10. 1014-bktng-in-sp-0006_rev 0

FRONT-END ENGINEERING DESIGN (FEED)

SERVICE FOR BK-TNG WELLHEAD PLATFORM GENERAL SPECIFICATION FOR INSTRUMENTS

DOC NO. 1014-BKTNG-IN-SP-0006

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TABLE OF CONTENTS

1.0 GENERAL 4 1.1 Background 4 1.2 Purpose of document 4

1.3 Definitions and Abbreviations 4 1.4 Reference Documents 7

2.0 CODES & STANDARDS 8

2.1 General 8 2.2 International Codes & Standards 8

3.0 ENVIRONMENTAL CONDITIONS 12 4.0 UTILITIES SUPPLIES 13

4.1 Electrical Power 13

4.2 Instrument Air 13 4.3 Hydraulic System 13

5.0 INSTRUMENT GENERAL REQUIREMENT 13 5.1 Design Life 13 5.2 Protection Method 14

5.3 Heat Tracing 15 5.4 Material of Selection 15

5.5 Language, Unit and Measurement 15

5.6 Tagging System 16 5.7 Name plates 16

5.8 Data Sheets 17

5.9 Painting 17 6.0 FIELD INSTRUMENTATIONS REQUIREMENT 17

6.1 General 17 6.2 Pressure Instrument 17

6.3 Temperature Instrument 18

6.4 Level Instrument 21 6.5 Flow Instrument 22

6.6 Restriction Orifice 24

6.7 Pig Signaller 25 6.8 Process On Line Analyser 25

6.9 Sand Detection System 25 7.0 VALVES GENERAL REQUIREMENTS 26

7.1 Control Valves 26

7.2 Regulators 30 7.3 Choke Valves 30




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7.4 Actuated Valves 30

7.5 Safety Relief Valves 33 8.0 MISCELLANEOUS INSTRUMENT ITEM 35

8.1 Junction Boxes 35 8.2 Instrumentation Cable 35

8.3 Instrument Cable Glands 37 8.4 Cable Trays/Ladders 37 8.5 Earthing System (Grounding) 38

8.6 Cable Transits 38

8.7 Tubing, Fittings and Trays 39 9.0 INSTRUMENT INSTALLATION 39

10.0 INSPECTION AND TESTING REQUIREMENTS 40 10.1 General 40

10.2 Factory Inspection And Testing 40

10.3 Inspection and Testing at Fabrication Yard/Offshore 41 11.0 DRAWINGS AND DOCUMENTS 41




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1.0 GENERAL

1.1 Background

Thien Ung field is located in the middle part of Block 04-3 in the Nam Con Son Basin, offshore the Socialist Republic of Vietnam, approximately 15 km of Dai Hung field, and approximately 270 km southeast of Vung Tau. The Block 04-3 covers an area of approximately 2600 km2. The Thien Ung field is including its 2 structural parts. Thien Ung structure discovery was made in 2004 with the 04-3-TU-1X well. Two subsequent appraisal wells (04.3-TU-2X and 04.3-TU-3X), drilled and tested respectively, delineated the field.

Location of Thien Ung field is shown in Figure 1.1 below.

Figure 1.1: Thien Ung Reservoir Location

1.2 Purpose of document The prime objective of this document is to provide a common philosophy for instrumentation equipment for the BKTNG Weelhead Platform.

Field instrumentation provides the interface between the actual process and the control and safety systems. The integrity and reliability of the overall control system and safeguarding systems, which in turn affect plant availability and safety, is dependant on the use of the correct type and quality of the field instrumentation. Therefore selection & installation of instrumentation shall meet the specified requirements herein, and data sheet developed during detailed design.

1.3 Definitions and Abbreviations

1.3.1 Definitions

PROJECT FEED service for BK-TNG Wellhead Platform

COMPANY The party, which initiates the project and ultimately pays for its design and construction and owns the facilities. Here the COMPANY is Vietsovpetro (Referred to as VSP)




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CONTRACTOR The party who carries out all or part of the design, engineering, procurement, construction and commissioning of the project

VENDOR The party on which the order or contract for supply of the equipment / package or services is placed

Shall Refers to mandatory requirement

Should Refers to a recommendation

WILL Refers to mandatory requirement

CONSIDER Is a mandatory requirement unless a technical justification exists for not implementing and an equivalent solution is implemented

MAY Indicates an acceptable course of action

MIGHT Indicates an acceptable course of action

CAN Indicates an acceptable course of action

“Fit for Purpose” A standard of work or design which has no specified design parameters but which is generally accepted will meet the performance requirements required of it over its intended life of service, specifically including but not limited to safety, operability and maintainability.

1.3.2 Abbreviations

AC Alternating Current

API American Petroleum Institute

BDV Blowdown Valve

BK-TNG Thien Ung Wellhead Platform

CCR Central Control Room

CPP Central Processing Platform

DCS Distributed Control System

DP Differential Pressure

EMI Electromagnetic Interference

ESD Emergency Shutdown System

ESDV Emergency Shutdown Valve

FAT Factory Acceptance test

FEED Front End Engineering Design

FGS Fire & Gas System

FWS Full Well Stream

GWR Guided Wave Radar

HART Highway Addressable Remote Transducer

HDD Human Machine Interface




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HMI Human Machine Interface

HVAC Heating Ventilation and Air Conditioning

ICSS Integrated Control & Safety System

IEC International Electrotechnical Commission

IER Instrument Equipment Room

IMCS Integrated Motor Control System

IP Ingress Protection

IS Intrinsically Safe

ISO International Organization for Standardization

I/O Input/Output

I/P Current to Pressure

JB Junction Box

LV Low Voltage

LSZH Low Smoke Zero Halogen

MCT Multi Cable Transit

MODBUS Serial Communication Protocol by Modicon

MV Medium Voltage

NPS Nominal Pipe Size

NPT National Pipe Thread

NPTF National Pipe Thread Female

OD Outside Diameter

OWS Operator Workstation

PVC Poly Vinyl Chloride

RFI Radio Frequency Interference

RTD Resistance Temperature Detector

RTJ Ring Type Joint

SCSSV Surface Controlled Subsurface Safety Valve

SDV Shutdown Valve

SS Stainless Steel

SSV Surface Safety Valve

SWB Steel Wire Braided

TC Thermocouple

UCP Unit Control Panel

UPS Un-interruptible Power Supply

USM Ultrasonic Flowmeter

UV UltraViolet

VAC Volts Alternating Current

VDC Volts Direct Current




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1.4 Reference Documents

DRAWING/DOCUMENT NO.

TITLES

1014-BKTNG-IN-DW-0001 Overall System Architecture Diagram

1014-BKTNG-IN-RPT-0001 Instrument Design Basis

1014-BKTNG-IN-SP-0007 Specification for Package Equipment Instrumentation

1014-BKTNG-PR-RPT-0001 Process and Utilities Design Basis

1014-BKTNG-PR-RPT-1001 Process Control and Operating Philosophy

1014-BKTNG-EL-SP-0010 Specification for Electrical Cables

1014-BKTNG-EL-SP-0013 Specification for Electrical Heat Tracing

1014-BKTNG-PI-SP-0005 Piping Material Specification

1014-BKTNG-PI-SP-0006 Specification for Manual Valves

1014-BKTNG-PM-PCP-0001 Project Coordination Procedure




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2.0 CODES & STANDARDS

2.1 General

The equipment shall be designed, fabricated and tested in accordance with the latest revision of all relevant international Codes and Standards including but not limited to the standards listed below.

In the event of conflict between codes and standards and/or this specification, the matter shall be highlighted for COMPANY’s attention/approval.

2.2 International Codes & Standards

American National Standards Institute (ANSI)

ANSI/FCI 70.2 Control Valve Seat Leakage

ANSI/ISA 5.1 Instrument Symbols & Identification

ANSI/ISA 51.1 Process Instrumentation Terminology

ANSI/ISA 75.08.01 Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (ANSI Classes 125, 150, 250, 300, & 600)

ANSI/ISA 75.08.06 Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (ANSI Classes 900, 1500, & 600)

ANSI/ISA 75.01.01 Flow Equations for Sizing Control Valves

American Petroleum Institute (API)

API MPMS Manual of Petroleum Measurement Standards

API SPEC 6A Specification for Wellhead & Christmas Tree Equipment

API SPEC 6D Specification for Pipeline Valves (Gate, Plug, Ball, and Check Valves)

API SPEC 6FA Specification for Fire Test for Valves

API RP 14C Analysis, Design, Installation and Testing of Basic Surface Safety Systems for offshore Production Platforms

API RP 520 Part I Sizing, Selection and Installation of Pressure Relieving Systems in Refineries, Sizing and Selection

API RP 520 Part II Sizing, Selection and Installation of Pressure Relieving Systems in Refineries, Installation

API RP 521 Guide for Pressure Relieving and Depressurizing Systems

API STD 526 Flanged Steel Pressure Relief Valves

API STD 527 Commercial Seat Tightness of Pressure Relief Valves with Metal to Metal Seats

API RP 551 Process Measurement Instrumentation

http://www.api.org/




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API RP 552 Transmission Systems

API RP 554 Process Instrumentation and Control

API RP 555 Process Analyzers

API STD 598 Valve Inspection & Testing

API STD 600 Bolted Bonnet Steel Gate Valves for Petroleum & Natural Gas Industries

API STD 602 Compact Steel Gate Valves Flanged, Threaded, Welding and Extended-Body Ends

API STD 607 Fire Test for Soft Seated Quarter Turn Valves

API STD 2000 Venting atmosphere and low pressure storage tanks

API STD 609 Butterfly Valves Double Flanged, Lug & Wafer Type

API STD 670 Machinery Protection Systems

API MPMS 5.2 Measurement of liquid hydrocarbons by Displacement flow meters

API MPMS 5.3 Measurement of liquid hydrocarbon by Turbine flow meters

American Society of Mechanical Engineers (ASME)

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.34 Valves Flanged, Threaded and Welding Ends

ASME B16.10 Face to Face & End to End Dimensions of Valves

ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60 Metric/Inch Standard

ASME B31.3 Process Piping

ASME B46.1 Surface Texture, Surface Roughness, Waviness, & Lay

ASME B1.20.1 Pipe Threads, General Purpose

ASME Boiler and Pressure Vessel Code Division I & II

ASME VIII Boiler and Pressure Vessel Code

ASME PTC 19.3 Temperature Measurement




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ASME/MFC 16M Measurement of Fluid Flow in Closed Conduits by means of Electromagnetic Flow meters

ASME/MFC 11M Measurement of Fluid Flow by Means of Coriolis Mass Flow meters

ASME B40.3 Bimetallic Actuated Thermometers Standard

American Society for Testing and Material (ASTM)

ASTM A269-04 Standard Specification for Seamless & Welded Austenitic Stainless Steel Tubing for General Service

Det Norske Veritas

DNV-OS-D201 Electrical Installations

DNV-OS-D202 Automation, Safety and Telecommunication Systems

Euro-Norm (EN)

EN 837-1 & EN 837-2 Pressure gauges, Bourdon tube pressure gauges. Dimensions, metrology, requirements & testing. Also capsule gauges.

