60a1 (Reading)

C& I ENGINEERING
60A1 (READING)
C&I GENERAL FWUK OU PAGE 1 OF 58
SPECIFICATION STANDARD ENGINEERING REV 2
REVISION: ORIG.
Signature
DATE: 07 OCT 2013
ORIG. BY: T. THANGMAHASUK
APP. BY: DINKAR PATEL
CONTENTS
1.0 INTRODUCTION .................................................................................................................. 5

1.1 Purpose ............................................................................................................................ 5
1.2 Definitions ......................................................................................................................... 5
1.3 Abbreviations .................................................................................................................... 5
2.0 SCOPE ................................................................................................................................ 6
3.0 REFERENCE DOCUMENTATION ....................................................................................... 6
3.1 Engineering Specifications................................................................................................ 6
3.2 International standards ..................................................................................................... 8
4.0 GENERAL .......................................................................................................................... 10
4.1 Instrument Identification .................................................................................................. 10
4.2 Instrument Index ............................................................................................................. 10
4.3 Packaged Units .............................................................................................................. 10
4.4 Supplier List .................................................................................................................... 10
4.5 Standardisation ............................................................................................................... 10
4.6 Directives of the European Community ........................................................................... 10
5.0 GENERAL DESIGN REQUIREMENTS .............................................................................. 11
5.1 General........................................................................................................................... 11
5.2 Units of Measurement ..................................................................................................... 12
5.3 Instrument Ranges ......................................................................................................... 12
5.4 Accuracy ......................................................................................................................... 12
5.5 Accessibility .................................................................................................................... 12
5.6 Location .......................................................................................................................... 12
5.7 Instrument Connections .................................................................................................. 13
5.8 Signal Transmission ....................................................................................................... 13
5.9 Electromagnetic Compatibility Requirements .................................................................. 14
5.10 SIL Requirements ........................................................................................................... 15
5.11 Selection of Materials ..................................................................................................... 15
5.12 Instrument Database ...................................................................................................... 16
5.13 Power Supplies ............................................................................................................... 16
5.14 Earthing Systems............................................................................................................ 16
6.0 INSTRUMENTATION IN HAZARDOUS AREAS ................................................................ 18
6.1 Standards ....................................................................................................................... 18
6.2 Protection ....................................................................................................................... 18
7.0 INSTRUMENT AIR SYSTEMS ........................................................................................... 18
7.1 General........................................................................................................................... 18
7.2 Distribution...................................................................................................................... 18
8.0 DESIGN REQUIREMENTS FOR TEMPERATURE INSTRUMENTS ................................. 19
8.1 Temperature Sensing ..................................................................................................... 19
8.2 Local Indicating Thermometers ....................................................................................... 19
8.3 Thermocouples ............................................................................................................... 19
8.4 Electrical Resistance Thermometers (RTD) .................................................................... 20
8.5 Thermowells ................................................................................................................... 20
8.6 Transmitters.................................................................................................................... 20
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8.7 Infra-red Pyrometers ....................................................................................................... 21

9.0 DESIGN REQUIREMENTS FOR FLOW INSTRUMENTS .................................................. 21
9.1 Applications .................................................................................................................... 21
9.2 Orifice Plates & Other Differential Pressure Elements .................................................... 22
9.3 Metering runs for Differential Meters ............................................................................... 22
9.4 Compensation ................................................................................................................ 23
9.5 Impulse Lines and Connections. ..................................................................................... 23
9.6 Differential Pressure Flow Instruments ........................................................................... 23
9.7 Variable Area Flow Meters.............................................................................................. 23
9.8 Positive Displacement and Turbine Meters ..................................................................... 24
9.9 Magnetic Flow Meters ..................................................................................................... 24
9.10 Ultra-Sonic Flow Meters.................................................................................................. 24
9.11 Vortex Flow Meters ......................................................................................................... 25
9.12 Coriolis Flow Meters ....................................................................................................... 25
10.0 DESIGN REQUIREMENTS FOR LIQUID LEVEL INSTRUMENTS .................................... 25
10.1 General........................................................................................................................... 25
10.2 Local Indication ............................................................................................................... 26
10.3 Continuous Measurement ............................................................................................... 26
10.4 Point Level Detection ...................................................................................................... 26
10.5 Magnetic Gauges............................................................................................................ 27
10.6 Gauge Glasses ............................................................................................................... 27
10.7 Differential Pressure Level Instruments .......................................................................... 28
10.8 Diaphragm Seals (Level and Pressure) .......................................................................... 28
10.9 Guided Wave Radar ....................................................................................................... 29
10.10 Displacer Type Instruments ......................................................................................... 29
10.11 Float Type Instruments................................................................................................ 29
10.12 Radar Level Instrument ............................................................................................... 29
10.13 Capacitance Level Instruments ................................................................................... 29
11.0 DESIGN REQUIREMENTS FOR NUCLEONIC INSTRUMENTS ....................................... 30
11.1 Regulatory Requirements ............................................................................................... 30
11.2 General........................................................................................................................... 30
11.3 Measurement Device ...................................................................................................... 30
11.4 Labelling, Identification and Warning Requirements ....................................................... 31
11.5 Commissioning Requirements ........................................................................................ 31
12.0 DESIGN REQUIREMENTS FOR PRESSURE INSTRUMENTS......................................... 31
12.1 General........................................................................................................................... 31
12.2 Range Selection ............................................................................................................. 31
12.3 Local Indication ............................................................................................................... 32
12.4 Installation ...................................................................................................................... 32
12.5 Instrument Process Entries ............................................................................................. 33
12.6 Pressure Transmitters .................................................................................................... 33
13.0 DESIGN REQUIREMENTS FOR REGULATING CONTROL VALVES............................... 33
13.1 Valve Selection ............................................................................................................... 33
13.2 Valve Characteristic ........................................................................................................ 34
13.3 Valve Sizing .................................................................................................................... 35
13.4 Noise .............................................................................................................................. 35
13.5 Failure Position ............................................................................................................... 35
13.6 Valve Construction.......................................................................................................... 36
13.7 End Connections ............................................................................................................ 36
13.8 Valve Materials ............................................................................................................... 37
13.9 Actuators ........................................................................................................................ 37
13.10 Accessories ................................................................................................................. 38
13.11 Hand Wheels for Control Valves ................................................................................. 39
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13.12 Hand Operated Bypass Valves ................................................................................... 39

13.13 Block Valves ............................................................................................................... 40
13.14 Protective Coating and End Protection ........................................................................ 40
13.15 Testing ........................................................................................................................ 41
13.16 Non-Destructive Examination ...................................................................................... 41
13.17 Standards and Specifications ...................................................................................... 41
13.18 Pressure Containing Components ............................................................................... 41
14.0 MOTOR OPERATED VALVES........................................................................................... 42
14.1 General........................................................................................................................... 42
14.2 Valve Selection ............................................................................................................... 42
14.3 Actuators ........................................................................................................................ 42
15.0 SAFETY INSTRUMENTED SYSTEM VALVES .................................................................. 44
15.1 General........................................................................................................................... 44
15.2 Valve Selection ............................................................................................................... 44
15.3 Valve Body and Process Connections ............................................................................ 44
15.4 Failure Direction.............................................................................................................. 45
15.5 Firesafe Valves ............................................................................................................... 45
15.6 Actuators ........................................................................................................................ 45
15.7 Accessories .................................................................................................................... 46
15.8 Reset Facility .................................................................................................................. 46
15.9 Testing............................................................................................................................ 47
16.0 PRESSURE RELIEF VALVES ........................................................................................... 47
16.1 Selection ......................................................................................................................... 47
16.2 Sizing.............................................................................................................................. 47
16.3 Design ............................................................................................................................ 48
16.4 Installation ...................................................................................................................... 48
16.5 Application ...................................................................................................................... 48
17.0 DESIGN REQUIREMENT FOR ANALYSERS AND SAMPLING SYSTEMS ...................... 49
18.0 INSTRUMENTS IN OXYGEN SERVICES .......................................................................... 49
18.1 Guidelines for selecting materials for instruments in oxygen services ............................. 49
19.0 INSTRUMENTS IN HYDROGEN SERVICES..................................................................... 50
19.1 Risk to instrumentation and valves in Hydrogen services ................................................ 51
19.2 Valve considerations ....................................................................................................... 51
19.3 Inspection ....................................................................................................................... 52
19.4 Flange Finish for Hydrogen services ............................................................................... 52
20.0 FIRE AND GAS DETECTORS ........................................................................................... 52
20.1 General........................................................................................................................... 52
20.2 Flame Detectors ............................................................................................................. 53
21.0 DESIGN REQUIREMENTS FOR INTEGRATED CONTROL & SAFETY SYSTEM ............ 53
21.1 General........................................................................................................................... 53
21.2 Distributed Control System (DCS) .................................................................................. 54
21.3 Safety Instrumented System (SIS) .................................................................................. 54
21.4 Fire & Gas System (FGS) ............................................................................................... 55
21.5 Burner Management System .......................................................................................... 55
21.6 Machine Monitoring System (MMS) ................................................................................ 56
21.7 Compressor Control System (CCS) ................................................................................ 56
21.8 Packaged Proprietary Control and Trip System .............................................................. 56
21.9 Custody Metering System ............................................................................................... 57
22.0 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS) ............................................ 57
23.0 AMBIENT AIR MONITORING SYSTEM (AAMS) ............................................................... 57
24.0 C&I / ELECTRICAL INTERFACE ....................................................................................... 57

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This document has been substantially revised therefore changes are not highlighted. A
summary of the changes of the changes is provided on the appropriate Quality.net
webpage.

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1.0 INTRODUCTION
1.1 Purpose
This specification, together with other referenced documentations in Section 3.0
defines the minimum general requirements for the Control and Instrumentation.
1.2 Definitions
Term Definition
Contractor The party which has contractual responsibility for the design,
procurement and construction of the plant.
Supplier The Company having a purchase order with the Contractor for
the supply of specified equipment and associated services.
Client The owner of the Plant
Shall Refers to a mandatory requirement
Should Refers to a recommendation
1.3 Abbreviations
Abbreviations Description
AAMS Ambient Air Monitoring System
BEDD Basic Engineering Design Data
BMS Burner Management System
CCR Central Control Room
CCS Compressor Control System
CEMS Continuous Emission Monitoring System
CRER Control Room Equipment Room
DC Direct Current
DCS Distributed Control System
EU European Union
FGS Fire & Gas System
FMS Fiscal Metering System
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
ICSS Integrated Control and Safety System
I/O Input /Output
ISB Instrument Satellite Building
ISO International Organisation for Standardization
MCC Motor Control Centre
MMS Machine Monitoring System
MOV Motor Operated Valve
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Abbreviations Description
NPS Nominal Pipe Size
NPT National Pipe Tread
NPT(F) National Pipe Taper Female
PDP Power Distribution Panels
PED Pressure Equipment Directive
SIF Safety Instrument Function
SIS Safety Instrumented System
UPS Uninterruptible Power Supply
2.0 SCOPE
All instrumentation and system equipment shall be furnished in accordance with this
specification as well as standards and specifications referenced in Section 3.0.
The operations philosophy and extent of control and instrumentation shall be as

defined on the Project’s Piping & Instrumentation Diagrams (P&IDs), Cause & Effect
Diagrams (C&Es), Control & Shutdown Narratives, Emergency Shutdown Philosophy
and Control & Operating Philosophy.
3.0 REFERENCE DOCUMENTATION

The order of precedence of referenced documents shall be as follows:
 Statutory Laws and Regulations

 Mandatory National and Local Authority Requirements
 Plant Specific Specifications and Standards
 International Codes and Standards
Where conflicts exist between the different standards and codes, Client shall be
consulted and the most stringent apply.
3.1 Engineering Specifications

The following engineering specifications and typical drawings shall be read in
conjunction with this specification.
Document Number Title
01A1 Basic Engineering Design Data (BEDD)

50A10 Piping Material Specification
51A2 Technical Requirements for the Supply of Valves
60A2 C&I Cable Specification
60A3 C&I Symbols and Identification Specification

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Burner Management System for Fired Equipment
60A9
Specification
60A10 C&I Piping Material Specification
60A11 Safety Instrumented System Specification
60A20 C&I for Packaged Units Specification
60A22 Fire & Gas System Specification
60A23 Distributed Control System Specification
60A24 C&I Installation Specification
60A25 Process Analyser System Specification
Analyser Data Acquisition and Maintenance System
60A29
Specification
60A30 Machine Monitoring System Specification
60A31 Compressor Control System Specification
60A34 Custody Metering System – Gas Specification
60A35 Custody Metering System – Liquid Specification
60A39 Ambient Air Monitoring System Specification
60A40 Continuous Emissions Monitoring System Specification
SmartPlant Instrumentation Database (SPI)
60A42
Specification
60A43 SmatPlant Loop Templates Specification
61A1 Inspection and Testing of Electronic Control System
64A1 Control System Cabinet Specification
64A2 Field Cabinet and Enclosure Specification
64A3 Instrument Label Specification
65A1 C&I / Piping Interface Specification
66A1 C&I / Electrical Interface Specification
67A1 Protection of Instruments Specification
67A2 Instrument Bulk Material Control Questionnaire
Submission of Welding and Manufacturing Procedures
88A1
for Review
95A2 Equipment Noise Specification

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3.2 International standards

The following standards and codes of practice are applicable to this specification. The
latest published issue or amendment at the time of contract placement shall apply
unless otherwise stated.
3.2.1 American Standards and Documents

Recommended Practice for the Sizing, Selection and
API RP 520
Installation of Pressure-Relieving Systems in Refineries
Guide for Pressure Relieving and Depressurising
API RP 521
Systems
API RP 526 Flanged Steel Pressure Relief Valves
API RP 527 Seat Tightness of Pressure Relief Valves
API 598 Valve Inspection and Testing
ASME B1.20.1 Pipe Threads, General Purpose
ASME B16.5 Pipe Flanges and Flanged fittings
ASME B16.10 Face to Face and End to End Dimensions of Valves
Large Diameter Steel Flanges: NPS 26 Through NPS
ASME B16.47
60
ANSI/FCI 70-2 Control Valve Seat leakage
ASME I Power boilers
ASME VIII, Div. 1 Pressure Vessels
ASME B16.36 Orifice flanges
ASME PTC 19.3 TW-2010 Thermowells Performance Test Codes
ASME B40.100 Gauges- Pressure Indicating Dial Type, Elastic Element
BS 7430 Code of practice for Earthing
BS 7671 Requirements for Electrical Installations
Industrial thermo-processing equipment, part 1,
EN 746-1 common safety requirements for industrial thermo-
processing equipment
Industrial thermo-processing equipment, part 2, safety
EN 746-2
requirements for combustion and fuel handling systems
Explosive atmospheres – Part 30-2: Electrical
EN 60079-30-2 resistance trace heating – Application guide for design,
installation and maintenance
Electrical apparatus for use in the presence of
EN 61241-10 combustible dust. Classification of areas where
combustible dusts are or may be present
EN 837 Pressure gauges

