Instrumentation General Procedure-Installation

PROYEK PEMASANGAN LINE CO2, N2, SYNGAS,
NATURAL GAS, AMONIAK DAN WASTE WATER

PT. PETROKIMIA GRESIK
GENERAL PROCEDURE OF INSTRUMENTATION FIELD INSTALLATION

Document No. Rev. Contract No. : 1500/TU.04.06/59/SP/2016
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GENERAL PROCEDURE
OF
INSTRUMENTATION FIELD INSTALLATION
INSTRUMENTATION GENERAL PROCEDURE

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REV. Page Date Description PRE’D REV’D APP’D

0 ALL 28-Feb-2017 Issued For Review DWG FJR NNG
Table of Contents
1. GENERAL .............................................................................................................................. 3
2. PURPOSE ............................................................................................................................... 3
3. SCOPE OF WORK ................................................................................................................. 3
4. SAFETY PRECAUTION ....................................................................................................... 3
5. INSTALLATION PROCEDURE ........................................................................................... 3


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5.1 CORIOLIS FLOW TRANSMITTER ............................................................................... 3
5.2 MAGNETIC FLOWMETER............................................................................................ 5
5.3 PRESSURE SAFETY VALVE ........................................................................................ 8
5.4 PRESSURE TRANSMITTER .......................................................................................... 9
5.5 PRESURE INDICATOR ................................................................................................ 11
5.6 DIFFERENTIAL PRESSURE TRANSMITTER .......................................................... 11
5.1 TEMPERATURE TRANSMITTER ............................................................................. 13
5.2 TEMPERATURE INDICATOR ................................................................................... 14
5.3 ORIFICE FITTING ....................................................................................................... 15


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1. GENERAL
This procedure gives general guidance for the “General Procedure Field Installation of
Instrumentation equipments” prior to Field Inspection and Testing of Instrumentation Installation
belong to PIJ’s scope for Ammonia-Urea II Project.
2. PURPOSE
This procedure is used to ensure that all the installation process instrumentation equipments are
in accordance with the construction drawing, manufacturer’s drawings and instructions.
3. SCOPE OF WORK
This procedure covers the requirements for field installation of instrumentation equipments for
Ammonia-Urea II Project.
4. SAFETY PRECAUTION
1. Unauthorized personnel must be kept away from installation work.

2. Workers take reasonable care for their own safety and that of other person who may be
affected by their act or missions at work.
3. workers should not hesitate to stop potentially dangerous activities.
4. Proper safety procedures shall be reviewed and followed before each activity listed in this
procedure. Job Safety Analysis followed by a toolbox/pre-job meeting shall be conducted prior
to any activity listed in this procedure.
5. Ensure body condition fit and wear PPE properly when working.
6. All the installation steps carried out by using a PTW (Permit to Work).

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5. INSTALLATION PROCEDURE
5.1. Coriolis Flow Transmitter
1. Mounting
1) Transmitter
Procedure
a. If desired, re-orient the transmitter on the mounting bracket.
a) Remove the junction end-cap from the junction housing.
b) Loosen each of the four cap screws (4 mm).
c) Rotate the bracket so that the transmitter is oriented as desired.
d) Tighten the cap screws, torquing to 30 to 38 in-lbs (3 to 4 N-m).
e) Replace the junction end-cap.
Figure 5-1: Components of 4-wire remote mount transmitter


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b. Attach the mounting bracket to an instrument pole.
2) Sensor
Figure 5-2: Mounting the sensor

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2. Wire the transmitter to sensor

Procedure
a. Connect the 4-wire cable to the sensor-mounted core processor
Figure 5-3: Core processor terminals
Terminal 1 (Power supply +)
Terminal 2 (Power supply -)
Terminal 3 (RS-485/A)
Terminal 4 (RS-485/B)

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b. Feed the wires from the sensor through the conduit opening on the transmitter.
c. Connect wires to the appropriate terminals on the mating connector.
Figure 5-4: Wiring path for transmitter
A. 4-wire cable
B. Transmitter conduit opening
C. Mating connector
3. Wiring The Power Supply

Procedure
a) Remove the transmitter housing cover.

b) Open the warning flap.
c) Connect the power supply wires to terminals 9 and 10.
Terminate the positive (line) wire on terminal 10 and the return (neutral) wire on
terminal 9 (see figure 5-3).