EEMUA138 Design & Installation of On-line Analyser Systems

International Electro technical Committee (IEC)

IEC 60034-5 Classification of degrees of protection provided by enclosures

for rotating machinery

IEC 60079-0 Electrical Apparatus for Explosive Gas Atmospheres, Part 0: General Requirements

IEC 60079-1 Electrical Apparatus for Explosive Gas Atmospheres, Part 1: Flameproof enclosures “d”

IEC60079-7 Electrical Apparatus for Explosive gas Atmospheres, Part 7: Increased Safety “e”

IEC 60079-11 Electrical Apparatus for Explosive Gas Atmosphere, Part 11: Intrinsic Safety “i”

IEC 60092-376 Electrical Installations in Ships Part 376: Cables for Control and Instrumentation Circuits 150/250 V (300 V) - Second Edition

IEC 60092-359 Electrical Installations in Ships - Part 359: Sheathing Materials for Shipboard Power and Telecommunication Cables - Edition 1.2

IEC 60331 Test of Electrical Cables Under Fire Conditions

IEC 60332 Test on Electrical and Optical Cables Under Fire Conditions

IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)




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IEC 60584-1 Thermocouples Part 1: Reference Tables - Second Edition

IEC 60584-2 Thermocouples Part 2: Tolerances - First Edition; Amendment 1: 06-1989

IEC 60584-3 Thermocouples. Part 3: Extension and compensating cables – Tolerances and identification system

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 60947-5-6 Low voltage switchgear and control gear – Part 5-6: Control circuit devices and switching elements – DC interface for proximity sensors and switching amplifiers (NAMUR)

IEC 61000 Electromagnetic Compatibility (EMC)

IEC 61289-4 Code of practice for the Installation of Fiber Optical Cabling.

IEC 61326 Electrical Equipment for Measurement, Control & Laboratory use

IEC 61508 Functional Safety of Electrical/ Electronic/ Programmable Electronic Safety Related Systems

IEC 61511 Functional Safety – Safety instrumented systems for process industry sector

IEC 61537 Cable Management - Cable Tray Systems and

Cable Ladder Systems

IEC 61892 Mobile and fixed offshore units - Electrical installations

Instrument Systems & Automation Society (ISA)

ISA 5.2 Binary Logic Diagram for Process Operations

ISA 5.5 Graphical Symbols for Process Displays

International Organization for Standardisation (ISO)

ISO 1000 SI Units and recommendations for use of their multiples and of certain other units

ISO 4126 Safety Devices For Protection Against Excess Pressure

ISO 5167 Measurement for Fluid Flow by means of Pressure Differential Devices inserted in Circular Cross Section Conduits Running Full, Parts 1 to 4

ISO 5168 Measurement for Fluid Flow – Procedure for the Evaluation of Uncertainties

ISO 5208 Industrial Valves – Pressure Testing of Valves

ISO 5209 General Purpose Industrial Valves – Marking




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ISO 5210 Industrial Valves – Multi turn Valve Actuator Attachments

ISO 5211 Industrial Valves – Part turn Actuator Attachment

ISO 6551 Petroleum Liquids and Gases – Fidelity and Security of Dynamic Measurement Cabled Transmission of Electric and/or Electric Pulsed Data

ISO 6718 Bursting Disc and Bursting Disc Devices

ISO 6976 Natural Gas – Calculation of Calorific Value, Density and Relative Density & Wobbe index from composition

ISO / CD 10715 Natural Gas, Sampling Guidelines

ISO 7278-3 Liquid Hydrocarbons – Dynamic measurement – Proving systems for volumetric meters Parts 3 – Pulse Interpolation Techniques

ISO 9000 – 9004 Quality Management Systems

ISO 10790 Measurement of fluid in closed conduits: Guidance to the selection, installation and the use of Coriolis Meters

NACE International

NACE MR-01-75 Sulphide stress cracking resistant metallic material for oil field equipment.

NEK (The Norwegian Electrotechnical Committee)

NEK 606 Norwegian industry standard cable for the offshore oil and gas, ship and marine industries.

Flow Measurement Handbook by R.W. Miller Relevant TCVN Codes & Standards

3.0 ENVIRONMENTAL CONDITIONS

All Instrument and Control equipment shall be suitable for operation on offshore platform. The equipment shall be suitable for continuous and short time duty, in the environmental conditions prevailing at site.

The environmental and climatic data are summarized below:

Atmosphere: Offshore, dusty, salt laden, marine air condition, expose to monsoon storm and winter depression

Ambient Temperature: 39°C (Max) 21°C (Min)

Relative Humidity: 98% (max) 62% (min)

Wind Velocity: 18.8 m/s

Rainfall: 50 mm/hr




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Indoor Temperature: (CCR/IER)

27°C (max) 18°C (min)

Indoor Humidity: (CCR/IER)

75% (max) 35% (min)

4.0 UTILITIES SUPPLIES

4.1 Electrical Power

Power supply to Instrument and Control systems shall be as follows:

• 230 VAC, 50 Hz, 1-phase, UPS

• 230 VAC, 50 Hz, 1-phase, Non-UPS

• 400 VAC, 50 Hz, 3-phase

24 VDC power supplies, if required, shall be derived from the respective power supply unit within the systems.

Note 1: For UPS backup time definition, reference shall be made to Electrical Basis of Design. 4.2 Instrument Air

The facilities will be equipped instrument air system. Oil free, water free, dry and clean instrument air system shall be made available with header pressure maintained at 7~9 barg. However, all valve actuators shall be sized for a minimum instrument air supply pressure of 4 barg and shall withstand maximum design instrument air pressure of 13 barg.

Design Instrument Air pressure : 13 barg

Normal Instrument Air pressure : 7~9 barg

Minimum Instrument Air pressure : 4 barg

Each instrument/valve requiring air supply shall be provided with individual air filter regulator and isolation valve.

Where valves require high torque, which cannot be met by pneumatic actuator, hydraulic actuator may be considered.

4.3 Hydraulic System

The hydraulic power unit shall be located as part of the Well head control panel and shall derive the following pressures for the wellhead valves. The Hydraulic pump shall be power driven backed up by pneumatic driven pump. The hydraulic system shall be sized based on the worst case figures below but sizing calculation shall be carried out during detailed design by vendor for each individual application and worst case figures will be revisited where necessary.

SSV (Wing and Master) supply pressure : 415 Barg (Maximum)

SCSSV Supply Pressure : 420 Barg (Maximum)

5.0 INSTRUMENT GENERAL REQUIREMENT

5.1 Design Life All equipment must have at least two (2) years proven offshore & onshore field experience. The design life shall be minimum 25 years.




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5.2 Protection Method

5.2.1 Hazardous Area Protection All instruments shall be certified suitable for the hazardous area classification in which they are located.

The selection of type of protection for instrumentations shall be in accordance with IEC 60079.

In general, EEx”d” protection shall be used for field devices. Unless EEx”d” protection is not available for the particular devices, other type of protection e.g. EEx”i” can be used with approval by COMPANY.

Junction boxes shall be EEx”e” type for IS and non IS circuits. Enclosures (LCP) shall be EEx’e’/EEx’d’ type, where installed in hazardous area.

All applicable instruments shall be provided with hazardous area certification IEC / CENELEC standards. All certificates shall be issued by an Approved national authority (e.g. UL, BASEEFA, etc.) and shall be in English.

All instrument equipment to be installed in a hazardous area meets all the relevant requirements of the ATEX Directive (94/9/EC) and shall have the symbol clearly fixed to indicate compliance.

In addition, all equipment and protective systems must be marked legibly and indelibly with the following minimum particulars:

• Name and Address of the Manufacturer

• Type of device

• Designation of Series or Type

• Serial Number

• Year of Construction

• The specific marking of explosion protection (e.g. Ex ‘d’) followed by the symbol of

the equipment group and category

• Maximum voltage for instrument.

• Frequency of the connected voltage.

• IP- classification.

• The letter G (denoting explosive atmospheres caused by gases, vapours or mists)

• All information essential to their safe use

5.2.2 Ingress Protection

Ingress protection for instruments / equipment shall be in accordance with IEC 61892 and as

follows:

• Minimum IP 56 for outdoor installations

• Minimum IP 44 for installations inside enclosed rooms without air-conditioner

• Minimum IP 22 for installations inside enclosed rooms with air-conditioner

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5.2.3 Lightning Protection

All instruments & controls are inherently protected against lightning due to the welded / bolted steel construction of the facilities.

Hence no separate surge protection devices are required.

5.3 Heat Tracing

When required by process conditions or as indicated in the P&ID, field instruments and instrument impulse lines shall be suitably protected against freezing by electrical heat tracing.

The source of electrical heat tracing will be provided by Electrical. For details refer to 1014-BKTNG-EL-SP-0013 Specification for Electrical Heat Tracing.

5.4 Material of Selection

All instrument and control equipment provided shall be safe, operable and reliable. Every care shall be taken to select materials that will resist the detrimental effects of the environment, corrosion by process fluids and damage due to fire.