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Code of Practice for the Selection, Installation &
IEC 60079
Maintenance of Electrical Apparatus for use in
Potentially Explosive Atmospheres.
IEC 60529 Degrees of protection provided by enclosures (IP)
IEC 60534 Industrial Process Control Valves
IEC 60584 Thermocouples
IEC 60751 Industrial platinum resistance thermometer sensors
IEC 61000 Electromagnetic Compatibility (EMC)
Safety Requirements for Electrical Equipment for
IEC 61010 Section 1
Measurement, Control and Laboratory
IEC 61158 Fieldbus Standard for use in Industrial Control Systems.
Functional Safety of Electrical/Electronic/Programmable
IEC 61508
electronic Safety-related Systems
Functional safety – Safety instrumented systems for the
IEC 61511
process industry sector
Measurement of fluid flow by means of pressure
ISO 5167-1, 2, 3, 4 differential devices, orifice plates, nozzles and venture
ISO/TR 15377 tubes inserted in circular cross-section conduits running
full
Acoustics - Determination of sound power levels and
sound energy levels of noise sources using sound
ISO 3744
pressure - Engineering methods for an essentially free
field over a reflecting plane
Materials for use in H2S- Containing Environments in
ACE MR0175
Oil and Gas
NFPA 85 Boiler and Combustion Systems Hazards Code
3.2.2 Local Standards (As applicable)
The following Local standards are applicable to this specification. The latest published
issue or amendment at the time of contract placement shall apply unless otherwise
stated.

BS 3463 Observation and Gauge Glasses for Pressure Vessels
Code of practice for instrumentation in process control
BS 6739
systems: installation design and practice
BS 6755 Testing of Valves

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4.0 GENERAL
4.1 Instrument Identification

Control & Instrumentation equipment shall be identified and numbered in accordance
with 60A3, C&I Symbols and Identification Specification.
Logic Diagrams shall be in accordance with ISA standard S5-2.
4.2 Instrument Index

An instrument index, listing all instruments shall be provided in accordance with 60A42,
SmartPlant Instrumentation Specification.
Typical loops and their associated tags that shall be used to populate the SmartPlant
Instrumentation (SPI) database shall be provided in accordance with 60A43,
SmartPlant Loop Template Specification.
4.3 Packaged Units

A package unit may comprise of a localised assembly, process section, or complete
process unit and it is intended that a minimum engineering and design input is required
to meet the Project’s requirements.
Control and Instrumentation requirement for packaged units shall generally comply with
60A20, C&I for Packaged Units Specification, together with the related reference
documents and technical description of the packaged equipment requisition.
4.4 Supplier List

The number of manufacturers and types of the instruments and control equipment shall
be minimised and shall be selected from the Approved Suppliers List prepared for the
Plant.
4.5 Standardisation
Control and Instrumentation equipment shall be standardised including equipment
used in packaged units, to reduce spares holding capacity and to simplify
maintenance. This is not only includes standardisation in terms of instrument or valve
make and models, but includes standardisation of design approaches such as JB
layouts, hook up drawings, loop design, linearization algorithms, DCS and SIS software
function blocks, etc.
4.6 Directives of the European Community

On European project or when specially required by Client, equipment provided for the
Plant shall comply with all EU directives and shall be labelled with the official “CE”
mark.
The directives applicable to the Plant shall include, but not be limited to the following:
 Low Voltage Directive, 73/23/EEC and amendment 93/68/EEC

 Electromagnetism Compatibility Directive, 83/336/EEC and amendments
92/31//EEC and 93/68/EEC

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 ATEX Directive, 94/9/EC, Equipment for explosive atmospheres

 Pressure Equipment Directive (PED), 97/23/EC
All in-line items such as flow elements, control valves, isolation valves, relief valves and
thermowells that have pressure containing parts shall be CE Marked in accordance
with PED and shall be supplied with a declaration of conformity to all EC Directives.
5.0 GENERAL DESIGN REQUIREMENTS
5.1 General
All instrumentation shall be identified by Tag Number in accordance with 60A3, C&I
Symbols and Identification Specification.
Instrumentation and control systems shall be designed to operate within limits of

performance specified and shall be “fit-for-purpose”.
Instruments and their installation shall be selected for reliability in the working
environment without the need for special environmental control. Particular attention
shall be paid to possible effects of corrosion, vibration, humidity, and extremes of
temperature.
All field Instruments / enclosures shall be protected to IP65 as a minimum and shall be
finished to the manufacturer’s standard practice suitable for the environmental
conditions. For details of site environmental conditions refer to 01A1, Basic
Engineering Design Data (BEDD).
All control system equipment shall be located in a Central Control Building (CCB) or
Instrument Satellite Building (ISB).
Control systems shall be designed to avoid interaction between associated electrical

circuits. Spurious signals that cause interference shall be suppressed, preferably at
source.
All process control shall be by the DCS. Local controllers shall not be used.
Instruments with mercury shall not be used.
Instruments and their pneumatic process piping shall be provided with protection to
mitigate the effects of damage from process fluids, maintain the process fluid in a state
to achieve accurate measurement and to prevent freezing in accordance with 67A1,
Protection of Instruments Specification.
Instruments and their equipment shall be installed in accordance with 60A24, C&I
Installation Specification.
All Instrument process and pneumatic tubing/piping shall be in accordance with 60A10,
C&I Piping Material Specification.
Instrument cables/wiring requirement and installation shall be in accordance with 60A2,

C&I Cable Specification.

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5.2 Units of Measurement

Metric units of measurement shall be used on the Plant and shall be in accordance
with 01A1, Basic Engineering Design Data (BEDD).
5.3 Instrument Ranges

The calibration range for all instruments shall be selected such that the greater of the
normal process measurement plus 30% or the maximum process measurement plus
10%. Any other range may be used by exception.
Multiple transmitters with different ranges may be used as necessary depending on the
measurement range required.
Separate low range transmitter shall be used to achieve required accuracy where the
minimum process measurement is lower than the maximum possible turndown point of
the high range transmitter
All instruments used in multiple voting and comparison loop shall have the same
calibration range.
5.4 Accuracy
Unless otherwise stated, accuracy of normal applications instruments shall be:
 Pressure Gauges : ± 1.0% of full scale.

 Temperature Gauges : ± 1.5% of full scale.
 Electronic Transmitters : ± 0.25% of full scale.
5.5 Accessibility
All locally mounted indicators, including thermometers shall be readable from grade or
permanent platforms. All other measuring elements with pipework connections
including fire and gas detectors shall be accessible from grade or platforms.
Instruments including isolation valves shall be installed so as to be easily accessible

from grade or permanent platforms. Where agreed, access via temporary means may
be warranted for economic reasons.
Post or Gauge Board mounted instruments shall be located at a minimum 1400mm and
maximum 1600mm above grade or permanent platform level.
Detailed requirements for locations of instrumentation, relative spacing between

equipment and other accessibility requirements shall be in accordance with 60A24, C&I
Installation Specification.
5.6 Location
Instrumentation shall be positioned to minimise the effects of fire, solar radiation, heat
from adjacent equipment, condensation, spillage, rain, wash water and maintenance
activities.
Instrumentation may be post or gauge board mounted. Posts or gauge board shall not
be attached to piping, removable flooring, handrails or mounted directly on machinery
and equipment subject to vibration.
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5.7 Instrument Connections

5.7.1 Instrument Process Connections
Each instrument shall have its own process connections with dedicated process
isolation valves to minimise the potential of common mode failure.
Shared vessel nozzles are permitted for multiple instrument connections on standpipes
although safety instruments shall be via dedicated nozzles.
Shared impulse lines are permitted for differential flow measurement where high and
low range transmitters are required for flow accuracy.
Vent and drain valves shall be incorporated as discrete valves or incorporated within
the instrument manifold (preferred). Vent plugs shall be used.
Impulse lines shall be as short as possible, free from blockages and directed to ensure
self draining and venting, and ensuring that vibration is avoided.
When process fluids are liable to separate, solidify or deposit in impulse lines, or have
extreme temperatures or pressures, the choice of instrumentation coupling should be
designed to prevent damage to the transmitter or unreliable measurement. Typically
direct mount diaphragm seals with equal length capillaries are preferred. All diaphragm
seals shall be installed on dedicated process isolation valves and full size flanged
bleed ring with vent and drain valves.
Capillary systems shall be routed and protected against differential heating especially
when used for differential pressure measurement.
For detail of Instrument process connection requirements refer to 65A1, C&I / Piping
Interface Specification.
5.7.2 Instrument Pneumatic Connections
Pneumatic connections shall be NPT (F), normally ¼” or ½”, but larger as required, e.g.
for high speed actuators. Compression fittings shall be double ferrule type.
5.7.3 Instrument Electrical Connections
Electrical entries to instruments shall be metric (M20 x 1.5).
5.8 Signal Transmission

The preferred signal type for all field instrumentation shall be:
Signal Type Signal Level

SMART transmitters with 4-20mA, 24V DC
Analogue (non-safety
“HART” protocol / Foundation Fieldbus protocol (based
applications, e.g. DCS)
on Plant philosophy)
Analogue (safety SMART transmitters with 4-20mA, 24V DC
applications, e.g. SIS) “HART” protocol
Discrete signals 24V DC

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Signal Type Signal Level
Discrete Motor control

24V DC
signals
Solenoids 24V DC
Refer to 60A24, C&I Installation Specification for details of signal segregation

requirements.
Pneumatic instrumentation shall be limited to the actuator for the final control element.
5.8.1 Transmitters
Transmitters shall be used for all process indication, control, alarm, and shutdown
services.
Transmitters shall be electronic and of the Smart type with HART / Foundation Fieldbus
protocol technology in order to facilitate easier maintenance, simple adjustment,
provide improved diagnostics, and additional functionality, such as linearization.
Integral indication shall be provided on all transmitters for operator use.
Linearization of measurement shall be accomplished in the transmitters.
Wireless transmission shall only be used for monitoring instrumentation located in

remote plant areas that are not serviced by any cable routes.
Nucleonic transmitters and switches may only be used by exception and then only if
the application cannot be handled by any other instrument type. Nucleonic
instrumentation shall also only be used with the Client’s written approval.
5.8.2 Switches
Switches shall only be considered on non-critical auxiliary systems, e.g. seal oil
systems for non critical pumps and shall only be used with the Client’s written approval.
Switches shall have reliable, high integrity switch mechanisms, e.g. flow switches shall
be avoided.
Switches shall have adjustable set points and have DPDT or SPDT contacts rated at
1A at 24V DC. Switch modules shall be hermetically sealed and vibration resistant.
5.9 Electromagnetic Compatibility Requirements

Instrument systems shall be designed to avoid interaction between associated
electrical circuits. Spurious signals that cause interference shall be suppressed,
preferably at source.
All equipment shall comply with:
 IEC 61000 Sections 2, 3, 4 - Electromagnetic Compatibility.

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 IEC 61010 Section 1 - Safety Requirements for Electrical Equipment

for Measurement, Control and Laboratory
Control systems and Instrumentation shall be tested by the Manufacturer to meet the
requirements of Level 4 severity for contact discharge and air discharge as per IEC
61000 Part 2 (8kV for contact discharge and 15kV for air discharge).
Control systems and Instrumentation shall be tested by the Manufacturer to meet the
requirements of Level 3 severity for susceptibility to effects of electromagnetic fields
generated by portable radio transceivers or any other device that generates continuous
wave electromagnetic energy as per IEC 61000 Part 3. Test shall be carried out at field
strength of 10 V/m in the frequency band 27 MHz to 500 MHz.
Control Systems and Instrumentation shall be tested by the Manufacturer to meet the
requirements of Level 4 severity for susceptibility to effects of repetitive fast transient /
burst on supply, signal or control lines as per IEC 61000 Part 4.
5.10 SIL Requirements

All safeguarding instrument loops (SIF) connected to the SIS shall be allocated a SIL,
which shall be met with the selection and design of the instruments and validated by
calculation prior to the purchase of the instruments.
The allocation of the SIL, the selection and design of the instrumentation and
supporting equipment, and the validation calculations shall be performed in accordance
with IEC 61508 and IEC 61511.
The SIL target requirement for each instrument, together with any supporting
infrastructure or equipment required to ensure that the instrument meets the required
SIL target, shall be indicated on the instrument data sheet and C&I database.
All supporting infrastructure and equipment, such as partial valve stroke testing
systems etc. shall be provided to ensure that the instrumentation meets the SIL
requirements.
Each SIS system shall have Safety Requirement Specification(s) describing the SIL
requirements for each SIF loop with supporting calculations, justifications for the SIL
targets selected, references to the applicable data sheets of the instruments, and any
other supporting information.
5.11 Selection of Materials

The selection of materials for in-line instruments such as control valves shall follow the
associated piping material specification as a minimum.
The selection of materials for on-line instruments such as level displacers shall follow
the associated vessel material specification as a minimum.
Where the material of the instrument differs to that of the associated piping / vessel
connection, yield stress requirements of the pipe work / vessel shall not be
compromised.
Thermowells and orifice plates shall be 316 stainless steel unless process conditions
require a higher grade of material.