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Figure 5-5: Power supply wiring terminals
d) Ground the power supply using the equipment ground, also under the warning
flap.
4. Grounding
Procedure
1) Sensor
Check the joints in the pipeline.
 If the joints in the pipeline are ground-bonded, the sensor is automatically

grounded and no further action is necessary (unless required by local code).
 If the joints in the pipeline are not grounded, connect a ground wire to the
grounding screw located on the sensor electronics.
2) Transmitter

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Ground via the piping, if possible (see sensor grounding). If grounding via the piping is
not possible, ground according to applicable local standards using the transmitter’s
internal or external ground screw.
Figure 5-6: Transmitter internal grounding screw
Figure 5-7: Transmitter external grounding screw


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5.2. MAGNETIC FLOW METER
1. Mounting
a) Mount the flowmeter so that the flow direction of the fluid to be measured is in line
with the direction of the arrow mark on the flowmeter.
Figure 5-8: Mounting the flowmeter
2. Wiring
a) Sensor Wiring
Connect wire to the sensor as shown on the Figure 5-9

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Figure 5-9: Sensor cable connections
b) Transmitter Wiring
Connect wire to the transmitter as shown on the Figure 5-10
Figure 5-10: Current Output Wiring


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c) Wiring the power supply

Connect wire to the transmitter as shown on the Figure 5-11
Figure 5-11: Power supply wiring
5.3. PRESSURE SAFETY VALVE
1. Mount SRVs in a vertical (upright) position (in accordance with API RP 530). Installing
a safety relief valve in any position other than vertical (±1 degree) will adversely affect
its operation as a result of the induced misalignment of moving parts.
2. A stop valve may be placed between the pressure vessel and its relief valve only as
permitted by code regulations. If a stop valve is located between the pressure vessel
and SRV, the stop valve port area should equal or exceed the nominal internal area
associated with the pipe size of the SRV inlet. The pressure drop from the vessel to
the SRV shall not exceed three (3) percent of the valve’s set pressure, when ﬂowing
at full capacity.
3. The threaded inlet and outlet ports and sealing faces of the valve and all connecting
piping must be free from dirt, sediment and scale.

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4. In the case of screwed/portable valves, use caution to avoid unscrewing bonnet from
the base; if a pipe wrench is used to install or remove the base, ensure that the
wrench is placed on the ﬂats of the base and not on the bonnet. If the bonnet/ base
joint is broken, the valve should be retested to ensure proper set pressure and
function of the valve.
5. Position SRVs for easy access and/or removal so that servicing can be properly
performed. Ensure suffcient working space is provided around and above the valve.
5.4. PRESSURE TRANSMITTER
1. Mount The Transmitter
Procedure
a) Process flange orientation

Mount the process flanges with sufficient clearance for process connections. For
safety reasons, place the drain/vent valves so the process fluid is directed away
from possible human contact when the vents are used. In addition, consider the
need for a testing or calibration input.
b) Housing rotation
 Loosen the housing rotation set screw using a -in. hex wrench.
 Turn the housing left or right up to 180° from its original position. Over rotating
will damage the transmitter.
 Retighten the housing rotation set screw.


