REAFFIRMATION

June 2013

Process Industry Practices

Process Control

PIP PCSPS010
Small, General Purpose Packaged Equipment
Instrumentation Specification
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence
over this Practice. Determinations concerning fitness for purpose and particular matters
or application of the Practice to particular project or engineering situations should not
be made solely on information contained in these materials. The use of trade names
from time to time should not be viewed as an expression of preference but rather
recognized as normal usage in the trade. Other brands having the same specifications
are equally correct and may be substituted for those named. All Practices or guidelines
are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these Practices or guidelines should conflict with OSHA or
other applicable laws or regulations, such laws or regulations must be followed.
Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of

Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member
Companies and Subscribers may copy this Practice for their internal use. Changes or
modifications of any kind are not permitted within any PIP Practice without the express
written authorization of PIP. Authorized Users may attach addenda or overlays to clearly
indicate modifications or exceptions to specific sections of PIP Practices. Authorized
Users may provide their clients, suppliers and contractors with copies of the Practice
solely for Authorized Users’ purposes. These purposes include but are not limited to the
procurement process (e.g., as attachments to requests for quotation/ purchase orders or
requests for proposals/contracts) and preparation and issue of design engineering
deliverables for use on a specific project by Authorized User’s client. PIP’s copyright
notices must be clearly indicated and unequivocally incorporated in documents where an
Authorized User desires to provide any third party with copies of the Practice.

PUBLISHING HISTORY
July 2002 Issued
March 2008 Complete Revision
June 2013 Reaffirmation

Not printed with State funds

 REAFFIRMATION
June 2013

Process Industry Practices

Process Control

PIP PCSPS010
Small, General Purpose Packaged Equipment
Instrumentation Specification
Table of Contents
1. Introduction...............................................................................................2
1.1 Purpose ....................................................................................................................... 2
1.2 Scope .......................................................................................................................... 2

2. References ................................................................................................2
2.1 Process Industry Practices ......................................................................................... 2
2.2 Industry Codes and Standards ................................................................................... 2

3. Requirements............................................................................................3
3.1 Instrument Selection and Installation .......................................................................... 3
3.2 Signal Wiring and Power............................................................................................. 5
3.3 Inspection and Testing ................................................................................................ 7
3.4 Documentation ............................................................................................................ 7

Data Form
PCSPS010D – Small, General Purpose Packaged Equipment Instrumentation Data Sheet

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

1. Introduction

1.1 Purpose
This Practice provides minimum requirements for instrumentation and controls
incorporated on small, general purpose packaged equipment units.

1.2 Scope
This Practice describes the minimum requirements for the performance, design,
fabrication, testing, and inspection of instrumentation systems installed on small
general purpose packaged equipment units.
This Practice is not intended for packaged analyzers systems or for safety-
instrumented systems (SIS).

2. References
Applicable parts of the following Practices, industry codes and standards, and references shall
be considered an integral part of this Practice. The edition in effect on the date of contract
award shall be used, except as otherwise noted. Short titles are used herein where appropriate.

2.1 Process Industry Practices (PIP)

– PIP PCTPS001 - Packaged Equipment Instrumentation Inspection and Testing
Requirements Data Sheet
– PIP PCDPS001-R - Packaged Equipment Instrumentation Documentation
Requirements Sheet
2.2 Industry Codes and Standards

 American Petroleum Institute (API)

– API RP 520 - Sizing, Selection and Installation of Pressure Relieving Devices
in HydroCarbon Facilities
– API RP 576 - Inspection of Pressure Relieving Devices
– API 598 - Valve Inspection and Testing
 American Society of Mechanical Engineers (ASME)
– ASME Boiler and Pressure Vessel Code
– Section I - Rules for Construction of Power Boilers
– Section IV - Rules for Construction of Heating-Boilers
– Section VIII - Rules for construction of Pressure Vessels
 Fluid Controls Institute (FCI)
– FCI/ANSI 70-2 - Quality Control Standard for Control Valve Seat Leakage

