Instrumentation Specification

O
OWNER :
LORDEGAN UTILITY
U
AN
ND OFFSIT
TE
DETAIL
L ENGINEE
ERING
Lordega
an
UREA FERTILIIZER CO. (PUBLIC STOCK)
P
Project No.:
CO
OVER SHEET
T
D
DOC. NO.: 1333-ESS-00-IN-076
P
Page 1 of 63
Project No.: 1333

1
Rev. 0
DOCUME
ENT TITLE:
ENG
GINEER
RING STANDARD
D SPEC
CIFICA
ATION
N
OR
FO
IN
NSTRU
UMEN
NTION OF MECHA
ANICAL
L
EQ
QUIPM
MENT PACKA
P
AGES
The docu
ument is co
ompletely ad
dapt from the original document Nu
umber 2103-ESS-00-IN--001, REV.1,
ISSUED DATE 26.08
8.2008
25.06.2015
FOR AP
PPROVAL
D.G. LI
L.L.. LIU
T.Y. HU
REV.
DATE
DESC
CRIPTION
DES
S.
CHKD.
AP
PPR.
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LORDEGAN
PETROCHEMICAL
COMPANY
Hampa Energy
Engineering & Design Company
Project No.:
TITLE
Project No.:
INSTRUMENTATION OF
MECHANICAL EQUIPMENT PACKAGES
2103
DOC. NO.: 2103-ESS-00-IN-001
Rev.
REVISION INDEX SHEET

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PETROCHEMICAL
COMPANY
Project No.:
TITLE
2103
INSTRUMENTATION OF
GENERAL
DOC. NO.: 2103-ESS-00-IN-001
Rev.
6
1.1
SCOPE
1.2
CODES AND STANDARDS
1.3
GENERAL DESIGN
10
1.4
INSTRUMENT NUMBERING STRUCTURE
11
1.5
UNITS OF MEASUREMENT
13
1.6
SELECTION OF RANGES
14
1.7
ACCURACY
16
1.8
INSTRUMENT MATERIAL
17
1.9
INSTRUMENT CONNECTIONS
17
1.10
PROTECTION REQUIREMENTS
19
1.11
UTILITIES
20
1.12
MARKING
20
1.13
CERTIFICATION
21
1.14
TRANSMITTERS
21
1.15
SITE CONDITION
21
FLOW INSTRUMENTS
22
2.1
ORIFICE PLATES AND FLANGES
22
2.2
POSITIVE DISPLACEMENT METER
23
2.3
VARIABLE AREA FLOWMETER
23
2.4
TURBINE FLOWMETER
24
3
3.1
LEVEL INSTRUMENTS
GENERAL
24
24
PRESSURE INSTRUMENTS
25
4.1
PRESSURE INDICATOR
25
4.2
DRAFT GAUGES
26
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2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
4.3
PRESSURE TRANSMITTER
27
4.4
PRESSURE SWITCH
27
TEMPERATURE INSTRUMENTS
28
5.1
TEMPERATURE INDICATOR
28
5.2
THERMOCOUPLE
28
5.3
RESISTANCE TEMPERATURE DETECTOR
29
5.4
THERMOWELL
29
5.5
TEMPERATURE TRANSMITTER
29
CONTROL VALVES AND RELIEVING DEVICES
30
6.1
CONTROL VALVES
30
6.2
PRESSURE RELIEVING DEVICES
33
ANALYTICAL INSTRUMENTS
33
7.1
GENERAL
33
7.2
SAMPLE TAPPING
34
CONSTRUCTION AND INSTALLATION
35
8.1
DESIGN AND CONSTRUCTION OF CABLES
35
8.2
CABLING AND INSTALLATION OF CABLES
37
8.3
JUNCTION BOXES
38
8.4
GROUNDING
38
8.5
AIR SUPPLY SYSTEM
39
8.6
INSTRUMENT PROCESS PIPING
39
8.7
INSTALLATION OF INSTRUMENTS
39
8.8
INSTRUMENT ACCESSIBILITY
40
8.9
INSTRUMENT ELECTRICAL CONNECTION
41
EQUIPMENT PROTECTION & MONITORING SYSTEM
42
9.1
CODES AND STANDARDS
42
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LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
9.2
GOVERNING SYSTEM
42
9.3
MACHINE MONITORING SYSTEM.
43
9.4
OVERSPEED SHUTDOWN SYSTEM
45
9.5
FIRED HEATER FLAME MANAGMENT
46
10
PLC SPECIFICATION
47
10.1
SYSTEM DESIGN BASIS
47
10.2
SYSTEM HARDWARE REQUIREMENTS
48
10.3
PROCESSOR
49
10.4
CABINETS AND CABLING
53
10.5
SOFTWARE / FUNCTIONAL REQUIREMENTS
57
10.6
ENGINEERING TOOLS
59
10.7
SPARE CAPACITIES / SPARE PARTS
59
11
FACTORY ACCEPTANCE TEST
61
12.
SITE ACCEPT TEST (SAT)
62
13
TRAINING
63
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1.1
1.1.1
1.2
1.2.1
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
GENERAL
SCOPE
The purpose of this specification is to define qualitatively the general requirements for
mechanical packages instruments, protective devices and control system for LORDEGAN
AMMONIA & UREA PROJECT.
CODES AND STANDARDS
The following codes, regulation and standards shall be used where applicable.
Differential Pressure Flow Measuring Elements
- ISO 2714
- ISO 2715
- ISO 6551
Liquid hydrocarbons Volumetric measurement by

displacement meter systems other than dispensing
pumps.
Liquid hydrocarbons Volumetric measurement by
turbine meter systems.
Petroleum liquid and gases Fidelity and security of
dynamic measurement cabled transmission of electric
and/or electronic data.
- ISO5167
Section 1,2,3 and 4
- BSI 1042
Section 2.2 : methods of measurement of velocity at one

point of a conduit of circular cross section measurement of
fluid flow in closed conduits
- BSI 1042
Section 1.2 : specification for square edged orifice plates

and nozzles & other orifice plates and board inlets
- BSI 1042
Section 1.4 : guide to use of devices specified in section

1.1 and 1.2 : measurement of fluid flow in closed conduits
- BSI 1042
- ASME B16.36
Section 2.3 : methods of flow measurement in swirling or

asymmetric flow conditions circular ducts measurement of
fluid flow in closed conduits
Orifice Flanges
- ASME B16.5
Pipe flanges and flanged fittings
- ASME B1.20.1
Pipe threads, general purpose (inch)
- ISA RP 16.1, 2, 3
Terminology, dimensions and safety practices for

indicating variable area meters (rotameters, glass tube,
metal tube, extension type glass tube)
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- API MPMS 3.1 section A
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Standard practice for the manual gauging of petroleum

and petroleum products.
ELECTRICAL
- API 500
- IEC 34.5
For hazardous area classification

Degree of ingress protection
Cenelec-50014 to 50020 & 50039 or ATEX (for explosion protection)

- IEC-60529
Degrees of protection provided by enclosures (IP code)
- API RP 505
Recommended practice for classification of locations for

electrical installations at petroleum facilities classified as
class i, zone 0, zone 1, and zone 2
- IEC 60079_14
Electrical apparatus for explosive gas atmospheres Part

14: electrical installation in hazardous areas ( other than
mines )
- BSI 5308
Part 1: instrumentation cables
- ISA-RP 60.8
Electrical guide for control center
- ISA-RP-12.6
(Installation of Intrinsically Safe Instrument Systems in

Class 1 Hazard locations)
- ANSI/ISA RP 12.06.01-1995
- (R2002)
Wiring practices for hazardous locations instrumentation

Part I: Intrinsic safety
- IEC 61285
-IEC 60297-1
Industrial-process control - safety of analyzer houses

Dimensions of mechanical structures of the 482.6 mm (19
in) series. Part 1: Panels and racks
CONTROL VALVES
- ANSI / ISA 75.01.01
Flow equations for sizing control valves
- ANSI/ISA S 75.02
Control valve capacity test procedure
- ANSI / ISA 75.19

- FCI 70.2
Hydrostatic testing of control valves

Control valve seal leakage
ANSI/ISA 75.08.01-2002
Face-to-face dimensions for flanged globe-style control

valve bodies: ANSI classes 125, 150, 250, 300 & 600
- ANSI/ISA 75.04
Face-to-face dimensions for flangeless control valves
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- NAMUR
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
- ANSI B 1.20.1
For proximity switch mounting and solenoid valve

connection
Pipe Thread
- ANSI B 16.5
Pipe Flange & Flange Fitting
- ANSI B 16.47 series B
Large Diameter Steel Flanges
- ANSI B 46.1
Flange Face & Finishing
- ANSI B 16.10
Face to Face & End to End Dimensions of Valves
THERMOCOUPLE/RTD
- IEC 584 parts 1-3
Thermocouples
- IEC 751
Industrial platinum resistance thermometer sensors
INSTRUMENT AND CONTROL SYSTEMS

-
API-RP 550 through 555
INSTRUMENT SYMBOLS
- ANSI/ISA S 5.1
Instrumentation symbols and identification
- ISA S 5.3
Graphic symbols for distributed control/shared display

instrumentation, logic and computer systems
CONTROLLERS/PLC
- IEC 61131-1
programmable controllers - part 1: general information
- IEC 61131-2
programmable controllers
requirements and tests
- IEC 61131-3
programmable
languages
- IEC 61131-4
programmable controllers - part 4: user guidelines
- IEC 61131-5
programmable controllers - part 5: communications
- IEC 61131-7
programmable controllers - part 7: fuzzy control

programming
programmable controllers - part 8: guidelines for the
application and implementation of programming languages
- IEC 61131-8
- ISA 85.2
controllers
part
part
2:
3:
equipment
programming
For process operation

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2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
OPENNESS
- OPC DA 2.0 and A & E1
BATCH PROCESS CONTROL
- ISA S 88.01
SAFETY
- IEC-61508
Functional safety of electrical/electronic/programmable

electronic safety-related systems
COMPUTER OPERATING SYSTEM

- MS Windows (Latest proven revision)
INSTRUMENT PROCESS (IMPULSE) PIPING
- ASME B 31.3
Process piping
- ASME B16.5
- ASME B1.20.1
- ASME B 46.1
surface texture (surface roughness, waviness, and lay)
- API 58
Recommended practices for testing sand used in gravel

packing operations
MATERIAL
- ASTM
American Society of Testing & Material
- ASME B 31.3
Process piping
- NACE MR 01-75
- MSS SP-55
(Wetted parts in sour services)

Quality assurance standards for valves, flanges and fitting
steel casting.
RELIEF VALVES
- ASME
Unfired pressure vessel code section VIII division I parts

UG-125 through UG-136 and division 2, part AR
- ASME
Boiler and pressure vessel code P-269 through P-290
- API 2000
Venting atmospheric & low-pressure storage tanks nonPage 9 of 63
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Project No.:
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2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
refrigerated & refrigerated

- API RP 520-1
Sizing, selection, and installation of pressure-relieving

devices in refineries: part I
sizing and selection
- API RP 520-2
Recommended practice 520: sizing, selection, and

installation of pressure-relieving devices in refineries-part
II, installation
- API 526
Flanged steel pressure relief valves
- API 527
Seat tightness of pressure relief valves
ALARM SEQUENCES
- ISA S 18.1
Annunciator sequences and specifications
BOILER
NFPA 85
1.3
GENERAL DESIGN
1.3.1
The instrument design philosophy shall facilitate operation and maintenance activities. The
design shall provide adequate features to handle the specified design conditions and all
predictable occurrences resulting from process upsets, operational failures, weather, or
interruption of utilities.
1.3.2
The following concepts should be adopted into the design of the package:
- Instrumentation systems shall include high quality control loops.
- Where possible, standardization of instrument should be implemented, as it will result in a
smaller variety of items to be purchased, installed and maintained. The standardization
shall cover, as a minimum the instrument section (e.g. sizes, materials, manufacturers
etc), instrument installation and hook-ups (e.g. sizes, connections, tubing and fittings etc.),
instrument cables and junction box (e.g. types, sizes etc.).
- Use of instruments which are less susceptible to failures and have the capability to
implement an automatic functional test.
- Use of smart/intelligent instruments, which have remote accessibility and can provide
document, useful information for maintenance and operation. (e.g. zero point calibration,
range calibration, remote diagnostic, etc.)
1.3.3
Field instruments for control and monitoring the package shall be 4-20 mA HART protocol as
far as commercially available.
1.3.4
Fail Safe Philosophy shall be adopted (Contacts open/De-energized to shut-down).