Generally, instruments shall have minimum SS316 wetted parts unless the process fluid requires superior material.

All housing material of electronic instrument shall be minimum SS316. All materials shall be suitable for long-term, minimum maintenance in a saline and marine environment. Material such as plastic, aluminium, brass or copper shall not be used.

Instruments using mercury or asbestos are prohibited.

Particular attention shall be paid to the saline atmosphere and the related operating temperatures to assure that chloride stress cracking, pitting, and the like does not occur.

Material selection shall ensure dissimilar galvanic corrosion does not cause a decrease in the life of the facilities.

Selection of suitable elastomers shall depend on process/service conditions, service application, chemical composition of fluid, etc.

5.5 Language, Unit and Measurement

Documentation utilized throughout this project shall be in the English Language.

Units of measurement for this project shall in general be in accordance with the International System of Units (SI System) except for flow and pressure. Preferred units of measurement are as follows:

Parameter Units

Density Kg/m3

Differential Pressure Bar or mbar

Energy kJ

Heat kW

Length m or mm

Area m2 or mm2

Power W or kW

Velocity m/s

Level %

Mass Kg

Pressure bar(g) or bar(a)

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Parameter Units

Temperature °C

Time Yr, mo, d, h, min, s

Viscosity m2/s or cP

Volume flow rate (Liquid) m3/hr

Volume flow rate (Gas) Sm3/hr

Mass flow rate (Liquid) Kg /hr

Mass flow rate (Gas) Kg /hr

Steam flow rate Kg /hr

Gas flow (Metering) mmscfd

Charts and Scales

Temperature Direct Reading

Pressure Direct Reading

Flow Direct reading (Linear for Field),

Level 0-100 % Linear

Others Direct Reading

All measuring and indicating instruments shall cover the full operating range.

5.6 Tagging System

Instruments, junction boxes and cables tag numbering shall be as per the Project Coordination Procedure;

5.7 Name plates

All panel mounted instruments shall be provided with nameplates.

Permanent nameplates or tags shall be fitted at the back of the panel for all instruments, components, terminal strips, circuit isolators/fuses, bulkhead fittings and any items to which field connections are to be made. These nameplates shall be made from white/black/white laminated phenolic plastic.

All nameplates shall, unless otherwise specified, be in plain block letters, 4mm high and furnished in a minimum practical number of standard sizes.

Field mounted instruments shall be provided with stainless steel tags wired to the instrument with stainless steel wire. The metal tag shall be engraved or hard stamped with the applicable tag number. This is in addition to a permanently attached stainless steel nameplate that shall contain the following data:

- Tag number

- Manufacturer's name

- Purchase Order number

- Model number

- Hazardous area certification

- Ingress Protection classification

- Certifying authority

- Range




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- Power supply

- Year of Manufacture

Thermowells shall be stamped on the flange periphery with the tag number and in the case of separate flange thermowells, the tag number shall also be stamped on the top flat surface of the well.

5.8 Data Sheets All data sheets shall adhere to the ISA S5.1 form as far as practical. Data sheets shall be standardised as far as practical.

5.9 Painting

All field instruments in carbon steel, frame works and supports shall be painted to suit the marine saliferous tropical environment as indicated in section 3.0.

Stainless steel instruments/equipments shall not be painted.

6.0 FIELD INSTRUMENTATIONS REQUIREMENT

6.1 General

All instruments shall be selected from Manufacturer’s standard product range. Instruments shall be tropicalised and materials of construction suitable to ensure adequate mechanical protection.

Field Transmitters shall be 4-20 mA SMART type with HART, 24VDC, 2 wire, loop powered transmitter. As far as possible, field transmitters for pressure, DP level, DP flow and temperature measurement should be standardised from the same make.

The transmitters shall be provided with integral digital indicator having user configurable engineering units. Transmitter circuit shall ensure signal loop continuity is not lost in case of local indicator failure or removal.

Transmitters shall be used for all alarm and shutdown initiation due to their increased reliability and lower probability of latent failures. The use of switches is not allowed.

Separate transmitter shall be use for DCS and ESD signals. Where both signals are present to measure same process parameter, the transmitters shall be calibrated with the same range for measurement comparison at OWS.

Instrument electrical entries shall generally be ISO M20.

6.2 Pressure Instrument 6.2.1 General

All pressure instruments shall be provided with a 2 valve block and bleed manifold. All differential pressure instruments shall be provided with a 5 valve manifold.

Instruments measuring absolute pressure shall be compensated for barometric pressure changes.

Pressure instruments shall have direct-reading indicating scales.

Instruments exposed to vacuum shall have an under-range protection for full vacuum.

Pressure element shall be minimum SS316 or superior material suitable to the service. Diaphragm seal with capillary shall be used for highly corrosive, viscous and solid services. Diaphragm seal shall have 2” flanged process connection. Material construction shall be in accordance with the Project Piping Specification. Capillary shall be SS316 armoured with flushing and calibration ring arrangement.

The process connection for all pressure instruments shall be 1/2-inch NPT.

All transmitters shall be capable of in situ calibration. Calibration ports or terminals shall be provided.

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6.2.2 Pressure and differential Pressure Gauges

Pressure and differential pressure gauge ranges shall be selected from the range as indicated below as such the normal operating pressure is between 1/3 to 2/3 of scale. However, the selected range shall always be able to withstand, without zero or calibration change, the full vacuum and the process design pressure. External over range protection shall be provided when the process design pressure exceeds the over range protection of the gauges.

The following standard ranges shall apply to the gauges:

Vacuum Service: -1 to 0 Barg

Pressure Service: 0-1, 0-1.6, 0-2.5, 0-4, 0-6, 0-10 barg,

0-10, 0-16, 0-25, 0-40, 0-60, 0-100 barg

0-100, 0-160, 0-250, 0-400, 0-600, 0-1000 barg

0-1000, 0-1600, 0-2500, 0-4000, 0-6000, 0-10000 barg

Pressure gauge shall be bourdon tube type with concentric scale and shall be of the safety pattern type in accordance with EN 837-1. Differential pressure gauge shall be bellow diaphragm type.

Accuracy shall be +/- 1% of Range.

The Gauges case shall be SS316 with blow-out back disc and safety shatterproof glass. Oil filled gauges shall be avoided and may only be used with COMPANY approval. Dials shall have a diameter of 100mm for all measurement readings and 63mm for filter regulators or other pneumatic instrument. The scale background shall be white with black lettering over 270o.

Snubber shall be provided on pulsating service. Siphon shall be provided on steam or high temperature service.

Pointer stops shall be fitted on the dial so that the pointer can pass the maximum value by not more than 30o in order to indicate the overrange condition. The pointer shall stand clear of any end-stop when reading zero.

6.2.3 Pressure and Differential Pressure Transmitters

Electronic transmitters shall use a capacitive measurement cell or equal proven design. Force balance and motion balance types are not acceptable.

Transmitter process pressure connections shall be 1/2-inch NPTF.

Overall accuracy for transmitters in general use shall be within ±0.25 percent of calibrated span, taking into account the reference accuracy with ambient temperature and static pressure effect. Higher accuracy shall be used depending on application like custody transfer metering etc.

6.3 Temperature Instrument 6.3.1 General

Temperature Instrument for remote indication shall include the temperature element, thermowell, head mounted electronic temperature transmitter and the associated fittings supplied as one assembly. Temperature gauge shall be supplied as an assembly of the temperature element, thermowell, gauge and the required fittings.

Temperature element shall be spring loaded with nipple-union-nipple assembly.mounted directly on the thermowell. The tip of the sensing element and the thermowell shall have a good thermal contact.

Filled thermal system transmitters/switches shall not be used unless specifically agreed by the COMPANY in writing.

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In general for remote signal application, resistance thermometer devices (RTD) shall be used for all temperature measurements up to 400oC. Temperatures above 400oC shall use Thermocouple (TC).

6.3.2 Thermowells Thermowell shall be installed for all temperature sensing elements to permit their removal during operation. Where the application of Thermowells would be impractical, temperature sensing element may be located on the surface of pipes or vessels, etc.

The thermowell shall be Van Stone type machined from solid bar stock. Thermowell shall be 1 ½” flanged for rating up to 1500# and 2” flanged for rating 2500# and above. Higher sizes shall be used if the pipe nozzle schedule does not permit thermowell to enter. Thermowells on vessels shall have 2” connection.

The internal diameter of the well shall match the external diameter of the sensing element. This will be, if possible, standard for all thermowells on the project.

Thermowell material of construction shall be compatible with the medium in contact and shall be minimum SS316. Superior material and flange material shall be according to the Piping Material Specification, 1014-BKTNG-PI-SP-0005.

Special attention shall be given to selection of Thermowell lengths in order to achieve minimum deviation between measured and actual temperatures. For pipe sizes up to 150mm immersion shall be 1/2D. For pipe sizes above 150mm immersion length shall be at least 1/3D. Wherever possible the thermowell lengths shall be standardised at 230 and 255 for installation on piping. Thermowell installed on vessel shall be either 305, 355, 405 and 455mm length.

The preferred Thermowell installation shall be 90o to the line. Pipe size from 1/2” to 3” shall be swaged to 4”. Where for piping reasons it is more convenient to use elbow installations these are also acceptable. For this application, pipe sizes from 1/2” to 2” shall be swaged up to 3” and the Thermowell shall be installed against the direction of flow.

For Thermowells installed upstream of rotating equipment e.g. compressors, the immersion length shall be limited to 230mm irrespective of pipe size, to prevent endangering the downstream equipment.

Calculations shall be performed to show that all Thermowells are suitable for stress due to stream velocity conditions. The wake frequency (commonly referred to as a “Strouhal” or “Von Karmon Trail”) shall not exceed 80% of the natural frequency of the Thermowell. Suitable calculations method shall be as per ASME PTC 19.3, Performance Test Code Temperature Measurement.

Plastic plugs for internal thread protection shall be furnished for all wells.

Wells for insulated vessels and lines shall have extension necks.

