system, housing at least the following items: • ESD push button, duly protected • Partial stroke test button (PSTB) - key accessible • “PST in progress” lamp • “Trip indication lamp” – red colour Further indications or buttons may be considered case by case.
m. Partial Stroke Test Facility
Whenever needed with pneumatic actuators, the partial stroke test facility shall be performed by the Smart Positioner. In case of hydraulic actuators the PST facility shall be provided in the HPU itself.
SMART POSITIONER OPERATED PST – MINIMUM REQUIREMENTS This solution is to be preferred due to the possibility to obtain a digitally signed PST success report which is the output of the PST software package. The positioner shall be driven by the ESD system (ensuring the best spurious trip avoidance). The solenoid valve/s involved in the pneumatic circuit shall be monitored by ESD system as well, and pneumatically connected to the smart positioner This leads to both main valve/actuator assembly and solenoid monitoring ensuring the dangerous undetected failures figure to reduce. The valve closure percentage shall not exceed 15%, which may be reduced to 10% in case of smaller bores, in order to minimise potential process unwanted behaviour. Here following, a schematic drawing explains the connection.
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PST IMPLEMENTED ON HPU The HPU, fed by a redundant UPS, shall be equipped with a Partial Stroke Test (PST) facility. The valve closure percentage shall not exceed 15%, which may be reduced to 10% in case of smaller bores, in order to minimise potential process unwanted behaviour. The PST dedicated solenoid valve shall be NO type (energise to drain) in order to avoid unwanted valve trips.
5.11.7 Additional Requirements for EIVs
Power actuated remote operated Emergency Isolation Valves shall be electric motor operated unless otherwise dictated by specific process requirements (e.g. speed of closure, fail safe design) In case of fail-safe action the emergency isolation valves shall be pneumatic type with solenoid valves. Emergency Isolation Valves installed to isolate flammable liquids or severely toxic materials inventory shall be electric motor operated from remote. If installed in fire risk areas, power operated Emergency Isolation Valves shall be fireproofed type, including exposed actuators/cables/air piping and all the associated equipment to maintain its operational integrity for a minimum of 20 minutes when exposed to a hydrocarbon fire. All EIV motors (or pneumatic actuators) must meet the design criteria for installation within hazardous areas. The actuators of all power actuated EIVs will be equipped with position switches to indicate that the valve is in the open or closed position. Appropriate interlock logic is required to prevent the relevant machine driver(s) to operate when EIVs, that are required to be open for safe operation, are closed. All power actuated remote operated EIVs shall be actuated at least from two different push-button stations located: a) on the valve actuator, b) on control room console. Need of an additional push button to be located at a safety distance from the hazardous situation (at least 15 meters away) will be evaluated on a case-by-case basis during HAZOP. Any deviation to above requirements shall be approved by CONTRACTOR’s Engineer. Where fire proofing is requested, EIV electric motor operators shall be coated with Intumescent poxy paintings, meeting UL1709 requirements. For specific applications involving EIV valves being open for long periods, it shall be discussed with CONTRACTOR the possibility to foresee partial stroke test facilities shall be provided according to the types specified at para. 5.11.5. Where applicable, EIV valves shall be specified as Fire safe, according to API 607.
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5.11.8 Additional Requirements for MOVs
a. MOVs shall normally be gate type valves according to the applicable piping specification. b. MOVs shall be flanged and line size. Body and flanges shall be of the same rating of the line
where they are installed.
c. MOV actuator shall consist of a totally enclosed self contained electro-mechanical unit, consisting of an electric motor driver, stem nut reduction gearing, lost motion device, thrust bearings (where applicable), handwheel, and local position indicator. The operator also contains electrical control equipment, including torque and position sensing devices, space heater where needed, and wiring terminals. Actuators shall also contain control power transformer, integral reversing motor starter with electrical and/or mechanical interlocks, and motor starter controls.
d. MOVs shall be operated from a local push button station with open/close indication lights, integral with the valve actuator and where required on P&IDs from remote (i.e from DCS). e. Motors shall be rated for intermittent duty, three-phase and single-speed with high starting torque, and totally enclosed with lifetime pre-lubricated (sealed) ball bearings. Insulation rating shall be Class F.
f. MOV actuator shall be fed at 400 VAC 3 ph 50Hz., properly isolated by means of local isolator breakers, and the relevant control circuits shall be at 24 VDC internally generated by the valve actuator; in case the latter is not provided the control circuits shall be isolated as well.
g. When installed in hazardous area, the actuator shall be supplied with the relevant certification.