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2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
1.3.5
Solenoid valves in instrument air services shall be normally energized (de-energized by shut
down command)
1.3.6
The instrumentation shall be rated to withstand the local ambient conditions.
1.3.7
Pneumatic control signal is not allowed except for the actuation of final control element.
1.3.8
All instruments exposed to direct sunlight shall be protected with sunshade.
1.3.9
Field instruments shall generally be supplied from 24VDC supply from control system.
1.3.10 Instruments installed in classified area shall be selected in according with CENELEC code
requirements. Electronic transmitters in hazardous area shall be basically intrinsic safe.
Where intrinsically safe instruments are not commercially available, explosionproof
instruments may be used.
1.3.11 All electrical and electronic instruments shall be supplied with threaded electrical connection
of M20x1.5.
1.3.12 All instruments shall be supplied with nameplates indicating tag no., type, model no., serial
no., calibration range, type of protection, material of construction, certifying authority.
1.3.13 Procedure for instrumentation painting shall be as manufacturers standard.
1.3.14 The solenoid valves shall be 24VDC Eexi.
1.4
INSTRUMENT NUMBERING STRUCTURE
1.4.1
Project Instrument Tag Number Designation

Standards listed below shall be consulted in the following precedence
P&ID Diagram Legend
Instrument society of America
ISA-S5.1
Instrument society of America
ISA-S5.3
Basic package P&IDs will be followed for tag numbering as general.
1.4.2
Project Instrument Component Identification

This section gives an in-sight into the numbering philosophy, for all components such as
Cabinets, Cables etc. which will be mounted in the plant.
1.4.2.1 Cabinet Identification System

The cabinet shall be identified according to its service
FCS
PLC
Fieldbus Control System

Programmable Logic Controller
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Project No.:
MMS
BMS
IC
MC
PDC
INSTRUMENTATION OF
2103
LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Machine Monitoring System

Burner Management System
Instrument Cabinets
Marshalling Cabinets
Power Distribution Cabinet
1.4.2.2 Junction Box Identification System:

Junction Boxes shall be identified according to the Unit where they are installed.
J.B. numbering to be as follows:
JB
XX
-XX
X XX
ab
a: Represents the type of signals from IS or NIS point of view. I for IS and N for
NIS.
b: Represent the type of cables as follows:
I:
Miliampere
K:
Thermocouple K type
E:
Thermocouple E type
J:
Thermocouple J type
S:
Thermocouple S type
T:
Thermocouple T type
D:
Discrete
V:
Solenoid
R:
RTD
P:
Power
X:
Proximity switch
Z:
Special
HW: Data High Way
H1: FF H1 Hub
HSE: HSE Hub
L:
Serial Link
c: Represent the unit key number from section 1.2.2.
d: Represent the sequential number beginning from 001
e: Represent the destination of cable as follows:
E:
N:
S:
For ESD JB
For N ESD JB
For Safety JB
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Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
1.4.2.3 Multi-Core Cable Identification System

Multi-core cables shall be identified according to the junction box numbering.
1.4.2.4 Single Cable Identification System
Single cables shall be identified according to the instrument tag number.
Suffix for loops with more than one instrument with the same function (e.g. split range valves
A and B) to be added where necessary.
1.4.2.5 Cable Drum Coding and Numbering
Cable drum shall be coded and numbered in accordance with the following:
I
XX
a
b
a: I (as Instrument)
XXX
c
b: Cable codes as specified in cable MTO codes.

c: sequential NO. beginning from 001
1.5
UNITS OF MEASUREMENT
1.5.1
Process variable units shall be as listed in the table 1.1.

Liquid
(Volume
)
Flow
Gas
Level
Pressure
Temperatur
e
Other Units
Steam
%, mm
Gauge
Absolute
Vacuum
Different
ial
m3/h
Nm3/h
(@ 0 C, 1.013
bara)
Kg/h, t/h
See note below

See note below
barg, mbarg
bara
bara, mbara
Bar, mbar, mmH2O
C
Density
Kg/m3
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Project No.:
2103
Viscosity
Rotation
Velocity
Power
Voltage
Current
Concent
ration
Conducti
vity
Weight
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
cp
rpm
m/s
kw
V
A
mol%, ppm
s/m
kg
Note: In case flow transmitter provides mass flow measurement, like coriolis type,
kg/h is used instead
1.5.2
Scales of measurements shall be as follows:

TABLE 1.2
Local Indicator
Scale
Flow
0-100 / linear
Pressure
barg / linear
Low press. or vac.
mbar / linear
Temperature
C / linear
Level-Percentage
0-100% / linear
Note: Square root shall be extracted in transmitters.
1.6
SELECTION OF RANGES
1.6.1
General
Unless otherwise specified, the instrument ranges shall be selected such that the normal
operation value is normally between 50% and 75% of the range. The maximum value should
be less than 90% of the range in general.
For flow measurement by means of pressure differential devices, the maximum range should
be selected so that the normal operation value represents between 60 % and 80%.
The minimum flow should not be less than 10% of the range.
For level measurement, normal level should be positioned at 50% of the range as far as
possible.
1.6.2
Standard Range
As far as practical, the following standard range shall be used:
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INSTRUMENTATION OF
2103
LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-001
Rev.
D/P Transmitter for Flow:

500 mm H2O
750 mmH2O
1000 mmH2O
1250 mmH2O
2500 mmH2O (preferred range)
5000 mmH2O
6250 mmH2O
10000 mmH2O
15000mm H2O
Displacer LT :
356 mm (14)
813 mm (32)
1219 mm (48)
Other on special application
D/P Transmitter for Level
As required
Gauge Glass
Manufacturers standard ranges, however, the center to center of
nozzles should be in accordance with quantity of glasses (size 8).
Level Switch
356 mm (center to center of nozzles)
Temperature Gauge/Switch
-50 to 50 deg C
-50 to 100 deg C
0 to 60 deg C
0 to 100 deg C
0 to 160 deg C
0 to 200 deg C
0 to 300 deg C
0 to 400 deg C
0 to 600 deg C
0 to 800 deg C
0 to 1200 deg C
0 to 1400 deg C
Temperature Transmitter
Manufacturers standard ranges
Pressure Instrument/Gauge
-1 to 1 bar (g)
-1 to 1.5 bar (g)
-1 to 3 bar (g)
-1 to 4 bar (g)
0 to 0.6 bar (g)
0 to 1.0 bar (g)
0 to 16 bar (g)
0 to 25 bar (g)
0 to 40 bar (g)
0 to 60 bar (g)
0 to 100 bar (g)
0 to 160 bar (g)
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Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
0 to 1.6 bar (g)

0 to 2.5 bar (g)
0 to 4.0 bar (g)
0 to 6.0 bar (g)
0 to 10 bar (g)
DOC. NO.: 2103-ESS-00-IN-001
Rev.
0 to 250 bar (g)

0 to 600 bar (g)
Draft Gauges
-10 mbar to 0 mbar
-3 mbar to 3 mbar
-20 mbar to 0 mbar
-1 mbar to 10 mbar
-40 mbar to 0 mbar
-50 mbar to 50 mbar
0 to 10 mbar
0 to 20 mbar
0 to 50 mmH2O
Pressure Transmitter/ Switch
As required
1.7
ACCURACY
1.7.1
Instrument accuracy shall conform to the following table.

TABLE 1.3
INSTRUMENT
Orifice plates and venturi tubes> 50%
measuring range
Local Digital Indicator
D.P. Transmitter
Pressure Transmitter
P.D Flowmeter for fiscal services
P.D Flowmeter
Turbine Flowmeter
Turbine Flowmeter for fiscal services
Annubar
Rotameters
Rotameters with PTFE lining
Rotameter for purging
Mass Flowmeter
Electromagnetic Flowmeter
Displacer type Level Transmitter
Radar Level Instrument
Thermocouple
Resistance Temperature Detector
Pressure Gauge
Bimetallic Thermometer
ACCURACY
1.5% FS
1 digit
0.1% FS
0.1% FS
0.15% FS
0. 25% FS
0.25% FS
0.15% FS
1% FS
1.6% at 100% flow
2.5% at 100% flow
4% at 100% flow
0.2 % mv
1 % FS
0.5 % FS
1 mm
IEC-60584
IEC751 (Class A)
1% FS (Flanged 2.5%)
1% FS
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INSTRUMENTATION OF
2103
LORDEGAN
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Temperature Transmitters
I/P Transducers
A/D or D/A Converters
Liquid Expansion Thermometer
Electric indicators
DOC. NO.: 2103-ESS-00-IN-001
Rev.
0.1 % FS
0.6% FS
0.2% FS
1% FS
0.5% FS
1.8
INSTRUMENT MATERIAL
1.8.1
Standard generally applicable to the material of different parts of instruments is ASTM.
1.8.2
Wetted parts of all instruments including sensing elements shall be minimum Stainless
Steels 316 and in sour services shall be in accordance with NACE MR 01-75 except where
the process condition requires other materials.
1.8.3
Movement (linkages, etc.) for instruments shall be stainless steel.
1.8.4
The material of components that come into contact with process fluid shall be selected to be
resistant to stress resulting from pressure, temperature, corrosion, etc. and shall further be
compatible with the piping material with regard to welding or other methods of connection/
joint.
1.8.5
Electronic printed circuit boards shall be troplicalized and coated with suitable material
against corrosive or conductive dust wherever required.
1.9
INSTRUMENT CONNECTIONS
1.9.1
The following standards apply to the different kind of instrument connections to the pipe or
equipment:
1.9.2
- ASME B16.5
- ASME B1.20.1
Connections of instruments shall be as listed in the table 1.4:
Type of Instruments
) Equipment
/pipe
connection
First
block
valve
Instrument
connection
Instrument
on
block connection
valve /Nipple
Notes
) Part 1: Connection on equipment

) Pressure
) Pressure gauge
) 1 1/2"
nozzle
3/4"
3/4" NPTM
1/2" NPTF
(1)
) Diaphragm gauge
) 2" nozzle
2"
2" flanged
(2)
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) Pressure transmitter
LORDEGAN
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COMPANY
1 1/2"
nozzle
DOC. NO.: 2103-ESS-00-IN-001
Rev.
3/4"
3/4" NPTM
1/2" NPTF
) Flanged pressure
transmitter
) 2" nozzle
2"
2" flanged
2" flanged
(2)
) Diaphragm sealed
pressure transmitter
) 2" nozzle
2"
2" flanged
(2)
) 1 1/2"
nozzle
1 1/2"
flanged
) Level indicator
) 1 1/2"
nozzle
3/4"
3/4"
flanged
3/4"
flanged
) Level switch (External

float and side mounted)
) 1 1/2"
nozzle
1 1/2"
1 1/2"
flanged
1 1/2"
flanged
3/4"
3/4" NPTF
1/2" NPTM
(1)
) Diaphragm sealed level

) 2" nozzle
transmitter (Drum, Tower,
Vessel)
2"
2" flanged
(2)
) Diaphragm sealed level

) 3" Nozzle
transmitter (Storage Tank)
3"
3" flanged
) Displacer level transmitter

(External)
2"
2" flanged
2" flanged
) Temperature
) Thermowell
) Level
) DP level transmitter
1 1/2"
nozzle
2" nozzle
) Level transmitter
(Internal float and
displacer)
) 4" nozzle
4" flanged
) Part 2: Connection on piping

) Pressure
) Pressure gauge
) 3/4" nozzle
3/4"
3/4" NPTM
1/2" NPTF
(1)
) Diaphragm gauge
) 2" nozzle
2"
2" flanged
(2)
3/4" nozzle
3/4"
3/4" NPTM
1/2" NPTF
(1)
) 1/2" nozzle
1/2"
1/2" NPTM
1/2" NPTF
(1)
) Pressure transmitter
) DP transmitter for orifice
flange
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) Flanged pressure
transmitter
INSTRUMENTATION OF
2103
) 2" nozzle
2"
2" nozzle
2"
) Diaphragm sealed
pressure transmitter
LORDEGAN
PETROCHEMICAL
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DOC. NO.: 2103-ESS-00-IN-001
2" flanged
Rev.
2" flanged
(2)
2" flanged
(2)
) Orifice tap
) 1/2" NPT
1/2"
1/2"NPTM
1/2"NPTF
) Analyzer tap-Liquid
(Prob Type)
) 1 1/2"
nozzle
3/4"
flanged
3/4"
flanged
) Analyzer tap-Gas
(Sample Type)
1 1/2"
nozzle
3/4"
3/4" NPTF
3/4" NPTF
) Annubar flow element
1 1/2"
nozzle
1 1/2"
flanged
1 1/2"
flanged
) 1 1/2"
nozzle
1 1/2"
flanged
(1)
) Temperature
) Thermowell
Notes:
1) Manifold shall be female on both sides.
2) Instrument accuracy could required 3" connection (if required), a swage adaptor will be provided.
1.10 PROTECTION REQUIREMENTS

1.10.1 General
1.10.1.1 In general for Zone 0, 1 and 2, intrinsically safe design shall be considered for hazard
protection.
1.10.1.2 For Zone 1 and Zone 2 flameproof instrument may be used if intrinsically safe instrument
is not available due to project restrictions.
1.10.1.3 Junction boxes will be increased safety.
1.10.1.4 Instrument installations shall be in accordance with the table 1.5.
TABLE 1.5
MINIMUM DEGREE OF PROTECTION
Outdoor
panels
Instruments
ZONE 0
ZONE 1
ZONE 2
Not allowed
Exd , Exp
Exd , Exp
Exi
Exi, Exd
Exi, Exd
UNCLASSIFIE
D
Industrial
IP54
Industrial
IP65
1.10.1.5 Gas groups and temperature class shall not differ for each process unit and shall be of
highest degree determined from the area classification drawings.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
1.10.1.6 All the relevant instruments would have to be individually certified by any one of the
following recognized testing authorities and certificates will be provided to employer as per
item 1.13.2 (Ex-proof certification).
1.10.2 Weather Protection:
1.10.2.1 Applicable codes to Weather protection of the instruments are as follows:
- IEC-60529
Degrees of protection provided by enclosures (IP code)
1.10.2.2 All equipments shall be furnished with all necessary weather and antifreeze protection to
prevent damage due to climate or from the plant atmosphere. (if required).
1.10.2.3Field instruments shall be damp and dust proof, with the minimum type of protection being
IP65.
1.11
UTILITIES
The following electrical power supply and instrument air supply shall be applied to the
appropriate instruments for design purposes.
The control voltage for instrument shall be as follows:
Electrical Energy
110 VAC / 50 Hz
24 VDC
230 VAC / 50 Hz
Voltage supply with battery back-up via UPS.