Test wells shall be fitted with a SS316 screwed plug and chain.

Pressure testing of Thermowells and non-destructive examinations shall be carried out. Hydrotest pressure test shall be applied to the outside of the Thermowell to full test pressure. The external surface of forged wells shall be subject to Dye Penetrate Examination.

6.3.3 Temperature Element 6.3.3.1 PT 100 Resistance Thermometers (RTD’S)

The resistance thermometer element shall be single type of the platinum PT100 (100Ω at 0oC), 3 wire type with Class A resistance tolerance. The design, temperature – resistance relationship and resistance tolerance class shall be in accordance with IEC 60751.

6.3.3.2 Thermocouples

Thermocouples shall be mineral insulated and sheathed. The hot junction shall be electrically insulated from the sheath.




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Thermoelectric properties, color coding, and limits of error of thermocouples and thermocouple extension wires shall conform to IEC 60584.

In general thermocouples shall be type K, Nickel Chromium/Nickel-Aluminium (Ni-Cr/Ni-Ai). Other type shall be used only when K type thermocouples are not suitable.

Thermocouples for temperature-differential measurements shall be electrically isolated from ground.

All thermocouple instruments shall have thermocouple burn-out indication. This will be full up scale or down scale as per specific requirement.

Thermocouple wires (if and when required) shall be as short possible prior to the temperature transmitter.

6.3.4 Temperature Transmitter Temperatures transmitter in general shall be head mounted type, however where high vibrations and high temperature are expected & accessibility is a problem then remote mounted can be used.

Transmitter design shall include appropriate failure protections such as open circuit for RTDs or upscale burnout for thermocouples.

Transmitter output shall be linear with temperature.

The transmitter shall have the capability of accepting 2/3/4 –Wire RTD or thermocouple inputs. The accuracy for transmitter shall be within +/- 0.1% of calibrated span.

Transmitter shall have built-in cold junction compensation for thermocouple inputs.

Remote mounted transmitter shall be provided with stainless steel universal type mounting brackets and fixings. Remote mounted temperature transmitter shall be provided for the following sensor type:

• Surface mounted temperature sensor.

• Machine shaft/bearing temperature sensor.

• Where local temperature indication is required and the temperature take off point is

not easily accessible.

6.3.5 Temperature Gauges Temperature gauges shall be heavy duty Bi-metal type. For easy readability the “any angle” type indicator shall be provided with 100mm dial diameter. They shall be manufactured to ASME B40.3 Grade A accuracy in deg C as per Class I, DIN 16203. Temperature gauge stem shall be SS316 minimum.

Gas filled with capillary shall be used for high temperatures and for remote mounting application. Mercury filled-in shall not be used.

Normal operating temperature shall be in 1/3 to 2/3 of scale selected from following temperature range:

-30 to 60°C,

0 to 160°C,

0 to 250°C,

0 to 400°C

The scale background shall be white with black lettering.




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6.4 Level Instrument

6.4.1 General Level transmitters shall generally be the differential pressure type. Differential pressure transmitters used for level applications shall use remote diaphragm seal type where there is a probability of condensation in the dry leg. Where the specific gravity of the liquid varies largely and for interface level application, guided wave radar shall be considered.

The use of other forms of level measurement, such as magnetostrictive, displacer, capacitance type level transmitter, etc shall be considered on a case by case basis if the above methods are unsuitable and shall be subjected to approval by COMPANY.

Level gauges shall be provided on all vessels to cover the complete vessel operating range. The measuring range for level gauges shall be equal or greater than the corresponding level transmitters measuring range.

Magnetic float follower type shall be used instead of conventional level gauges except where varying specific gravity make the use of these impractical. But for Interface service Conventional gauges are acceptable. Interface level shall utilise transparent type level gauge.

Level bridle if required shall only be considered for level indications and level transmitter connected to DCS for monitoring and control application. Level instruments in shutdown service shall be directly connected to the vessel. Materials of bridles shall be as per piping/vessel specifications. Level bridle shall have independent vent and drain valves.

Level Instrument except for differential pressure type could be externally mounted using external chamber or top mounted. The chamber shall normally orientate as side/side process connection. The chamber and probe material shall be in accordance to the material class and suitable to the process characteristic. The chamber shall be provided with a double block and bleed isolation drains / vents. On hazardous and corrosive duties, consideration shall be given to pre-piped drain legs to suitable drain points.

Each level instrument shall be provided with isolation valves for on-line removal of the Level Instrument.

Separate and independent devices shall be used for level gauge and level transmitter. Integral gauge and transmitter shall not be used.

6.4.2 Level Gauges 6.4.2.1 Magnetic Level Gauge

Magnetic level gauge shall be of the magnetic-coupled level indicator type. The indicator shall be two coloured fluorescent bar graph housed in a hermetically sealed glass tube.

The float inside the chamber shall be suspended in the liquid at the same depth and shall have the centerline of its magnetic field at the surface of the liquid. Float specific gravity shall be properly selected such that magnetic coverage is 360 degrees.

Top and bottom spring loaded float stoppers shall be provided in the chamber.

Chamber material shall suit to the wetted material requirement and shall be minimum SS316. The chamber’s process connection shall be 2” flanged to the required ASME standard.

6.4.2.2 Gauge Glass

Gauge Glass shall be armoured type, tubular type gauge glass is not permitted. The gauge glass columns shall be mounted immediately adjacent to the level transmitter.

Glass for glass columns shall be tempered borosilicate that is resistant to thermal and mechanical shock. The glass shall be treated or manufactured so that if the glass is broken will result an interlocking crystalline fracture without loose and flying particles.

Gauges glass assemblies shall consist of one or a maximum of four sections of glass combined to form a single gauge column. Each section shall have a visible length of approximately 300mm, standardised throughout the platform. Where more than one column is




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required for coverage of the vessel, they shall overlap with a minimum of 25mm of visible length.

Gauge glass shall be fitted with a safety ball-check valves and vent and drain connections.

Transparent gauge glasses shall be backlit with 230VAC gauge illuminator, certified EEx’d’ suitable for the hazardous area classification.

6.4.3 Differential Pressure Level Instruments The transmitter body shall be suitable for either direct flange-mounted to vessel piping isolation valve or remote mounted type with capillary. The transmitter body and diaphragm sensor materials shall be manufactured from 316 stainless steel or superior metals.

The differential sensor unit shall be able to withstand loss of design static pressure on either side of the diaphragm without permanent damage to the sensor.

Where plugging, condensation of vapour or vaporization is liable to occur chemical seals shall be utilised together with flushing/calibration ring. ‘Wet’ reference legs for level measurements are not acceptable.

6.4.4 Guided Wave Radar Transmitter

Guided wave radar instruments shall be based on Time Domain Reflectometry (TDR) technology.

Vessel connections of GWR transmitter’s head shall be flanged and removal of the transmitter shall be possible in situ with the vessel still pressurized. Stilling wells if required shall be provided. Manufacturer shall advise the type of probe as selection is dependant on service applications.

6.4.5 Measurement of Level by other Instruments If none of the above types satisfies the requirement of specified application, other type such as Displacer, capacitance, ultrasonic etc can be used with approval by COMPANY.

6.5 Flow Instrument

Flow meters shall be selected to suit the environmental conditions of facilities stated herein, and process fluid flow design conditions taking into account flow turndown, accuracy and uncertainties requirements.

Flow meter material of construction shall be minimum SS316 (including wetted parts) unless the process fluid requires another material.

The preferred primary device for normal flow measurements is the square edged concentric orifice plate. These shall be specified in accordance with ISO 5167.

Where conditions dictate, other in-line flow meters such as turbines, Coriolis Meter, V-Cone Meter, Venturi Meter, positive displacement, vortex, ultrasonic, and variable area shall be considered. Rotameter shall be limited to meters up to 2” size.

Wherever pressure and temperature compensation are carried out for flow measurement, temperature shall be measured on the down stream side of the flow element.

The upstream piping installation shall also include Y or basket type mesh filters for meters (such as turbine types) that may be affected by solid particles entrained in the process fluids.

6.5.1 Orifice Plate Assemblies

6.5.1.1 Primary Devices

Orifice Plates shall comply with ISO 5167 in their geometry, method of use and installation.

Square edged concentric orifice plates with flange taps are the preferred primary element for flow measurement of single-phase clean liquids and gases.

The calculation for orifice plates shall be produced in accordance with ISO 5167 and calculation together with the data sheet shall be passed to the CONTRACTOR for approval.




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Orifice plate thickness shall be to manufacturer's standard, however as a minimum shall be to ISO 5167 requirements.

Orifice plate material shall be minimum SS316, higher grade alloy can be used if required by the process fluid.

The range for differential pressure shall be preferably approximately 0 to 250 mbar.

The use of seal pots shall be avoided.

The minimum pipe size for orifice plates shall be 2”. If similar accuracy flow measurement is required for pipe sizes less than 2”, consideration shall be given to the use of integral orifice transmitter.

Drain / vent holes shall be provided for orifice plates as required by the services.

For orifice plates on RTJ flanges, ring-type plate holder shall be used. Ring facings shall be as per piping general specification.

Where senior orifice fittings are required, they shall be of the design with two isolated chambers with valve seal in the plate removal. The design shall allow the plate to be removed from the service with the line under pressure.

Limitations of bore to pipe diameter ratios (Beta) for orifice plate shall be between 0.2 and 0.7

The following data shall be stamped on the upstream side of each orifice plate handle:

• Tag Number

• The word ‘UPSTREAM’

• Differential Pressure

• Beta Ratio

• Orifice bore size in mm

Eccentric orifice plates shall be considered where fluids are liable to contain solids.

6.5.1.2 Flow Transmitter

Refer section 6.2 for Differential pressure transmitter requirement.

For flow turn-down greater than 3:1 the use of multiple or variable range DP transmitters shall be considered.

Square root extraction shall be done in the transmitter.

6.5.2 Rotameter

Rotameter shall be of the tapered tube and float type. All wetted parts of rotameter shall be minimum stainless steel (SS316).