Ex-d protection is required.
h. Control circuit shall be designed in order to allow remote operation. OPEN, CLOSE, STOP commands and open and close position contacts shall be wired to a dedicated actuator terminal strip.
i. Auxiliary contacts such as local/remote status, motor failure, overload, etc shall be available on
actuator terminal strip.
j. Actuators shall be designed to fully open or close the valve against a pressure drop equal to
the maximum upstream design pressure.
k. Where fire proofing is requested, MOV electric motor operators shall be coated with
Intumescent epoxy paintings, meeting IEC60331-11 requirements.
l. Valve shall be specified Fire Safe as per API 607
ON/OFF Valves design criteria
The following criteria will be considered for on/off safety valve: Emergency shutdown valves will be fitted with single acting diaphragm/piston type spring return actuators; the actuation will be by de-energizing solenoid valves, if not otherwise specified by Licensor. SIL certified electronic transmitters will be used for SIS certified application (Initiators to ESD). SIL certified Solenoid Valves will be used to activate SIS Final Elements. As a general rule, data communication technology between field devices and DCS/ESD/F&G system ill be:
• Analogue input/output: 4-20 mA, with superimposed HART protocol • On/off input/output • Solenoid valve output
Solenoid Valves will be low-consumption type, enabling the use of 24VDC as supply voltage; Emergency shutdown valves will be fitted with single acting diaphragm/piston type spring return actuators; the actuation will be by de-energizing solenoid valves, if not otherwise specified by Licensor. The coupling part between the ball axis and the actuator must comply with ISO 5211 and allow a 90°
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rotation. The valve supplier is responsible for the overall assembly and proper adaptation of the actuator of the valve. Depressurizing valves, when required, will be modulating control from DCS or ESD with emergency trip SOV. Instrument stainless steel tubing and double ferrule compression fittings (Swagelok type or equivalent) will be used. Some of the above listed design criteria could not be applied in the licensed units in case of particular Licensor requirements.
VALVE IDENTIFICATION
Each valve shall have a Stainless-Steel nameplate riveted to the actuator yoke, which shall be visible when the valve is in service and fully insulated. This nameplate shall include following information:
• Manufacturer’s name and trademark. • Purchase Order Number • Valve/Actuator serial number/model number. • Valve tag number. • Maximum valve body pressure rating. • Maximum Shut-off pressure for actuator. • Valve body material and nominal body size • Valve action on air failure. • Operating signal range
In addition, the tight shut-off (TSO) direction(s) shall be clearly marked where applicable by a permanent mark cast in or stamped on the valve body. Painted marks are not acceptable.
5.12 Pressure relieving devices
a. The selection, sizing, design, and installation of relief valves, rupture discs, and relieving systems shall be generally in accordance with API RP 520 for liquid, steam, vapor and two- phase services. In general, valves shall have metal-to-metal seating surfaces. Soft seats, linings, etc. may be required for special services such as slurries.
b. All relief valves manufacturing material shall conform to the applicable piping specification. If the relief valve is installed on a vessel/column, the same minimum rating shall be applied for the vessel/column nozzle and for the connecting line.
c. Pressure relief valves (PSV) for fire contingency shall be specified for a maximum accumulation
of 121% of set pressure, in agreement with API RP 520 Part 1.
d. Pressure relief valves discharging two-phase liquid/vapour shall be sized in accordance with the recommended method for sizing pressure relief devices in two-phase service reported in Annex C of API RP 520 Part 1.
e. The maximum back pressure (defined as the sum of superimposed and built-up back pressure) shall be specified on the outlet flange of pressure relief valves discharging to the Flare System: with the purpose of keeping the ratio between the gauge total back pressure on PSV outlet flange and the gauge relieving pressure of protected equipment not higher than 0.3, for any contingency including plant wide failures. The sizing of flare headers and sub-headers will be then defined accordingly. The maximum back pressure shall not be higher than flare system design pressure normal.
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f. As a general rule pilot operated relief valves shall be installed only upon agreement with
CONTRACTOR’s Engineer.
g. No relieving to atmosphere is allowed for process lines. Thermal relief valves discharging
hydrocarbons or hazardous liquids shall be connected to the closed safety system.
h. Electrical power failure, with the result loss of cooling water and steam, will normally be
considered in the specification of pressure relief valve requirement.
i. A single operating pressure relief valve will be specified for each service unless:
- Multiple valves are necessary because the required capacity cannot be provided in a single
valve;
- Dual valves are required in accordance with the ASME Boiler and Pressure Vessel Code,
Section I.
j. For steam service governed by ASME Boiler and Pressure Vessel Code, Section I, the use of
inlet or outlet block valves on PSV is not permitted.
k. When one or more relieving devices, with relevant spare, are installed with block valves on the inlet and/or the outlet piping, the block valves shall be key-interlocked to ensure that the protected equipment will be never isolated from the relieving device(s).
l. A by-pass line shall be provided on all PSVs (single common line for two or more PSVs in parallel), equipped with double block valve and spectacle blind. Minimum by-pass line size will be PSV inlet line size.
m. Thermal expansion valves, typically ¾” x 1” flanged, shall be provided when shown on the
P&IDs.
n. Tank Venting shall be provided in accordance with API 2000 standard. o. Pressure relief valves shall be manufacturer’s standard types as recommended for the specified
services. These valves shall conform to the following:
- API Std. 526 - “Flanged Steel Pressure Relief Valves” for materials and sizes on flanged
valves.
- API Std. 527 - “Seat Tightness of Pressure Relief Valves” for permissible leakage.
p. Inspection of pressure relief devices shall be as per API 576.