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Figure 5-12: Housing rotation
c) Terminal side of electronics housing

Mount the transmitter so the terminal side is accessible. Clearance of 0.75 in. (19
mm) is required for cover removal. Use a conduit plug in the unused conduit
opening.
d) Circuit side of electronics housing

Provide Three inches of clearance is required for cover removal.
e) Mounting bracket
Figure 5-13: 3051T pipe mounting configuration


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Dimensions are in inches (millimeters)
Figure 5-14: Wiring pair and ground


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5.5. PRESSURE INDICATOR
1. Tightening of gauge
Torque should never be applied to the gauge case. Instead, an open end or
adjustable wrench should always be used on the wrench flats of the gauge socket to
tighten the gauge into the fitting or pipe. NPT threads require the use of a suitable
thread sealant, such as pipe dope or teflon tape, and must be tightened very securely
to ensure a leak tight seal.
2. Process isolation
A shut-off valve should be installed between the gauge and the process in order to be
able to isolate the gauge for inspection or replacement without shutting down the
process.
3. Surface mounting
Also known as wall mounting. Gauges should be kept free of piping strains. The
gauge case mounting feet, if applicable, will ensure clearance between the pressure
relieving back and the mounting surface.
5.6. DIFFERENTIAL PRESSURE TRANSMITTER
Procedure
a) Process flange orientation

Mount the process flanges with sufficient clearance for process connections. For
safety reasons, place the drain/vent valves so the process fluid is directed away
from possible human contact when the vents are used. In addition, consider the
need for a testing or calibration input.

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b) Housing rotation
 Loosen the housing rotation set screw using a -in. hex wrench.
 Turn the housing left or right up to 180° from its original position. Over rotating
will damage the transmitter.
 Retighten the housing rotation set screw.
Figure 5-15: Housing rotation
c) Terminal side of electronics housing

Mount the transmitter so the terminal side is accessible. Clearance of 0.75 in. (19
mm) is required for cover removal. Use a conduit plug in the unused conduit
opening.
d) Circuit side of electronics housing
Provide Three inches of clearance is required for cover removal.
e) Mounting bracket
Figure 5-16: 3051C pipe mounting configuration


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Dimensions are in inches (millimeters)
Figure 5-17: Wiring pair and ground
5.7. TEMPERATURE TRANSMITTER


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a) Mount the thermowell to the pipe or the process container wall. Install and tighten
thermowells and sensors then apply pressure and perform a leak check before
starting the process.
b) Attach a connection head to the thermowell.
c) Insert the sensor into the thermowell and wire it to the connection head, using the
wiring diagram located on the inside of the connection head.
d) Mount the transmitter to a 2-inch (50 mm) pipe or a suitable panel using one of the
optional mounting brackets. The B4 bracket is shown in Figure 5-10.
e) Attach cable glands to the shielded cable running from the connection head to the
transmitter conduit entry.
f) Run the shielded cable from the opposite conduit entry on the transmitter back to
the control room.
g) Insert the shielded cable leads through the cable entries into the connection head
and the transmitter. Connect and tighten the cable glands.
h) Connect the shielded cable leads to the connection head terminals, located inside
of the connection head, and the sensor wiring terminals, located inside of the
transmitter housing. Avoid contact with the leads and the terminals.
Figure 5-18: Typical Remote Mounted Configuration with Cable Glands


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2. Wiring
Figure 5-19: Transmitter terminal block & sensor wiring configuration for 3-wire
5.8. TEMPERATURE INDICATOR


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1. Locate the stem so that at least two inches will be subjected to the average
temperature to be measured. Exposing the stem to a temperature in excess of the
highest dial reading should be avoided.
2. The thermometer is normally provided with a threaded connection. To tighten the
thermometer to the apparatus or into the well, use an open-end wrench applied to the
hexagon head of the threaded connection.Turn until reasonably tight, then tighten still
further in the same manner as a pipe elbow or similar pipe fitting until the scale is in
the desired position for reading.
5.9. ORIFICE FITTING
1. Preliminary Steps
Before installing the fitting into the line, clean piping of all foreign material such as
welding chips, scale, oil, grease, and dirt.
Remove all foreign matter such as scale, oil, grease, and dirt from the fitting line
connections and internal cavities of the fitting that may have collected during the time
of final factory inspection and line installation.
2. Orifice Fitting Installation
a) Before installing the meter tube containing the Orifice Fitting, clean the meter tube
interior as well as the piping sections where the fitting meter tube will be installed.
Remove all foreign materials such as welding debris, scale, oil, grease or dirt.
b) Select and install the proper gaskets and tighten all bolting to insure
gasket seating and tightness.
c) After the meter tube is in place and all connections are made, the meter tube
containing the Orifice Fitting should be pressure tested.
d) Tighten fitting clamping bar screws securely.
e) Pressure test the line containing the meter tube with Orifice Fitting using an
appropriate test procedure. NOTE: No orifice plate should be in the fitting during
testing.