Rotameter for remote monitoring shall be provided with transmitter.

Rotameter shall have a metal or glass (for non-hazardous fluids only) metering tube depending on the application, process conditions, etc. Where metal tube is required, material shall meet the relevant piping specification as well as connecting flanges.

For the Rotameter with metallic tube, the connection between the moving and indicating /transmitting parts shall be glandless magnetic coupling.

Floats shall be self-cleaning and shall be designed for maximum immunity to viscosity variations and dimensional stability.

Rotameter shall be fitted with inlet and outlet float stops.

Rotameter fitted with a constant flow regulator shall only be used for fixed rate flows such as flushing or purging.




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Process connections shall be:

• Flanged, according to the relevant piping specification and ASME B16.5.

• Screwed NPT for flushing or purging service.

The rangeability of the rotameter shall be 10:1 and shall have and accuracy of ± 2 % or better.

6.5.3 Turbine Meter

The VENDOR shall calibrate the liquid turbine meters in accordance with the API Manual of Petroleum Measurement Standards, Chapter 5, Section 3.

All meters shall be equipped with pre-amplifiers. Preamplifiers shall be compatible with the turbine meter pickups both in connection and signal. Preamplifiers shall operate on 24V DC.

The meter body housings shall be a minimum 316 stainless steel unless otherwise specified.

Turbine meters for liquids shall have 10:1 turndown with a linearity of +/- 1% and a repeatability of 0.05% on non custody services.

For liquid meters rotor hubs, blades, and rims shall be, as a minimum, stainless steel.

Turbine meter shall have straight length distance calculated in accordance with the API MPMS, Section 5.3.

6.5.4 Coriolis Flowmeters

Coriolis flowmeters shall include density measurement, and is suitable for direct mass flow rate measurement for liquid hydrocarbon, produced water or liquid with high viscosity where pressure drop across the meter is not significant to the process downstream.

Rangeability of coriolis meter shall be 10:1.

Accuracy shall be +/- 0.5% or better of normal flow range.

Process connection shall be of flange connection conform to pipe rating.

Meter body material shall be min SS316 and shall be in accordance with piping material classification.

Measurement shall in compliance with ASME MFC 11. “Measurement of Fluid Flow by Means of Coriolis Mass Flow meters”.

6.5.5 Ultrasonic Flowmeters

Ultrasonic Flow Meters (USM) can be used to measure both liquid and gas and shall be based on time-of-travel method.

USM shall be in-line type with flanged end connections. Flange shall be in accordance to ASME B16.5.

The USM’s flow turndown shall be at least 30:1.

USMs specially designed for flare shall be utilised for flow measurement of flare-stack gas, where very high rangeability is required. The USM shall be able to operate reliably even under unsteady flow, pulsating pressure, varying gas composition and temperature, and the wide flow turndown ranges typical of flare systems.

In general, accuracy shall be better than +/-1% of span.

6.6 Restriction Orifice

Restriction orifice plates shall be used for high differential pressure drops. Restriction orifice plates on high differential pressure drops, on flashing liquids and on cavitating services shall be hard faced. Restriction orifice plate thickness shall be verified by stress calculation.




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6.7 Pig Signaller

Pig signaller shall be clamp on non intrusive type sensor utilising ultrasonic detection principle. The pig signaller shall be provided with local and remote indication to indicate the passing pig. Remote indication shall be 4-20mA signal wired to the platform’s DCS.

6.8 Process On Line Analyser

6.8.1 Sample Extraction Probe Analysers sampling system shall be designed to extract a representative sample, to ensure reliable operation with minimum maintenance.

Liquid samples should be taken from the side of horizontal lines via a sample probe. Particular care should be taken where there is a possibility of contamination, or where pockets of gas/vapour/liquid hydrocarbon/water/dirt may accumulate in the plant stream. For liquid phase samples, care should be taken that the pressure at any part of the sampling system shall always be higher than the vapour pressure of the sample to prevent flashing.

Gas samples shall be taken via a sample probe from the top of lines. Special consideration should be given when a representative sample from lines containing two phase mixture is required.

Natural frequency calculations of sample probes shall be carried out by VENDOR and probe shall be designed accordingly.

6.8.2 Sample Conditioning System

Sample conditioning systems (sample probe, pre-conditioning, transport and conditioning) will be in general designed by the analyser VENDOR and agreed with CONTRACTOR/COMPANY. The VENDOR shall provide and install all components, tubing and equipment required to achieve these designs. However, full consideration should be given to the functionality and correct operation of each system.

For extractive type analysers, fast loops shall be considered where sample transportation time is high.

Fast loop maybe installed across plant equipment which creates a differential pressure. e.g. pumps and process equipment.

The return points for the fast loops will be chosen such that the pressure at the sample points is always as minimum 50% above the return line pressure to prevent backpressure.

In general, sample lines for fast loops shall be built with 3/8” OD 316L SS tubing and single loops with 1/4 OD 316L SS tubing, subject to calculations on transport time delay provided by VENDOR. The tubing shall be in continuous runs without intermediate joints, between sample extraction probe and sample conditioning cabinet and from conditioning cabinet to sample return point.

6.8.3 Analyser

All analysers shall be micro-processor based. Self-diagnostic routines and calibration functions shall be provided as standard. The test method shall be selected based on the service, taking into consideration the sensitivity of the analyser for other component in the fluid.

Where possible the analyser output shall be provided with HART protocol.

All analysers shall be provided with necessary calibration gas for zero and span check.

6.9 Sand Detection System

The system shall be selected based on proven performance for gas production flow lines and good references from major oil companies.

The principle of the system will be quantity of the sand production and not to measure the erosion. The system shall be suitable to detect sand particles.




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The sand detector shall be non-intrusive type supplied complete with mounting accessories, to clamp on to the pipe.

The sand detection system shall support simultaneous multi channel input, data storage, channel (input/output) selection, etc. The system shall be complete with a sand detection computer (with software & HMI) providing serial interface (using MODBUS protocol) with DCS.

7.0 VALVES GENERAL REQUIREMENTS 7.1 Control Valves

Control valves shall be pre-assembled with actuators, transducers, solenoids, limit switches and position indicators, boosters, speed controls, locks etc. as required. Actuation medium shall be instrument air.

Smart positioners shall be provided unless deemed unacceptable due to the critical aspects of the service in which case separate I/P converters and pneumatic positioners shall be provided. Smart positioners shall be 4 - 20 mA with a superimposed digital data signal using HART protocol, for diagnostic purpose.

All actuators shall be spring return to failure position under worst conditions without the use of volume bottles except where unavoidable, subject to COMPANY approval.

Control valves shall be designed to prevent damage to the valve body, trim and the downstream pipework.

Control valves shall not be used as primary shutdown isolation valves.

High speed valves shall be fitted with safety guards over exposed moving parts.

Anti-surge control valve shall be suited for its service i.e. high performance, quick responses. Valve shall have a linear flow characteristic and shall be sized large enough to prevent surge.

Control valves required specific respond speed shall be calculated and achieved with boosters. Systems utilising quick exhausts shall not be acceptable.

7.1.1 Valve Construction

7.1.1.1 Valve Body & Bonnet

Control valves shall generally be of single seated globe type. Other valve type e.g. segmented ball, butterfly valve shall be considered on case to case basis.

Angle valves shall be considered for high pressure drops and shall be available with single stage and multiple stage trim designs. Angle valves shall have full venturi throat.

The valve body material shall be in accordance with the Project Piping Specification. Cast iron bodies shall not be used.

Bonnets shall be of the same material as the valve body and of integral or bolted construction with fully retained gaskets. Threaded bonnets are not acceptable. For toxic & corrosive services bellow seal bonnets shall be used.

Extended bonnet shall be provided for temperature above 230°C and below -18°C or in accordance with manufacturers’ recommendation.

The control valve shall be provided with flange connection. Flanges NPS 24" and smaller shall comply with ASME B16.5. Flanges NPS 26" and larger shall comply with ASME B16.47 Series A.

Face to face dimension for control valve shall be to ASME B16.10.

7.1.1.2 Valve Guiding

Valves below 3” may be top guided or as per VENDOR recommendation. Valves 3” and larger shall be either cage or top guided or as per VENDOR recommendation.




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7.1.1.3 Valve Trim

Standard trim (plugs, seat rings, valve plug stems, stem lock pins, packing springs, spacers, and packing followers) shall be fabricated as minimum from 316 stainless steel, unless otherwise specified in Piping Classes or Datasheet for Control Valve; 1014-BKTNG-IN-DS-0001. Hardened SS416, Duplex SS, 17-4 pH are also acceptable depending upon the service condition.

Trim styles may be solid plug or cage type. Cage type trim shall be avoided on services with solids presence, high viscous, etc.

For corrosive services, i.e. acid service, consideration to be given to other suitable materials, taking into account the full process conditions in each case.

Hardened metal facing (SS316 Stellited or Alloy 6) shall be provided if trim is used for:-

• High Pressure drops.

• High Temperatures.

• Fluids containing solids

• Flashing liquids

• Cavitating flow conditions or as specified in piping specification.

Reduced trims in oversized bodies shall be used for:-

• Situations where the calculated flow co-efficiency would result in a standard valve two or more sizes smaller than the line.

• Flashing or cavitating flow conditions.

• When calculated size is below 1”.

Trim Characteristics:

• Trim Characteristics shall generally be equal percentage or linear, depending on the process duty.

• As a guide, linear characteristic should be used for level control in gravity service, minimum flow protection for centrifugal pump and compressor anti-surge control. Otherwise equal percentage trim should be used.

• For valves with Low noise trim/ Anti-cavitation trim, manufacturer’s standard characteristics like Modified Equal% or Modified Linear are acceptable.

• Valve plugs with special characteristics may be used to satisfy the demands of process requirements.

In general, the seat leakage shall be Class IV as defined in FCI 70-2, unless specified otherwise.

7.1.2 Valve Packing

For applications where temperatures are 230°C and below, Teflon can be used.

For applications where temperatures are above 230°C pure graphite shall be used which eliminates use of lubricants.