VALVE IDENTIFICATION
All relief valves shall be fitted with a permanently attached stainless steel labels (not wired-on) showing the following information: • Valve Serial no. • SELLER’s standard data • Purchase Order Number • Valve tag number • Manufacturer’s name and/or Trademark • Valve and orifice size: Inlet & Outlet flange rating • Valve spring, disc and disc holder and body materials (show ASTM numbers as applicable) • Rated capacity (in units specified on the valve data sheet) • • •
• Set Pressure and Cold Differential Set Pressure • Valves spring range • Where applicable the valve body shall be stamped with the code (ASME stamp) along with tag number.
In case of rupture disk the flow direction shall be clearly marked on the disk holder.
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INSTRUMENT GENERAL SPECIFICATION
5.13 Analysers
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TCM IDENTIFICATION CODE
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SHEET 49 / 61
ISSUE 2
a. Analysers shall be furnished in accordance with the P&IDs. b. Analysers shall be normally purchased as a complete and installed systems with sampling system, pre-commissioning systems, calibration facilities and a housing. Analyzer vendor will be responsible for the engineering and supply of whole system.
c. Analysers and analyser systems design and installation shall generally be in accordance with
API 555.
d. Where required, analysers shall have a dedicated recorder suitable for calibration and display. For some complex analyzer system, it may be required the connection to DCS via serial link, for monitoring and diagnostic purpose.
e. The sampling system shall generally conform to API 555. The system shall preferably be obtained from the analyzer vendor. If this is impractical, the system design shall be supplied or approved by the analyzer vendor. Each proposed sample system shall be described in detail, in writing, for final CONTRACTOR engineer’s approval prior to purchase.
f. Provision shall be made for manual injection of a standard sample for calibration and check
purposes.
g. Refer to API 555 for a description of sample probes. An ASTM type nozzle shall be used for liquids and the typical gas sample probe for gases. If threaded joints are not applicable, use 1 ½” flanged connections.
h. The analyser operation shall not be affected by:
- Ambient or sample temperature fluctuations.
- Barometric or sample pressure changes.
i. All materials shall be suitable for the sample stream and the surrounding atmosphere. j. Where specified, analytical detector systems shall be
in non-combustible, weatherproof, heated, well ventilated and/or air conditioned walk-in type houses provided with all necessary utilities and with sufficient space for adequate access to all part of the analyzer. Analyzer installation shall be located to minimize obstruction to other equipment.
installed
k. The minimum specifications for the above analyzer buildings shall be as follows: Steel frame, galvanized (16 gauge) siding and roof, sheet steel door. Heat steam is required to maintain 16°C when the ambient temperature is 0°C. Provide gravity ventilation for air circulation. Provide adequate lighting. Provide a floor drain.
l. Vent and drain connection shall be collected to a closed collection system, if required. m. A power isolating switch shall be included at the local analyzer installation in the field and also
in the Technical Room located outside the shelter and near the door.
n. Where applicable, analyser buildings may be furnished by the analyzer vendor as
subcontractor.
o. In general standard analysers used in the petrochemical industry can be used in LNG applications. The only requirement specific to cryogenic LNG liquid and vapour is the need to vaporise/warm-up the liquid/gas to a temperature acceptable to the analyzer.
p. For additional requirements refer to specification: 4439-KA-SE-032001001. q. All analysers shall be certified intrinsic safe as per Hazardous area classification. When intrinsically safe execution is not available/suitable another type of protection method shall be used only if approved by CLIENT.
5.14 Fire and gas system (F&G)
Refer to specification Fire and Gas Alarm System (F&G) Technical Specification 4439-JK-SE- 050001001, Fire and Gas general specification 4439-KF-SG-000000001 and 4439-SZ-SG-
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INSTRUMENT GENERAL SPECIFICATION
0000000001 HSE Design Philosophy
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a. The F&G system shall be designed to detect smoke, fire, toxic gas and flammable gas in both manned and unmanned sections of the plant. It shall be completely independent from any other control and protection function. Refer also to specifications 4439-JK-SE-050001001.
b. Manual Alarm Call Points shall be installed in the field and wired to the F&G system to allow
operators to manually activate F&G alarms.
c. The F&G system shall provide the user with graphic displays, incorporated in the DCS graphic pages, based on the physical plant layout and shall include the functional facilities to perform automatically or manually initiated trips and sequences directly to actuating devices or via ESD system.
d. As a general rule, buildings shall be equipped with dedicated F&G detection systems connected to dedicated Local F&G Panels. These panels shall operate directly all actions within the building, including the signals to the HVAC systems in order to close the necessary dampers and shut-down fans etc. These Local F&G Panels shall provide hardwired signals: “Common Fire”, “Common Fault” and a separate “Fire Alarm” for each sub-zone, to the plant F&G system. e. The plant F&G system shall be based upon ESD architecture (refer to para 5.1) in compliance with IEC 61508 and IEC 61511, with redundancy down to I/O level and power supply units. f. All field mounted sensors and actuating devices shall be connected to the plant F&G system. g. As a general rule, the data communication technology between field devices and F&G system
shall be based on:
- analog inputs: 4-20mA/HART protocol (3 or 4 wire standard is preferred);
- on/off inputs/outputs.