Voltage supply
For instrument cabinet lighting/receptacles
The air supply for pneumatic instrument shall be as follows:

Design pressure
10.5 barg
Temperature
ambient
Normal pressure
7 barg
Minimum pressure at device
5 barg
Dew point
-37C at 7.5 BAR G
1.12
MARKING
1.12.1 All instrumentation equipment shall be provided with permanent identification of the
instrument tag number. Nameplates for field-mounted instruments shall be stainless steel.
1.12.2 Terminal strips shall be furnished with the terminal markers. Wire markers shall be installed
on the wires inside panels and junction boxes at their termination point. Cable markers shall
be installed to identify field cables inside panels and junction boxes.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
CERTIFICATION
Shop inspection, mill test and other QC certification shall be provided in accordance with
Shop Inspection Requirement (SIR).
1.13.1 Material Certification

The pressure containing part of in-line instruments shall be provided with material
certification in accordance with the requirements stipulated in Piping Material Specification.
1.13.2 Ex-Proof Certification
All electrical or electronic instruments or devices for use in hazardous areas shall be certified
and approved for the installation location by an internationally recognized authority:
Comite European de normalization Electro technique (CENELEC) Europe
British Approval Service for Electrical Equipment in
UK
Flammable Atmosphere (BASSEFA)
Centro Elettrotecnica Sperimentale Italian (CESI)
Italy
Physikalische Technische Bundesanstalt (PTB)
FRG
Technical Recommendation of the Research Institute
Japan
of Industrial Safety Japan (RIIS)
Laboratories Central des Industries Electriques (LCIE)
France
Factory Mutual (FM)
USA
Underwriters Laboratories (UL)
USA
1.14
TRANSMITTERS
1.14.1 All signals shall be routed to vendors PLC/BMS including analogue signals for continuous
control and/or related to duty control module of the package if control system requested in
the requisition.
1.14.2 The transmitters shall generally be provided with integral indicators and be furnished with
test terminals and bypass diode to facilitate field-testing without disconnection of integral
indicator.
1.14.3 Pressure & pressure differential pressure transmitters, except for transmitters furnished with
diaphragm seals, shall be provided with close-coupled 3-way valve manifolds. For piped
drain and vent 5-way valve to be provided.
1.14.4 All process wetted parts of pressure transmitters and differential pressure transmitters
including manifolds shall be type 316 stainless steel or better. Other materials shall be used
as required by the process conditions.
1.15
SITE CONDITION
Field instruments and control equipments shall be suitable and designed for the following
climatic and environmental conditions:
Ambient temperature:
Minimum temperature:
-27c
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Maximum temperature:
Maximum temperature for
Equipment exposed tosunlight:
Rev.
+44c
+80c
Humidity:
Design:
71%
Barometric pressure:
Use 840 mbar for design.
Plant elevation:
Plant is located at 1840m above sea level.
Due to presence of Ammonia vapors, in the surrounding atmosphere, the use of copper or
copper alloy is not allowed.
FLOW INSTRUMENTS
This section covers the minimum requirements for primary flow elements and transmitters.
2.1
ORIFICE PLATES AND FLANGES
2.1.1
Orifice plates shall generally be used for flow measurement in lines except in the following
circumstances:
a)
b)
c)
d)
e)
Where accuracy required is higher than normally obtained from an orifice plate.
Where wide variations in flow rate occur.
Where system allowable pressure drop is very small.
Where measuring highly viscous liquids and slurries. (low Reynolds No.)
Where piping layouts prevent the use of adequate straight lengths.
2.1.2
The minimum pipe size for an orifice shall be 1 1/2. For pipe size below 1 1/2 special
calibrated meter run shall be considered.
2.1.3
Orifice plates shall be installed in tapped orifice flanges.
2.1.4
Orifice bores shall be calculated by using the formula based on ISO-5167 or BSI-1042.
2.1.5
For orifice plates metering range shall be selected such that normal flow rate produces a
differential pressure of approximately 70% of the design value (preferably 2500 mmH2O).
2.1.6
Drain holes or weep holes where specified on the individual datasheet for concentric orifices
shall be provided at the top of the plate on all liquid services and at the bottom of the plate
for steam and gas applications. The drain hole or weep hole may be excluded from the
orifice bore calculation.
2.1.7
Each plate shall be provided with a tab which projects beyond the flange. The tag number,
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
plate material, the actual measured bore and the ID of the pipe shall be stamped on the inlet
side of this tab. The tab shall be in line with the drain or weep hole and shall indicate the
direction of flow (inlet).
2.1.8
Plate material shall be S.S. 316 or superior material as demanded by process conditions.
2.1.9
Orifice flanges shall be in accordance with ASME B16.36.
2.2
POSITIVE DISPLACEMENT METERS
2.2.1
Positive displacement flow meters shall be used as per P&ID.
2.2.2
Installation of positive displacement meters for liquid services shall be arranged to ensure
continuous flooding of the meter and shall include a strainer with indication of differential
pressure and upstream drain of the meter. Careful consideration shall be given to bearing
type, lubrication and protection against abrasive materials.
2.2.3
Body material and rating shall be in accordance with the piping material specification.
2.2.4
The amplifier and converter shall be signal line powered. Otherwise, the available power
supply is 110 V AC, 50 Hz.
2.3
VARIABLE AREA FLOW METERS
2.3.1
Variable area flowmeters shall be selected such that process minimum and maximum flow to
be between 10% and 95% of the measuring range offered by the instrument and normal flow
rate shall be between 60%-80% of capacity.
2.3.2
Variable area flow meters shall be of metal tube type (normally S.S.316)
2.3.3
Glass tube type meters may be used for the following services:
a)
Air, water and inert gas at pressure below 3 barg.
b)
Analyzer sampling line and all other similar services.
2.3.4
Purge Rotameter shall be supplied complete with the needle valve.
2.3.5
Metal tube type meters shall have magnetic coupling mechanism for float position detection.
2.3.6
Process connections of meters shall be bottom-top. (Exception: Instrument service,

Analyzer)
2.3.7
Rotameters shall always be mounted in vertical positions and in such a way that strain or
stress caused by the weight of the unsupported lines or by thermal expansion is kept to a
minimum.
2.3.8
Connection shall be flange type in principle. But threaded connection may also be used for
1/2 line sizes and below.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
2.3.9.
Sight glasses may be used only for lubricating oil, sealing and cooling water.
2.4
TURBINE FLOW METER
2.4.1
All turbine meters shall be designed to cover maximum operating flow rate considering the
turn down ratio.
2.4.2
Strainers with the suitable mesh size, material and rating shall be installed preceding each
meter.
2.4.3
Measurement of pulsating flow is difficult and should be avoided. This type of measurement
is not dependable and the pulsing may contribute to premature wear of the mechanical
parts.
LEVEL INSTRUMENTS
3.1
General
Generally, for remote transmission or local control on process units, differential-pressure
level instruments should be considered as the first choice, with displacer type level
instruments as the second choice. However, displacement-type instruments of external
type with side-side connections and rotatable heads should normally be used for
interface level measurements.
The standard ranges of displacer type level instruments are 356, 813 and 1219, 1524,
1828 mm.
Level switches should be float type, externally mounted.
Other types of level sensors like ultrasonic, capacitance, thermal dispersion, radioactive,
microwave, conductivity and tank gauges may be required to meet particular service
conditions.
Gauge glasses shall be armored type and cover the operating ranges of all associate
level instruments the reflex gauge glasses shall be used on all clean service
applications, whereas the transparent gauge glasses shall be used for following services
with protective shield of glasses as required:
- Fluids containing acid and caustic
-Fluids containing dirty (dark colored) liquids
-High pressure steam applications
-Liquid-Liquid interface services
In services where internal lining is required or fluid is toxic, use of magnetic gauges may be
considered.
Gauge glasses shall normally be provided with standard angle gauge valves containing ball
checks, a 1/2" drain valve and a 1/2" NPT blind vent plug.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Level instruments rating shall follow pipe/vessel pressure rating.

Visible length of level gauge shall cover the operating range of all level instruments.
For vessels with both alarm and shut-down devices, the visible range of the gauge shall
cover these points.
Magnetic type level gauges shall be used in general as local level gauge.
For services below 0C, transparent gauges with non-frost extensions and integral
illumination could be used.
Gauge glasses shall be connected as close as possible to the vessel, with the minimum
number of fittings.
The damage pressure of armored-type gauge glasses shall be at least 150% higher than the
maximum process pressure of the vessel.
Special problems such as high temperature and choking services shall be considered
individually and the most suitable type shall be specified.
Maximum length of each gauge instrument normally shall be limited to about 2500 mm, if
greater distance is to be covered, several instruments with minimum overlapping of about 50
mm shall be considered.
Level switch mechanism shall be two wire snap acting, SPDT, hermetically sealed.
Switches without mechanically actuated components shall preferably be used.
Level switches shall normally be of external float type. In high pressure and high
temperature services displacer level switches may be used.
Process connection of level switches shall be side-side unless technically not possible.
Every level transmitter with displacer chamber shall have drain valves. Vent nozzles are
closed with plug. In exceptional cases (in accordance with the P&ID), permanently mounted
valves may be used according to the piping specification, and if required with drain lines for
safe discharge.
Stilling wells shall be provided for all level instruments with internal displacers to prevent
damage to the displacer and faulty operation of the instruments.
PRESSURE INSTRUMENTS
4.1
PRESSURE INDICATOR
4.1.1
The selection of a pressure measurement shall correspond to the required accuracy,

measuring range, availability and measuring duty.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
4.1.2
Diaphragm, bellows or capsule type pressure gauges may be used for the low pressure
service. Diaphragms are normally more durable and repeatable and consequently are
preferable to bellows for low ranges.
4.1.3
Pressure gauge case sizes shall generally be 100 mm and connection shall be 1/2 NPTM
except those which specified in accordance with installation location. The SS 3way, 2valve
manifold shall be furnished.
4.1.4
All gauges shall be equipped with slot screw adjustment for calibration purposes.
4.1.5
Pressure ranges will be such that the normal pressure will be in the middle third of the span.
Gauge ranges shall normally be specified for not less than 1.2 times the relief valve setting.
Special cases, such as vacuum unit, will be considered individually.
4.1.6
Pressure elements shall have an overrange protection of at least 1.3 times the maximum
range of the instrument. Elements in vacuum service shall be capable of withstanding full
vacuum regardless of range, without shifting calibrations.
4.1.7
Whenever more than 120% overrange is predicted, external overrange protection shall be
provided.
4.1.8
Blow-out device shall be fitted for all gauges. Gauges measuring absolute pressure shall
have compensation for barometric pressure changes.
4.1.9
Oil filled type pressure gauges to be specified for vibration services such as compressors or
other rotating machines.
4.1.10 Pulsation dampener shall be furnished for all pressure gauges on the discharge of
reciprocating pumps and the suction and discharge of reciprocating compressors and
pulsating services.
4.1.11 Pulsation dampeners shall be externally adjustable type.
4.1.12 Pulsation dampeners shall have 1/2 NPT female connections on instrument side and 1/2
NPT male on process side. Body material shall normally be 316 Stainless Steel.
4.1.13 Gauges employing sealing chambers and sealing fluids for protection against chemical
attack shall be labeled with the name of the sealing fluid.
4.1.14 Syphon shall be provided on hot water or steam services, when operating temperature
exceeds 120C.
4.1.15 Gauge syphon assembly is preferable to "pig-tail" syphon.
4.2
DRAFT GAUGES
4.2.1
Draft gauges shall be provided for the fired heaters, draft measurement. (As per P&ID
requirements)
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
4.2.2
Draft gauges shall be o-ring type and grouped into the manifold system for stream selection.
4.2.3
Draft gauges shall be flush mounting type.
4.2.4
Elements shall be diaphragm type or equal.
4.2.5
Bezel glass shall be provided for draft gauges protection.
4.3
PRESSURE TRANSMITTER
4.3.1
Electronic pressure transmitters shall generally be used for remote signal transmission and
should be 4-20mA with HART protocol.
4.3.2
The measuring chamber, all internals that come in to contact with the process fluid and the
bolts shall be of stainless steel or special corrosion resistant material.
4.3.3
Transmitters shall be capable to withstand 130% overrange pressure.
4.3.4
Field transmitters shall generally be with integral indicator.
4.3.5
Transmitters shall be manifold support type.
4.3.6
Pressure instruments shall be located so that the head of the liquid between the instrument
and the point of measurement does not exceed the span of the measurement.
4.4
PRESSURE SWITCH
4.4.1
Unless otherwise mentioned, the pressure sensor shall be bourdon tube or diaphragm.
4.4.2
Unless otherwise mentioned, the pressure switch shall have an over-range protection of at
least 130%.
4.4.3
The set point shall be adjustable. Vendor shall provide a locking mechanism for locking the
set point adjuster. An indicating scale shall be provided for set point adjustment and
indication of already adjusted set point.
4.4.4
Pressure switches shall have adjustable or fixed differential gap throughout the span.
4.4.5
Unless otherwise mentioned, switches shall be of the mechanical snap action micro type ,
hermetically sealed and SPDT type.
4.4.6
Switch mechanism shall be designed to minimize the effects of vibration.
4.4.7
S.S. manifold shall be furnished for switch
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
TEMPERATURE INSTRUMENTS
5.1
TEMPERATURE INDICATOR
5.1.1
Bimetallic thermometers shall generally be used wherever local temperature indication up to

500C is required. For temperatures above 500C liquid or gas expansion type thermometer
shall be provided.
5.1.2
Bimetallic thermometers shall have weatherproof dials of approximately 150mm diameter.