For valves on corrosive applications or sub zero temperatures, special consideration should be given to the packing and the VENDOR shall propose suitable materials meet the process conditions as specified on the datasheets.

7.1.3 Valve sizing

Valves shall be sized in accordance with ISA S75.01.01; Control Valve Sizing Equations. The supplier shall state his sizing method, indicating any deviation from ISA Standard.




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The control valve body size shall not be lower than half of the Line size. VENDOR shall calculate and record on the data sheet the minimum, normal and maximum required valve Cv. Control valve shall be sized to ensure controllable % opening at various conditions.

Control valve shall be sized to comply the following valve travel:

• Control valves with equal percentage characteristics shall be sized to operate at approximately 60-75 percent travel under normal flow conditions and less than 90 percent travel under maximum flow conditions.

• Control valves with linear valve characteristic shall be sized to operate at approximately 50-70 percent travel under normal flow conditions and less than 90 percent travel under maximum flow conditions.

• In general control valves shall pass the minimum design flow at no less than 20 percent of valve travel, unless specifically agreed by COMPANY in writing.

In cases where high rangeability (design minimum flow occurs at less than 20 percent of valve travel), or where high capacity is required, two control valves, split-ranged in parallel, shall be used. The valves shall be sized to split the flow equally.

Butterfly valves shall be sized for maximum angle opening of 60 degrees.

Anti-surge control valve sizing shall follow the specialists recommendations.

7.1.4 Valve Actuators Spring opposed pneumatic diaphragm actuators shall be the preferred actuation. Spring opposed pneumatic piston actuators shall be used where requirement of high thrust, long stroke or higher speed of response cannot be achieved by diaphragm actuators. Material of construction for spring shall be corrosion resistant, cadmium plated or equal and fully enclosed in metal housing to withstand the conditions of the operating media, over a wide range of ambient temperatures.

Actuators shall be furnished with stem travel indicators with scales.

Valve actuators shall be sized to operate against the maximum differential pressure that can be experienced in the field, with minimum instrument air supply pressure to the actuator as specified in data sheet i.e. 4.0 barg.

Where it is necessary to improve the valve stroking time, VENDOR shall recommend the type of instrument accessories that would best serve the application. Volume boosters, quick exhaust valves etc., shall be provided wherever required to improve response time.

Actuator casing shall be of steel construction, suitably protected against corrosion for the environmental conditions. Cast iron or Aluminium shall not be used.

Diaphragms shall be of moulded age resistant material, suitable for withstanding the conditions of the operating media, over a wide range of ambient temperatures.

The required fail position of the valve shall be determined by analysis of the process.

The use of springless double acting actuator shall be avoided and shall only be used with approval by COMPANY. Double acting actuator when used shall be provided with volume tanks and switching valves to accomplish ‘fail open’ or ‘fail closed’ failure mode requirement. The tank shall be sized for at least three full travel operations (open/close/open) in the event of supply failure.

Where specified, the open/close limit switches housed in junction box and solenoid valve suitable for the area classification shall be provided with control valves. The requirement of the limit switches & solenoid valves shall be defined on the P&ID’s

Hydraulically operated actuators shall not be used.

7.1.5 Noise Noise levels of control valves and accessories shall be in accordance with the following requirements:




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• The noise generated by a control valve installation in gas or vapour service shall not be greater than 85 dBA measured at 1 meter from the valve assembly under all normal operating conditions including intermittent maximum flow.

• Special noise-control trim shall be considered for valves with a calculated noise level above 85 dBA at 1 meter. Additionally if required, upstream and downstream silencers shall be used.

• Exceptions to noise level requirements may be granted based on such factors as frequency of valve operation and worker proximity. Exceptions shall require the written approval of COMPANY.

• Hydrodynamic noise, caused by cavitation in control valves, shall be controlled by selecting valve type and trim to preclude cavitation within the control valve and downstream piping.

• Only during shutdown or extreme upset conditions may noise level exceed 85dBA. Under no circumstance shall noise exceed 105dBA.

7.1.6 Valve Accessories

7.1.6.1 Valve positioner

All control valves shall be furnished with electro-pneumatic valve positioners, except where specifically precluded on the data sheet. Electro-pneumatic positioners shall be 4-20mA, 24V DC SMART electronic type with HART protocol in conjunction with a handheld communicator. Material shall be of corrosion resistance material. Cable entry shall be ISO M20.

Positioners shall be fitted with stainless steel supply and output pressure gauges.

Positioners shall be bolted to the valve yoke and shall be unaffected functionally and mechanically by vibration. These shall be furnished assembled and mounted on the valve.

Positioners shall have provision to change the action from direct to reverse without any additional hardware.

7.1.6.2 Booster

A booster shall be provided on applications where high speed of response is required.

7.1.6.3 Solenoid valves

If required, solenoid valves shall be furnished and mounted to the control valve’s actuator. On control valves with valve positioners, solenoid valves shall be installed in the tubing between the positioner output and the valve actuator, and shall be mounted on the control valve yoke.

Solenoid valve shall be 3 way normally energised. Power supply shall be 24 VDC. Power consumption shall not exceed 8 watt. Coil type shall be Class H. Solenoid valve shall be EEx ‘d’ certified for applicable hazardous area. Ingress protection class shall be IP 56 as a minimum. Solenoid valve body material shall be SS316.

Cable entry for solenoid valve shall be ISO M20. Flying lead for solenoid valve shall be avoided.

Solenoid valve shall include quench diodes and shall be suitable for continuous energisation.

7.1.6.4 Air Filter Regulator

Filter regulator shall be supplied with each control valve positioner assembly.

Filter regulator shall be supplied with output gauge, provision for outlet pressure adjustment and a drain. Body material shall be 316 SS & filter element shall be 5 micron size.

7.1.6.5 Miscellaneous

Control valves shall be furnished with stem travel indicators with scales.

Bug screens shall be installed on the exhaust ports of all pneumatic instruments.




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Accessories to be installed on the control valve shall be mounted and piped with seamless 316L stainless steel tubing.

7.2 Regulators Special consideration shall be given to the ratings of the downstream section of regulators with respect to the maximum upstream shut in pressure based on the assumption that the regulators will leak.

Self-contained regulators shall be minimised for utility services and shall be considered for services such as Fuel gas or air, blanket gas, etc.

The regulators body and spring case material shall be in accordance to the piping material specification where it installed. Regulators on tubing shall be minimum SS316 material of construction.

7.3 Choke Valves Choke valves design shall comply to API 6A. Choke valves shall have angle type design & shall be manually operated by hand wheel.

If required, each choke valves shall be fitted with a mechanical limit stop to prevent the well being overproduced.

A 4-20 mA position transmitter shall be provided for remote monitoring of actual choke valve open/ close position at the DCS. Stepping function shall be performed as part of valve position.

Choke valves body/bonnet materials shall be as per piping material specification. Trim shall be of Tungsten Carbide.

Noise level for each Choke valve shall not exceed 85 dBA at 1m from the surface and downstream of the valve. In case the noise exceeds this figure under the specified process conditions, VENDOR shall suggest mitigation methods to reduce the noise level below 85 dBA.

7.4 Actuated Valves All shutdown, blowdown and on/off valves shall be supplied as a fully assembled unit, fully tested and ready for operation which include the valve, actuator, combined position indicator and switch (proximity type) and sub-plate mounted with all the required interconnected pneumatic supply and control accessories e.g. solenoid valve, filter regulators, speed controllers etc. All shall be readily accessible from a single location.

7.4.1 Valve Construction

The valve body specification shall be in accordance with the Project Piping Specification. Cast iron bodies shall not be used.

The shutdown valve body and port size shall be either full line size or reduced bore as specified by the Piping Design Specification and Valve Data Sheet.

The valve closing speed shall be approximately 1 inch per second and shall be indicated in datasheets.

Direction of flow shall be clearly stamped or cast on the valve body.

Valves shall have zero leakage in accordance with ISO 5208/API 6D. Valve shall be fire safe to API 607/ API 6FA requirement.

All ball valves shall be fitted with suitable 'end of travel' stops at the fully open and fully closed positions and a local position indicator. The design shall prevent the ingress of foreign material and corrosion products which would impair the operation of the stops. Devices capable of locking the valves in the fully open or fully closed position shall be provided.




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7.4.2 Actuator

7.4.2.1 Actuator type

Shutdown valves shall utilise single acting spring return pneumatic actuators. Actuator shall be scotch yoke design type or rack and pinion type actuator for small size valve.

Double acting actuators and / or electric motor operators shall not be used for Safety Shutdowns or Blowdown without COMPANY approval. Double acting actuators are acceptable for non shutdown unit isolation or switching.

7.4.2.2 Sizing

The actuator size and torque requirements shall be calculated by the VENDOR. Actuators for the general on / off valve application shall be sized using a factor of 1.5 times the maximum required torque over the full opening and closing stroke of the valve at a minimum air supply pressure of 4.0 barg and differential pressure equal to maximum inlet pressure. This over-sizing factor shall be increased to 2 for those valves designated for Safety Shutdown valves and 2.5 times for Riser valves.

Calculations shall be provided for each type of valve/actuator combination thereby proving that the specification requirements are satisfied.

VENDOR shall provide safety valve in the pneumatic control circuit to protect actuator, valve and control circuit accessories considering following two cases:

• Maximum permissible pressure of actuator which is if lower than instrument air design pressure (i.e. 8.0 barg).

• Maximum permissible pressure at which actuator produced torque exceed the maximum allowable valve torque, i.e. MAST which is if lower than instrument air pressure design (i.e. 8.0 barg).

Safety valve shall be set to open at a pressure that is least of the value of above two cases. VENDOR note that air filter regulator is not considered as safety device.

7.4.2.3 Actuator Design and Construction

The actuator shall be designed to operate the valve through its full stroke. The design shall be such that actuation of the valve is possible in all planes through 360°. Opposing piston type actuators to be fully balanced with offset cylinder.

The actuator shall be totally enclosed and sealed to give complete protection to all internal moving parts.