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3. Requirements

3.1 Instrument Selection and Installation

3.1.1 All instruments shall be provided with permanently attached stainless steel
tags engraved with customers tag numbers.
3.1.2 All instruments shall be installed according to the Manufacturer's instructions
in addition to the requirements stated herein.
3.1.3 The entire instrumentation system shall be fully assembled and piped.
Comment: Some components may be removed prior to shipment.
3.1.4 All instruments shall be installed so that they are easily accessible for
operation maintenance and inspection. They shall not be located under
grating or in any place or manner that would make it difficult or dangerous
for personnel to inspect or work on them during operation or shutdown.
3.1.5 Instruments that are connected to the process shall have a primary (root)
block valve to permit safe maintenance while equipment is operating.
3.1.6 Process instruments that are not line mounted shall have a secondary
isolating valve and bleeder valve or manifold at the instrument.
3.1.7 Instrument primary (root) block valves shall be in accordance with the
applicable piping specification.
3.1.8 Instruments shall be located and installed such that accuracy and reliability
are not impaired by vibration, pulsation, temperature, or contamination.
3.1.9 Length of impulse lines connected to process pipelines or equipment shall be
minimized. Impulse lines shall be supported and protected.
3.1.10 Process transmitters shall be used preferentially to process switches (e.g., level,
flow, pressure, temperature, etc.). Use of switches shall be approved by owner.
3.1.11 Transmitter outputs shall be owner specified per the attached datasheet.
3.1.12 Nominal working pressure for transmitters shall be between 30% and 70% of
scale range.
3.1.13 Pressure instruments in steam, liquid, liquid-sealed, and condensing services
shall be located below process connections, and impulse tubing/piping shall
slope continuously down to instruments.
3.1.14 Pressure instruments in gas and vapor services shall be located above process
connections, and impulse tubing/piping shall slope continuously up to
instruments.
3.1.15 Process tubing to instrumentation shall be 1/2-inch OD minimum (outside
diameter), 316 stainless steel, with 0.049-in. minimum wall thickness.
3.1.16 Instrument supports shall be designed and installed in such a way to avoid
strain on equipment, piping connections, and instruments, and shall allow for
flexibility required for thermal expansion of equipment and piping.
3.1.17 Dips and/or sags where vapor/liquid can collect in piping and tubing runs
shall not be permitted.

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3.1.18 Piping from level gauges and external displacer-type level instruments shall
be self-draining into a vessel or standpipe.
3.1.19 Displacer chambers shall have a maximum allowable working pressure
(MAWP) and coincident temperature rating equal to or greater than that of
the associated vessel.
3.1.20 Level instrument chambers shall not have cast iron bodies.
3.1.21 Tubular glass shall not be used in process applications.
3.1.22 Instrument capillary tubing shall be armored 316 stainless steel.
3.1.23 Temperature-sensing devices shall be mounted in thermowells if exposed to
process streams.
3.1.24 Process stream temperatures shall be measured using thermocouples/RTDs.
3.1.25 RTDs shall be 3 or 4-wire, 100 ohm platinum.
3.1.26 Thermowells shall not be used for applications such as machinery bearings
(e.g., compressor bearings) and skin temperature (e.g., boiler tube)
measurement.
3.1.27 Preferred installation of a thermowell installed in piping shall be in an elbow
pointed away from the flow.
3.1.28 Automated valves installed in lines less than 1 inch (25 mm) shall use a 1 inch
(25 mm) body with reduced trim.
3.1.29 Valves in line sizes NPS 1 inch and greater shall be sized to satisfy the
process conditions.
Comment: Valve bodies are typically no less than half the pipe size.
3.1.30 Valve body sizes shall not be NPS 1-1/4 inch, NPS 2-1/2 inch, NPS 3-1/2
inch, or NPS 5 inch.
3.1.31 Automated valve bodies or regulators shall not be cast iron, brass, or bronze.
ASME Class 125 valves or ASME Class 250 flanges shall not be permitted.
3.1.32 Integral flanged-type globe valves are preferred for throttling (modulating)
services.
3.1.33 Rotary style valves may be considered where their unique qualities of high
capacity, low cost, and small size do not conflict with design requirements.
3.1.34 Throttling (modulating) valve seat leakage shall be in accordance with
FCI/ANSI 70-2.
3.1.35 Face-to-face dimensions for control valves shall be in accordance with
ANSI/ISA standards.
3.1.36 Ball or rotary valves used for on-off service shall be leak test rated per API 598.
3.1.37 Valve actuators, including springs, shall be designed to fully stroke the
valves against unbalanced forces, which can result from a pressure drop
across the valve equal to the maximum upstream pressure specified.
3.1.38 Control valves shall have positioners as specified on the datasheet. Bonnet
bolts shall not be used for attaching actuators or mounting brackets.