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Off-line instruments such as transmitters shall have 316 stainless steel process wetted
parts unless process conditions require a more suitable material.
5.12 Instrument Database

Intergraph SmartPlant Instrumentation (SPI) shall be used to its fullest capacity with
respect to population of data and the use of index module, calculation module, process
module, specification module, wiring module, hook-up modules and loop module is
mandatory. Data for all instrumentation, including packages, shall be contained within
SPI.
System, wiring and instrumentation design tools shall be selected to provide a

framework to enable the Engineering Procurement and Construction (EPC)
contractor(s) selected to deliver a facility that has uniformity of design across all units
irrespective of the contractor selected. In order to achieve this, SmartPlant
Instrumentation shall be used for all systems, wiring and instrumentation design. For
SPI implementation refer to 60A42, SmartPlant Instrumentation Specification for further
details.
The version of SPI to be used shall require approval by the Client but shall generally be
the latest version available at the commencement of detailed design.
5.13 Power Supplies

All control systems and instrumentation shall be supplied via the respective
Uninterruptible Power Supplies (UPS) systems located within the ISBs and CRER.
These shall be redundant AC, 50 HZ, 3 phase with 30 minute battery back-up for all
ICSS equipment and a separate redundant UPS with 8 hour battery back-up for all
FGS and Telecom equipments.
For Instrument Power Supply voltage level refer to 01A1, Basic Engineering Design
Data (BEDD).
Where possible, all instruments shall be loop-powered with 24V DC supply from their
respective systems.
Suitable segregation of the UPS supply feeds shall be incorporated to prevent common
mode failures to the Power Distribution Panels (PDPs).
PDPs shall be utilised to distribute feeds, via isolators, directly to system cabinets,
marshalling cabinets and to field instrumentation where required. The PDPs shall have
protection to isolate the fault of any system or logical grouping of instruments, to
maximise the availability of the process equipment.
Non UPS power supplies for lighting, rotation beacons and utility outlets shall be kept
separate from the instrument power supplies so as to restrict UPS usage to critical
applications.
5.14 Earthing Systems

The earthing of measurement, control and computer systems shall be arranged to
prevent electrical interference. Particular attention shall be given to the arrangement of
earthing circuits to prevent unwanted circulating currents in earthing, signal and
measurement conductors and screens.

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For details of the earthing of instruments refer to the 60A24, C&I Installation
Specification and Project Instrument Earthing Philosophy Diagram.
Two grounding systems shall be provided in the CRER and ISBs in order to prevent
start-up and circulating currents of large motors and other electrical equipment from
interfering with the sensitive low current/power instrumentation equipment:
 Safety earth grounding for personnel safety

All electrical equipment shall be grounded to the safety earth for personnel
protection to satisfy BS 7430 and BS 7671.
 Instrument earth for signal reference
The instrument ground wiring shall be installed to provide a stable voltage
reference for all instruments and control systems.
The following signal and equipment connections shall be made to the instrument
earth:
 Instrument power supplies 24V DC (negative leads)

 DCS, SIS, BMS, FGS, and other control modules (signal common, logic
ground, network ground, etc.)
 Instrument (individual and overall) cable shields
A dedicated Instrument Intrinsic Safety (IS) Earth shall be avoided by the use of
galvanic isolators where possible.
Where ICSS subsystems require a segregated system earth, then separate system
earth grounding shall be provided.
The Instrument earth, safety earth and system earth shall join electrically at a single
point as close as possible to a high-quality earth ground mat to prevent earth loops
between the two earthing systems.
Since various suppliers have different grounding requirements, care must be taken to
develop a scheme that meets those requirements, meets the BS 7430 and BS 7671
requirements, has testing capabilities and has the Supplier approval.
Removable link shall be provided between the safety earth ground and the instrument
ground to allow testing of the instrument ground.
All instrument earth bars, plates, and wire shall be isolated from building safety earth
ground path, except at the one point specified above.
Each cabinet used in the instrumentation system shall have a redundant connection to
the high quality earth.
Each ISB shall have its own high quality earth mat installed to reduce the cable lengths
from the system cabinets to the high quality earth mat.
Where instruments fall outside the protective shadow of a lightning conductor, the
instrument signal shall be connected via a lightning barrier such that any voltage /
current surges are isolated or directed to the safety earth.

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6.0 INSTRUMENTATION IN HAZARDOUS AREAS
6.1 Standards
Equipment for use in potentially hazardous atmospheres shall be selected in
accordance with IEC 60079.
6.2 Protection
Electrical signals out to the field shall be designed to prevent causing ignition of a
hazardous gas or dust in the vicinity of the instrumentation in the field.
The type of protection selected shall be as follows:-
 Electrical Apparatus for gas atmospheres

Zone 0/1 - Type Ex i
Zone 2 - Type Ex n
 Electrical Apparatus for combustible dust
Zone 20/21/22 - Type Ex i
Instruments located in Zone 0/20 areas shall be avoided.
Where Intrinsically Safe is used as a method of hazardous area protection, zener type
safety barriers shall only be used when an equivalent galvanic isolator is not available.
IS calculations shall be done for all intrinsically safe instruments taking into account
worst case scenario for cable length and cable parameters.
A hazardous schedule dossier with all the required information shall be prepared for
instruments that are located in hazardous areas. A hazardous area certificate shall be
issued for each associated device.
In addition, all components in hazardous areas shall be certified per ATEX directive
94/9/EC which shall be actively managed to ensure full compliance before
commissioning.
7.0 INSTRUMENT AIR SYSTEMS
7.1 General
Dried, filtered, oil-free compressed air shall normally be made available at plot limits at
a pressure detailed in 01A1 Basic Engineering Design Data (BEDD). The minimum
supply pressure for actuator sizing shall be 3.5 barg.
Filter regulators of ≤ 5µm shall be installed on each valve positioner and solenoid valve
to protect the equipment from particles coming off the pipe walls of the distribution
piping.
7.2 Distribution
Instrument air shall be locally distributed in the field through the use of air distribution
manifolds. Where the density of air users is low in a particular area, a ‘spider’ air
distribution arrangement shall be used.

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There shall be no interconnection between the instrument air distribution system and
any service air distribution system.
8.0 DESIGN REQUIREMENTS FOR TEMPERATURE INSTRUMENTS
8.1 Temperature Sensing

Resistance Temperature Devices (RTDs) are the preferred means of temperature
measurements for centralised control, indication, multipoint indication or recording.
Thermocouples may be used in selected cases, especially for high temperature
applications.
The choice between RTDs and Thermocouples shall take the following into account
 Where accuracy of measurement is required greater than obtainable with a

thermocouple, a RTD shall be used.
 RTDs shall not be used where high frequent vibration is present, e.g. in high
velocity steam or gas streams.
 Where narrow range duty is required i.e. less than 100ºC range a RTD shall be
used.
Temperature sensing elements, except skin-mounted elements, shall be installed
inside thermowells.
Temperature transmitters shall be provided for all control, indication and safety
applications
All thermocouple actuated control systems shall contain 'burn-out' protection. The
design shall enable this feature to be switched between upscale and downscale
operation.
Thermocouple and resistance thermometer circuits operating high temperature alarms

shall have upscale element burn-out. Those on low temperature alarms shall fail to
downscale position.
8.2 Local Indicating Thermometers

Bi-metallic, minimum 100mm diameter, every angle dial thermometers shall be used for
local indication.
The range of any temperature measuring instrument shall be the Manufacturer's

narrowest standard span appropriate to the application.
Gas or liquid filled systems shall be used only where Bi-metallic type are not suitable.
All capillary tubing shall be corrosion resistant and sheathed or armoured. Preferred
lengths are 3m and 10m (maximum). Capillary tubing shall be supported throughout its
length.
8.3 Thermocouples
For temperatures up to 1100°C, thermocouples shall be manufactured from nickel /
chromium – nickel / aluminium (Type K) wires with reference characteristics in
accordance with IEC 60584.
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For temperatures above 1100°C or for H2 service above 750 oC, thermocouple shall be
manufacturer from platinum / 10% rhodium – platinum (Type S) wires with reference
characteristics in accordance with IEC 60584.
Thermocouples shall be mineral insulated, with 6mm diameter and hot junction
insulated from the sheath.
Thermocouple head terminals shall be marked with positive and negative symbols.
The signal from any thermocouple used in conjunction with SIS shall not be connected
to any other systems.
Where duplex thermocouples are identified on the P&IDs, the purpose must be clearly
stated, e.g. spare, and separately tagged, if appropriate.
8.4 Electrical Resistance Thermometers (RTD)

Resistance thermometer elements shall comply with IEC 60751 and have a resistance
of 100 ohms at 0°C, with a fundamental interval of 38.5 ohms. They shall be of the
grade of accuracy appropriate to the application.
To compensate for changes in lead resistance, resistance thermometers shall be

connected to measuring or transmitting instruments by a three wire system, unless
special high accuracy applications dictate four wires.
The use of resistance thermometers is normally limited to the range – 175 to 475°C.
8.5 Thermowells
Thermowells shall be machined from solid bar stock and have flange connection not
screwed.
Thermowells shall be made of 316 stainless steel unless process conditions require a
higher grade of material.
Calculations shall be tabulated by the thermowell Supplier to show that all thermowells
are suitable for stress due to maximum stream velocity conditions (Vortex shedding
effect). Thermowell wake frequency calculation shall be carried out in accordance with
ASME PTC 19.3.
Thermowells shall be installed in a minimum DN 100 (4") pipe. Pipe sizes DN 80 (3”)
and below shall be swaged up locally to 4” to accommodate the thermowell. Where a
connection is on a stream axis, in a bend or tee, DN 80 (3”) minimum line size is
acceptable.
Thermowell connections to the process as well as recommended insertion length shall

be in accordance with 65A1, C&I / Piping Interface Specification.
8.6 Transmitters
Head-mounted SMART type temperature transmitters shall be used where possible for
thermocouples or RTDs. Remote-mounted SMART type temperature transmitters shall
be used for multi-element types (e.g. skin temperatures or bearing temperatures, in
order to minimise the use of compensation cables).

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The output signal shall be linear with respect to temperature.
Cold junction compensation shall be carried out in the transmitter.
Multipoint temperature indication may be accomplished by connecting the

thermocouples to the DCS directly or via a multiplexing system as determined by the
required speed of response.
8.7 Infra-red Pyrometers

Infra-red Pyrometers shall be used for indication only and shall be placed to measure
the temperature of an object where the emissivity is the highest and / or where the
change in radiated energy is more sensitive to changes in temperature than the
changes in emissivity of the object.
The field of view of the pyrometer, the transmission qualities of the collector system
and the band pass sensitivity of the detector are key design parameters for the
specification of a pyrometer.
The pyrometer shall be mounted so that it is not subject to vibration or movement, and
that the object to be measured fills up the cone of vision of the pyrometer.
An internal air purge should be used to keep the window of the pyrometer clear of
steam, smoke and dust. The pyrometer should also be shielded from excessive heat.
Multi-wavelength pyrometers are preferred over ratio pyrometers.
9.0 DESIGN REQUIREMENTS FOR FLOW INSTRUMENTS
9.1 Applications
Rates of flow shall normally be measured by square edged, concentric, orifice plates.
If process conditions dictate other meter types may be considered including turbine
meters, variable area meters, positive displacement meters, coriolis mass flow meters,
ultrasonic flow meters, magnetic flow meters, vortex, thermal mass flow meters and
annubars or other differential pressure meters.
Flow meters for standard flow measuring applications shall be designed for accuracy of
±5%. For commercial or fiscal metering application where high accuracy is required,
refer to 60A34, Custody Metering System - Gas Specification and 60A35, Custody
Metering System – Liquid Specification
Small flows of liquid or gas such as purges to instrument tapings or sample flows to on-
line analysers shall be measured by variable area meters. Alternatively, they may be
measured by differential pressure transmitters fitted with integral orifices.
Care should be taken to ensure that the maximum velocity for a particular substance is
not exceeded (e.g. oxygen) and that choked flow conditions and cavitation do not occur
as a result of the selection of the flow measurement device.
Installation requirement of flow instrumentation shall be in accordance with 65A1,

C&I/Piping Interface Specification.

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9.2 Orifice Plates & Other Differential Pressure Elements

Primary elements shall be calculated, manufactured and installed in accordance with
ISO 5167. The ratio between orifice bore diameter and pipe internal diameter or 'beta'
ratio shall be in the range 0.3 to 0.7. The reference conditions shall be:
Liquids : 1.01325 mmHg, 20°C
Gas / Vapours : 1.01325 mmHg, 0°C
Differential pressure type flow transmitters shall be sized so that normal flow falls below
70% of flow range, minimum flow is not less than 30% of flow range and maximum flow
is not more than 90% of flow range. If the actual operating range exceeds the minimum
or maximum limits described above, then an additional transmitter should be installed
across the same orifice plate with shared impulse lines to cater for the additional range.
Square edged, concentric, orifice plates are preferred, others type may be considered
if the application dictates.
The material for orifice plates shall be compatible with the fluid handles and shall be
made of 316 stainless steel unless process conditions require a higher grade of
material.
Orifice plates with flange taps in accordance with ISO 5167 shall generally be used.
Installation of orifice plates and pressure tapping orientation shall be designed to
ensure flow characteristics are as close as possible to laminar flow to ensure high
accuracy/reliability measurement of flow and shall be in accordance with 65A1,
C&I/Piping Interface Specification. Orifice plates in carrier rings with integral corner
tapings shall be in accordance with ISO 5167.
Conical entrance or quarter circle orifice plates to ISO 5167 or venturi tubes, may be
used to measure high viscosity liquids or slurries.
Segmental orifice plates may be used to measure liquids containing large amounts of
solids and for flows in large conduits.
Low loss flow tubes or venturi meters shall be used where good pressure recovery is
essential.
Averaging pitot tubes may be considered only where no appreciable pressure drop can
be tolerated and may be considered for economic reasons for large line sizes (greater
than 12”). Average pitot tubes shall be used for clean gas and clean liquid
measurement only.
Orifice flanges shall be to ANSI/ASME B16.36.
9.3 Metering runs for Differential Meters

For lines up to DN 50 (2”) prefabricated metering runs shall be used. They shall have
flanged ends connection in accordance with pipe specification. Orifice bore diameters
shall not be less than 10mm (3/8").
Horizontal metering runs are preferred for liquid flow measurement and in all cases
where segmental orifices are used. Vertical runs with downward flow are acceptable
for steam and condensable gas.
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Minimum straight metering length of pipe upstream and downstream shall be in

accordance with ISO 5167.
9.4 Compensation
Static Pressure and Fluid Temperature compensation to improve the accuracy of the
flow measurement shall be performed in the ICSS. The pressure and temperature
transmitters shall be located at least 8 pipe diameters downstream of the orifice plate to
avoid affecting the flow measurement.
9.5 Impulse Lines and Connections.