Scales shall be direct reading and conform to manufacturer's standard ranges as far as
possible. Dial shall be white with black scale.
5.1.3
Operating temperature of temperature indicators shall be between 50% and 75% of full
scale.
5.1.4
130% minimum overrange protection shall be specified for bimetallic thermometers.
5.1.5
Thermometers shall be provided with thermowells. Well shall fit stem to provide for
maximum heat transfer rate.
5.1.6
Movements shall be Stainless Steel. No nylon shall be used.
5.1.7
Thermometers of the filled capillary type shall be used, where bimetallic type might be
damaged by the mechanical vibration.
5.1.8
Case of Temperature indicator shall be made of S.S 304/aluminum.
5.2
THERMOCOUPLES
5.2.1
In general RTD shall be used for temperatures below 500C and thermocouple type K for
higher temperatures. Other types of thermocouples shall only be used for extremely high or
low temperatures.
5.2.2
Normally ungrounded type is used except some conditions require grounding.
5.2.3
Thermocouples shall be metal sheath ceramic filled elements.
5.2.4
For services where thermowells must be considered to be an obstacle in the process

(turbulence /clogging) skin type thermocouple may be considered. Skin type thermocouple
will be used to measure heater coil, reactor wall temperatures, as per process and licenser
specification. Skin type thermocouples will preferably be welded to the surface and as a
minimum be spring loaded or clamped. Open air skin thermocouple installations will be
insulated.
5.2.5
Connection of thermocouple to thermowell shall be through 1/2 nipple plus union.
5.2.6
If duplex type thermocouple is used, smaller wire thickness is acceptable.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
5.2.7
Thermocouple head shall have two cable entries for duplex type. Otherwise two pair
extension cable shall be used.
5.2.8
Thermocouple shall be spring loaded.
5.3
RESISTANCE TEMPERATURE DETECTORS
5.3.1
Three wire Platinum Resistance Temperature Detector with 100 resistance at 0C (PT100)
according to IEC 751 class A shall normally be used for 0-500C.
5.3.2
RTD's are normally mounted in thermowell but when very fast response time is required (5-6
seconds) they shall be designed to be used bare.
5.3.3
If the transmitter is mounted separately from the element (in the plant or control room area),
the three wire circuit shall be used for remote transmission of Pt 100 temperature signal.
5.3.4
RTD shall be spring loaded.
5.4
THERMOWELL
5.4.1
Flanged thermowells shall be used on vessels and lines with size 1.5" and the rating shall be
as per the piping specification according to ANSI B16.5, The instrument connection shall be
1/2" NPTF. In special cases welded type may be selected.
5.4.2
Material of welded type thermowell shall be according to piping material specification. As

min thermowell material shall be 316 S.S.
5.4.3
Normally drilled bar-stock thermowell shall be used. For special materials other type of
thermowell construction is acceptable.
5.4.4
To ensure compatibility, wells shall be supplied with the relevant temperature element.
5.4.5
For pipes size smaller than 4, the line shall be increased to 4" to accommodate the
thermowell. For pipes 4" and larger, thermowell shall be located directly on the pipe. The tip
of the thermowell shall be in the central third of the pipe cross section.
5.4.6
Thermowell shall be checked for vibration according to ANSI/ASME PTC 19.3 part 3. The
wake frequency shall not exceed 66% of the thermowell natural frequency.
5.5
TEMPERATURE TRANSMITTER
5.5.1
Temperature transmitters shall be 4-20mA HART protocol.
5.5.2
Smart Temperature transmitters shall be used for all signals connected to the PLC system.
The transmitters should be mounted directly on T/C or RTD connection head.
5.5.3
Temperature transmitters shall be preferably head mounted. If not possible, due to high
temperatures, the transmitter shall be installed separately.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
CONTROL VALVES AND RELIEVING DEVICES
6.1
CONTROL VALVES
6.1.1
When tight shut off is required, single seat valves with the soft seat shall be used.
6.1.2
The internal parts of the control valves, e.g. valve plug, seat ring, and valve stem with safety
pin shall normally be made of S.S.316 or better as required for service conditions. Other
materials shall be used if required by process conditions and/or the piping specifications.
6.1.3
FCI 70.2, Control Valve Seat Leakage standard shall generally be followed in the
specification of control valve. Leakage class shall be defined in datasheets as per process
requirements.
6.1.4
Valve Body
6.1.4.1 The valve body material shall be in accordance with piping specification
6.1.4.2 Body size shall normally be 1" minimum. The use of odd sizes, such as 1 1/4", 2 1/2, 3 1/2,
4 1/2, 5, 7 and 9" shall be avoided.
6.1.4.3 If process conditions require below 1 valve size, 1 body with reduced trim shall be used.
6.1.4.4 Oversized bodies with reduced trims shall be used for valves in severe flashing or cavitation
service. Angle type, multiple seat type valves or any other suitable solution may be
considered for this service.
6.1.4.5 Flange facing of the valve shall follow piping material specification.
6.1.4.6 Valve body sizes shall not be smaller than half upstream line size.
6.1.4.7 Face-to-face dimensions shall be in accordance with ISA S75.08.01 for globe valve style
control valve, ISA 75.04 for flangeless valve.
6.1.4.8 The direction of flow shall be clearly marked on the valve body.
6.1.5
Plug, Stem and Guide
6.1.5.1 Valve trim includes wetted parts of a valve body assembly, excluding the valve body, bonnet
assembly and bottom flange.(seat ring, valve plug stem, valve plug, valve plug guide, guide
bushing and cage).
6.1.5.2 Valve flow characteristics shall be as follows:
a)
Linear :
Capacity (Cv) directly proportional to valve stem travel.
b)
Equal Percentage:
A plot of valve stem travel versus capacity (Cv) shall be a

straight line function on semi-log graph paper.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Supplier's standard design.
6.1.5.3 Class VI of FCI 70.2 control valve leakage standard shall be generally followed in the
specification of the control valves.
6.1.5.4 Valve trim shall be 316 S.S (seat & plug to be hard facing) unless process conditions require
special materials.
6.1.5.4 Stellited trim shall be used for cavitating and/or flashing liquids, fluid containing solids, valve
pressure drop exceeding 10 bar & service temperature above 350 C.
6.1.6
Packing, Lubrication
6.1.6.1 The packing box shall be flange bolted to the bonnet.

6.1.6.2 For graphite and Teflon packing, no lubrication is required.
6.1.6.3 Graphite shall be use for more than 200C.
6.1.7
Valve Calculation
6.1.7.1 Required valve capacities will be referred to in terms of Cv coefficients. Cv for these
purposes will be defined as the U.S. gpm of water at 60F that the valve will pass with 1.0
psi pressure drop at rated stroke. Vendor has to give his calculation sheets indicating the
recovery factor used.
6.1.7.2 Generally valves shall be selected according to the following criteria:
- Cv value for maximum process flow is approximately 80% of the maximum controllable Cv
value for the control valve.
- Rangeability of the valve shall be such that the opening of the valve is never less than
20% of the controllable Cv value for the minimum flow through the valve.
6.1.7.3 Valve calculations shall be based on ISA S75.01.01 or IEC/DIN standards.
6.1.7.4 Noise generated by control valves shall be less than 85 dBA at 1 m distance from the valve.
6.1.8
Actuator
6.1.8.1 Valve actuators shall normally be the spring and diaphragm type. Piston, electric or electrohydraulic types may be considered in special cases where specified.
6.1.8.2 Air-operated diaphragms and springs shall be selected on a bench setting range of 0.2-1
barg. The "bench setting range" shall be specified on the control valve data plates.
6.1.8.3 Actuator stems shall have adequate strength to withstand maximum developed thrust of
actuator.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
6.1.8.4 All valves shall be equipped with a valve stem travel indicator, where so feasible.
6.1.8.5 All necessary pneumatic equipment for operation of actuators shall be provided by supplier.
6.1.8.6 Actuator shall be sized to operate assuming differential pressure of maximum upstream
pressure & atmospheric pressure (or vaccum conditions, if stated) downstream or design
pressure indicated on individual data sheet.
6.1.8.7 The control valves used for ON/OFF applications shall have a maximum stroking time of 10
seconds, unless other stroking times are required.
6.1.9
Accessories
6.1.9.1 All electric accessories (I/P, positioner,limit switch, solenoid valve, etc) shall be Eexia IIC T6.
6.1.9.2 All control valves shall be equipped with I/P positioner 4-20 mA HART protocol.
6.1.9.3 Diaphragm and Piston type actuator for proportional control generally requires the use of
valve positioner.
6.1.9.4 I/P converter shall be actuator yoke mounted.
6.1.9.5 I/P positioner shall have miniature pressure gauges for the pneumatic supply and output
signal.
6.1.9.6 Pneumatic connections shall be 1/4" NPTF to ASME B 1.20.1. If they are different, suitable
adapters shall be provided.
6.1.9.7 Generally I/P positioner shall be intrinsically safe and weather proof to IP65 as minimum.
6.1.9.8 Limit switches for on/off valves shall be hermetically sealed, inductive two wire proximity type
according to NAMUR suitable for mounting on the valve. They shall not be affected
mechanically or functionally by any vibration.
6.1.9.9 3-way direct operated solenoid valves shall normally be used to actuate control valves of
quick action or ON/OFF valves. They shall be selected from point of view of maximum air
flow rate and minimum electric power requirement.
6.1.9.10 Coils for solenoid valves shall be molded and encapsulated and specified for continuous
duty at rated voltage and frequency, with the insulation class F as a minimum.
6.1.9.11 Valve bodies and trims for solenoid valves shall be 316 S.S.
6.1.9.12 Air entry for solenoid valves shall be 1/4 or 1/2 NPTF.
6.1.9.13 For special cases, volume booster shall be considered for control valve positioners to
get fast operation as per process requirements.
6.1.9.14The coil shall be wired to a terminal block located inside the housing. Flying lead wires of
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
the coil are not acceptable.

6.1.9.15 Solenoid valve housing shall be cast aluminum and weather protection IP65.
6.1.9.16 hand wheels are required for control valves installed without block and bypass manifold.
6.1.10 Control Valve Installation
6.1.10.1
Control valve stem shall be installed vertically and be accessible from the ground or
platform. Sufficient space shall be given above and below the control valve to allow
sufficient access and clearance.
6.2
PRESSURE RELIEVING DEVICES
6.2.1
All pressure relieving devices shall be sized in strict accordance with applicable code
requirements. Formula shall be in accordance with API RP520.
6.2.2
Nomenclature used shall be in accordance with API RP520.
6.2.3
Safety and relief valves shall be direct spring loaded full nozzle construction and flange inlet
in accordance with piping specification.
6.2.4
The body material shall be in accordance with piping specifications.
6.2.5
Material and rating of pressure relief valves shall follow the piping material specification.
6.2.6
Normally commercial tightness (as expressed in API RP 527) at specified percent of set
pressure is permitted. Bubble tightness, which permits no leakage at specified percent of set
pressure, will be specified when required by process conditions.
6.2.7
Testing for tightness shall be in accordance with API RP527. In other subjects
manufacturers procedures of inspection and testing are acceptable.
6.2.8
Safety relief valves , except for thermal relief of liquid shall be full nozzle with adjustable
blow-down.
6.2.9
Balanced bellows shall be specified for variable backpressures in excess of 10% of the set
pressure.
6.2.10 All valves shall be furnished with a threaded cap over the spring-adjusting screw.
6.2.11 The safety valves shall be provided with a plain lifting lever for steam and air services and
with packed lever for hot water (over 60C) applications.
ANALYTICAL INSTRUMENTS
7.1
GENERAL
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
7.1.1
Devices using physical measuring methods shall be preferred to devices using chemical or
chemo-physical methods.
7.1.2
The analyzer sample conditioning system shall be in accordance with the vendor's
recommendations and where possible should be purchased with the analyzer.
7.1.3
It is imperative that maintenance and calibration work can be done during plant operation.
7.1.4
Electrical wiring of instruments shall confirm to IEC-331 and IEC-332.
7.1.5
For analyzers that cannot be mounted in an explosion proof box, air purging must be
required. IEC (NAMUR) should be followed. If possible, analyzer in a non hazardous area
shall be installed.
7.1.6
In general, analyzers shall be designed and constructed in accordance with API RP-550
Part-II.
7.1.7
Cylinders, used for operation of analyzers, shall be located in a well-sheltered area and
properly secured on the side of the analyzer housing. Cylinders shall not be kept inside.
7.1.8
Analyzers shall be supplied with electrical protection suitable for the area classification in
which they are installed.
7.1.9
The following should be seen in the scope of supply:

a) Any special tools/devices needed for installation and maintenance work on the
analyzer.
b) Complete calibration and standardization kits for a period of one year, consisting of
zero gas and span gas for each gas analyzer.
c) List of recommended two years operational spares for each analyzer system.
d) Commissioning spares.
7.1.10 The tubing for the analyzer systems shall be of seamless stainless steel precision type
(material no. 1.4571 or equivalent). The sizes 0.236 x 0.028 / 0.315 x 0.028 /
0.472x0.028 shall preferably be used. Corrosive fluids to be measured require that PTFE
tubes or hoses be installed. Other materials such as Monel, Haselloy, etc. shall be if
required.
7.2
SAMPLE TAPPING
7.2.1
The following factors shall be applied in designing the sampling units:

a)
b)
The analyzer unit shall be modular design so that functional groups performing
identical operations exhibit the same appearance.
Ease of operation is a prerequisite. The individual assemblies and components shall
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
be easily accessible and removable. Instruments and operation elements shall also
be freely accessible.
The component and materials shall be suitable for the intended operation and
specified rating. Said materials shall be resistant to the fluids to be handled and shall
neither deteriorate nor contaminate said fluids.
7.2.2
Sample tapping for gas samples shall be from the top of the main line.
For liquid samples, tapping shall be done from the side so that they always are flooded but
will not accumulate sludge or grit.
7.2.3
Gas and Vapor Systems

a)
The sample time lag shall be kept to a minimum.
b)
For gas samples, the pressure should be reduced at the sampling point to increase
the velocity through the sample system and reduce time lag. This pressure reducing
valve is normally included in the sampling system supplied by the instrument vendor.
Sample bypasses around the analyzers shall normally be provided. This ensures that
the sample lines are purged and it reduces the time lag of sampling. The sample bypass is either vented to atmosphere or back to a lower pressure part of the process.
Time lag shall be depending on the case.
The sample must be clean and free of particles. Additional filters, strainers and drains
maybe required. They should be specified as part of the system.
Normally, desiccants should be avoided when drying a sample stream. Chilling and
trapping the moisture is preferred. Desiccants may become spent and not functioning
or they may absorb constituents other than water.
Heat tracing or insulation of the sample line is required, if condensation of the sample
can occur at ambient conditions.
c)
d)
e)
f)
7.2.4
Liquid Systems
a)
b)
When a liquid stream must be taken to the analyzer, the sampling problem is similar
to a gas or vapor system. Filtering, pressure reduction, cooling or heating may be
required.
Liquid by-pass around the analyzer shall normally be provided to reduce sampling
lag. They shall be drained to a sewer or a lower pressure part of the process. Time
lag shall be depended on the case.
CONSTRUCTION AND INSTALLATION
8.1
DESIGN AND CONSTRUCTION OF CABLES
8.1.1
The conductor of instrument cables shall be stranded bare copper. Single pair and multi-pair
cables shall have total coverage of electrostatic shield, and 0.5mm2, 7-stranded copper
drain wire.
Individual electrostatic shield will be implemented only in analogue signal multi-pair cables.
8.1.2
The cables shall meet the requirements of IEC-331 and IEC 332.
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Rev.
8.1.3
For IS system the overall inductance and capacitance shall be within the allowable limits.
8.1.4
The insulation voltage shall be as per IEC / CENELEC code.
8.1.5
Suggested core cross sections are as follows:

1.5 mm2 for single pair or triad
0.75 mm2 for multi-pair
0.75 mm2 for Data highway (or manufacturer recommendation)
8.1.6
All cables except power cables shall be overall shielded.
8.1.7
All outdoor cables shall be steel wire armored and low smoke type, except for special cables
for which armored type may not be commercially available. In this case adequate
mechanical protection shall be provided.
8.1.8
The following multicore cables are preferred:

-2 pair (arranged in twisted pair)
-10 pairs (arranged in twisted pair)
-20 pairs (arranged in twisted pair)
-10 triads (arranged in twisted triad)
-20 triads (arranged in twisted triad)
8.1.9
A means of identifying shall be provided throughout the entire length of all cables.
8.1.10 The unscreened cables shall generally be the same as screened cables, except those points
applied to shield.
8.1.11
Following wiring color codes shall be used if the SUPPLIER does not have a standard
color coding. However, acceptance of SUPPLIERs color coding will be subjected to
PURCHASER / COMPANYs approval.
I.S. Signal
Black / White
Analog signal (non-IS)
Black / white
Digital signal (non-IS)
Black / white
Safety Earth
Green with Yellow Stripe
Instrument earth
Green
Power (AC)
brown
blue
green/yellow
+ ve
Red
Power (DC)
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- ve
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Black
Cable outer sheath color shall be:

IS instrument cables
-Flame retardant
-Light Blue
Non-IS instrument cables
-Flame retardant
-Grey
IS instrument cables (ESD)
-Fire resistant
-Light Blue
Non-IS instrument cables (ESD)
-Fire resistant
-Grey
Public Address and Telecom cables -Fire resistant
-Black / Grey
Grounding (Safety)
-Green with Yellow Stripe
Isolated Grounding (Instrument Earth)
-Green
Designation of colors shall be in accordance with IEC 60757.

8.1.12 Each cable and wiring conductor (including panel wiring) shall be clearly and indelibly
identified at both ends with closed ring shaped codings, the marking shall include at
minimum the cable number and the destination terminal and row numbers.
8.1.13 Cables from instrument to junction box & from junction box to control panel shall be
identified with instrument stainless steel tag plate close to the panel/junction
box/instrument.
8.2
CABLING AND INSTALLATION OF CABLES
8.2.1
Single-pair and triad cabling will be all overhead on perforated close cover cable tray/ladder,
open conduit.
8.2.2
Intrinsically safe instrument signals (cables) up to intrinsically safe barriers shall not be
permitted in one multi-core with signals of other types and must be kept properly segregated
all over the loop.
8.2.3
Each multi-pair cable shall have about 20% spare cores for runs between auxiliary room and
junction boxes.
8.2.4
Parallel runs, next to noise generating equipment, should be avoided. However, if parallel
runs cannot be avoided, the following minimum spacing will be maintained between power
cables and instrument signal cables:
Power Wiring
____________
400 V, 200A
6 KV, 80A
Minimum Separation
________________
910 mm (36")
1200 mm (48")
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DOC. NO.: 2103-ESS-00-IN-001
Rev.
As a general rule, a minimum of 1,500 mm (5 feet) of clearance will be allowed between

electrical noise generating equipment and a parallel run of signal carrying conductors.
Crossovers, that bring power and signal cables into close proximity, will be made at right
angles.
Instrument cables for contacts, solenoid valves, power supply for instrument, below 3 A, will
not be included in this separation rule.
8.2.5
All wires of multicore cables shall be terminated. All electrical terminals shall be marked.
8.3
JUNCTION BOXES
8.3.1
All junction boxes shall be cast aluminum or S.S and have a minimum protection of IP-65
and certified to "EExe" depending on its signal classification.
8.3.2
Entry for single pair cables to junction box to be made on sides through threaded entries and
for multi-pair cable should be from bottom.
8.3.3
The junction boxes generally should be designed to accommodate up to about 80% of its
recommended signal capacity. Where this is either not possible or impractical then there
should be at least 20% spare junction box capacity.
8.4
GROUNDING
8.4.1
The equipment energized with a power 50 VAC or 120 VDC shall be provided with earth
grounding protection against accidental contact in accordance with the applicable codes.
8.4.2
Vendor's recommendation shall be followed for design and implementation of the grounds.
8.4.3
Cable shielding shall be connected at one end (in control room) to the bonding system of the
plant. The non connected end of the shielding shall be insulated. In the field junction boxes,
the shielding of single cables / lines (e.g. of field instruments) shall be connected to shielding
of the multicore cable with the aid of the insulated connectors, said multicore cable being
linked with the bonding system in the control room.
8.4.4
The creation of earth loops in the signal screening shall be avoided. A star configuration
shall be used in which the marshaling racks will be the center.
8.4.5
The screen of the single cable shall be isolated at the field instrument transmitter or
thermocouple. The overall screen of the multicore cable shall be isolated at the junction box.
8.4.6
The Steel wire armor of all multicore cables shall be grounded in the control room safety
earth
at the marshaling rack and at the junction boxes to the plant earth.
8.4.7
Earth grounding systems will vary with the condition of the soil.
8.4.8
In general a low resistance ground connection is required when energy limiting is depend on
shunting to ground in order to prevent a large difference in potential from developing
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between circuit ground in hazardous locations.
8.5
AIR SUPPLY SYSTEM
8.5.1
Air supply to local mounted instrument shall be provided from main header serving the plant
area , having branches feeding the instrument in each section of the area.
8.5.2
Purge air for instruments shall be supplied from individual reducing regulators.
8.5.3
Instrument air header shall be galvanized carbon steel. Pipe and size of branches shall
conform to the following:
a)
1/2" for 1 to 5 taps.
b)
3/4" for 6 to 10 taps.
c)
1" for 11 to 15 taps.
d)
1 1/2" for 16 to 20 taps.
8.5.4
Each instrument shall be connected to a 1/2" galvanized line pipe and a valve at the
instrument.
8.5.5
Instrument air piping to the local individual users will be 1/4" O.D. x 0.028 wall thickness,
Stainless Steel tubing. Each user will be provided with an air set and indicator. Components
that require higher air flow rate shall be connected via precision S.S. tubes of 1/2O.D x
0.049.
8.6
INSTRUMENT PROCESS PIPING
8.6.1
The instrument tubing shall be connected to the respective piping/ vessel nozzle by means
of shut-off valves located on the pipeline or vessel side.
8.6.2
In general 1/2"x0.065 Stainless Steel tubing and compression fitting will be used.
8.6.3
For all pressure or differential pressure sensing and/or indicating installations, a block valve
shall be provided at the process side and a manifold valve at the instrument side.
8.7
INSTALLATION OF INSTRUMENTS
8.7.1
Transmitters will be mounted on 2" pipe supports. Wherever practical, instruments may be
mounted on Steel columns, masonry structure, etc.; they shall not be mounted on vibration
equipment pipelines and structures or exposed to high temperature from adjacent
equipment.
8.7.2
Instruments will be generally mounted on about 1.5 m above grade, platform or walkway.
Impulse lines shall be kept as small as possible.
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8.7.3
Locally mounted instruments, which are not available in weatherproof housing, shall be
mounted inside a weatherproof casing.
8.7.4
Orifice plates and other differential pressure producing devices shall be installed with the
minimum length of straight pipe upstream and downstream as required by ISO 5167
standards.
8.7.5
Differential pressure producing devices shall be mounted in horizontal lines. However when
this is not possible, the mounting in vertical lines may be considered. For steam and gas the
flow direction shall be downward and for liquids the flow direction shall be upward.
8.7.6
Adequate supports for externally mounted level instruments shall be provided where it is
necessary to ensure that no excess loads are transmitted to vessel connections.
8.7.7
Drain valve and plugged vent shall normally be used for external mounted displacers, float
type instruments and level gauges.
8.7.8
All pressure gauges will be installed direct on gauge valves.
8.7.9
Level transmitters even differential pressure transmitters must be installed in the

neighborhood of the level gauges to enable a good setting of these instruments.
8.8
INSTRUMENT ACCESSIBILITY
8.8.1
Control valve stems shall be accessible from the ground or platforms. Sufficient distance
shall be given above and below the control valve to allow access and clearance for
servicing. Clearance for hand-wheel operations and valve positioners shall be provided as
per vendor's drawing.
8.8.2
Connections for local pressure gauges, dial thermometers and test wells, shall be located so
that gauges will be at a visible level and test points will be readily accessible.
8.8.3
Orifices, direct-coupled differential pressure transmitters and thermocouples or RTDs, which

are located less than 3m above grade, may be accessible from portable ladders and for
above 3m, they shall be accessible from walkways, ladders or platforms.
8.8.4
Connections on vessels for gauge glasses and level instruments shall be oriented to
minimize the effect of inlet and outlet streams on the instruments.
8.8.5
Gauge glasses and level instruments shall be adjacently located and, if possible; the gauge
glass shall be visible from any valve, which controls the level in the vessel.
8.8.6
All electronic instruments in direct sunlight require sunshade.
8.8.7
Process condensate pot for special instrument hookup should be supplied.
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
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INSTRUMENT ELECTRICAL CONNECTIONS
8.9.1
All electrical instruments should be wired to the local control panel. If the local panel is not
skid mounted or is not called for in the requisition, then all instruments requiring off-skid
connections shall be wired to junction boxes at the skid edge.
8.9.2
All cabling shall be mounted on cable trays. Cable trays shall be made from hot dip
galvanized and heavy-duty design. The cable trays shall have equipotential bonding with
the base plate. Cable extensions from cable trays to equipment shall be supported and
protected against mechanical damage. The cables shall be fastened to the tray with UV
resistant ties.
8.9.3
All single and multi-pair signal cables shall have twisted pair(s) and overall screen with drain
wire. Cables for vibration, winding temperature and speed control shall have individually
screened pairs.
8.9.4
Instrument IS-signal cables shall be polyethylene(PE) and NON-IS signals shall be polyvinyl
chloride (PVC) insulated, single steel wire armored and polyvinyl chloride (PVC) outersheathed cables of rated voltages, 300/500 V, generally in accordance with BS 5308, Part
2.
8.9.5
Instrument power supply ( AC) cables shall be 2-core cross linked polyethelen (XLPE)
insulated, single steel wire armored and PVC outer sheathed cables of rated voltages
600/1000 V, generally in accordance with IEC 60502.
8.9.6
Drain wires of cable screens shall be connected to dedicated terminals in the junction
boxes or local panel. Drain wires shall be individually sleeved up to the terminals with
green plastic sleeving. Drain wires shall be cut and taped at instrument end.
8.9.7
As a general rule, the following power supplies will be available for each package unit at the
battery limit (only at one point) of the package unit. However, SUPPLIER shall clearly
indicate and commit the total power requirements for each type of power supply during the
bid stage itself.
8.9.8
110 VAC + 10%, 50 Hz + 5%, single phase, neutral isolated, from UPS. Any other voltage
namely 24 VDC requirements for package PLCs or instruments, etc shall be derived by the
SUPPLIER as part of his scope of supply within the package unit.
8.9.9
Instruments and associated equipment shall be adequately earthed. This includes

enclosures and cable armoring. A separate earth shall be provided for computer reference.
8.9.10
Inductive devices (solenoids, relay coils, etc.) operating on DC shall have suitably rated
suppression diodes connected directly across the coil.
8.9.11
Cable glands shall be applied at all places where cables enter the enclosures of
instruments, junction boxes and panels in the field.
8.9.12
Flameproof type cable glands shall be used for EExd apparatus.
8.9.13
The material of cable glands shall be nickel plated brass.