- solenoid valves and signaling devices outputs (e.g. for automatic Deluge valve activation or for signaling station activation).
h. The status and condition of all various fire and gas detectors and fire fighting systems shall be communicated to the DCS through data links; the DCS graphic displays shall include a geographical mimic diagram, including the relevant location of all devices.
i. Line monitoring (End of Line Voltage Partitors) shall be provided, with an equivalent resistance compatible to F&G control system I/O boards, in order to detect short-circuits and open loop occurrences.
5.15 Tank gauging system (TGS)
A Tank Gauging System is foreseen for monitoring, analysis, diagnostic and reporting the levels measurement information on tanks storage area. Instruments, transmitters and systems dedicated to safety functions shall be completely independent to instruments, transmitters and systems dedicated to control functions. The TGS shall have the capability to operate in a stand-alone mode and display level data on the local indicators without any assistance from the operator display unit(s).
a. In addition to the Codes and Standards specified at para. 2.1, the following shall apply:
- API MPMS 3, 3.3, 3.6, 7, 9, 10, 11, 12, 16.2
- ISO 3993, 4266, 4512, 5024, 11223, 15169.
b. The TGS shall be made of:
- field instruments (indicators and transmitters suitable for specific services) as required to completely supervise the storage tanks;
- local digital level indicators at the grade level;
- field communication unit(s) or its equivalent connected to field instruments;
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- local shelter(s) belonging to one or more tankage areas with data acquisition and remote display unit(s) for monitoring and historicization connected to field communication units as well as maintenance station(s) for system configuration.
c. Where custody transfer or assessment of taxes, duties or royalties are involved, the gauging instruments and inventory control system are required to be officially approved and certified for this purpose.
d. The TGS shall also be directly interfaced with DCS via serial links. e. The system architecture shall be flexible to accommodate modular expansion of TGS. f. The TGS shall have the capability to operate in a stand alone mode and display level data on
the local indicators without any assistance from the operator display unit(s).
g. As a general rule, the data communication technology between field devices and TGS system
shall be based on:
- analog inputs/outputs: 4-20mA/HART protocol;
- on/off inputs/outputs.
h. Requirements for overfill protection shall comply with API 2350.
For details please refer to Tank Gauging System Specification doc. № 4439-KK-SE-067001001
6
INSTALLATION
6.1 Connections for instruments on vessels and piping
a. Instrument connection to vessel:
• standpipe dimension shall be 2 “and the connections of the instruments:
- DP level transmitter on the standpipe must be ¾’’
- Radar level instruments (GWR) on the standpipe must be 2’’
- Magnetic level gauge on the standpipe must be 1”
b. The connection of the analyzers must be the same as that of the pressure, unless the supplier
recommends larger dimensions. c. Isolation valve shall be provided. Typology and material as per piping class specification. d. For impulse lines of instruments 316 stainless steel impulse tubes of size 1/2” OD X 0.049” thickness, with double compression fittings shall be used. An integrated manifold or small 316 stainless steel valves shall be provided.
e. For pneumatic signals and air supply instrument a 316 stainless steel tubing ¼’’ OD in diameter
and 0.035’’ thickness shall be used.
f. Tubing for steam tracing of the instruments shall be of outside diameter (OD) of ½’’ OD and
0.049’’ thick with fittings in double compression brass.
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Instrument type
On Pipe
On Vessel
Thermowells
1 1/2” Flanged (Note-4)
2” Flanged
Flow Orifice Flanged Taps (below 900 lb)
Flanged Taps (900 lb & above)
1/2” NPT F (Note-3) 3/4” SW
NA NA
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SHEET 52 / 61
ISSUE 2
Instrument Connection
NA
NA
NA
NA
3” Flanged
2” Flanged
4” Flanged
3” Flanged
2” Flanged
2” Flanged
4” Flanged
3” Flanged
3” Flanged
4” Flanged
3/4” NPT F (Note-3)
½” NPT M ½” NPT F ½” NPT F
2” Flanged 2” Flanged 2” Flanged
3/4” NPT F (Note-3) 3/4” NPT F (Note-3) 3/4” NPT F (Note-3)
Pressure Gauge Transmitter Diff. Pressure Remote pressure transmitter and gauges with diaphragm seal with capillary Threaded diaphragm seal pressure gauge Diff. Pressure with diaphragm seal with capillary Level External Displacer Internal Displacer (top mounted) Diff. Pressure Diff. Pressure with Diaphragm seal with capillary Level Switches, Internal Float (top mounted) Level Switches, External Float (side mounted) Tuning Fork Level Switch Dielectric Probe and Conductivity Level gauges or magnetic level Servo Tank Gauge (TGS) Radar Level transmitter (top mounted) Radar Level transmitter (External chamber mounted) Standpipe NA Note-1: Flanged (300# min) When required by Standard on specific Process Applications. Note-2: Flange up grade to 2” on cladded equipment. Note-3: Socket Weld (SW) connection shall be considered where threaded connections are not allowed as per pipe class. Note-4: 2” Flanged or 1” Screwed connection can be considered as special case based on application/ requirements. Note-5: Magnetic level gauge on standpipe connection as 1”, DP level transmitter on standpipe connection as ¾”, Radar and displacer level transmitter on standpipe connection as 2”
NA Manufacturer Std. 2” Flanged 8” Flanged
2” Flanged 8” Flanged
2” Flanged
2” Flanged
4” Flanged
4” Flanged
2” Flanged
2” Flanged
4” Flanged
2” Flanged
4” Flanged
3” Flanged
2” Flanged
4” Flanged
2” Flanged
3” Flanged
NA NA
Note-5
NA
NA
NA
NA
NA
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6.2
Instrument air supply and electrical power distribution
6.2.1
Instrument Air supply
The main instrument air supply shall be furnished without interruption from other general air user requirements. It shall be oil / solids free and dry according with ISA 7.0.01 “Quality Standard for Instrument Air”. The instrument air supply shall be distributed with following:
Utility Service
Plant Air Note 2 Instrument Air Note 1, 2
Pressure, barg
Min. Norm. Max. Design Min.