All process line tapings shall be fitted with isolating valves to process piping
specification.
Whenever immiscible liquids are measured, impulse lines shall be horizontal

throughout their length and the connections of the differential pressure measuring
instruments shall be at the same level as the orifice tapping points, so as to avoid head
errors due to density differences.
For non immiscible liquids impulse lines shall be gently sloped downwards, for gases
impulse lines shall be gently sloped upwards.
Impulse line shall be kept to a minimum length and each impulse line within a
measurement set shall be kept to as equal a length as possible.
9.6 Differential Pressure Flow Instruments

Bellows / Diaphragm type meters shall be selected from the Manufacturer's standard
ranges. Bellows type meters shall only use for local indication.
The full scale of a differential pressure meter shall be optimised to one of the following
values, after taking into consideration calculation variables such as flow range, beta
ratio, unrecovered pressure loss, static pressure, meter type, etc.
 50 mbar
 100 mbar
 250 mbar
 500 mbar
The preferred full scale differential for orifice plate measurements shall be 250mbar
wherever possible.
Diaphragm seals shall be used where it is necessary to protect the instrument from the
process fluid or from viscous liquids. Liquid seals shall not be used for this application.
9.7 Variable Area Flow Meters

Protected Glass tube meters may be used in non-hazardous service for temperatures
below 55°C. For all other services Metal tube meters shall be used.
Variable area meters shall not be used for fluids that may contain solids.

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Variable area meters shall be located with sufficient clearance to permit tube and float
removal without removing the meter body.
If the flow cannot be interrupted during plant operation, line size block and bypass
valves shall be provided.
9.8 Positive Displacement and Turbine Meters

Positive displacement and turbine meters may be considered for application as follows:
 Positive displacement meters : Viscous liquids

 Turbine meters : High accuracy and high rangeability on clean fluids
Strainers shall be installed upstream of metering installations if the product has
impurities. The mesh of the strainer shall be as advised by the meter manufacturer.
An indicating device shall be installed across each strainer of a metering system to

measure the differential pressure. It shall be arranged to activate a high differential
pressure alarm.
Where fluid properties can have an adverse effect on meter mechanical performance,
turbine meters with tungsten carbide, or similar, bearings are preferred. Adverse fluid
conditions may include solids, poor lubricity (e.g. liquefied gases), rouge and sulphur
compounds.
Temperature elements for automatic temperature compensators for positive

displacement metering installations shall cater for all temperatures which can be
expected under operational and static conditions. The effects of line and tank heating
shall be taken into account.
Meter selection shall take into account maximum process conditions to ensure the
meter does not over speed.
9.9 Magnetic Flow Meters

Magnetic flow meters shall only be used in fluids with a conductivity of higher than
5µS/cm. Typical applications include water and waste water flow measurement. For
slurries and chemical effluents that are electrically conductive, magnetic flow meters
may be used.
Magnetic flow meters shall have automatic empty pipe detection capability
incorporated.
Where magnetic flow meters are installed in non-conducting piping then the option of
either reference electrodes or earth rings shall be used depending on the meter
selected.
9.10 Ultra-Sonic Flow Meters

Ultra-sonic flow meters shall be considered for use in corrosive service and where a
low pressure drop is required since they can be mounted on the outside of the pipe.
Care should be taken to provide sufficient straight run in the piping for the ultra-sonic
flow meter and that the pipe through the meter is always full of fluid to ensure the
accuracy meets requirements.
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Ultrasonic flow meters shall not be used where gas bubbles may be present in single
phase liquid flow applications.
Care should be taken in the installation to avoid dirt, air gaps and other piping
inclusions in the sensor area as this will adversely affect the accuracy. Ultra-sonic flow
meters shall be installed so that there is no vibration effect on the meter.
9.11 Vortex Flow Meters

Vortex meters should not be used in viscous, dirty applications, or where the fluid has
Reynolds numbers below 10000.
Vortex flow meters shall be installed so that there is no vibration effect on the meter.
Venting and draining shall be considered during placing and installation, especially for
hazardous and toxic fluids.
9.12 Coriolis Flow Meters

Coriolis flow meters may be selected as alternative flow devices to obtain a higher
accuracy and turndown for either gas or liquid.
Coriolis flow meters shall be installed so that there is no vibration effect on the meter.
All coriolis installations shall be checked for cavitation and choked flow conditions due
to the high velocities of the fluid through the meter.
Coriolis meter’s sensitivity to specific heat variations in the process fluid due to
variation in composition or temperature of the fluid should be compensated for to
ensure the accuracy of the measurement.
Venting and draining shall be considered during placing and installation, especially for
hazardous and toxic fluids.
10.0 DESIGN REQUIREMENTS FOR LIQUID LEVEL INSTRUMENTS
10.1 General
Each individual instrument shall be supplied with dedicated process connections,
process isolation, drain and vent valves.
Instruments may be directly connected to the vessel or via a standpipe as indicated on

the P&IDs. Instruments for safety application shall have separate vessel connections
from those for control application.
Level nozzles should be placed such that influences of inlet / outlet disturbances are
minimised or deflectors should be installed to improve the accuracy of the
measurement.
Nozzle elevation should be selected so that offsets are eliminated and reduced range
calibrations are minimised.
A secondary method of checking the process level shall be provided, e.g. a level
gauge. The range of level gauges shall cover the completed operating range of any
related level transmitter installed on the same vessel section to provide the field
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operator with a means of verifying the actual level compared to the measurement on
the level transmitter.
Measurement is preferred to be directly to the vessel, however, testing facilities must

be considered. If the level is measured externally to the vessel, consideration should
be given in design to the fact that the external level may be different to the level in the
vessel.
Vessel extensions (standpipes) are permitted for multiple instrument connections

although safety instruments shall be via dedicated vessel nozzles. The design of the
vessel extension shall ensure that there is no possibility of isolating the connection
between the vessel and its extension, there is free flow between the vessel and its
extension, each instrument shall has its own isolation valves, and the vessel extension
is treated as part of the vessel for pressure testing and other statutory requirements.
This will ensure that the level in the extension is the same as the level in the vessel,
that the risk of common mode failure is reduced, and that the vessel extension does
not reduce the structural integrity of the vessel.
Level instruments connected directly on the vessel shall be in accordance with the
65A1, C&I / Piping Interface Specification.
Where the number of vessel tapping is excessive, standpipes may be used although
safety instruments shall be via dedicated nozzles.
10.2 Local Indication

The following local level instrument types shall be used:
 For vessels and columns: Magnetic level glasses shall be the first choice.
 For tanks: Float type instruments or differential pressure instruments are
preferred.
 For viscous fluids or high temperature applications: Magnetic type shall be used.
10.3 Continuous Measurement

The following instrument types shall be used:
 Differential pressure instruments are preferred for the continuous measurement

of level.
 Displacer type instruments may be used for interface measurements where the
range does not exceed 1219mm.
 Radar level measurement shall be the preferred method for any tank gauging
requirement.
 Other types of measurement, e.g. R.F. admittance, capacitance, radar, ultrasonic
and nucleonic, may be used where differential pressure instruments or displacers
(for interface) are unsuitable or the accuracy is not sufficient.
10.4 Point Level Detection

The following instrument types shall be used:

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 For safety application, electronic transmitters shall be used, either differential

pressure or displacer (for interface) depending on application. Other types of
measurement, e.g. R.F., capacitance, ultrasonic and nucleonic, may be used if
more suitable or the accuracy is not sufficient.
 Ball float operated instruments shall be used for point level detection in non-
critical applications
 For dual level detection, adjustable displacers mounted on a support wire or tube
may be used on non-process small vessels, e.g. sumps.
10.5 Magnetic Gauges

 Magnetic level gauges shall be provided with vessel connections, vent and drain
connections as detailed in 65A1, C&I/Piping Interface specification.
 Level indicating flags/rollers shall be red/white.
 Magnetic level gauges shall have (flange connection-connection) maximum length
of 4000mm (160”).
10.6 Gauge Glasses

Gauge glasses shall conform to BS 3463, size 7 or 9, and the following:-
 Tubular glass type gauges shall not be used, except where specified by a
Process Licensor.
 Each gauge shall be stamped with the maximum working pressure and
temperature.
 Through vision and reflex gauges shall be fitted with toughened glass.
 Expansion and contraction of gauges used on hot or cold liquids shall be
compensated by integrally fitted pipe work.
 Integral illuminators may be provided for through vision gauges. The power
supply to the illuminator shall be AC, 50Hz single phase.
Where multiple gauges are required to cover the required visible span, each gauge
shall overlap by at least 25 mm.
Reflex gauges shall be used for liquid and vapour interface detection except in the
following circumstances, where through vision gauges shall be used:-
 Interface between immiscible liquids

 Viscous service
 Glass corrosive duty (e.g. acid, caustic, high pressure steam or condensate),
when the glass shall be protected with a mica sheet between glass and gasket
 Colour or turbidity observation
Gauges that require heat tracing shall be supplied with the manufacturer standard
integral steam tracing tube / jacket.
Gauges on service below ambient temperatures shall be of the non-frosting type.

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Gauges on vaporising service shall be manufactured with larger chambers than

gauges on other services.
All gauges shall be supplied with manual shut-off valves with ball check facilities on the
top and bottom mountings and full bore vent and drain valves. Valves shall be of a
quick acting, offset type and shall have bolted bonnets.
All gauges shall be designed for the design conditions of the vessel and should be
suitable for full vacuum conditions.
10.7 Differential Pressure Level Instruments

DP transmitters may be used on open or closed vessels using close coupled flange
mounting or remote mounting with sensing lines.
Nozzle elevation should be chosen to remove offsets (elevated zeros) and reduced
range calibrations minimised.
On viscous or corrosive duties or where process materials are liable to separate,

solidify or deposit in impulse lines, direct mounting diaphragms shall be used.
Where accuracy is not of prime importance, and where the tank is vented to
atmosphere, contents measurement may be made by a hydrostatic level instrument.
10.8 Diaphragm Seals (Level and Pressure)

Remote diaphragm seals and capillary systems shall be designed, engineered,
specified and selected according to the manufactures recommendation.
Diaphragm and capillaries should be designed as a tuned system in order to achieve

optimal measurement. Supplier shall be consulted during specification and design.
Diaphragm seals shall be of the flanged type. A “flushing ring” shall be fitted between
the primary isolation valve and the diaphragm seal. The “flushing ring” may serve as
flushing connections and/or calibration connection and/or be provided with a bleed plug
and/or drain valve to allow safe removal of the diaphragm seal. The flushing ring and
valves where required shall be supplied with the diaphragm seal assembly.
Where identified on the P&ID, diaphragm seals should be specified with extended
seals and not flushing rings. This is necessary to avoid collection of solids within the
vessel nozzle assembly.
While selecting pressure instruments with remote diaphragm seals and capillary,
consideration shall be given to material selection in view of design pressure (vacuum),
temperature (vapour pressure fill fluid) and chemical resistance. In general, remote
seals shall not be applied in services with an operating temperature in excess of 550F
(300C) or operating pressure in excess of 750 psig (50 barg). Seals in vacuum
services shall be avoided.
The diaphragm seal size and type of connections must match the vessel piping design.

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10.9 Guided Wave Radar

Guided Wave Radar (GWR) transmitters may be used for most applications, but should
be evaluated against other measurement technologies. When specified, the
transmitter shall be mounted in a chamber external to the vessel.
10.10 Displacer Type Instruments

Displacer type instruments may be used for interface measurements where the range
does not exceed 1219mm. The standard manufacturer ranges for displacer of 356mm,
813mm and 1219mm shall be used.
Displacers shall use externally mounted chambers. Chambers shall be designed with
side-and-side connections wherever possible.
Only one level instrument is allowed per chamber, and the chamber shall have block,
drain and vent valves. Design should address the fact that the level in the chamber
could differ from the level in the vessel e.g. density differences.
Internal displacers may be used where an external arrangement is not possible e.g.
sumps. Where the displacer is subjected to turbulence, the effect shall be minimised by
shielding, guidance or other means.
10.11 Float Type Instruments

Float type switches shall not be used unless in exceptional circumstances. They shall
not be used for safety application.
Float type instruments shall use switches in externally mounted chambers. Float
operated level switches shall be glandless.
Integral stops shall be provided to limit the angle of float travel and shall be located as
near to the float as practical.
The float arm and float shall be able to pass through and clear the nozzle through
which they are installed.
10.12 Radar Level Instrument

Radar level instruments shall be the used for tank gauging systems. Special
consideration should be given to applications involving foam, turbulent surfaces, tanks
with stirrers, substances with low dielectric constants and substances which are likely
to condense on the antenna of the radar.
Stilling wells can be used to reduce the effect of turbulent surfaces, stirrers and other
vessel internals on the measurement.
10.13 Capacitance Level Instruments

Capacitance probe may be used for continuous level measurement of liquids or point
measurement for both liquids and solids
Manufacturer standard probe lengths shall be used wherever possible. Use of non-
standard lengths shall not be permitted. Probe shall be normally be fully insulated with
flange connections in accordance with the vessel trim specification.