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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
EQUIPMENT PROTECTION & MONITORING SYSTEMS

Machine protection system may have the following systems as per mechanical data sheet
and API standard:
- Woodward digital governor or equivalent suitable for HP and LP valves control and turbine
over-speed protection.
- Bentley Nevada system or equivalent for vibration and axial displacement monitoring.
- Bearing temperature monitoring system.
- Over-speed protection system.
9.1
CODE AND STANDARDS

- API 612
Special Purpose Steam Turbines For Refinery Services
- API 670
Vibration, Axial Position,

Monitoring System
and Bearing
Temperature
9.2
GOVERNING SYSTEM
9.2.1
The governing system shall be included the speed governor, control mechanism, and
governor control valve(s).
9.2.2
If specified as per data sheet and API standard requirement, a dedicated digital
microprocessor-based speed governor unit shall be furnished. The unit shall be capable of
meeting or exceeding the specifications of NEMA SM 23,table 3-1,class D, with no service
exclusions.
9.2.3
The criteria for speed governor shall include but not be limited to the following:
a)
An assignable speed range corresponding to the normal range of operation (typically
70-105 percent of rated operating speed).
b)
Speed set-point adjustment.
c)
Remote process or speed set-point.
d)
Digital speed indication.
e)
Individual outputs to each control mechanism actuator.
f)
Slow roll control.
g)
Critical speed band avoidance.
h)
Manually activated override for testing the external over-speed trip system.
i)
Settings which are field changeable and protected through controlled access.
9.2.4
The speed of the turbine shall vary linearly with set-point signal. An increase in set-point
signal will increase turbine speed.
9.2.5
The failure of the speed governor shall initiate a trip.

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9.2.6
Activation of any trip device shall cause the governor-controlled valve(s) and the trip
valve(s)/combined trip and throttle valve(s) to close and initiate to non-return valve(s).
9.2.7
The trip system shall prevent opening of the trip valve(s) if the governor-controlled are not
fully closed.
9.3
MACHINE MONITORING SYSTEM
9.3.1
Vibration monitoring and switching as well as rotating machinery bearing temperature

measurement and monitoring shall be provided according to machine manufacturer
recommendations and applicable API standard as per data sheet as minimum
requirements.
9.3.2
Machine monitoring system shall be supplied by the package SUPPLIER as required for
the package machinery protection or as requested in the respective package unit
specification / requisitions.
9.3.3
MMS racks shall be installed and wired in the package Control Panels.
9.3.4
MMS shall interface the field mounted vibration probes (type to be finalized during detailed
design), key-phaser probes and temperature detector probes via the barriers to enable the
operation of field probes in the specified hazardous area.
9.3.5
All temperature inputs shall have burnout detection. The direction of the output signal upon
temperature sensor burnout shall be selectable (either upscale or downscale).
9.3.6
Both the alarm and shutdown outputs shall be annunciated in MMS / PLC on a visual
display with an audible alert signal
9.3.7
The shutdown outputs from MMS relays (based on vibration or bearing temperature
probes) shall be hard wired to separate terminals for wiring to the PLC.
9.3.8
Any main modules installed in front of the MMS racks, shall be capable of being removed
and replaced while the system is running, without affecting the operation of other unrelated
modules.
9.3.9
As far as possible, one MMS rack shall interface and monitor one equipment only. Parallel
/redundant equipment shall be interfaced to different racks.
9.3.10
In the case of equipments with less number of monitoring signals, it is permissible to install
the I/O modules of more than one equipment in one rack, provided redundant power
supplies are used for that rack.
9.3.11
Each rotating equipment train (including duty/standby) shall be terminated on separate

monitors.
9.3.12
If MMS uses a programmable relay module which can use alarm and trip signals from any
monitor channel or any combination of monitor channels in a rack, then each equipment
train shall have a separate relay module.
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9.3.13
Each rack in MMS shall be capable of accepting redundant power supply modules. Each
power supply shall have the capacity to power a fully loaded rack. Removing or inserting
an individual power supply module shall not disrupt the operation of any modules within
the rack.
9.3.14
MMS containing more than one rack, all A power supply modules shall be connected to
one feeder of UPS and all B power supply modules shall be connected to the other
feeder of UPS.
9.3.15
MMS shall be capable of interfacing to an external host computer for on-line condition
monitoring of steady state and transient machinery operating conditions. This connection
port shall be a separate and independent to the one provided for communication with FCS.
9.3.16
MMS shall have provisions for communication to plant FCS via a redundant RS-485 serial
link with MODBUS protocol or ETHERNET while hardware connection shall be used for
any input to the ESD system and control function to the FCS. The following listed signals
shall be communicated to FCS for display on HMI, as a minimum:
Channel value for each variable
Probe OK (Status) limit for each channel
Hardware and software diagnostics
Gap alarm for each channel, when applicable
Channel status of alarm or no alarm
Measured values as scaled engineering unit values or a percentage of alarm and

shutdown values to 1% resolution
Alarm and Shutdown set points
9.3.17
A Lap top PC based programming unit that communicates directly to the Machine
Monitoring System via a communication link shall be supplied.
9.3.18
Failure of programming unit including all associated communication devices shall not affect
the operation of MMS.
9.3.19
Comprehensive online electronic documentation shall be loaded onto the hard disk of the
programming unit.
9.3.20
As a minimum, programming unit software shall incorporate the following features:
Configuration must be easily understood via dialog boxes with embedded help
screens in the software.
Configure points, machine trains, machine train labels and system preferences.
Configuration templates shall be provided along with a feature to apply to multiple

points at once.
Two levels of configurable alarm level points per point.

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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
Off-line test software to check for possibility of system communication faults with a
history file recording such faults.
Windows style online Help and Glossary that is context-sensitive and has flexible
search capabilities, hypertext information and graphics. Must be printable by
selected topics.
9.3.21
The FCS could give control signals (As speed set point and etc.) to package PLC. These
signals shall be hardwired
9.4
OVERSPEED SHUTDOWN SYSTEM
9.4.1
An overspeed shutdown system, independent of the governing system, shall be provided.

The system shall prevent the turbine rotor speed from exceeding 127% of the rated speed
on an instantaneous, complete loss of coupled inertia while operating at the rated conditions.
This system consists of the following:
a)
b)
c)
Electronic overspeed circuit (speed sensors and logic device).

Electro-hydraulic solenoid valves.
Hydraulic/mechanical emergency trip valve/combined trip and throttle valve.
The turbine manufacturer shall have unit responsibility for the overspeed shutdown system.
9.4.2
Electronic Overspeed Circuit

-An overspeed shutdown system consisting of speed sensors and logic devices shall be
provided. circuits consisting of speed sensors. The minimum criteria include the following:
a)
b)
c)
d)
e)
f)
g)
h)
9.4.3
An overspeed condition sensed by either circuit shall initiate a shutdown.

Failure of a speed sensor or logic device in either circuit shall initiate an alarm only
(deenergized).
Failure of both circuits shall initiate a shutdown.
Items a,b,c require manual reset.
All setting incorporated in the overspeed circuits shall be field changeable and shall
be protected through controlled access.
Each overspeed circuit shall accept inputs from a frequency generator for verifying
the trip speed setting. A controlled access lockout shall be provided for on-line
testing.
Each overspeed circuit shall provide an output for speed readout with indicator.
The overspeed system speed sensors shall not be shared with any other system.
Electro-Hydraulic Solenoid Valves

- The turbine shall be provided with two separate electro-hydraulic solenoid-operated valves
located in the trip system. The solenoid valves shall be de-energized to trip.
- The solenoid valves and any required interposing relay shall be capable of on-line testing
without defeating trip protection.
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Note 1:
Solenoids can draw significantly high currents. Interposing relays may be used when
the current requirements of the solenoid exceed the current rating of the relay in the
overspeed shutdown system
Note 2:
The electronic over-speed shutdown system should be powered by an uninterruptable
power source.
9.5
FIRED HEATER FLAME MANAGEMENT
9.5.1
Flame monitors sensitive only to ultra violet radiation with piloting logic is necessary to be
installed and shall be used to shutdown the heater to avoid hazardous accumulation of fuel
in the firebox. Detectors to be located so that the flame can be monitored under all
conditions.(the transducer shall be installed locally in Eexd JB and the analog signal shall
be send to BMS)
9.5.2
To avoid nuisance shutdown the system alarms on loss of flame shall be generated.
Automatic shutdown occurs only when monitors indicate loss of flames.
9.5.3
To keep the lens clean, continuous purge of clean dry air must be considered for the
sighting lens to prevent becoming coated with dust or soot as well as to keep the detection
tube temperature within safe limits.
9.5.4
Fire box installation should be designed to minimize the possibility of flame failure by
providing a reliable fuel system, reliable pilots and reliable minimum by pass flow etc. The
pilot fuel supply must be from a reliable source
9.5.5
The following to be considered for flame detector installation:

- The function of a flame detector is to give an on-off signal indication that a flame is
present or not. It does not give a signal relative to flame quality or quantity.
- Adjustable time delay to be considered for flame detection.
- The mounting base should be designed so that the flame scanning angle can be adjusted
for better sighting. The detectors should be located to keep dirt from falling on the
detector lens or sight glass
- At least one alternative base for locating a flame detector to be considered.
- Flame scanners to be aimed at the intersection of the pilot and the main burner flames so
that the two scanners can prove both set of flames.
- On pressurized furnaces purge air and a gate valve to be considered for sealing in
furnace gases when a flame detector is removed.
- The system design and quality of all other components to be carefully investigated.
- A permanently installed meter to be considered for monitoring the output of each sensor
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INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
for better sensor sighting.

- Automatic self checking feature to be provided
10
PLC SPECIFICATION
10.1
SYSTEM DESIGN BASIS

The PLC shall have TV approval according to IEC-61508 with the following requirements:
- Redundant CPU.
- Redundant bus system.
- Redundant power supplies.
- Redundant communication modules and link.
- On-line loading of software (Online configuration possibility)
- On-line changing of modules (CPUs or I/Os)
NOTE:
For BMS,SIL3 approval & I/O redundancy is required too.
The PLC system shall interface directly with the following devices, but not limited to:
INPUTS:
- Analogue transmitters (4-20 mA) smart type supporting HART protocol (Transmitter
configuration/check can be done with Hand Held Communicator not with ESD EWS)
- Field contacts (Voltage free contacts, ESD 24VDC powered)
- Proximity switches
- Pushbuttons/key switches
OUTPUTS:
- Solenoid valves
- Digital outputs (1SPDT voltage free contacts)
- Contact from/to local panels
- Motor Control Center and switchgear devices
- Contact from/to package Units
Note (*): contact rating for SPDT contact shall be specified by purchaser depending on
required application (MCC, Package, etc)
DATA LINKS:
- Redundant Bi-directional communication to FCS, shall be realized with MODBUS PLUS
RTU RS-485,while hardware connection shall be used for any input/output to ESD
system.
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All I/O signals from and to hazardous area will be provided with suitable EEx protection
measures and intrinsically galvanic isolators are in vendors scope of supply. I/O signals
between. Active barriers shall be plug-in type with the terminal block on base unit.
Input signals will be in the form of potential-free contacts or proximity switches or derived
separately from analog inputs by PLC software and shall not be built inside the software of
other systems.
24 VDC will drive the EExi solenoid valves. The PLC system will distribute this energy. In the
other word the system will supply power to field input devices in two wire technique and to
external actuating devices.
For power supply distribution to barriers, etc. Miniature circuit breakers shall be used.
The system has a modular architecture which will make it possible to service parts or
components without changing the function of the remained part of the system.
The system logic shall be fail-safe, de-energized on alarm state. This implies that in the
normal
conditions, closed input sensor switches shall keep the logic outputs active providing a
closed circuit for supplying electrical power to remote devices such as solenoid valves &
relays.
Software reliability shall be considered in order to reduce effects on the overall system
reliability.
For the visualization of status and signals on FCS workstations, PLC shall be linked to the
FCS via redundant interface bus, generally implemented with MODBUS PLUS RTU protocol
based on RS-485.
Master of the communication will be the FCS (PLC slave).
Analog signals shall not change by more than 0.5% span and digital signals shall not change
status under conditions given immediately above.
Vendor will be technically evaluated based on the following qualitative aspects:
- Minimizing the use of diverse software
- Utilizing high quality software
- Minimizing software modifications /updating
Each instrument/equipment, cabinet, panel included in vendors scope of supply shall have
its own individual name and tag plates. All name and tag plates shall be designed and
supplied by the vendor. English lettering shall be used.
10.2
SYSTEM HARDWARE REQUIREMENTS

The hardware shall be included in cabinets, completely wired & connected to plug sockets
and including:
- Intrinsically safe safety barriers for inputs from proximity probes (inductive) NAMUR, fail
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safe, testable, with short circuit controlling, according to SIL 3.