Temperature, °C Norm. Max. Design
5
4
7.5
7
9
9
11
11
0
0
Amb.
Amb.
50
50
85°C
85°C
Note 1: Dew point minus -20 °C at 8 barg Note 2: refer also to document 4439-YZ-SG-0000001’’BASIC ENGINEERING DESIGN DATA’.
Utility Service For RA1K
Instrument Air Note 1
Pressure, barg
Temperature, °C
Min.
Norm. Max. Design Min.
Norm. Max. Design
5,5
6.5
7
11
25
40
Note 1: Dew point minus -40 °C at Atm. Subdistribution from main header to single users will be through air distribution manifolds, with isolating valve for each tap and drain valve. I.A. subheaders to air distributioDn pots shall be in galvanized steel according the applicable piping specification.
6.2.2 Electrical Power Distribution
Below the distribution and utilization system for the whole project:
Service
Voltage (V) Phase
Frequency (Hz)
DCS/ESD/PLC/Marshalling cabinets/ Local Panels (UPS supply)
DCS/ESD/PLC/Marshalling cabinets/ Local panels Aux. Circuits (non UPS supply) Motor Operated Valves, Small Power Distribution Switchgear Control
Field Instruments (powered from relevant control system / marshalling)
230VAC 24VDC (1) 230VAC 24VDC (2)
400 (380)
230VDC
24VDC
Field Instruments (powered IPDP)
230VAC
1
1
3
1
50
50
50
50
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Service Solenoid Valves, signalling lamps/horns (powered from relevant DCS/ESD/PLC/F&G) Emergency and Safety Lighting Normal Lighting Convenience Outlets
Electrical Heaters, Electrical Tracing
Voltage (V) Phase
Frequency (Hz)
24VDC
230VAC 230VAC 230VAC
230VAC
1 1 1
1
50 50 50
50
Notes:
- 24 VDC obtained from power supply units 230VAC/24VDC powered from UPS source.
- 24 VDC obtained from power supply units 230VAC/24VDC powered from non UPS source.
6.3
Instrumentation installation and interconnection
6.3.1 General Requirements
a. Field instrumentation shall be installed and connected according to API RP 551 and API 552
standards, standards and Vendor’s recommended practices.
b. Mounting principles and details shall be chosen in order to meet the following requirements: 1.
instruments shall maintain accuracy and repeatability all along their working life, 2. the easy access to instruments shall particularly be taken into account, 3. the need for avoiding as far as possible the instruments tracing, 4. Vendor’s recommendations.
c. All instruments shall be mounted as close as possible to the process unless otherwise specified. d. For instruments mounting, the tubing technology shall be normally used except for level instruments directly flanged to the equipment and where piping classes require the use of rigid pipe or materials not covered by tubing technology.
e. Instrument installation material dedicated to process and pneumatic connections shall be in
accordance with the Instrument piping specification.
f. Compression fittings shall be double ferrule type. Swagelok or equivalent manufacturer shall
be used for tube fittings.
g. Choice between flanged or NPT screwed connection to process block valve shall be done
taking into account parameters as pressure, temperature, fluid type and piping class.
h. A particular attention shall be paid to instruments submitted to vibrations (e.g. instruments related to reciprocating compressors) and/or heavy instruments. In such cases instruments shall be suitably supported and process nozzles for instrument impulse pipe shall be bracketed. Instruments connected to small size process pipes or pipes made of synthetic material shall be suitably supported.
i.
j. Transmitters shall be normally mounted at grade or at platforms, using 2” (50 mm) pipe
supports.
k. All transmitters shall be provided with local LCD indicator. l. Drain pots shall be installed on wet gas services for instruments installed below the tap and
with a range of less then 100 kPa (subject to CONTRACTOR Engineer’s approval).
m. Electrical connections shall be lSO M20x1.5.