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f) Check the entire assembly for leaks.

Instrumentation General Procedure-Installation

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PROYEK PEMASANGAN LINE CO2, N2, SYNGAS,

NATURAL GAS, AMONIAK DAN WASTE WATER

GENERAL PROCEDURE OF INSTRUMENTATION FIELD INSTALLATION

INSTRUMENTATION GENERAL PROCEDURE

REV. Page Date Description PRE’D REV’D APP’D

3. SCOPE OF WORK ................................................................................................................. 3

4. SAFETY PRECAUTION ....................................................................................................... 3

5. INSTALLATION PROCEDURE ........................................................................................... 3

INSTRUMENTATION GENERAL PROCEDURE

5.1 CORIOLIS FLOW TRANSMITTER ............................................................................... 3

5.2 MAGNETIC FLOWMETER............................................................................................ 5

5.3 PRESSURE SAFETY VALVE ........................................................................................ 8

5.4 PRESSURE TRANSMITTER .......................................................................................... 9

5.5 PRESURE INDICATOR ................................................................................................ 11

5.6 DIFFERENTIAL PRESSURE TRANSMITTER .......................................................... 11

5.1 TEMPERATURE TRANSMITTER ............................................................................. 13

5.2 TEMPERATURE INDICATOR ................................................................................... 14

5.3 ORIFICE FITTING ....................................................................................................... 15

INSTRUMENTATION GENERAL PROCEDURE

1. Unauthorized personnel must be kept away from installation work.

INSTRUMENTATION GENERAL PROCEDURE

5.1. Coriolis Flow Transmitter

Figure 5-1: Components of 4-wire remote mount transmitter

INSTRUMENTATION GENERAL PROCEDURE

b. Attach the mounting bracket to an instrument pole.

INSTRUMENTATION GENERAL PROCEDURE

2. Wire the transmitter to sensor

Terminal 1 (Power supply +)

Terminal 2 (Power supply -)

INSTRUMENTATION GENERAL PROCEDURE

Figure 5-4: Wiring path for transmitter

3. Wiring The Power Supply

a) Remove the transmitter housing cover.

INSTRUMENTATION GENERAL PROCEDURE

Figure 5-5: Power supply wiring terminals

 If the joints in the pipeline are ground-bonded, the sensor is automatically

INSTRUMENTATION GENERAL PROCEDURE

Figure 5-6: Transmitter internal grounding screw

Figure 5-7: Transmitter external grounding screw

INSTRUMENTATION GENERAL PROCEDURE

5.2. MAGNETIC FLOW METER

Figure 5-8: Mounting the flowmeter

INSTRUMENTATION GENERAL PROCEDURE

Figure 5-9: Sensor cable connections

Figure 5-10: Current Output Wiring

INSTRUMENTATION GENERAL PROCEDURE

c) Wiring the power supply

Figure 5-11: Power supply wiring

5.3. PRESSURE SAFETY VALVE

INSTRUMENTATION GENERAL PROCEDURE

5.4. PRESSURE TRANSMITTER

1. Mount The Transmitter

a) Process flange orientation

 Retighten the housing rotation set screw.

INSTRUMENTATION GENERAL PROCEDURE

Figure 5-12: Housing rotation

c) Terminal side of electronics housing

d) Circuit side of electronics housing

Figure 5-13: 3051T pipe mounting configuration

INSTRUMENTATION GENERAL PROCEDURE

Dimensions are in inches (millimeters)

2. Wiring The Power Supply

Figure 5-14: Wiring pair and ground

INSTRUMENTATION GENERAL PROCEDURE