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3.1.39 Packing for automated valves shall meet or exceed the process conditions in
which they are installed.
3.1.40 Automated valves in volatile organic compound (VOC) services shall have
fugitive emission packing in accordance with EPA 40, CFR Part 60 and Part 63.
3.1.41 Sizing of control valves shall be based on ISA valve-sizing equations or on
sizing programs of approved valve manufacturers. In general, valves shall be
sized according to the following criteria:
a. Normal flow rates at 50% to 80% of maximum opening of the valve
b. Maximum expected flow rates less than or equal to 90% of the fully open
position
c. Minimum flow rates equal to or greater than the 10% open position and
calculated flow rates using the anticipated valve differential pressure
3.1.42 Noise emission shall not be greater than 80 dB(A) at a distance of 3 feet
(1 meter).
3.1.43 Unless otherwise approved by purchaser, solenoid valves shall not be used in
services other than instrument air.
3.1.44 Solenoid valves shall have Class H high-temperature molded coils and shall
be designed for normally energized operation.
3.1.45 Pressure relief valve application and design shall be provided and shall be in
accordance with ASME Code, Sections I, IV, or VIII as applicable;
API RP 520; and applicable local/state requirements.
3.1.46 Pressure relief valves shall be tested in accordance with API RP 576.
3.1.47 Pressure relief valves shall be accessible for inspection and maintenance.
3.1.48 Pressure relief valve discharge piping shall prevent liquid accumulation.
3.1.49 Rupture discs shall be used in combination with a pressure relief valve, but
not as a primary relief device.
3.1.50 Pneumatic control instruments shall operate with 20-100 kPa (3 to 15 psig)
input and output signals.
3.1.51 Each pneumatic instrument shall have an individual air supply complete with
shutoff valve and air set (i.e., air filter/regulator with output gauge).
3.1.52 Teflon tape for pneumatic connections shall not be used for thread sealant.

3.2 Signal Wiring and Power

3.2.1 All electrical and electronic equipment and circuits for instrumentation shall
be designed and certified for the electrical classification in which they are to
be installed.
3.2.2 Signals to and from the equipment shall be in accordance with the
purchaser’s PIP PCSPS010-D Data Sheet.
3.2.3 The entire instrumentation system shall be fully wired to junction boxes or
control panels.

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3.2.4 Wiring shall be appropriately labeled to identify the instrument to which it is

associated.
3.2.5 Junction boxes shall be located for easy access. Junction boxes shall be
provided with a name plate, with text provided by the owner.
3.2.6 Electrical power wiring (AC) shall be clearly labeled and physically
separated (e.g., separate conduit, separate terminal strips) from low-voltage
(DC) wiring.
3.2.7 Design and use of AC power greater than 120 VAC for instrumentation shall
be approved by purchaser.
3.2.8 AC and DC power wiring shall be a minimum of 14 AWG stranded copper
THHN/THWN 600-volt rated.
3.2.9 Wiring shall be permanently labeled at both ends.
3.2.10 If power distribution is provided within a local panel, fused terminals shall be
provided for individual circuit protection.
3.2.11 Single conductor panel wiring provided for AC shall be 16 AWG Type
MTW minimum size, stranded copper construction, and shall have 90°C
insulation suitable for AC circuits in accordance with NEC Article 310.13.
3.2.12 Single conductor panel wiring provided for DC shall be 18 AWG Type
MTW minimum size, stranded copper construction, and shall have 90°C
insulation suitable for DC circuits in accordance with NEC Article 310.13.
3.2.13 Wiring from junction boxes to individual instruments shall be shielded
twisted pair or triad 16 AWG minimum in conduit.
3.2.14 Use of AC receptacles shall be minimized but if required shall be the three-
wire type (i.e., hot (black), neutral (white), and ground (green)) with the
ground wire connected to ground in accordance with NEC Article 310.13.
3.2.15 Each instrument that has power supplied at 50 volts or higher shall have a
disconnecting means for removal of power source.
3.2.16 Wiring shall be designed and installed to permit the removal of any single
device without affecting any other device.
3.2.17 Wiring and conduit shall “dead-end” at each device.
3.2.18 Terminal strips in junction boxes and local panels shall have field external
connections on one side and internal panel connections on the other side. The
wiring pattern shall be consistent throughout the skid unit.
3.2.19 Control panels shall be designed to meet the conditions of the location in
which they will be mounted and operated.
3.2.20 Control panels shall be furnished with terminal blocks, terminal marking
strips, wireways and all necessary wire management devices.
3.2.21 Control panels shall be totally enclosed and provide sufficient clearance for
full internal access.
3.2.22 Opening(s) and designated space shall be provided in control panels for wire
and tubing that will be installed after package arrives at site.