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6.3.2 Flow Instruments
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a. Differential pressure devices (Orifice plates, venture, flow nozzles, etc)
Differential pressure devices shall be normally mounted on horizontal part of the piping. If not possible, vertical mounting shall be up flow for liquids and down flow for gases. Straight length requirements are given by norm ISO 5167-2. Before installation, orifice plate bores shall be carefully inspected for concentric roundness, sharpness and absence of burns and nicks.
b. Differential pressure transmitters
When process conditions allow close coupled flow meters shall be preferred instead of remotely mounted flow meters. Transmitters shall be easily accessible from permanent access at platforms and foot bridges. Sufficient clearance shall be made available between adjacent process lines in order to allow easy installation and handling of block valves and associated fittings.
c. Two flow meters mounted in parallel on the same flow element
If two flow meters are mounted on the same orifice plate, one for control and one for safety, they shall use different taps for both instruments.
d. Gas flow meters
Taps will be up side orifice plate and flow meters shall be installed above orifice plate; the impulse pipes to transmitters shall have 8° minimum slope in order for the condenses to flow back to the process pipe.
e. Liquid flow meters
Taps shall be on side or down side orifice plate and the transmitters shall be mounted under the orifice plate.
f. Superheated and saturated steam
Taps shall be on left and right side orifice plate (on the horizontal axis); pots shall be mounted as close as possible to the taps and at the same height from the ground.
g. Custody transfer
Where custody transfer or assessment of taxes, duties or royalties are involved, the flow metering system is required to be officially approved and certified for this purpose (refer to specification: 4439-KK-SE-066001001 Metering skid specification.
h. Space constrains
Where limited spacing dictates, taps located 45 degrees from the horizontal may be used (up for gas and steam, down for liquid). Diaphragm and liquid seal The use of diaphragms and liquid seals shall be avoided as far as possible. Use of diaphragm seal shall be preferred if accuracy is not affected. Liquid seal shall be used for freeze, viscous, corrective or polymerise liquids. Integrated manifolds Compact 3 and or 5 valve manifolds shall be used on clean products only, except where prohibited by the instrument piping class. Compact valve manifolds shall never be used in combination with liquid sealing systems.
i.
6.3.3 Level Instruments
a. Level instruments supplied with an external cage and/or body, including external displacers, float type level switches, guided wave radar type transmitters, gauge glasses and magnetic type indicators shall be supplied with vent and drain connections.
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b. Typically hydrocarbons drains and vents shall be connected to draining and venting systems
respectively, if any.
c. Where the use of external cages is not feasible, level instruments shall be located on top of
vessels and a stilling well shall be installed.
d. Radar type level transmitters will be top mounted and shall be installed on stand pipe. The
connection flange shall be ≥ ND 4”.
e. Top mounted 4” flanged connections shall be considered for installation on tanks. f. The preferred type of level measurement for cryogenic applications is differential pressure, with the transmitter mounted above the top tapping point. DP transmitter shall require an access platform, with a self purged process hook-up. (NOTE: all cryogenic vessels, where DP transmitters are to be installed, would require platforms on top of the vessel).
g. When using differential pressure type level instruments for cryogenic service, the instrument shall be mounted above the top tapping point of the vessel. To ensure fluid vaporization, both HP and LP legs shall be heat traced. Suitable maintenance access shall be provided for these instruments.
h. The possibility of changing and/or different levels (static heads) of liquid occurring in the high and low pressure legs of the connecting impulse lines shall be prevented. These problems can particularly occur in cryogenic service, where a build up of ice can affect the heat transfer rate from impulse lines, so heat tracing on the impulse lines shall be installed to ensure continuous vaporization of liquid and hence a consistent and reliable liquid/vapor interface level (static head) in both impulse connections. In cryogenic service the impulse tubing installation shall allow pipe movement during cooldown and temperature changes during operation.
i.
6.3.4 Pressure Instruments
a. Gauge/vent block valves manifolds shall be installed adjacent to the instrument when close
coupling mounting is not possible.
b. Pressure instrument taps Horizontal process pipe
- Gas and steam services: The instrument taps shall be located on the upper side of the process pipe line.
- Liquid service: The instrument taps shall be located at side of the process pipe line only where side space is not an issue. Otherwise 45° down taps shall be provided. Pressure gauges shall have vertical impulse pipe and taps located on the process pipe line. Vertical process pipe For all services the instrument tap shall be horizontal. In all cases, the impulse pipe axis shall be perpendicular to the process pipe axis.
c. The impulse tubing installation shall allow pipe movement during cooldown and temperature
changes during operation.
6.3.5 Temperature Instruments
a. On horizontal piping thermowell taps shall be located in the upper half of the piping. Installation in vertical plane is preferred (with temperature probe head upwards) on vertical piping Taps shall be installed with an angle of 90°. Thermowells shall not be installed in a location where stagnation of the flow stream is possible.
b. For pipe ≤ ND 4” either an increase in pipe diameter to 4” shall be made (expander and reducer)
or the thermowell shall be mounted on pipe elbow.