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11.0 DESIGN REQUIREMENTS FOR NUCLEONIC INSTRUMENTS
11.1 Regulatory Requirements

Due to the sensitive nature of nuclear installations, national codes and standards of the
country in which the instrument is being installed should be consulted for detailed
purchasing, design, installation, operation and maintenance procedures to be followed.
11.2 General
Nucleonic instruments are not preferred and should only be considered as a last resort
and subject to Client approval.
Before a nucleonic instrument is selected the effect of industrial radiography in nearby

areas should be considered as bursts from these larger sources will affect readings on
installations used for process control.
Appropriate human resources should be appointed and maintenance training and

appropriate maintenance facilities for nucleonic handling should be provided.
11.3 Measurement Device

Source material energy and activity is dictated by design requirements and calculation
should be provided taking into account density of fluid, path length, wall thickness,
lagging / insulation and any other equipment resulting in source to detector separation.
However, the minimum energy and activity possible to achieve the desired accuracy of
measurement shall be selected.
Automatic compensation for source decay shall be incorporated.
The absorption of the radiation is affected by varying pressure so pressure

compensation shall be provided. Source containers for point and rod sources shall
shield the spherical nuclear radiation of the source to such an extent that it does not
exceed a dose rate of 7.5 micro Sv/h at the nearest accessible point.
The shielded container consisting of a steel encased lead holder with suitable
mounting facility shall house the nuclide.
Suitable top, bottom and side guards should be installed between the source container
face and the vessel or pipe wall such that the gap through which the radiation beam
passes is not accessible.
Bracket material supporting the measurement device should be suitably sized to

absorb scattered radiation.
The shielded container design allows for either pencil (typically 5 degrees) or fan
(typically 20, 30 or 40 degrees) collimated beam of radiation for point or continuous
gauging respectively. The container shall be supplied with in-built shutter assembly and
shutter lock assembly.
When in the open position, the shutter design shall provide for automatic closure when
the locking device is removed from the lock assembly.
The converter analogue output signal shall be 4 to 20 mA and potential free contacts
for point measurement.
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11.4 Labelling, Identification and Warning Requirements

To identify the presence of a nuclide, a source container shall be equipped with the
international radioactive trefoil sign, supplemented with the names and contact
numbers of the maintenance personnel responsible for the installation.
The source serial number, type of isotope material, source activity, date of activity
measurement and design type shall be identified on a stainless steel label permanently
attached to the source container.
Radiation warning signs shall be displayed at all entrances to areas where radioactive
sources are used or installed (typically at 30 m), and where persons could be exposed
to ionizing radiation.
Personnel exposure shall be minimised by locating the installation outside normal

operational areas however, the installation shall be such that all equipment is
accessible for removal / re-instatement as well as normal maintenance from grade or
permanent platform only.
11.5 Commissioning Requirements

Background radiation testing shall be performed on the source holder associated with a
system after commissioning to verify that the maximum dose rate at the nearest
accessible point is less than 7,5 micro Sv/h.
12.0 DESIGN REQUIREMENTS FOR PRESSURE INSTRUMENTS
12.1 General
Close coupling of the pressure transmitter to the process fluid is preferred, but
diaphragm seals are acceptable where the fluid will damage or foul the pressure
transmitter or impulse lines.
For the measurement of slurries, viscous or highly corrosive fluids for which a Bourdon
tube or a bellows element is unsuitable, a diaphragm sealed element shall be used.
The measuring element shall be designed to withstand over-ranging without a

permanent off-set that affects calibration.
Instruments measuring pulsating pressures shall be fitted with pulsation dampers. The
use of partially closed isolation valves is not permitted.
All pressure type measurements shall be provided with direct mount manifolds - two-
way manifolds for single pressure and five-way manifolds for DP measurements.
Manifolds shall be minimum 316 stainless steel.
12.2 Range Selection

Gauge pressure transmitters shall be specified with the exception of low pressure
applications, in which case absolute pressure transmitters shall be considered. This will
allow greater use of the total calibrated range.
Ranges of pressure gauges shall normally be in accordance with ANSI / ASME

B40.100 and EN 837. For greater discrimination, narrow span transmitters with

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elevated zero may be used. In such instances a pressure gauge shall be installed
adjacent to the transmitter for start-up and shutdown operations.
Pressure elements measuring a steady normal operating pressure shall not exceed
75% of their maximum range. Pressure elements measuring a fluctuating pressure
shall not normally be operated beyond 60% of their maximum range.
For pressure gauges with ranges less than the process design pressure, over-range
protection shall be provided by design or by the use of a separate over-range protector.
12.3 Local Indication

Pressure gauges shall be in accordance with ASME B40.100 with the following
specifications:
All pressure gauges shall have minimum 100mm dials.
Measuring elements shall be C-type Bourdon Tube, manufactured from 316 stainless
steel unless process fluid requires the use of other materials.
The measuring element shall withstand over-ranging to a pressure of 1.3 times the
maximum scale reading without a permanent off set that affects gauge calibration.
Gauge movements shall be constructed from stainless steel and shall be zero
adjustable.
The case shall be solid-front, weather proof and furnished with a blow-out back or
blow-out disc. Cases shall be made of stainless steel.
A visible stop pin shall be used to restrict the upper limit of the pointer travel.
The gauge window shall be shatter-resistant safety glass.
Liquid filled gauges shall be used for pulsating and vibrating services where the
process conditions allow. Liquid filled gauges shall have a small vapour space for
thermal expansion of the liquid fill.
Gauges for the measurement of low pressure or differential pressure shall be of the
bellows or diaphragm type. Dual element gauges shall only be used when the
differential pressure exceeds 10% of the available static pressure.
Zero, normal and full scale pressure readings shall be indicated on the gauge. If the
required range is too large to provide the required accuracy, then another gauge
should be provided to indicate the reduced range.
12.4 Installation
Gauges and indicators shall be located so as to be easily read. Siphons shall be fitted
on steam and hot services.
Pulsation dampers and over-pressure protectors shall be fitted close to the pressure
measuring element. Where space is limited close coupled transmitters may be used.
Pressure gauges shall be connected through excess flow shut-off valves for safety in
the event of element rupture that could cause a hazardous release of process fluid.
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Refer to 60A24, C&I Installation Specification and 65A1 C&I / Piping Interface
Specification for further requirements.
12.5 Instrument Process Entries

Entries to pressure instruments (without diaphragm seals) shall be ½” NPT to ASTM
B1.20.1
 Pressure gauges – male

 Pressure switches – male
 All others – female
Refer to the 65A1, C&I / Piping Interface Specification for tap-in details.
12.6 Pressure Transmitters

Pressure Transmitters shall have diaphragm sensors selected from the Manufacturer's
standard ranges.
Body and sensor material shall be suitable for process conditions and be 316 stainless
steel as a minimum.
Diaphragm seals shall be used where it is necessary to protect the instrument from the
process fluid or from viscous liquids. Liquid seals shall not be used for this application.
13.0 DESIGN REQUIREMENTS FOR REGULATING CONTROL VALVES
13.1 Valve Selection

Control valves shall be selected according to the application required and compliant
with the International Standard IEC 60534.
Control valves shall be grouped into general purpose and severe service application
categories.
 General purpose valves category shall be maximised for standardisation which in

turn shall result in minimising spares holding and simplifying associated
maintenance.
 Valves for severe service applications shall be selected on a case by case basis
where the general purpose valve category cannot meet the specific
requirements, e.g.:-
 Velocity (e.g. high flow through valve)
 Flow conditions (e.g. cavitation, erosion service)
 Noise (e.g. noise levels in valve exceeding 80 dBA)
 Temperature (e.g. cryogenic service)
Control valves for process liquids and high pressure steam and gases shall in general
be globe type or rotary eccentric plug valves.
Other valve styles may be used where process conditions are such that a globe bodied
valve is not suitable. These valve styles are:

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 Segmental ball valves

 Full bore ball valves
 Characterised butterfly valves
Globe valves may be fitted with double seated trim which shall be top and bottom
guided, or single seated trim with plug or stem guiding or with cage trim.
Control valves with special trim for noise reduction shall have globe bodies and cage
trims.
Angle valves may be used where necessary to prevent the accumulation of solids, on
erosive or flashing service, and for unusually high differential pressures. For very
severe service multi stage low noise valves may be used.
For stream mixing and diverting service such as temperature control of heat exchanger
fluids, dual control valves, one reverse and one direct acting, shall be used. Three-way
control valves shall be avoided.
Larger volume flows and high shut-off differential pressure may be controlled by
segmental ball valves or full bore ball valves. Larger volume flows at lower differential
pressure may be controlled by butterfly valves or rotary eccentric plug valves
All valves shall be supplied with stem position or rotation indicators.
Self-acting control valves may be used for local, fixed gain control of utilities, such as
pilot gas systems, nitrogen and potable water streams and where failure action and
lower precision of such devices is acceptable.
 The maximum size shall be 1½”.

 Self-acting valves shall not be used for process isolation. They may only be used
where the process fluids do not contain condensate, materials that could block
the regulator or substances that are not compatible with materials used in the
valve. In addition, self-acting valves may only be used where it is acceptable to
vent small quantities of actuation gas into the atmosphere.
13.2 Valve Characteristic

The selection of the inherent valve characteristic shall ensure that the installed
characteristic of the valve in the associated piping and process configuration is linear to
facilitate optimal control performance.
Valve characteristics are to be equal percentage, with the following exceptions:
 When 50% or more of the dynamic pressure drop is to be sustained by the

control valve at normal flow conditions, the valve should have a linear
characteristic.
 When the control valve is in level control service, the valve shall have a linear
characteristic.
 When the control valve is one of a parallel pair and both valves in the pair are
normally simultaneously in service. The valve shall have a linear characteristic.

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The final selection of all valve characteristics, including specialist noise reduction and
anti surge valve trims etc shall be made in consultation with the valve manufacturer.
13.3 Valve Sizing

The size of control valves shall be calculated according to an agreed international
specification or manufacturer’s specifications. Valve sizing shall be based on IEC
60534 Part 2.
In general, control valves shall be sized to pass at least the anticipated maximum flow
rate at the permissible pressure drop for the flow rate. Control valves shall be checked
to ensure operability at normal and minimum flow rates and associated pressure drops.
Rangeability shall be checked for the anticipated minimum flow rate.
The valve shall be sized to provide the design flow coefficient Cv plus 10-15% above
the maximum specified flow. Each Control valve shall have their specified design flow
coefficient Cv in the following operating range unless otherwise noted.
Linear plug : Max. flow at 50 to 80% of full stroke.
Min. flow at 10% of full stroke.
Equal percent plug : Max. flow at 60 to 90% of full stroke.
Min. flow at 20% of full stroke
The effect of reduced inlet and outlet pipe sizes shall be taken into account when sizing
control valves and checks for cavitation and choked flow conditions shall be performed
at maximum, minimum and normal process conditions.
Where possible, cavitation shall be avoided by selection of suitable pressure recovery

factors and choice of valve type. Where cavitation is unavoidable, the valve selection is
to be in conjunction with the valve manufacturer to provide a suitable valve with correct
characteristics to suit the process conditions.
13.4 Noise
All valves shall be assessed for their noise SPL (Sound Pressure Level). Noise
calculations in accordance with ISO 3744 shall be provided. Predicted noise level at
1m downstream of the valve and 1m normal to the pipe shall not be greater than 80
dBA.
Where the above SPL could not meet with the standard valve then special noise
reduction trims shall be specified if available for application.
13.5 Failure Position

The failure direction for air and instrument signal shall be the same to provide a
predictable failure direction for the control valve which allows predictable behaviour in
hazardous conditions.
Each valve shall have a clearly defined failure action to meet the process application
requirements.

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All automated valves opening to flare are fail closed valves in order to minimise the
release to the flare in case of air or power failures. Specific HAZOP Study approval is
required for the use of fail open valves.
13.6 Valve Construction

Manufacturer standard body size shall be selected for each application.
Globe valves up to NPS 24” shall be flanged to ASME B16.5 and to ASME B16.47 for
valves larger than NPS 24”.
The face to face dimensions shall comply with ASME B16.10 for all designs of valves.
The minimum nominal size of globe and ball valve bodies shall be DN25 (1").
The minimum nominal sizes of butterfly valves shall be DN100 (4").
The body rating and flange rating for all flanged control valves shall be minimum rating
of class 300lb. Body and flange ratings for on / off valves shall be as per line class.
Flangeless valves employing long bolting are not acceptable where process
temperature is below –10°C, above 120°C or in high fire risk areas to prevent failure of
gaskets due to differential expansion.
The shaft on a butterfly valve shall be continuous, through the vane and shall be rigidly
locked to the shaft.
The direction of flow through a valve shall be permanently marked on the body or
flanges.
The degree of seat leakage shall be in accordance with ANSI/FCI 70-2. Control valves
shall have a leakage rate of ANSI/FCI 70-2 Class IV as a minimum.
Control valve leakage requirements will be shown on the instrument and process data
sheets as a minimum and may be included on the P&ID’s. Soft seated valves to meet
the classification “TSO” shall only be used by exception.
Special bonnets shall be specified in following circumstances:-
 Extension bonnet - for fluid temperatures from 0 to minus 100o C or above

+230oC.
 Bellows seal bonnet - shall be used only when stem leakage cannot be tolerated.
It shall be fitted with a monitor for bellows leakage, e.g. small pressure gauge
and excess flow valve.
13.7 End Connections

The body end flanges of all flanged valves shall be drilled for through bolting. Flanges
which are drilled and tapped for studs are not acceptable.
Gasket surface finish for raised face flanges shall be in accordance with ASME/ANSI
B16.5 paragraph 6.4.4.