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3.2.23 Field installation shall not require cutting holes in panel or installing
hardware inside the panel to secure purchaser-installed wire and tubing.
3.2.24 All panel openings shall be plugged for shipment to prevent water or dirt
from entering during shipment or storage before installation.
3.2.25 Mechanical protection of wire and cables shall be provided by use of conduit,
cable trays, or raceways.
3.2.26 Rigid conduit and piping shall not be routed over cases of rotating machinery
(or other equipment), over or in front of removable heads on vessels and
exchangers, nor where such routings would impair the functionality of
inspection openings or panel doors.
3.2.27 Drains shall be provided at low points, or drip loops with low-point drains
shall be provided to prevent water from draining down conduit systems into
an instrument or enclosure.
3.2.28 If installed outdoors, conduits shall be installed to prevent moisture (i.e.,
rainwater) from entering.
3.2.29 Liquid-tight, flexible metallic conduit shall be used at all apparatuses or
devices subject to vibration, movement for belt adjustments, operational
inspection and maintenance and may be as long as 36 inches (1 m).
3.2.30 Conduit lengths 36 inches (1 m) and greater shall be rigid.
3.2.31 Conduit seals shall not be poured by packaged equipment supplier.

3.3 Inspection and Testing

Inspection and testing of the packaged equipment instrumentation shall be performed
in accordance with PIP PCTPS001.

3.4 Documentation
3.4.1 All documentation shall be provided per PIP PCDPS001-R Packaged
Equipment Instrumentation Documentation Requirements Sheet.
3.4.2 P&ID or flow diagrams shall be provided.
3.4.3 All instruments shall be tagged with the owner’s approved non-repeating tag-
numbering system.
3.4.4 An instrument index shall be provided that includes tag number,
manufacturer and model number for all instruments.
3.4.5 Instruments that require field installation and items to be shipped loose shall
be identified on the instrument index, drawings, and packing list.
3.4.6 ISA or owner-formatted specification sheets for all instruments shall be
provided and shall include calibrated ranges of instruments, set points for
alarm and trip setting of instruments, flow meter and control valve sizing
calculations, and sizing calculations of safety relief valves including
certification sheets.
3.4.7 If specified on purchaser’s PIP PCSPS010-D Data Sheet, the packaged unit
control philosophy shall be provided with the proposal.

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PIP PCSPS010 REAFFIRMATION
Small, General Purpose Packaged Equipment Instrumentation Specification June 2013

3.4.8 If the unit controls are provided, control logic details and associated
programming shall be provided. The control logic details shall include unit
fail action in the event of an instrument or final element failure on loss of
utilities.
3.4.9 An estimate of total instrument air and instrument electric power
consumption required for both normal and upset conditions shall be
provided.
3.4.10 All field instruments and associated connections to equipment or process
lines shall be shown in the proper location on either of the following types of
drawings:
• Piping plans and elevations
• Instrument plan or location drawings
3.4.11 Drawings of local control panels shall include layout, front and rear, as well
as typical cross sections with dimensions.
3.4.12 A set of drawings depicting the mounting, process installation (including
connection to the process and the instrument), tracing (if required) and
wiring of all field instruments, shall be submitted.
3.4.13 Schematic or loop diagrams are required for all pneumatic, electrical, or
electronic instruments. Logic diagrams and elementary wiring diagrams are
required for all shutdown and interlock systems. Electrical terminal
arrangement drawings are required for all electrical devices.

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