- Fail safe safety barriers for inputs from mechanical contacts, testable according to SIL 3.
- Fail safe safety barriers for outputs to solenoid valves & motors testable, according to SIL
3.
- Fail safe safety barriers for field transmitter 4 20 mA output with HART protocol.
- Transmitter configuration/diagnostic shall be done with Hand Held Communicator.
- CPUs.
- Interface modules and communication cards.
- Power supplies.
Vendor shall avoid using I/O modules with built-in barriers.
System cables among PLC cabinets belong also to the delivery of the vendor.
10.3
PROCESSOR
The processors are in charge of all PLC sequences and test facilities. They shall be
operating synchronously and in parallel.
Each processor shall consist of microprocessor, memory, test circuits (if any) and necessary
communication blocks.
The processors shall be provided with both internal and external watchdog timers, to check
the program execution.
The PLC shall also be provided with internal self-checking programs, to be executed
regularly as part of the normal startup/running sequence.
The system-operating program shall be resident on EPROM memory. The central processing
unit should contain the application program in non-volatile memory.
If the application program is kept in a battery backed up memory then:
- A minimum 48 HOURS battery backup shall be provided.
- It shall be possible to replace the battery while the system is operating without losing the
contents of the memory.
- Indication of low battery power shall be provided locally by LED and remote on system
status display.
The CPU shall continuously scan the control program stored in memory, along with the
status of all inputs and execute specified commands to appropriate outputs.
In the event of a PLC processor failure, all outputs shall be de-energized. A common PLC
malfunction alarm contact shall be made available for informing to FCS of a fault in the PLC
system.
The system shall comply with above requirements, and the logic solver shall be suitably
distributed to several units accordingly.
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The system supplier shall provide calculation of program execution time based on the
estimated number of logic solvers and I/O points specified in this document.
10.3.1 CPU Hardware Security
Software password or key-lock shall be used for more level of security.
Each CPU shall provide sufficient loading capacity/memory for the initial configuration plus
30% excess for future expansion
10.3.2 CPU Status Indicators
The CPU shall continuously monitor its own status and indicate both normal operation and
error conditions via LED status indicators on each CPU module faceplate.
Vendor shall provide reliability data for the watchdog and advise how he avoids its
malfunctioning due to common mode failure.
Monitoring hardware shall be kept as simple as possible.
10.3.2.1 CPU Protection
Power line inputs to the CPU shall be protected against electrical transient.
The processors shall be mechanically and electrically isolated. Each shall provide protection
against overload current and line voltage spikes.
It shall be possible to remove any of the processors without disturbing the normal operation
of the overall system.
Upon re-installation of processor, it shall up-date its database automatically and ensures a
bump-less operation.
10.3.3 I/O Interface system
Binary inputs from hazardous areas are partly inductive contacts (fail-safe mode) and partly
mechanical contacts.
NOTE:
Vendor is requested to select proper barrier that shall meet the purchased solenoid
valve characteristics.
Digital input section shall be designed to receive input signals from field contacts that are
closed during normal conditions and will open on shutdown conditions as well as analog
input signal failure.
MCC output circuits shall be provided with protection against the switching of inductive loads
and protection against current overloads.
The I/O interface system shall connect all field -wiring signals to the safety system and shall
perform signal conversion, signal conditioning, and signal multiplexing features.
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All I/O signals from and to hazardous areas shall be provided with suitable Ex. protection
measures; as signal segregation general rule, IS circuit and terminals/raceway shall be blue.
The I/O interface shall comply with the following requirements:
- The number of different types of I/O units should be minimized.
- The I/O cards will be replaceable with the system energized (on-line) without affecting the
function of the remainder of the system.
- All I/Os shall be optically or galvanic isolated and adequately fused or short circuit
proof/negative proof.
- Indication shall be provided (by LED) on each module to show module status and power.
Input bypass facilities for each input should be provided to allow calibration, testing and
maintenance, they shall be enable via dedicated displays on the PLC engineering
workstations.
Activation of the said facilities shall be annunciated and logged at this workstation, and shall
not bypass output to signaling, VDU alarm display etc.
10.3.3.1 Digital Inputs
Some digital inputs will come from solid-state sensors (field contacts) acc. to DIN 19234
(NAMUR type). The input voltage shall be powered by PLC according to NAMUR operation
standard.
The operating voltage for digital inputs (contact inputs) shall be 24 VDC powered by the
PLC.
Each digital input module shall be individually fused with blown fuse indication or shall be
designed to be current limit / short circuit proof.
Galvanic isolating safety barrier shall be provided where required.
10.3.3.2 Digital Outputs
Contact relay output modules shall be provided to achieve output signal isolation
Each discrete output point shall be individually fused rated at the same voltage as output
module or shall be designed to be current limit / short circuit proof. The fuses shall be placed
in location readily accessible for maintenance.
All output signals shall be hard wired. Signal level shall be energized for normal and deenergized for alarm and shut down conditions.
The system output shall be connected to electrical substation by hardwired connections with
suitable interposing relays that included in electrical department duty.
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Isolation relays shall not be used for multiplication of PLC system inputs and outputs unless
they are specified to be essential for:
- Isolation of different input or output signals such as motor control circuits.
- Preventing the mixing of circuit voltage/currents.
Galvanic isolating safety barriers shall be provided where required.
10.3.3.3 Analog I/O
The PLC systems shall be capable of accepting both active and passive analog signals
directly
through an input module.
Analog signals are 4-20 mA smart type supporting HART protocol.
Analog inputs/ outputs shall be powered by the PLC system.
Galvanic isolating safety barriers shall be provided where required.
10.3.3.4 Ground Fault Detection Circuitry
A ground fault detection circuitry shall monitor floating electrical circuits in field wiring via an
alarm indicator, when resistance to earth fails.
10.3.4 Communication network
The only permitted software connection is for sending analog/ binary signals to the FCS.
10.3.4.1 FCS Interface
The PLC system shall be capable of synchronizing and Bi-directional communication with
MODBUS PLUS RTU RS-485 with plant control system.
The following parameter will be defined by package vendor and PURCHASER:
MODBUS device number (slave address)
Data flow range
Baud rate
: 19'200 preferable
Stop bit
: 1 preferable
Parity
: Even preferable
Data bits
: 8 preferable
Error checking
: CRC
Connection
: Four wire Multidrop
All communication ports shall permit connection and disconnection without interrupting
system operation of fail-safe system.
The data communication system shall be fully redundant.
Page 52 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
The vendor shall provide complete electrical and mechanical specifications, plus
manufacturer and model number for cable and fittings of the data communication system.
Data communication between FCS and PLC shall have the following characteristics:
- Redundant data bus and MODBUS interface.
- Detailed diagnostic information.
- Signal transmission with time controlled event recording.
- Transmission of data by TV certified communication protocol to avoid errors.
- Bus transmission time Safe time of process plant.
- During Loading of a new or changed software, no influence of data transmission between
PLC and FCS.
10.3.5 POWER SUPPLY
Redundant power 110 VAC 5%, 50 Hz 1% from UPS will be supplied via PDP located in
CAR by Purchaser.
System power supplies shall have galvanic isolation between input and output voltage, over
voltage protection, current limiting.
A dedicated redundant power supply unit, included in the scope of supply, shall be used to
feed power to racks of the system.
The vendor has to provide all the equipment necessary to generate the different voltage
levels needed by the PLC system. These power and distribution systems shall be full
redundant.
The vendor shall indicate the power consumption of the system (auxiliary and control room)
as well as the heat dissipation for each cabinet and engineering console.
Power supply unit status shall be indicated on its faceplate and shall be remotely
communicated via alarm contacts and software.
The system shall be designed to ensure that no incorrect command is given to the field
devices upon power on or power restore to the CPU or I/O modules.
10.4
CABINETS AND CABLING
10.4.1 Cabinet Construction

All modules and components of the PLC system shall be installed in standardized cabinets.
Construction criteria and internal equipment layout shall guarantee a high degree of safety,
reliability, accessibility and maintainability.
The cabinets shall comply with the following requirements: (RITTAL or equivalent)
Page 53 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
- Standard size shall be 2000 (2100 with plinth) mm in height, 800 mm in depth and 800 mm
Width (in comply with IEC-60297)
- Rack system design 19(max. number of 19 racks in a cabinet shall be 6).
- Removable lifting eyebolts at the top of each cabinet or section to facilitate unloading and
installation, standard belts to be provided and mounted after installation.
- Internal permanent metal drawing pocket.
-Color shall be RAL 7035.
- Protection earth termination for metallic parts (unpainted lug)
- Clamping of cables with earthing of the armors to protective earth
- Each cabinet shall be provided with an internal non-fluorescent type lamp with automatic
door switch and socket outlet.
- Access from front and rear sides with 180 door swing and door locks shall be provided.
other size shall require contractor written approval.
- The hinge joints shall be covered.
- The external sides of the cabinets shall be covered with bolted steel plates.
- The cabinets shall be provided with earth rails for grounding, separate earth rails for
intrinsic safe circuits and cable clamp rails.
- The cabinet shall be mountable on the false floor structure without additional base frame.
- The cable entries for cabinets, consoles etc. shall be from the button of the false floor
structure into the cabinet.
- A removable plate shall be incorporated at the bottom of the cabinet.
- All components of the same rating & construction that may need to be replaced shall be
interchangeable.
- The auxiliary cabinets shall be designed to prevent bucking or distortion of the cabinet
during shipment, handling & erection.
- All plug -in equipment shall be accessible and easy removable.
- A sufficient space & volume to be provided for the intake & the connection of external
cables.
- Nameplates indicating the cabinet No. shall be mounted on the top of front & rear of each
Page 54 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Hampa Energy
Project No.:
TITLE
Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
unit. Nameplates shall be of trifoliate and screwed on the cabinets.

- Each instrument that is mounted through-face of the slowing frame or mounting sheet shall
have a nameplate on the front face above or below showing the tag no.
- One nameplate shall be provided for each instrument that is installed in the auxiliary
cabinet.
- Nameplates shall be stainless steel with black lettering & with corrosion proof screws.
- The cabinets must be completely wired and connected preferably to plug in units (blocks)
- The installed circuit breakers must be provided with alarm contacts. These contacts have
to be connected in series in each cabinet for a common alarm.
10.4.2 Internal Equipment
Design door and instrumentation shall be such that the protection is IP 21 as per IEC 60529
when cabinet is closed.
Cabinets shall be provided with an internal ventilation system, in order to extract the heat
produced by electronic circuits assuring that all devices work properly in the specified
temperature range.
A temperature measuring system shall also be provided to generate an alarm signal in case
the temperature exceeds the set value.
Fan shall be suitable for continuous operation and mounted on self-lubricated bearings.
PLC and auxiliary cabinets shall be installed in an air-conditioned room.
Vendor shall state at quotation stage the working temperature limits of major components i.e.
- CPU
- I/O cards
- Safety barrier
- Interposing relays
- Power supply racks
10.4.3 Terminal
Terminal board with suitable input/ output connectors for quick interconnection will be used
to terminate single to multi-core cables coming from site or from other cabinets.
All terminal blocks shall be suitable for rail mounting with compression type conductor
termination.
The material employed shall be non-flammable type.
Page 55 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Hampa Energy
Project No.:
TITLE
Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
No more than one wire shall be connected to a single terminal block connection. For jumper
two wires together, jumper bar shall be used in the terminal blocks.
Note: Double Deck terminal is not acceptable.
Terminal blocks shall be segregated into the following types to allow quick identification of
wires:
- Discrete inputs
- Discrete outputs
- Analog inputs
- Analog outputs
- Power supply
Intrinsic safe circuits and safe circuits must be segregated in accordance with code
requirements.
All accessories for terminal installation shall be provided (blocking devices, earth bar and
strips, labeling accessories, etc,)
All terminals will be screwed terminal type for instrument side and marshaling side.
Wiring from terminals to multi-pin connectors shall be preferably soldered type.
Each terminal shall be designed according to incoming cable.
All terminal sizes shall be suitable for wires up to 2.5 mm.
10.4.4 Internal wiring
I/O and interconnecting wiring shall be tagged at each end with the identification tags. Selfadhesive type markers are not acceptable.
The cabinets shall be delivered entirely wired.
Cables enter from button, with supporting bar for clamping and armor earthing.
Cables enter through removable plates and sealed on site with compound. (if required)
Proper segregation among power lines, IS signal lines and NIS signal lines shall be made.
All cables and wires shall be installed in colored cable ducts (Blue for IS and gray for other
safe circuits).
Wiring between terminals shall be continuous runs and shall not be spliced.
Wiring carrying signals susceptible to electrical interference shall be adequately screened
and the conductors shall be uniformly twisted together to form a pair or triad.
All intrinsic safe circuits shall be terminated in accordance with the code requirements and
Page 56 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Hampa Energy
Project No.:
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
colored. Wire ways shall be blue for intrinsically safe circuits.