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13.8 Valve Materials

Valve material shall be equivalent to the material specified in the applicable pipe
specification, higher grade material may be selected provided the selected material is
chemically compatible with the process fluid and the pressure/temperature rating is
consistent with the design pressure/temperature.
Body and bolting materials shall comply with the ENG. STD 50A10, Piping Material
Specification.
Materials for sour service shall conform to the requirements of NACE MR0175.
Butterfly valves shall be fitted with stainless steel vanes and shafts in a precipitation
hardening material (e.g. 17-4 PH).
Valve internal trim materials shall be in accordance with ENG. STD 50A10, Piping
Material Specification. Manufacturer's equivalent specifications shall be used where
these are of a superior material and performance.
Hard faced trims or hardened trim materials at the seating surface shall be utilised
where fluid is erosive, choked, flashing or when cavitation exists at any flowing
condition
Soft seating materials shall be used only where tight shut off cannot be achieved with
hard seated valves and requires Client approval.
Prohibition - The use of crocidolite (blue asbestos) or amosite (brown asbestos) is

strictly prohibited in any valve packing or jointing material. Industry best alternatives
shall be used.
13.9 Actuators
Actuator selection will depend on upon valve selection, service, speed of response and
Supplier. Preferred operation of valves shall be by pneumatically-operated, spring
return, diaphragm or piston actuators. All actuators shall be capable of assuming a
given failure position as defined by the P&IDs
Hydraulically-operated piston actuators shall be limited to applications where

pneumatically-operated actuators cannot produce the required torque with the given air
supply pressures or the physical size of a pneumatically-operated actuator presents
major installation problems or is otherwise not cost-effective.
Electric actuators shall not be used for modulating services.
The torque provided by the actuator shall include a 1.5 safety factor in addition to the
basic valve torque requirements for seat material, fluid, operational frequency and
process conditions.
Valve actuators shall be designed to operate fully under a minimum instrument air
pressure in-line with current facility instrument air design.
For control valves, all actuators shall be sized for full range control.
Normal valve closing speeds shall be as below unless stated otherwise on the control
valve data sheet:
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 15 – 65 mm ≈ 2 seconds
 80 – 150 mm ≈ 3 – 6 seconds : dependant on size
 200 – 600 mm ≈ 8 – 24 seconds : dependant on size
Actuator material shall be steel or ductile iron unless stated otherwise on the control
valve data sheet.
13.9.1 Diaphragm Actuators
Valve shall be operated by spring return diaphragm actuators
Valve actuators shall be sized for the maximum pressure upstream of the valve with
the downstream pressure taken as the lower of zero or the minimum downstream
pressure, which may be less than zero in vacuum service.
13.9.2 Piston Actuators
Piston actuators shall be used to provide longer strokes or greater thrust than is
available from spring diaphragm units.
Double-acting piston actuators that do not automatically fail to safe position in the
event of air failure shall be avoided if possible. A local receiver, with sufficient capacity
for at least two operations over the full travel of the valve shall be supplied with these
actuators. Receivers shall be supplied with full pressure vessel certification.
13.10 Accessories
Actuators shall be provided with electro-pneumatic, SMART positioners which support
the HART / Foundation Fieldbus Protocol. All positioners shall be fitted with an air filter
regulator and gauges for supply and output pressures.
Trip solenoid valves initiated by a shutdown system to override modulating valves shall
be fitted directly into the actuator inlet line.
All valves shall be fitted with a corrosion proof label marked with tag number,
Manufacturer, valve model number, actuator model number, trim size and type, CV
value, failure mode and input signal as a minimum.
Where the size of control valve has an influence of the capacity of relief valves, such
valves shall have full size trims and shall not be equipped with limit stops. They must
carry a warning label. The inscription shall state:-
WARNING
TRIM SIZE AFFECT RELIEF VALVE CAPACITY
All instrument air tubing and fittings shall be 316 Stainless Steel as a minimum.
Compression fittings shall be double ferrule type.
Limit switches shall be 2 wire proximity type. Limit switches shall be specified and
purchased with the control valves and identified on the P&ID.

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All accessories shall be fully piped / wired as part of the valve assembly and shall be
suitably terminated in IP 65 enclosures as a minimum. No accessories shall be
supported by tubing or wiring.
Valves shall be shipped with the un-installed electronic stroke signature to be used as
a reference for set-up and configuration purposes.
13.11 Hand Wheels for Control Valves

Hand wheels shall only be fitted if the process can be kept on-line by means of the
manual operation of a control valve and where indicted on the P&ID.
Hand wheels shall be able to open or close the valve under full differential pressure.
Hand wheels are preferred to hand operated bypass valves provided that the service is
not severe. A non-severe condition means the valve is expected to last from shutdown
to shutdown. The following conditions are regarded as severe even if the valve is
expected to last from shutdown to shutdown:
 Pressure drop exceeds 4 barg for dry gasses or non-cavitating liquids

 All wet gasses
 All steam applications
 The fluid which is corrosive, erosive or fouling
 The flow condition is such that cavitation or flashing can occur or where the
velocities are high (greater than 0.15 mach for gasses)
Hand wheels shall not be fitted to trip valves.
Hand wheels shall also be supplied for fail open butterfly valves for installation and
removal. These valves shall be clearly labelled to ensure that the valve flap is not
damaged during removal.
13.12 Hand Operated Bypass Valves

Hand operated bypass valves shall only be installed if the process can be kept on-line
by means of the manual operation of a hand valve and when shown on the P&ID.
Hand operated bypass valves shall be used as follows:
 Control valve is in severe service

 Control valves with bodies DN40 (1½”) and smaller
Consideration shall be taken in determining the application of bypass valves where the
use of a bypass valve would exceed the relief valve capacity with or without the control
valve also fully open.
The sizing and specification of bypass valves shall be in accordance with the following:
 For control valves DN25 (1") provide a DN25 (1") globe valve, or a DN25 (1")
needle valve, with reduced trim as necessary. In all cases the Cv of the bypass
valve shall be at least equal to and not greater than double the Cv of the control
valve.
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 For control valves larger than DN25 (1"), provide a globe valve with Cv at least
equal to and not more than double the Cv of the control valve.
 Where the control valve is a butterfly or ball valve, i.e. high capacity, use a valve
of the same design but with a hand actuator.
Consider the use of special hardened trim for bypass valves on noisy, erosive or
corrosive service when the selected control valve has such a trim. Noise control trim
shall not normally be furnished for bypass valves.
Bypass valves shall have the same characteristics as the associated control valve.
Bypass valves are only allowed on trip valves if the valve is tripped to the open position
(FO) or if the valve is tripped closed (FC) and the bypass are sized for a safe flow. In
cases the bypass valve has to be a tagged item with a CV statement and data sheet.
(A ¾” globe valve is typically used in steam service for warm-up purposes).
13.13 Block Valves

Block valves are required around control valves as follows:-
 Where bypass valves are required

 The control valve has to be removed for maintenance purposes during operation
 Inventories before or after the valve are of such a nature (including volume) that it
should be blocked off for removal of the valve
 Safe isolation is difficult during a shutdown
 The valve gland or packing life is expected to be less than the shutdown interval
The block valves should be installed within reducers if the pressure drop and velocities
permit.
The application of block valves will be shown on the P&IDs.
13.14 Protective Coating and End Protection

Machined or threaded surfaces subject to atmospheric corrosion during shipment or
subsequent storage shall be coated with an easily removable rust preventative.
Austenitic stainless steel and non-ferrous valves shall not be painted.
Valves with screwed or socket weld ends shall have their ends protected with metal,
wood or plastic plugs.
Valves with flanged ends shall have the gasket surface protected by means of a
suitable wired on disc.
Valves with butt-weld ends shall have the bevels covered with a suitable close fitting
protector.

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13.15 Testing
13.15.1 Hydrostatic Test
Valves with carbon steel bodies shall be hydrostatically tested with water not
exceeding 50°C in accordance with ASME B16.5.
13.15.2 Seat Leakage Test
Valves leakage classes shall be specified and tested to ANSI / FCI 70-2 or API 598.
13.15.3 Mechanical Operation Tests
Valve shall be completely assembled with packing box fully packed and made up hand
tight. The test shall consist of measuring valve stem position for increasing and
decreasing input signals at 25%, 50% and 75% travel. For valves with positioners not
having a by-pass, dead band shall not exceed 0.5% of rated input signal.
13.16 Non-Destructive Examination

Control valve N.D.E. shall be made in accordance with ENG.STD 51A2, Technical
Requirement for Supply of Valves
For ‘fabricated’ valves, NDE procedures shall be submitted for review by Buyer in
accordance with ENG.STD 88A1, Submission of welding and manufacturing Procedure
for Review when specially requested.
13.17 Standards and Specifications

All valves shall comply with the requirements of this Standard, the relevant
Manufacturing Standards, Material Specifications and FWEL ENG.STDs as
appropriate.
13.18 Pressure Containing Components

All pressure containing components require full PED compliance
For all pressure containing components/equipment that does not require CE marking in
accordance with PED, the following minimum requirements apply unless the Project
specification indicates otherwise. In the event of conflict, the Project specification shall
take precedence.
Scope All forged, cast or fabricated equipment that will be

installed in the process piping system
Process Design Code ASME B31.3
Material Specification In accordance with Project specification. Supplier to

selected material grade(s) appropriate to duty as defined
in the Project specification.
Calculation By Supplier, as required by Code.
Welding ASME IX and ASME B31.3. Not applicable if pressure

containing parts are forged / cast.
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Heat Treatment In accordance with the material specification and grade(s)

selected
Inspection For fabricated parts, to pressure design code ASME

B31.3. Inspections tested to 1.5 x design pressure
Examination X ray of Welding:

 N2, Air, LP Steam, Water Service – not required.
 Flammable service – 100% X-ray
Protection Item shall be delivered free from corrosion or oxidation
Special requirement None
14.0 MOTOR OPERATED VALVES
14.1 General
MOV shall only be used for applications that require valve automation for reasons other
than safety or continuous control. Suitable applications for MOVs include product
routing. It shall be noted that MOVs generally require both motor power and a control
command to travel to a given position which makes these unsuitable for applications
with a defined open or closed failure direction.
Special design MOVs that do have a defined failure direction shall only be used with
prior Client approval where technical justification has been provided that the solution is
superior to one using pneumatically or hydraulically actuated valves.
Motor Operated Valves (MOVs) can be used to provide non-safety related isolation on
large process lines where use of manually operated hand valves would be impractical.
Motor Operated Valves are either controlled by the DCS or locally operated manually
by the process operator.

Motor operated valves shall meet all requirements for standard Control valves listed in
this document.
Motor operated valves generally shall be rising-stem type such as gate valves. Other
body styles may be used where a rising-stem gate bodied valve is not suitable.
Standard body sizes shall be selected for each application. (2½” and 5” are not allowed).
The body rating and flange rating for all flanged valves shall be as per line class.
14.3 Actuators
Motors shall be rated for heavy service and the maximum number of starts/operations
of the valve actuator, as recommended by the manufacturer for the life cycle of the
actuator/MOV, shall not be exceed by the required number of operations over the
same period. Where this is not possible, either an alternative valve that does meet the
operational requirement shall be provided, or prior approval from the Client shall be
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obtained so that a reduced lifecycle of the MOV can be taken into consideration as part
of a maintenance plan.
The actuator should be sized to be able to produce twice the amount of torque required
in the application to enable it to handle valves being stuck in position.
The actuator shall also have over current or alternative protection to prevent damage to
the motor in the case of the valve being stuck in position.
The equipment supplied shall be suitable for continuous operation under normal
operating site conditions. Refer to document ENG.STD 01A1, Basic Engineering
Design Data.
Housings for MOV actuators shall be a minimum rating of IP65.
Motor supply voltages to the MOV actuator controls shall be 400 VAC 3 phase and
Neutral at 50 Hz. Circuit protection shall be at the substation but a switch disconnector
and fuse shall be provided locally at the motor control centre for the valve actuator in
the field. All other required voltage levels shall be derived internally by MOV motor
controls.
Repositioning of the motor and control box around the centreline of the valve stem
shall be possible without the need for extra supports.
A limit switch and torque switch shall be used to stop the valve travel in the closing
direction. Similarly, a limit switch and torque switch shall be used to stop the valve
travel in the opening direction.
The reversing contactor shall be supplied as part of the valve actuator assembly. After
initiating a close or open action electrically, it shall be possible to reverse the action
without first completing the stroke to the end of valve travel.
The gearbox housing shall be either factory greased and sealed for long life or fitted
with sufficient grease nipples to enable proper maintenance.
Where actuators of the non-locking gear type are used, provisions shall be made to
prevent cycling of the motor due to repeated operations of the torque switches.
Each valve shall be provided with an integral valve position indicator showing
percentage of full travel.
A hand-wheel (suitably geared as required) shall be provided for manual operation of

each actuator. The assembly shall be designed so that it will disengage automatically
from the drive when the valve has been electrically activated to drive. The requirement
for hand-wheels shall be shown on the P&IDs.
Each valve actuator shall have integral pushbuttons to open or close and stop the
valve.
In addition each valve shall have an integral two position selector switch for “local” or
“remote” selection of operation. The switch shall be designed so that it can be locked
in either of the two positions and will only allow electrical actuation of the valve from the
selected position.

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Each actuator shall have auxiliary contacts for remote indication of ‘Open’ and ‘Closed’
positions and ‘Available’ Status. The contacts shall be rated for 2A @ 24 VDC.
Each actuator shall have relays for the remote operation of the valve for ‘Close’ ‘Open’
and ‘Stop’ actions. The relays shall be 24 VDC 1000 Ohm.
Each actuator shall include an auxiliary 24 VDC supply for use by remote lamps /
control buttons, if required.
15.0 SAFETY INSTRUMENTED SYSTEM VALVES
15.1 General
This section is applicable to automated on/off valves that perform a safety related
function. The term SIS valve as used in this section and the associated applicable
requirements shall not only apply to valves used in emergency isolation but shall also
be applied as relevant to any automated on/off valves on safety related service
including depressurisation and deluge. It should be further noted that the term SIS
valve is not limited to those valves operated by the SIS system and safety design
considerations equally apply to valves operated by other systems including BMS, FGS,
and proprietary packaged control systems.
SIS valves and their accessories shall be selected to meet the required SIL.

SIS valves shall meet all requirements for standard Control valves listed in this
document and in addition, they shall be selected according to following requirements:
 Robust actuated and failure action (typically quarter turn, spring return valves
shall be used)
 Confirmation of the valve position (typically limit switches, proximity type, shall be
provided in fully open and fully closed positions)
 Operation during fire (typically valves shall be fire-safe and approved for fire
isolation)
 Tight shut-off requirement (typically for liquid application and inventory isolation
shall have a leakage rate of ANSI/FCI 70-2 class V minimum)
 Facility for partial stroke testing (TÜV certified) shall be provided for all valves
that need to be tested on line, i.e. where the valve testing intervals are shorter
than the plant maintenance shutdown intervals
All inventory isolation valves shall comply with the above general requirements as well
as with the following specific requirements:
 Only flanged quarter turn type valve bodies approved for fire isolation.
 Only spring return actuators with fail close failure action.
 All inventory isolation valves have a default leakage rate of ANSI Class VI with
TSO. Soft seated valves shall not be used.
15.3 Valve Body and Process Connections

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SIS valves shall be ball and high performance butterfly (flanged) valves.
Standard body sizes shall be selected for each application. (2½” and 5” are not allowed).
The body rating and flange rating for all flanged valves shall be as per line class, with a
minimum rating of class of 300#.
15.3.1 Liquid Protective System Valves
Protective system valves for liquid shall have a minimum leakage class rating under the
non-fire conditions of Class V as defined by ANSI/FCI 70-2, Valve Leakage
Classifications. Valves shall have no internal cavities that may collect liquids.
15.3.2 Quarter Turn Valves
Quarter turn valves shall be used in a protective system service. All protective system
valves shall be flanged.
15.3.3 Full Port Valves
If full port ball valves are used they shall be double metal seated and trunnion
mounted.
15.4 Failure Direction

Failure Direction requirements for SIS valves which regards to instrument signal and air
supply shall be the same. Each SIS valve shall have a clearly defined failure action to
meet the process application requirements. The failure direction will be as shown on
the P&ID.
15.5 Firesafe Valves

SIS valves in piping containing combustible materials or in piping subject to fire
conditions shall be rated firesafe to ISO 10497 (or BS 6755 part 2). The minimum
temperature rating for firesafe valves shall be 1095C. Valves shall be metal seated.
15.6 Actuators
Pneumatically operated, spring return, piston or diaphragm actuators are preferred for
fail open or fail closed valve applications. Hydraulically operated, piston actuators shall
be limited to applications where pneumatically operated actuators cannot produce the
required torque with the given air supply pressures or the physical size of a
pneumatically operated actuator presents major installation problems or is otherwise
not cost effective.
Spring and diaphragm actuators used within hazardous areas shall be fireproofed.
Facility for partial stroke testing (TÜV certified) shall be provided for all valves that need
to be tested online, i.e. where the valve testing intervals are shorter that the plant
maintenance shutdowns.
All actuators shall be sized to operate with a minimum instrument air pressure of 3.5
barg.