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6.3.6
Instrument Accessibility
a. Each instrument requiring frequent maintenance (routine access) shall be properly located in
order to satisfy an easy access, workers safety conditions as well as efficiency.
b. Instrument accessibility, being able to induce heavy consequence on piping or platform layout,
shall be considered as soon as possible during the detailed engineering stage. c. Routine access locations shall be reached by means of platforms of fixed ladders. d. The following instruments and accessories shall be considered as routine access location: Control valves, ON/OFF actuated valves, transmitters, local controllers, local converters, in-line flow meters, retractable orifice plates, level gauges, level switches, pressure switches, pressure gauges, temperature gauges, sampling loops.
e. The following instruments shall be considered as non routine access location: Orifice plates (no retractable type), pressure taps, thermocouples and thermo-resistances, thermowells, analyser take off points.
f. Safety valves: shall be considered case by case. g. Particular care to be paid on installations requiring impulse lines to be as short as possible for applications requiring fast response time. In this case accessibility has to be checked case by case.
6.3.7 Electronic And Electrical Instrumentation Interconnecting
a. Field devices interconnecting to control systems shall be in accordance to the adopted
philosophy (4-20mA HART protocol, etc.). Field devices interconnecting to control systems shall be by means of junction boxes and marshalling cabinets (for interconnecting design between control system I/O card signals - I/O signals. Single pair/triad cables shall be used for the connection of field instrumentation to Junction boxes. Multi cables shall be used for the connection of Junction boxes to marshalling racks located in technical room. At least 20% spare conductors per multi-cable shall be provided.
b. Instrumentation cables shall run aboveground in hot dip galvanized steel cable trays with cover. Instrumentation cables shall be in accordance to the specification 4439-KK-SE-352001001 c. during engineering.
d. Electronic and signal wiring shall be adequately separated from power wiring and electrical
equipment to minimize electro-magnetic interferences.
e. When the instrument cables and power cables are running on parallel routes, the distances
shall be at minimum as follows:
POWER CABLE SPACING 230 V 400 (380) V ≥ 6 (5.5) kV
450 mm 600 mm 1500 mm
f. Separate routing shall be selected for redundant data links. g. Signal segregation in different core cables shall be according to the following multiple criteria:
• IS vs. not IS a) Intrinsically safe signals
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b) Non-intrinsically safe signals • Control system destination a) Signals connected to DCS or to other not safety related control equipment b) Signals connected to Packages PLCS c) Signals connected to ESD d) Signals connected to F&G system e) Signals connected to MMS
• Signal Type a) 4-20 mA analogue signals and 24 VDC digital signals (together) b) 24 VDC powered signals (instrument separate power supply, DO to SOVs, lamps) c) signals ≥ 48V DC d) mV signals e) three wires signals
h. Junction boxes segregation shall meet the same segregation applied to instrument cables. i. Junction boxes shall be in stainless steel 316L material with sunshade, with a minimum
degree of mechanical protection IP65 as per DIN EN 60529.
j. All cable wires shall be connected at both ends to terminals including spares one and shall be
earthed.
k. Only one multi pairs/cores cable shall be connected to each junction box. Cable entry will be
on the bottom part of the junction box.
l. Spare Junction box holes will be closed by means of Ex certified nickel plated metric plugs. m. Instrument cables shall be connected at both sides to field equipment by means of cable
glands.
n. Cable glands shall be suitable for the outdoor installations, weather proof IP 65 min per IEC
o. If installed in hazardous areas shall be Ex certified. Type of certification shall be according to
the selected method of equipment protection.
p. Cable glands must be compatible with instrument connections and junction boxes, shall be
brass nickel plated. And shall be utilized in the following typical size: M20/M25/M32/M40/M50. Threads shall be ISO Standard.
q. Instrument cable routing will be:
- Above ground (A/G) from instruments to junction boxes.
- Above ground (A/G) from unit Junction Boxes/local Panels to relevant RIB
- Above ground (A/G) for Fiber Optic cables
- Above ground for interconnecting cables outside units (excluding FO cables)
r. All outdoor instrument cables (single pair, single triad, multi-pair, multi triad, multi-core) and fiber optic cables shall be armoured. Flame retardant cable will have inner sheath and outer sheath in PVC, meanwhile Fire Resistant cables will have LSZH inner sheath and outer sheath in PVC.
s. As general rule cables are flame retardant in accordance with IEC 60332-22. Fire resistant cables shall be used for ESD, F&G system service and shall be in accordance with IEC 60331-21.
t. All indoor cables will be not armoured and will have low smoke zero halogen outer sheath
material.
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u. Separate routing will be selected for redundant data links. v. Junction Boxes modularity and multicable
formations required will be defined by
CONTRACTOR and submitted to CA for approval during engineering.
6.4 Tracing
a. Typically instrumentation tracing is specified on P&IDs. Steam is the standard medium for
instrument tracing.
b. Electrical tracing shall be used where steam is not available or where accurate and precise
temperature control is required (e.g. analytical systems).