Partitions shall be included between wires for different voltages and required by EExi
regulations.
All wiring runs inside the cabinets shall be laid in the Polyvinyl Chloride (PVC) close slotted
ducting with a cover.
All wires inside the cabinets shall be PVC insulated wire as a minimum. The conductor shall
be stranded , plain annealed copper.
For signal wiring minimum section is 0.5 mm stranded conductors PVC insulated.
For power wiring Minimum section is 1.5 mm stranded conductor, PVC insulated.
Sufficient room shall be left inside the cabinets for easy access to the spare terminals.
The system cables used between the barrier cabinets and the system cabinets shall be
supplied by the vendor in a prefabricated form and pre-connected at the PLC vendor factory
to the respective cabinet.
Inter connecting between marshaling cabinets and system cabinets shall be done by cables
with multi-pin plugs (Elco type or equivalent) at both ends.
The wire shall be appropriately identified by means of colored insulation as follows
(preferably):
- AC Phase (P):
black
- AC Neutral (N):
blue
- DC +24 V (positive): red
- DC -24 V (negative): black
- Thermocouple:
as per IEC 60584, part 3
10.4.5 System Cables
The plug and socket system shall have mechanical coding to avoid incorrect interconnection.
The vendors standard system cables, plugs and sockets shall be used to connect all items
of hardware within the system.
10.5
SOFTWARE / FUNCTIONAL REQUIREMENTS
10.5.1 General
If specified in the requisition, one engineering / programming workstation shall be provided to
develop the control program, the diagnose system status, and if necessary, to force points
for loop check or maintenance of field sensors.
Vendor as a minimum shall provide the following software utilities/ tools or equivalent
Page 57 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
functions:
- Industry standard Function block Programming.
- High-level language.
- Boolean operators with timing and voting functions
- System diagnostics.
- Online data changes (Online configuration ability).
Different levels of password shall prevent memory programs modifications from any external
source.
The programming languages shall be in accordance with IEC 61131-3 standard. The system
shall be programmed (as simply as possible) using, functional block diagram and Sequential
function chart (SFC)
Program development software shall be capable of supporting both on-line and off-line
programming.
It shall be possible to on-line back up all system / user programs and related data.
Program editing functions shall incorporate automatic time-date and revision level file saving
routines. Methods for off-line debugging and program simulation in the development station
shall be possible.
In case of change of system components the deliverer is obliged to install free of charge new
software (if required). This matters especially for the delivery of spare parts during an agreed
period. The owner should be informed about any further development.
PLC diagnostic information shall be sent to FCS via serial communication. The minimum
required diagnostics are:
CPU fault/ alarms
All cards fault/alarms
Internal power supplies failure, etc.
HART information of sensors as much as possible.
When a PLC alarm management system is used, it shall have the following minimum alarms
requirements:
At least two levels of alarm priority (pre, trip alarm) shall be distinguished.
Alarm masking facilities shall be provided with specific access levels
Alarms logging
First-up alarm identification
Acknowledgement and reset
Page 58 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
The PLC human machine interface will be provided by means of FCS Operator Workstations
(OWS) for PLCs inside auxiliary room on the cabinet for engineering. The exception is
compressors Unit Control Panel that have its own HMI.
Dedicated Operator Graphic pages shall be developed on FCS collecting the Package PLC
data transferred to FCS via serial. In addition, all data transferred shall be made available for
representation on FCS graphic Pages.
PLC vendor shall submit the sketches of the pages to be build in FCS graphic pages for
approval.
10.6
ENGINEERING TOOLS
10.6.1 The PLC vendor must provide all the software and hardware (engineering tools) necessary to
build and modify the configuration of operator stations, and PLC control units, computers and
network interfaces and will clearly identify and describe these tools.
The list of all available hardware and software packages will be provided for appropriate
evaluation of the system.
All engineering tools must be self-documenting, all required reports prints, and drawing, etc.
must be issued by the tool to allow engineering and maintenance people to control all the
configuration and programming.
10.6.2 Engineering workstation functional requirements or laptop

The engineering workstation or laptop (if any in the cabinet or engineering room) will be
provided to allow:
- Programming of the system.
- Modification of configuration.
- Validation and down load.
- Saving of configuration on external support.
- Bypass of the inputs/outputs for maintenance purposes.
- Testing as required to ensure availability and safety integrity of the system.
- Fault diagnostics.
- Application documentation.
- Simulation and test (facilities shall be provided in workstations).
10.7
SPARE CAPACITIES / SPARE PARTS
10.7.1 Spare capacities

The following spare capacities shall be provided as Minimum:
20% spare capacity (installed spare)
10% free space (in cabinets)
25% processor spare capacity
25% transfer spare capacity on bus system links
Page 59 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Hampa Energy
Project No.:
TITLE
Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
40% in the size of configured database

40% in memory
10.7.2 Spare parts
The vendor shall provide his best estimation for the supply of spare parts for different types
of items such as cards, hardware, equipment, etc.
The spare parts shall be quoted separately and classified in two categories:
- Startup and commissioning
- Two years operation
10.7.2.1 Start Up and Commissioning
The start up spare parts shall be delivered on site with the first system delivery.
The quantities and type of spares will be specified in the requisition attachments.
10.7.2.2 Two Years Operation Spares
The vendor shall prepare a recommended spare part list for two (2) years of operation, to
maintain the plant in a satisfactory working condition over a two years period of continuous
operation after plant start-up. The above spare parts list shall mention all parts able to be
changed at site by maintenance team. The vendor shall propose repair method of failed
equipment.
The spare parts lists provided by the vendor shall indicate:
- Identifying model and/or figure number of the piece of equipment for which the spare part
is being supplied.
- Spare part number and identifying name.
- Source of the part, when the part is not manufactured by main the vendor, the original
supplier identification must be given
- Total quantity installed in the ESD
- Quantity proposed.
The final spare parts recommendations shall be shown by the vendor on a Spare Parts
Interchangeability Record (SPIR) form.
The vendor shall clarify the spare parts depot nearest to site as well as which of the
recommended spare parts are currently stocked at this depot.
The spare parts recommendation shall include all special tools, auto test facilities or special
equipment necessary for preventive maintenance and/or troubleshooting.
The vendor shall guarantee the availability of all spare parts and replacement parts required
Page 60 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
by any equipment items supplied for a minimum ten years operational period.
11
FACTORY ACCEPTANCE TEST
11.1 All items are subject to inspection by PURCHASER / COMPANY or designated

representatives.
11.2
SUPPLIER shall confirm the availability of all facilities required to perform the necessary
shop tests, in the tender.
11.3
It is prior requirement to any final inspection that the drawings be certified / approved by
PURCHASER / Certifying agency where appropriate.
11.4
SUPPLIER to complete all the internal shop tests for all items completely and provide all
the internal test reports along with the final inspection reports.
11.5
Unless otherwise specified, the Factory Acceptance Testing (FAT) of the package
equipment shall be divided in to two parts:
Package Control System FAT in the SUPPLIERs factory
Package Control System Integrated FAT in the FCS Suppliers workshop
11.6
Vendor to provide a minimum system (cpu, communication moduls, software,database,etc)

to enable a serial link communication or ETHERNET fully tested in FCS Suppliers
workshop.
11.7
SUPPLIER shall submit the FAT procedure at least 8 weeks in advance to the
PURCHASER / COMPANY for review and approval.
11.8
SUPPLIER shall notify to PURCHASER / COMPANY at least forty five (45) calendar days
in advance for each scheduled witnessed tests / inspections.
11.9
SUPPLIER shall provide adequate facilities for the PURCHASER or designated

representatives during witnessed tests / inspections.
11.10 The SUPPLIER shall provide all necessary materials in order to test and check the
performances of all instrument and / or control system supplied with the package unit.
11.11 The SUPPLIER shall allocate adequate time, facilities and assistance to permit inspection
and testing according to the Inspector request. The SUPPLIER shall provide technicians
and materials as required to make measurements and connections to the Inspector, which
deems necessary to assure that all functions and accuracy are according to specifications.
11.12 During the FAT functional test, the Inspector shall develop a "punch list" of items to be
completed before the shipping of package unit. It is the responsibility of the SUPPLIER to
complete all the punch listed items and confirm in writing to the PURCHASER for approval
before shipping.
Page 61 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Project No.:
Hampa Energy
Project No.:
TITLE
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
11.13 Any rejections made during witnessed tests / inspections shall be rectified by the supplier.
The cost of rectification and replacement of defective items reported during inspection
shall be borne by the SUPPLIER.
11.14 The inspection shall in no way release the SUPPLIER from guarantees as to materials,
apparatus, workmanship and performance of the items.
11.15 Acceptance of shop tests shall not constitute a waiver of requirements to meet field test
under specified conditions.
11.16 The SUPPLIER shall not dispatch the items until it is released by PURCHASER /
COMPANY.
11.17 All the items shall be subjected to physical and dimensional checks for conformity with the
Specification and data sheets.
11.18 The material test certificates, internal shop test reports, etc. shall be verified during
inspection.
12
SITE ACCEPTANCE TEST(SAT)

SAT shall be performed at CONTRACTORs fabrication yard.
Comprehensive and detailed SAT procedure is to be prepared and issued by the Supplier
at least two months before the start of the SAT. This procedure shall include test
procedure and acceptance criteria. This document is subject to PURCHASER review and
approval. As a minimum all functions tested during FAT shall be re-tested during SAT.
Also integrated test with the plant control systems (FCS/ESD) shall be done as part of
SAT.
Serial link communication or ETHERNET with FCS including interface sequential
application, if any, has to be fully tested during SAT.
The Supplier shall be responsible for and shall provide the technical manpower necessary
for the supervision of connections of the power cables for the system equipment, serial link
cables and the system cables to the cabinets. CONTRACTOR will terminate all incoming
cables to the cabinets (i.e. on the field side of the terminal blocks). However, the Supplier
shall be responsible for the supply of special tools, test kit and all wiring (i.e. supply, install
and terminate) within UCP cabinet.
The Supplier shall be responsible for the correct installation and hook-up of the complete
equipment. The Supplier shall then load the system and application software and shall
demonstrate the system functionality to verify system conformance with this Specification
to the satisfaction of PURCHASER.
Page 62 of 63
CONTRACTOR:
DETAIL ENGINEER :
OWNER
LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
Hampa Energy
13
Project No.:
TITLE
Project No.:
2103
LORDEGAN
PETROCHEMICAL
COMPANY
INSTRUMENTATION OF
DOC. NO.: 2103-ESS-00-IN-001
Rev.
TRAINING
The Supplier shall quote a separate cost with the Tender, for the provision of
comprehensive training courses for the control system. The proposed courses shall cover
all levels of operation, maintenance and engineering, designed for operation and
maintenance personnel. The following courses are required:
Operator training.
Maintenance training.
Engineer training.
The Supplier shall develop the training courses based on Suppliers standard syllabus,
including project specific areas. Where possible, the HMI database and systems software
shall be used together with Supplier standard hardware, set-up for the full duration of the
training period. Supplier shall submit syllabus details of the training courses for review
during tender stage.
The training course shall be conducted in English. The costs shall include provision of
training personnel, training hardware and reference documentation. The training courses
will be conducted at Suppliers offices (location shall be advised by the Supplier).
Page 63 of 63

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Project No.: 1333

DOC. NO.: 2103-ESS-00-IN-001

REVISION INDEX SHEET

DOC. NO.: 2103-ESS-00-IN-001

CODES AND STANDARDS

INSTRUMENT NUMBERING STRUCTURE

ORIFICE PLATES AND FLANGES

POSITIVE DISPLACEMENT METER

VARIABLE AREA FLOWMETER

DOC. NO.: 2103-ESS-00-IN-001

RESISTANCE TEMPERATURE DETECTOR

CONTROL VALVES AND RELIEVING DEVICES

PRESSURE RELIEVING DEVICES

CONSTRUCTION AND INSTALLATION

DESIGN AND CONSTRUCTION OF CABLES

CABLING AND INSTALLATION OF CABLES

AIR SUPPLY SYSTEM

INSTRUMENT PROCESS PIPING

INSTRUMENT ELECTRICAL CONNECTION

EQUIPMENT PROTECTION & MONITORING SYSTEM

CODES AND STANDARDS

DOC. NO.: 2103-ESS-00-IN-001

MACHINE MONITORING SYSTEM.

OVERSPEED SHUTDOWN SYSTEM

FIRED HEATER FLAME MANAGMENT

SYSTEM DESIGN BASIS

SYSTEM HARDWARE REQUIREMENTS

CABINETS AND CABLING

SOFTWARE / FUNCTIONAL REQUIREMENTS

SPARE CAPACITIES / SPARE PARTS

FACTORY ACCEPTANCE TEST

SITE ACCEPT TEST (SAT)

DOC. NO.: 2103-ESS-00-IN-001

Liquid hydrocarbons Volumetric measurement by

Section 1,2,3 and 4

Section 2.2 : methods of measurement of velocity at one

Section 1.2 : specification for square edged orifice plates

Section 1.4 : guide to use of devices specified in section

Section 2.3 : methods of flow measurement in swirling or

Pipe flanges and flanged fittings

Pipe threads, general purpose (inch)

Terminology, dimensions and safety practices for

- API MPMS 3.1 section A

DOC. NO.: 2103-ESS-00-IN-001

Standard practice for the manual gauging of petroleum

For hazardous area classification

Cenelec-50014 to 50020 & 50039 or ATEX (for explosion protection)

Degrees of protection provided by enclosures (IP code)

Recommended practice for classification of locations for

Electrical apparatus for explosive gas atmospheres Part

Part 1: instrumentation cables

Electrical guide for control center

(Installation of Intrinsically Safe Instrument Systems in

Wiring practices for hazardous locations instrumentation

Industrial-process control - safety of analyzer houses

Flow equations for sizing control valves

Control valve capacity test procedure

- ANSI / ISA 75.19

Hydrostatic testing of control valves

Face-to-face dimensions for flanged globe-style control

Face-to-face dimensions for flangeless control valves