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A backup energy source shall be provided for valves that do not utilize spring return
actuators to drive the valve to the safe position. Any air storage drums provided shall
be sized to stroke the valve three times (i.e. from open to closed to open).
Pneumatically operated, spring return, piston or diaphragm actuators are preferred for
fail open or fail closed valve applications. Hydraulically operated, piston actuators shall
be limited to applications where pneumatically operated actuators cannot produce the
required torque with the given air supply pressures or the physical size of a
pneumatically operated actuator presents major installation problems or is otherwise
not cost effective. Spring and diaphragm actuators used within hazardous areas should
be fireproofed.
Facility for partial stroke testing shall be provided where required, e.g. to be tested in
service based on SIL testing interval or Client requirement.
15.7 Accessories
15.7.1 Position Switches
SIS valves shall be fitted with open and closed limit switches to confirm the position of
the valve in cases of emergency. Limit switches shall be 2 wire proximity type. Limit
switches shall be specified and purchased with the SIS valves and identified on the
P&ID.
15.7.2 Solenoid Valves
SIS valves shall be operated by solenoid valves. Solenoids shall be mounted on the
shutdown valve. Solenoid coils shall be of the epoxy-encapsulated type and quick
exhaust rated for continuous duty. The solenoid shall be of the three way type with a
316 stainless steel body. Solenoid Valves shall be certified for the SIL level
requirement.
A control valve with an independent SIS solenoid valve may be used to assist in
achieving a higher SIL rating, but shall not be used alone to perform a shutdown or
inventory isolation task. This shall be subject to SIL validation calculations.
Pilot operated solenoids shall not be used.
SIS valves shall be operated by solenoid valves with a robust fail action that are
mounted on the valve. Typically the solenoid valves shall be constructed from 316
stainless steel and shall only be installed in pneumatic signal lines.
15.8 Reset Facility

All resets including automatic reset (control room) and local reset (field) facilities shall
be implemented in accordance with the Project SIS Philosophy requirements.
The valve, including the actuator and any associated positioner or solenoid valves,
shall not have a facility to apply a manual locking device that could be used to defeat
the operation of the valve to the tripped position by latching the valve in the normally
open or closed operating state.
Typically SIS valves shall be remotely reset by the operator in the control room via the
SIS logic. However, in some instances manual local reset shall be specified for SIS

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valves when there is a specific action for the field operator to perform before the trip
can be cleared.
SIS valve, including the actuator and any associated positioner or solenoid valves,
shall not have a facility to apply a manual locking device that could be used to defeat
the operation of the SIS valve to the tripped position by latching the valve in the
normally open or closed operating state.
SIS valve accessories, such as air filter pressure regulator, solenoid valves, lock-up
relays, switches, etc., shall be specified and mounted on the valve as an integral part of
the valve assembly.
15.9 Testing
All SIS valves shall be completely assembled and tested in the factory. Tests shall
include hydrostatic test, seat leakage test, mechanical operation tests and testing of
valve opening and closing times.
In general, valves shall move to their de-energized (fail) position within 2 seconds.
When this target cannot be met with additional equipment (e.g. booster relay, quick
exhaust valve) the Client shall be consulted.
16.0 PRESSURE RELIEF VALVES
16.1 Selection
Safety relief valve types shall usually be determined based on a built up back pressure
at the valve no greater than:
 10% of the valve set pressure for a conventional (non-balanced) type valve
 30% of the valve set pressure for a balanced bellows type valve
In addition, total back pressure up to 50% of the valve set pressure is allowed for
balanced bellows type valve.
Pilot operated relief valves shall be used for back pressure greater than 50% of valve
set pressure.
Thermal relief valves shall be provided where liquid lines can be blocked in.
Rupture Disks and Rupture Pin Devices shall meet the relevant requirements of ASME
Sec VIII and be ASME Code Stamped UD.
16.2 Sizing
Relief valves shall be sized in accordance with the following basis:-
 API RP520.
16.2.1 Gas and Vapour Service Codes:
 ASME I for Fired Vessels

 ASME VIII for Unfired Vessels

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16.2.2 Liquid Services
 API RP 520 using the Liquid "Certified" formula
16.3 Design
Flanged Relief valves shall be designed in accordance with API RP 526. Minimum inlet
flange rating shall be ASME B 16.5 class 300 for relief valves with 16 inch and smaller
with exception to relief in atmospheric and low pressure tank services, where class 150
shall be used.
Seat tightness shall be in accordance with API RP 527.
Lifting lever shall be as per ASME SEC I and ASME SEC VIII requirements.
Refer to API RP 521 for noise limitation requirements where no regulatory authorities
have defined the allowable levels of noise exposure for personnel or at property limits
on the Project. Sound power calculations are required if there is a vibration risk.
16.4 Installation
Relief valves shall be installed in accordance with API RP 520.
16.5 Application
16.5.1 Conventional Type
Conventional type pressure relief valves shall only be used where the back pressure is
substantially constant (e.g. atmospheric relief) and the sum of maximum variable
superimposed back pressure plus built up back pressure is less than 10% of set
pressure and fouling or corrosive conditions are not expected.
Conventional type relief valves shall be of the nozzle entry type having enclosed
springs and conforming to API RP 526 except for steam or hot condensate when open
bonnets shall be used.
Bodies shall be carbon or alloy steel and trims 12% Cr alloy or other suitable corrosion
resistant alloy.
For flammable or toxic service, bonnets shall be vented to the discharge side of the
valve.
16.5.2 Balanced Type
Balanced type relief valves shall be used for all relief services into the flare systems. All
designs (piston type, bellows type etc.) may be considered.
Balanced type may be used for constant or variable back pressure.
Bonnet and bellows vent shall be routed with minimum restriction to a safe location.
In bellows type pressure relief valves, bonnet shall be vented separately from
discharge.
Bellows type valves shall not be used in fouling conditions.

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16.5.3 Pilot Operated Type
Pilot operated relief valves shall not be used in fouling or high temperature service.
A pilot assisted pressure relief valve is preferred to a pilot operated valve.
Pilot assisted valves shall be considered where accuracy or rapid opening and closing
are required.
17.0 DESIGN REQUIREMENT FOR ANALYSERS AND SAMPLING SYSTEMS

Analyser houses, local panels and sampling systems shall be designed in accordance
with 60A25, Process Analyser System Specification.
Analyser Data Acquisition and Maintenance System shall be designed in accordance

with 60A29, Analyser Data Acquisition and Maintenance System Specification.
Gas chromatographs and analysers shall be provided to meet Project’s process and
utilities requirements and shall be engineered as a complete analyser system package
which receives samples from the analyser process probe, transports and conditions the
sample, performs the measurements and transmits the process variable signals and
associated status and alarm signals to the Analyser Data Acquisition and Maintenance
System and the ICSS.
18.0 INSTRUMENTS IN OXYGEN SERVICES

All organic and inorganic materials will react with gaseous or liquid oxygen at certain
pressures and temperatures. The reaction that can occur can cause a fire or explosion.
Because of these inherent dangers, instrument design and control valve selection are
extremely important for oxygen services.
Many materials commonly used in control valves have ignition temperatures above the
normal flowing temperature of gaseous oxygen. The danger is when abnormal,
localized, high temperatures lead to ignition of these materials.
Use of organic materials in contact with oxygen should be avoided, particularly when
the material is directly in the flow stream. When an organic material must be used for
parts such as valve seats, diaphragms, or packing, it is preferable to select a material
with the highest possible ignition temperature, the lowest specific gravity and the
necessary mechanical properties.
The following materials are listed from highest to lowest resistance to ignite, in on
oxygen service:
 Copper, copper alloys and nickel-copper alloys

 Stainless Steel
 Carbon Steel
 Aluminium
18.1 Guidelines for selecting materials for instruments in oxygen services

All metals in contact with oxygen in the main stream should be of appropriate materials
suitable for the given oxygen service.
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In general, diaphragm casings, diaphragm plates, springs, and other parts not in the
main flow stream may be of ordinary materials such as carbon steel, stainless steel, or
cast iron. However all valve body and trim parts in contact with the flow stream shall be
made of copper, copper alloy or nickel-copper alloys.
All diaphragms in contact with oxygen gas shall be made of fluoroelastomer.
All O-rings in contact with oxygen shall be made of fluoroelastomer or a similar

fluorocarbon elastomer.
Organic materials shall be avoided for use in valve seats or other parts exposed to the
flow stream.
Non-ferrous, inorganic filters shall be placed upstream of valves and regulators. Filters
shall have regular maintenance and cleaning.
Plated parts shall not be used in the main oxygen flow stream because of their
potential contributions to foreign particle impingement.
The following standards should be referred for guidance in designing instrument hook-
ups, etc for oxygen services:
 ASTM G128
 ASTM G88
 NFPA 53
The basic criteria when designing hook-ups for oxygen enriched services are:
 No use of plug or ball valves.

 Elbows shall be avoided.
 Use pulled bends with generous radii.
 All pipe/tube, valves (including manifolds) and fittings are oxygen clean and
bagged in accordance with ASTM G93-88.
19.0 INSTRUMENTS IN HYDROGEN SERVICES

For the selection of instruments in a hydrogen service, consideration shall be taken on
the adverse effects that hydrogen at elevated temperatures and pressures can have on
carbon and low-alloy steels. They include hydrogen embrittlement, high-temperature
hydrogen attack and hydrogen blistering.
Hydrogen is colourless, odourless and highly explosive, low-viscosity, low-molecular-

weight gas. It is an asphyxiant. These characteristics make zero leakage a necessity.
Leakage must be addressed not only at the seat but also at all other valve
components. Metal gaskets, requiring more accurate and precise machining, can be
useful where temperature limits the use of soft materials. Packing design becomes
critical to avoid stem leakage. Additional inspection practices, such as radiography may
be necessary.
Adding to the detrimental effects that hydrogen can have on the valve, operating
conditions such as temperature, pressure and concentration of hydrogen should be

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considered when selecting the right materials. Additional steps, such as post-weld heat
treatment shall be required.
19.1 Risk to instrumentation and valves in Hydrogen services

The risk analysis for instrumentation and valves used in hydrogen service is based on
three primary factors: pressure, temperature and concentration of hydrogen.
Much of this risk analysis associates the presence of hydrogen in the stream to the
possibility of metallic material corrosion such as hydrogen attack, embrittlement and
blistering. API 941 Recommended Practices shall be considered when selecting
instruments and valves in a Hydrogen service.
Heat-treating and inspection methodologies shall be used to reduce the risk of valve
leakage in hydrogen environments.
Hydrogen leakage in valves occurs through two key paths. Leakage at the seat allows
hydrogen to pass when the valve is closed. In this leakage, the gas is contained within
the process. The more critical leakage is through the stem, which can result in gas
escaping to the atmosphere.
To prevent leakage at the seat, metal-to-metal technology is preferred. The technology

used in hydrogen service applies a flexible, resilient metal on the disk that seals
against a stellite hard-faced seat. The metal-to-metal design provides a durable, high-
temperature seal, thus ensuring a leak-proof seal.
Preventing stem leakage entails a number of basic design considerations, including:
 Live-loaded packing for temperature variations

 Packing to be prevented from rotation
 Providing a very efficient shaft seal
 Very smooth shaft surface
 Ensuring the packing segments are in touch with the stuffing box and the shaft
simultaneously
Standards and specifications shall include ISO 15848 1 and 2, and API 622.
19.2 Valve considerations

Hard-metal gaskets between the body and bonnet are necessary in hydrogen
processes. Softer metals are too porous for the application. The harder, nonporous
materials have significantly higher operating temperatures exceeding 250°C. However,
metal gaskets require more accurate machining. If the body or the gasket is not
perfectly round and precisely within tolerances, it will not seal effectively. For this
reason, valve bodies shall be precisely machined.
As with gaskets, graphite packing material also presents permeability problems. An

alternative in low-temperature applications (below 200°C) are packing designs that use

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O-rings in various rubber compounds or Chevron-type packing to provide leak

prevention with multiple seals.
However, these materials are not suitable for high-temperature, high-pressure

applications. Under these extreme environments, engineered graphite packing
technology provides an effective alternative. The technology uses special graphite
packing interposed with metal sheets to minimize gas losses.
19.3 Inspection
Radiographic x-rays and dye-penetration testing shall be used to check for internal
defects, including cracks, hot tears, holes and gas inclusions. The internal volume of
the valve is checked to address hydrogen blistering.
Testing fully assembled valves with high pressure helium to search for leakage shall be
considered. Because the helium atom is very close in size to the hydrogen, this testing
best simulates operating conditions. Low-pressure testing indicates losses due to leaks
and porosity, while the high pressure testing ensures there is no deformation of
sufficient magnitude to cause losses.
Post weld heat treatment shall be used on all valves in a hydrogen service. Post weld
heat treatment of 0.5 molybdenum (Mo) and chromium-Mo steels shall be considered.
The following factors shall be considered when specifying valves for hydrogen service:
 Metallurgy selected through API specifications