6.5 Grounding
a. All instruments, junction boxes, push button stations, local panels, cable trays, conduits,
cabinets (system, marshalling), console bays shall be properly grounded. In particular for field instruments the below criteria shall apply. Enclosures of field instruments shall be grounded as follows: Instruments operating at ≥ 48V: connecting the enclosure directly to the grid using 6mm2 min. ground wire; Instruments operating at less than 48V: the enclosure may be grounded using one of the following options:
i. connecting the enclosure directly to the grid using 6 mm2 min. ground wire; ii. connecting the enclosure to a grounded instrument stand or other supporting structure,
provided that the instrument device is properly fastened and the mounting clamp is mechanically and electrically in intimate contact with the stand;
iii. where i) or ii) methods are impractical, using the cable armor (assuming armored cable
is used) provided that the following criteria are met:
- the cable glands, on each end of the armored cable, shall be designed to bond the
armor to the gland;
- the armored cable runs in one continuous length from a properly grounded junction
box to the device being grounded, i.e., no splices are permitted.
b. In hazardous area, where instrument stands, local panel or junction box frames are provided and not installed on a metallic structure (i.e. on a paved area), the stand/frame shall be connected to an adjacent bonded bus bar/structural steelwork or directly to the main earthing grid, by mechanical connection via a 16 mm2 green and yellow sheathed conductor.
c. Grounding criteria are specified in International standards (IEC 60364-5-54), Electrical
Installation Standard Details and manufacturers’ prescriptions.
d. Three different type of earth shall be installed in the Instrument Control Room.
The three earthing system shall be provided fully segregated within the Instrument Control Room battery limit. Connection of IE bars and ISE bars to the main PE system is under Electrical scope.
i. Instrument Earthing (IE) Instrument earthing system shall be used for voltage references of electronic system and cable screens, which are not intrinsically safe. Instruments and screen of cables shall connect at only one point to IE system using grounding insulated wire colour Green. This point shall be located in the Instrument Control Room at the bottom of each marshalling cabinet. On field instruments side, cable screen shall be insulated and floating.
This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent
INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 60 / 61
ISSUE 2
IE system shall be installed on isolator and could be isolate from this one by a switch bar. At least the measured resistance of IE shall not exceed 1 ohm. ii. Protection earthing (PE) Protection earthing system (mechanical earth) shall be used for protection of personnel using grounding insulated wire colour Y/G All mechanical portion like supports, cable trays, frame junction boxes support, cabinet, frame support cabinets, etc… shall be connected to the PE. At least the measured resistance of PE shall not exceed 5 ohms. iii. Intrinsically safe earthing (ISE) As a general rule all instruments installed in hazardous area shall be intrinsically safe and connected to the ISE system at only one point, located in the Instrument Control Room at the bottom of each marshalling cabinet using grounding insulated wire colour Blue. At least the measured resistance of ISE shall not exceed 1 ohm.
7
INSPECTION
8
FIELD TESTING AND CALIBRATION
9
MARKING
9.1 Manufacturer Nameplate
All instruments will be supplied with a manufacturer’s nameplate. The nameplate shall be made of stainless steel (SS316) or other weather-resistant equivalent material and will be permanently attached to the equipment with stainless steel screws or clips (316). The following information, at a minimum, should appear:
• • • • •
Manufacturer’s Name Item/Model Number Manufacturer’s Serial Number Instrument tag number Further information applying to specific items such as, hazardous area certification, range, materials, pressure rating etc., shall be added during the detail engineering.
In addition, each instrument shall be provided with a stainless-steel tag plate which shall be fixed to the instrument with a stainless-steel wire. This plate shall be marked with the instrument tag number. The minimum text size will be 6 mm.
9.2
Junction Boxes
Each junction box, will be equipped with a label on which will appear its tag.
This Traffolyte label will be permanently attached to the front panel with stainless steel screws or clips (316SS) for outdoor equipment and plastic screws for indoor equipment.
This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent
INSTRUMENT GENERAL SPECIFICATION
REALISATION EN EPC
D’INSTALLATIONS DE PRODUCTION DE
LINEAR-ALKYL-BENZENE <
TCM IDENTIFICATION CODE
4439-KK-SG-000000001
SHEET 61 / 61
ISSUE 2
The text of the Traffolyte labels will be black on a white background with a text height of 10 mm on 2 lines maximum for the DCS/PLC. The size of the labels is 120mmx30mmx5mm. The text of the Traffolyte labels will be black on a red background with a text height of 10 mm on 2 lines maximum for ESD and F & G. The size of the labels is 120mmx30mmx5mm.
Example:
Additional nameplate shall be added for I.S. Junction boxes with following text: «THIS JB CONTAINS INTRINSICALLY SAFE CIRCUITS». The text of the Traffolyte labels will be white on a blue background. For further information please refer to: Junction Box Specification 4439-KK-SE-362001001.
9.3 Cabinets And Panels
Name Plate for Cabinets shall be as per document 4439-JK-SE-00000000601 Control and Instrumentation Cabinets Specification.
9.4 Cables
Each cable shall be equipped with a label. On each of its ends will appear its tag. Cables located outdoor will be equipped with a metal tag. Indoor the cable labels shall be plastic.
9.5 Labelling System
The installer will be responsible for submitting for approval by the CONTRACTOR Method, Components, Features and Labelling System.
9.6 Terminal
Each terminal block will be equipped with a label on which will appear its tag. This Traffolyte tag shall be attached just above the terminals.
9.7 Colors of the Cables
Please refer to document: 4439-KK-SE-352001001 Data Sheet for Signal/Special/Fiber Optic Instrumentation Cable.
This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent
Project: Q-32976 - Tecnmont SKIKDA Folder: Reference Documents