Full details of materials of construction, protective finishes, design codes, electrical and mechanical characteristics shall be supplied by the VENDOR.

Actuators shall be close loop breather system where vented air is drawn in to the spring chamber on closing thus minimizing corrosion. VENDOR shall use high integrity components as indicated in the control schematics.

The double acting actuator shall be provided with volume tanks, switching valves and required accessories e.g. relief valve, pressure gauge, to accomplish ‘fail open’ or ‘fail closed’ failure mode requirement. All volume tanks, accumulators and gas bottles shall be supplied with applicable pressure vessel certification. Volume tanks shall be fabricated in carbon steel in accordance with ASME VIII. Volume tanks, if used must be sized for three complete valve operations (close/open/close).

For services where the speed of operation is a critical factor then the VENDOR shall guarantee and demonstrate the required stroking speed, during the Functional Test (FAT).

Adjustment shall be provided in the actuator to set the open and fully closed position of the valve.

Air connections shall be 1/2” NPT minimum.




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7.4.3 Accessories for Valves

Actuator accessories such as pilot valve, air filter regulator, flow regulator etc shall be SS316 and shall be mounted on a single 3 mm thick SS316/SS316L plate. No item shall be hung from tubing.

All accessories mounted on the valve assemblies shall be capable of withstanding process line vibration.

7.4.3.1 Solenoid valves

Solenoid valve shall be 3 way normally energised. Power supply shall be 24 VDC. Power consumption shall not exceed 8 watt. Coil type shall be Class H. Solenoid valve shall be EEx ‘d’ certified for applicable hazardous area. Ingress protection class shall be IP 56 as a minimum. Solenoid valve body material shall be SS316.

Cable entry for solenoid valve shall be ISO M20. Flying lead for solenoid valve shall be avoided.

Solenoid valve shall include quench diodes and shall be suitable for continuous energisation.

7.4.3.2 Limit switches

Limit switches for remote indication of valve open and close position shall be of the proximity type. Limit switch shall be integral with position indicator for local indication of valve open and close position.

The switch enclosure material shall be SS316. Limit switches shall be supplied without any flying leads. Both the open and close limit switch shall be terminated in a common terminal box, certified EEx ‘d’ to the area class specified in the datasheet and the minimum ingress protection of IP 56.

Limit switches for SDV and BDV shall be wired to the ESD.

7.4.3.3 Air Filter Regulator

Air filter regulator shall be of reducing relief valve type with drain facility.

Air filter regulator shall be of tamperproof setting type. i.e. use of lock nuts to keep the air filter regulator locked in its position, thus preventing accidental or unintentional re-adjustment.

Filter regulator shall be supplied with output gauge, provision for outlet pressure adjustment and a drain. Body material shall be 316 SS & filter element shall be 5 micron size.

Air filter regulator shall be designed to withstand the design air pressure of 8.0 barg.

7.4.3.4 Pressure Gauges

Pressure gauges shall be 2” or 63mm diameter with 1/4" NPT male connections. Dials shall be circular, white laminate plastic with black numerals and markings. Casings shall be stainless steel and provided with blow out backs.

7.4.3.5 Flow Regulator

Adjustable flow regulators shall be fitted (within the exhausting line) to control the opening and closing speed when required. This shall be fitted with unique valve locks to prevent unauthorized adjustment.

7.4.3.6 Quick Exhaust Valve

Quick Exhausts shall be fitted to meet the speed requirement.

7.4.4 Motor Operated Valves Motor operated valve shall be supplied with motor, gearbox and handwheel and shall be complete with integral control unit, motor starter, control gear and selector switch for local-off-remote and spring-return rotary knob switch for open/ close and stop pushbutton.

The actuator shall include a local/ remote selector, local open/close push buttons, an integral limit switches to provide position indications and a phase discriminator. The remote/off/local




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selector shall be fitted with a key lock to prevent unauthorised operation of the valve. A local digital illuminated indicator (integral to the actuator housing) shall be provided for valve position.

Facilities for local manual operation shall be provided, to enable full valve operation in the event of total power failure.

Power supply at 400V AC, 3 Phase, 50 Hz shall be provided for each electrical motor actuator from the distribution board. Any other power/control supply requirement of actuator shall be internally derived from the actuator assembly.

Over torque protection shall be provided, to prevent torque in excess of the maximum permitted valve stem torque in the event of manual operation. The over torque protection shall be in the form of a torque switch.

A robust, permanently mounted mechanical indicator shall be fitted to show clearly the position of the valve under all operational conditions.

The actuator shall be removable from the valve without any disturbance to the valve.

In hazardous area, all electrical equipment supplied shall be certified to EEx’d’, and shall be installed to comply with the requirements of IEC for hazardous area classification specified.

The design shall be such that on isolation of power there shall be no hazardous voltages retained within the equipment.

The motor shall conform to IEC 60034-5 with as per electrical design specification.

The motor shall be provided with phase protection and a phase discriminator to inhibit movement of the actuator, if the phase rotation is reversed.

The motor shall be provided with winding over-temperature protection of the direct sensing type, e.g. thermistor or thermostat.

7.5 Safety Relief Valves

7.5.1 General

All safety relief valves shall comply with the referenced codes and standards including API 520/521/526/527 and ASME VIII.

Nomenclature shall be in accordance with API RP 520, Recommended Practice for the Design and Installation of pressure-relieving Systems in Refineries.

Lifting levers shall be provided only for air/steam service applications covered by ASME Section VIII.

Test gags shall be provided only if required by applicable codes. Test gags shall be used to hold the relief valve closed during hydrostatic testing when pressures are above the set point. Test gags shall be removed after hydrostatic testing.

7.5.2 Construction All safety relief valves shall be Manufacturer’s standard, of type conforming to the appropriate data sheet. Safety relieve valve shall normally spring loaded type either a Conventional Non-balance type or Balance Bellow type. Pilot operated valve may be use in case by case basis.

All valves shall be manufactured, tested as per ASME SEC VIII and shall be stamped with the ASME Code.

All safety relief valves shall be sized in accordance with API RP 520 and ASME Section VIII. VENDOR shall furnish sizing calculations for each relief valve supplied for CONTRACTOR’s review and approval.

All valves shall have screwed caps.

Body / bonnet material shall follow the valve outlet piping specification whereas the wetted parts material shall follow the valve inlet piping specification. Cast iron body is forbidden.




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Face-to-Face dimensions of flanged safety relief valves shall conform to API RP 526, Flanged Steel Safety Relief Valves.

Flanged connections shall be furnished on all process and utility service safety relief valves. Flanges shall conform to ANSI B16.5, Pipe Flanges and Flanged Fittings. Rating shall be in accordance with the Piping Class Specification. Flange facing shall be chosen in accordance with piping class specification.

Metal-to-metal seats shall be rated for commercial tightness, which permits a leakage in accordance with API RP 527, Commercial Seat Tightness of Safety Relief Valves with Metal-to-Metal Seats.

Tungsten alloy springs shall be provided for operating temperatures of 230°C and higher and carbon steel aluminium sprayed for lesser temperatures, subject to compatibility with process services. Other materials like Inconel 750 can also be considered.

7.5.3 Safety Relief Valve Types

7.5.3.1 Conventional Safety Relief Valves

Conventional relief valves are preferred for liquid, gas or vapor service if the sum of the maximum superimposed backpressure and built up backpressure is less than 10 percent of the set pressure.

The valves shall be of the direct spring loaded, top guided, high lift full nozzle type.

The valves shall have a closed bonnet. The bonnet shall be internally vented to the discharge side of the valve.

Full nozzles shall be provided for valve sizes 1 inch and larger. Modified nozzles shall be provided for thermal relief service for valve sizes no greater than 3/4 inch by 1 inch.

Plain closed bonnets shall be provided with a tapped and plugged vent for easy conversion to balanced relief valves.

7.5.3.2 Balanced Bellows Safety Relief Valves

Balanced bellow valves shall be used if the sum of the maximum superimposed backpressure and built up backpressure is more than 10% but not exceed 50% of valve set pressure. If the backpressure exceeds 50% of the set pressure, Manufacturer shall be required to confirm that the selected relief valve is still able to handle the required relief load.

The valves shall have a bonnet vented to the atmosphere. The bonnet shall not be vented toward possible sources of ignition.

The bellows area shall be equal to the area of the nozzle that overcomes the effect of backpressure on the set pressure.

The valves shall be installed so that vapour does not release into personnel areas or impinge on lines or equipment.

7.5.3.3 Pilot Operated Safety Relief Valves

The use of pilot operated valve shall be kept to minimum.

Generally, pilot operated valves may be used in a clean gas or liquid service where proper operation of the pilot valve is always assured and with consultation with COMPANY. Pilot operated valve shall be used when:

• high back pressure above 50%

• maximum operating pressure is greater than 90% of the set pressure

• the service require superior sealing qualities due to leakage problem when using the

spring loaded type valve

• in large capacity and high set pressure service




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Pilot operated relief valve shall be furnished with a field test connection complete with a check valve and a block valve in the pilot supply line.

Backflow preventers shall be supplied on all pilot operated relief valve.

All pilot sensing lines shall have filters.

Modulating pilots shall not be used unless approved by the COMPANY.

8.0 MISCELLANEOUS INSTRUMENT ITEM 8.1 Junction Boxes

All junction boxes shall be of 316 SS construction with side and bottom entries. Top entry shall be avoided. Separate junction boxes shall be provided for DCS, ESD and FGS signals. Junction boxes shall also be segregated for IS and Non-IS signals, analogue, digital and powered digital signals for these systems.

Junction box shall be pre-installed with terminal blocks suitable to the required conductor. The terminal block shall be mounted on rails or supports and shall not mounted on the surface of any box or enclosure. A separate terminal shall be provided for each conductor to be connected. Each junction box shall be provided with as minimum 20% spare terminals.

Junction boxes shall be equipped with 10mm diameter earth studs.