 Forming process, i.e., casting vs. welding
 Design features to avoid susceptibility to embrittlement, etc.
 Gasket/packing design and material selection
 A robust inspection process.
 Generally acceptable materials include austenitic stainless steels, aluminium
alloys, copper, and copper alloys.
 Nickel and most nickel alloys should not be used since they are subject to severe
hydrogen embrittlement.
 Gray, ductile, and malleable cast irons should also not be used for hydrogen
service.
19.4 Flange Finish for Hydrogen services

ANSI/ASTM B16.5 requires a flange face has a specific roughness to ensure that the
flange face has a specific roughness to ensure that this surface be compatible with the
gasket and provide a high quality seal. A serrated finish, either concentric or spiral, is
required with 30 to 55 grooves per inch.
The finish for the gasket contact surface, of metal flanges in hydrogen service is
typically between Ra 2 and 3.2 micrometers (79-125 micro inch).
20.0 FIRE AND GAS DETECTORS
20.1 General
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Requirements for Fire and Gas Detectors shall be in accordance with 60A22, Fire &
Gas System Specification.
Analyser houses shall be treated as a normal process area and not as a building. For
specifics on Fire and Gas detection in analyser houses refer to the 60A25, Process
Analyser System Specification.
20.2 Flame Detectors

The location and design of flame detectors shall be performed in accordance with
requirements specified in NFPA 85.
Field tests shall be required to establish optimum sighting angles of burners or nozzles
and to check the effective angular range of flame detectors in relation to burners or
nozzles.
Clean air, where necessary, shall be supplied to minimize problems with dirty detector
lenses. The cleanliness of the lens should be verified automatically by the detector.
Self-checking features shall be provided to ensure that the failure of any single
component cannot result in a false indication of flame.
Care should be taken to ensure that the effects of lighting, arc welding, radiation and
sunlight do not affect the accuracy or reliability of the flame detector.
21.0 DESIGN REQUIREMENTS FOR INTEGRATED CONTROL & SAFETY

SYSTEM
21.1 General
The Project shall provide for safe and reliable process operations by installing an
Integrated Control and Safety System (ICSS) consists of Distributed Control System
(DCS), Safety Instrumented System (SIS), Fire and Gas System (FGS), Burner
Management System (BMS) and other auxiliary monitoring and control systems which
are indicated in this section e.g. Compressor Control System (CCS), Machine
Monitoring System (MMS), Custody Metering System and Packaged proprietary control
and trip systems.
The ICSS shall maintain a fully integrated concept to provide a ‘single window’ to the
operator where all subsystem operator interface requirements are incorporated within
the same system.
All ICSS shall be time synchronised to an external GPS master clock system typically
using Network Time Protocol. In this way, information gathered by all the subsystems
within the ICSS system’s devices on alarms and events shall be accurately sequenced.
The ICSS shall generate and transfer all system maintenance diagnostics and trouble-
shooting data to the DCS which shall consolidate this information from all devices and
all subsystems into a graphical interface.

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All ICSS shall have centralised engineering and maintenance capability which enable
routine engineering and maintenance activities to be performed from engineering and
maintenance consoles located in the Engineering Room in the Central Control Building.
In addition, engineering and maintenance activities can also be conducted from the
operator consoles located in the respective ISBs. These consoles can also be used for
start-up and shutdown activities.
21.2 Distributed Control System (DCS)

The DCS shall provide process control and monitoring for the Project. At the process
control level it shall perform basic regulatory and sequential control, non SIL rated
interlocks and process monitoring, alarm management, data archiving, reporting,
trending, etc. The DCS shall be capable of performing higher level functions such as
advanced process control (multivariable control and optimisation), advanced
application execution, instrument asset management and advanced alarm
management.
The DCS processing equipment including networks, interfaces, system and marshalling
cabinets shall be located in the respective ISBs located close to the process
equipment. Field instrumentation shall be wired directly to the I/O processors within
the ISB.
Field mounted remote I/O processors shall, in principle, not be used unless distance
becomes a factor to be considered.
The DCS shall seamlessly interface with all ICSS subsystems (such as the SIS, BMS,
FGS, CCS, MMS, etc) allowing the operator to view the entire plant via operator
consoles.
Distributed Control System (DCS) shall be designed in accordance with 60A23,

Distributed Control System Specification.
21.3 Safety Instrumented System (SIS)

The SIS equipment and operation shall be completely independent from any other
systems and shall perform emergency shutdown and depressurisation functionality that
will ensure safe and orderly shutdown and depressurisation due to unexpected
emergencies and hence reduce the potential for uncontrolled release of flammable or
toxic materials to the atmosphere, and the resulting damage to people, equipment and
the environment that follows.
Pre-alarms shall be provided for all trip signals where operator intervention is possible
to prevent a trip situation. Additional alarms shall be provided to warn the operator of
impending shutdown or shutdown occurrence. All alarm signals shall be routed to the
DCS.
Instruments used on non voted shutdown duty shall be separate from those used on
control, indicating or recording duty and shall have separate process connections,
except in the case of flow trips with a common orifice plate which may be used. Each
DP flow instrument shall have separate tapings.
Where three or more transmitters are used in a multiple voting configuration for
safeguarding, the median value from transmitters may be used for the control

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application in the DCS. The signal is available in the DCS directly from the SIS and an
independent transmitter for the DCS is not required. The loop power for the transmitter
shall be provided by the SIS.
Safety Integrity level (SIL) classification shall be determined for all safeguarding
instrument loops (SIF) including within packaged units. For instruments and final
elements connected to the SIS, the field redundancy depends on Safety Integrity Level
(SIL) requirements and the reliability and integrity of the chosen devices and as such,
specific attention shall be applied during the equipment selection stage to meet these
requirements including overall PFDavg values. Suitable testing facilities shall be
provided to be able to test both the initiators and final elements in line with the
specified SIL requirements to meet IEC 61508 and IEC 61511 requirements.
The SIS shall be designed to meet the requirements of IEC 61508 and IEC 61511
specifications with a maximum scan time of 300 milliseconds and a minimum safety
system SIL rating of SIL 3 with full redundancy on all components.
The SIS shall be interfaced to the DCS via separate redundant communication links.
Safety Instrumented System (SIS) shall be designed in accordance with 60A11, Safety
Instrumented System Specification.
21.4 Fire & Gas System (FGS)

The FGS shall operate independently of other control systems. The FGS is intended
to monitor, record and alarm all the essential toxic gas leaks and any fire resulting from
leaking explosive gasses/combustible dust in process areas/buildings. This
automation level shall allow fail-safe control and allow for an orderly operation in case
of an emergency.
The FGS shall be designed to meet the requirements of IEC 61508 and IEC 61511
specifications and shall be based on the same hardware and software as used for the
SIS.
The FGS shall be interfaced to the DCS via separate redundant communication links.
Fire and Gas System (FGS) shall be designed in accordance with 60A22, Fire & Gas
System Specification.
21.5 Burner Management System

The BMS shall provide automatic surveillance and protection functions on all fired
equipment and shall include their safe start-up and shutdown functions. In addition,
the BMS shall also contain the flame front generator and flame supervision system,
where these are provided in the design.
The BMS is a stand-alone system that does not rely on any other system to protect the
fired equipment. In exceptional cases the BMS functions may be incorporated into the
SIS of the particular unit if the number of I/O involved is too small to warrant a stand-
alone BMS and shall only be used with the Client’s written approval.
The BMS shall be designed to meet the requirements of IEC 61508 and IEC 61511
specifications and shall be based on the same hardware and software as used for the
SIS.

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Each BMS shall be interfaced to the DCS via separate redundant communication links.
Burner Management System (BMS) shall be designed in accordance with 60A9, Burner
Management System for Fired Equipment Specification.
21.6 Machine Monitoring System (MMS)

The MMS shall provide automatic vibration, displacement and temperature condition
monitoring and protection functions on rotating machinery. In addition, the MMS shall
include long term equipment condition data storage, diagnostic analysis tools, decision
support and predictive maintenance functionality.
Machinery shall be categorised into critical, normal and low priority machines which in
turn will define the required level of condition monitoring requirements. These can vary
from offline monitoring to continuous monitoring including diagnostic analysis and
decision support functions.
The MMS shall be interfaced with the DCS via redundant communication links and
MMS trip outputs shall be hardwired to the SIS as required where the tripping function
shall be performed.
Machine Monitoring System (MMS) shall be designed in accordance with 60A30,

Machine Monitoring System Specification.
21.7 Compressor Control System (CCS)

All compressors are equipped with a Compressor Control System (CCS) providing
uninterrupted, automatic and accurate load control and protection of the compressors.
The CCS comprises a compressor load control system and a compressor protection
system on all centrifugal compressors, but only a compressor load control system on
all reciprocating and screw compressors.
The load control function shall be implemented in DCS where possible.
The protection functions (typically anti-surge protection, overload protection and over-
speed protection etc.) shall be handled by stand-alone compressor protection system
provided by Supplier, unless the compressor is equipped with a compressor
manufacturer’s proprietary control system comprising an integrated load control and
protection system.
Each CCS shall be interfaced to the DCS via redundant communication links.
Compressor Control System (CCS) shall be designed in accordance with 60A31,

Compressor Control System Specification.
21.8 Packaged Proprietary Control and Trip System

Package unit’s control, monitoring and safety functions shall generally be incorporated
in the plant ICSS. Packaged proprietary control and trip systems, such as Gas Turbine
Generator, required for package units shall be used by exception and only if it utilises
the plant DCS HMI as the operating window.
Packaged proprietary control and trip systems shall only be used with the Client’s
written approval.
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The DCS shall perform the following functions for the packaged equipment: alarm
management, trending, reporting, data archiving, and all advanced functionality. The
DCS shall also integrate the package unit into a single operator interface HMI and shall
integrate the package unit SOE information into a single SOE database.
Each packaged proprietary control and trip system shall be interfaced to the DCS via
redundant communication links.
21.9 Custody Metering System

The Custody Metering System shall be redundant from the field through to the
measurement processing with one system designated as pay (main) and the other as
check (standby). However, the requirements for multi-stream measurements and
provers shall be based on the type of metering systems required and 3rd party
agreements etc.
The Custody Metering System cabinet including flow computers shall be housed in the
associated ISB and shall be linked to a supervisory flow computer located in the CCR
which shall facilitate remote access for support and maintenance.
The Custody Metering System shall be interfaced to the DCS via redundant
communication links.
Each Custody Metering System shall be provided as a complete set of tested and
certified metering system including provers and all instrumentation and electronic
equipment in accordance with:-
 60A34, Custody Metering System – Gas Specification

 60A35, Custody Metering System – Liquid Specification
22.0 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)

A Continuous Emission Monitoring System shall be provided to continuously monitor
combustion gasses in accordance with Plant Philosophy requirements.
Continuous Emission Monitoring System (CEMS) shall be designed in accordance with

60A40, Continuous Emission Monitoring System Specification.
23.0 AMBIENT AIR MONITORING SYSTEM (AAMS)

An Ambient Air Monitoring System (AAMS) shall be provided to continuously monitor
air quality from fixed locations on site in accordance with Plant Philosophy
requirements.
Ambient Air Monitoring System (AAMS) shall be designed in accordance with 60A39,
Ambient Air Monitoring System Specification.
24.0 C&I / ELECTRICAL INTERFACE

The interface between instrument and electrical systems shall be designed in
accordance with 66A1, Instrument / Electrical Interface Specification.

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Intelligent Motor Control System (IMCS) shall be used with both status and control
signals transmitted over a redundant communications link to the DCS.
Operator starts and stops, and diagnostic information shall be transmitted over this
redundant communications link.
All safety related signals shall be hardwired through IRPs between the SIS and the
MCC.
Any relays installed as part of a safeguarding Instrument loops (SIF) are required to
meet the associated SIL targets.
The DCS shall also interface with the PMS for monitoring of power distribution status
and loads.
The extent of control and indication of motors and switchgear shall be shown on the
P&ID’s.

60a1 (Reading)

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60a1 (Reading)

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C& I ENGINEERING

1.0 INTRODUCTION .................................................................................................................. 5

8.7 Infra-red Pyrometers ....................................................................................................... 21

13.12 Hand Operated Bypass Valves ................................................................................... 39

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The operations philosophy and extent of control and instrumentation shall be as

3.0 REFERENCE DOCUMENTATION

 Statutory Laws and Regulations

3.1 Engineering Specifications

Document Number Title

01A1 Basic Engineering Design Data (BEDD)

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3.2 International standards

3.2.1 American Standards and Documents

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3.2.2 Local Standards (As applicable)

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4.1 Instrument Identification

Logic Diagrams shall be in accordance with ISA standard S5-2.

4.2 Instrument Index

4.3 Packaged Units

4.4 Supplier List

4.6 Directives of the European Community

 Low Voltage Directive, 73/23/EEC and amendment 93/68/EEC

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 ATEX Directive, 94/9/EC, Equipment for explosive atmospheres

5.0 GENERAL DESIGN REQUIREMENTS

Instrumentation and control systems shall be designed to operate within limits of

Control systems shall be designed to avoid interaction between associated electrical

Instruments with mercury shall not be used.

Instrument cables/wiring requirement and installation shall be in accordance with 60A2,

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5.2 Units of Measurement

5.3 Instrument Ranges

 Pressure Gauges : ± 1.0% of full scale.

Instruments including isolation valves shall be installed so as to be easily accessible

Detailed requirements for locations of instrumentation, relative spacing between

5.7 Instrument Connections

5.7.2 Instrument Pneumatic Connections

5.7.3 Instrument Electrical Connections

Electrical entries to instruments shall be metric (M20 x 1.5).

5.8 Signal Transmission

Signal Type Signal Level

Discrete signals 24V DC

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Signal Type Signal Level

Discrete Motor control

Refer to 60A24, C&I Installation Specification for details of signal segregation

Integral indication shall be provided on all transmitters for operator use.

Linearization of measurement shall be accomplished in the transmitters.

Wireless transmission shall only be used for monitoring instrumentation located in

5.9 Electromagnetic Compatibility Requirements

All equipment shall comply with:

 IEC 61000 Sections 2, 3, 4 - Electromagnetic Compatibility.

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 IEC 61010 Section 1 - Safety Requirements for Electrical Equipment

5.10 SIL Requirements