8.2 Instrumentation Cable

8.2.1 General Requirement All Instrumentation Cables shall in general be in accordance with Specification for Electrical Cables; 1014-BKTNG-EL-SP-0010 and have the following characteristics:-

• Cable construction shall be as per IEC 60092-376

• Armoured type Galvanised Steel Wire Braid (SWB)

• Tinned annealed copper conductors as per IEC 60228, class 2

• The capacitance, inductance and L/R ratio must not exceed certain values for intrinsically safe circuits depending on the hazardous area classification and equipment parameters. Reference should be made to equipment hazardous area classification.

• Low smoke in compliance to ASTM D2863-74.

• Halogen-free (<0.5% maximum by weight) or Low Halogen (<17% maximum by weight) as specified for each cable type in compliance with IEC 60754-1 & 2.

• Flame retardant as per IEC 60332-3 Cat. A.

• Fire resistance as per IEC 60331 ( for vital emergency service and Fire & Gas service)

• Temperature index not less than 260°C.

• Oxygen Index not less than 30.

• Maximum operating temperature 85°C.

The dimensional and other characteristic to be within specified tolerance.

Cables shall be segregated for the following services as a minimum

• 4 to 20 mA signals (Individually & Overall screen)

• mV signals (Individually & Overall screen)

• Pulse signals (Individually & Overall screen)

• RTDs (Individually & Overall screen)

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• 24 VDC solenoid signals (No screen)

• Digital signals (Overall screen)

• Vibration probes (Individually & Overall screen)

• Any other signal (as required )

• Each communication (as per required application)

• Earthing (1C)

Cross section for copper conductors shall be as follows:

• Power cables (i.e. for solenoids, lamps, 24VDC interface signals, etc.): 2.5 mm²

• Control cables (i.e. for transmitters, positioners, limit switches): 1.5 mm²

• Earthing cable : 6mm²

8.2.2 Materials All cable materials shall be new and unused, of current manufacture, of the highest grade and free from all defects and imperfections affecting performance.

8.2.3 Cable Core Identification

Colour coding for pair/triple identification shall be as described:

• Pairs and triples shall be identified by having the pair/triple number printed on the

insulation in contrasting colour.

• Pair colours : Blue and Black

• Triple colours : Black, Blue and Brown

8.2.4 Outer Sheath Colour

The outer sheath colour shall be as follow:

• Digital signals : Orange

• Analogue signals : Black

• IS signal (Digital/Analogue) : Blue

• Electrical signals (solenoid) : Black

• Earthing cable : Green and Yellow strips, lengthways along

the cable

8.2.5 Marking on cables The cable outer sheath shall be marked on its surface at every interval of 1 meter with the following information:

• Voltage grade

• Cable type

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• Number of Pairs/Triples and conductor size

• IEC standards

• Manufacturer’s name or trademark

• Year of manufacturer

8.2.6 Marking on drums

The wooden drum shall be marked with the following information:

• Drum Number

• Cable type

• Voltage grade

• Number of Pairs/Triples and conductor size

• Cable length (m)

• Net and gross weight

• Manufacturer’s name or trademark

• Month and year of manufacture

8.2.7 Packing

The cable shall be coiled in non-returnable wooden drums.

The ends of cables shall be sealed against the ingress of moisture, dirt and insects and the end projecting from the drum shall be adequately protected against mechanical damage during lifting, transportation, intermediate storage and site handling.

8.3 Instrument Cable Glands Cable glands shall be standardised on stainless steel or marine brass certified for the specified hazardous area classification with ISO metric threads, complete with locknut and earth tags. These shall be double compression type. All brass components shall be Electro-Nickel plated.

Cable glands shall be of a design which permits removal for maintenance of the items without having to remake the gland.

All cable glands shall be standardised to EEx’d’ certified irrespective of Hazardous area classification with Ingress protection of IP 56.

Glands shall be in metric sizes with ISO 1.5 thread connections.

Plugs/Stoppers with the same certification and material as cable glands shall be provided for spare entries/holes of junction boxes.

8.4 Cable Trays/Ladders

Cable trays and ladders shall be of SS316 for outdoor application and Hot-dip galvanized for indoor application with 1.5mm thickness as minimum.

Internal width of ladders shall be 150, 300, 450, 600 or 900 unless specified otherwise.

All cable trays/ ladders shall be treated for humidity and tested as per IEC 61537.




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Wherever main cables are exposed to sunlight, or mechanical damages are going to occur during installation or chemical spillage then the main cable ladder/ tray shall be fitted with suitable covers to protect them.

Cable trays shall be grounded to reduce the induced currents and consequently interference between signal cables.

Instrument supports, minor brackets and other instrument steelwork of mild steel construction shall be hot-dip galvanised. Any damage to galvanising shall be made good prior to installation.

IS and Non – IS cables shall be segregated through the installation. If IS and Non-IS cables have to share the same cable tray/rack then as a minimum an earthed metal partition should be installed between the IS cables and Non-IS cables.

Minimum segregation of instrument cables parallel to power cables shall be as follows:-

Power Cable Rating Min. Separation from Electronic or Signal Wiring

MV (above 400V AC) - instrument 1200mm

LV (up to 400V AC) - instrument 600mm

Up to 230V AC - instrument 300mm

Where intersection between power and signal cables is unavoidable, the routing shall be such that Instrument and power cables cross at right angles.

Maximum unsupported span for cable trays and ladders shall be in accordance with manufacturer's instruction and in no event shall exceed 1.5m and 3 m respectively.

A minimum of 15% spare rack, trays or ladders capacity shall be provided.

8.5 Earthing System (Grounding) All equipment shall be connected to the suitable earth of following:

• Instrument earth

• I.S earth (if required)

• Protective earth

All panels, JBs, frames etc shall be equipped with earth studs and all metalwork shall be earth bonded. All outdoor equipment shall have external earth studs for CONTRACTORs interface.

All instrument signal cable screens shall be earthed at one point only. This shall be at the equipment panels. All screens shall be continued through all junction boxes and insulated from earth at the field end.

Cable armouring shall be earthed at both ends with continuity through the junction box.

8.6 Cable Transits

Multi Cable Transits (MCT) shall be used for cable penetration in order to maintain hermetic levels and zone classification e.g. from hazardous area to non-hazardous area.

Multi cable transits shall be generally installed where cables pass through the following locations.

• Gas tight/fire walls

• Any continuous or sealed wall, bulkhead or deck

Cable transits shall not be installed in roofs or top entry applications.

Cable transit frame shall be minimum Steel.




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8.7 Tubing, Fittings and Trays

Instrument process impulse lines and pneumatic/hydraulic connection shall be SS316L with minimum Molybdenum content of 2.5% conform to ASTM A269, seamless, bright annealed and maximum hardness of Rb-80.

Fittings shall be SS316, double ferrule compression type.

All tubing and fittings shall be imperial in size.

Minimum tubing sizes, wall thickness and maximum allowable working pressure shall be as follows:

Tubing Size Max. Allowable Working

Pressure (barg)* Application OD

(inch) WT

(inch)

1/4 0.035 352 • Pneumatic signal tubing

• pneumatic safety shutdown

3/8 0.065 448 • process impulse lines

• analyzer sample lines

• Hydraulic supply lines

3/8 0.049 240 • Hydraulic return lines

1/2 0.035 179 • all instrument drains to the open drain

collection point

• air supply tubing for on/off piston-type valve

actuators

• pneumatic volume booster output lines

• air supply to individual instruments.

* Based on ultimate tensile strength 5167 bar, for metal temperature from -29°C to 37°C, calculated from S-values of 1378 bar as specified by ANSI B31.3.

All instrument air piping and tubing shall be adequately supported, protected and run in such a way as not to restrict areas of access for operators, and to allow ease of removal of the instrument. The Stainless Steel tubing shall be secured by 316 SS tubing traps, or stainless steel UV resistant PVC coated banding with PVC insulating stand-offs.

All stainless steel tubing shall be routed as far as possible through areas that provide shade from direct sunlight. To minimise cold working stress, each tube bend should be the largest practical radius for its particular location.

9.0 INSTRUMENT INSTALLATION All field instrumentation and equipment shall be installed such that they shall be accessible for maintenance, calibration and adjustment from the deck level. Where instruments are close coupled to the process piping resulting in elevated locations, permanent access platforms shall be provided.




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Best trade practices shall be used for installation work. Where special tools or procedures are recommended by the equipment Manufacturer these shall be used.

All materials shall be new and of first class quality.

Attention shall be given to the following:

• good general appearance of the work

• good visibility of indicating instruments

• accessibility for maintenance of all instruments and equipment,

• the use of tools in good condition.

• Protection during construction, of equipment and materials, against construction damage and external weather conditions.

Steel supports and fixing devices shall be properly fabricated and fitted.

Overhead runs of instrument piping, tubing and electric cables shall be routed to avoid obstructing maintenance withdrawal for items of equipment, hot pipes, areas of high ambient temperature and areas of high fire risk.

10.0 INSPECTION AND TESTING REQUIREMENTS 10.1 General

All instruments/equipment supplied shall undergo inspection and test before despatch to fabrication yard. CONTRACTOR/VENDOR shall furnish factory inspection and test plan during detailed engineering stage for COMPANY’s review.

Before factory inspection and test along with COMPANY, VENDOR shall perform their internal inspection and test as per VENDOR’s standard.

All instruments shall be factory calibrated and calibration certificate shall be furnished for COMPANY’s review.

All master test equipment used for calibration shall have valid calibration test certificate from a nationally recognised testing laboratory.

FAT of ESDV, SDV, BDV and Safety Relief Valve set pressure test shall be witnessed by third party.

COMPANY and or his representative may or may not participate in the inspection and testing depending on their choice, however, all factory inspection and test activities to be notified in advance before the scheduled date.

10.2 Factory Inspection And Testing Factory inspection and testing shall fulfil, but not be limited to the inspection and test requirements indicated below:

• Review of VENDOR’s internal inspection and test reports

• Review of hazardous area and ingress protection certificates

• Review of NDE test certificates where applicable. Percentage of NDE testing to be carried out as mentioned in the relevant standards unless otherwise mentioned

• Visual Inspection and dimensional check for all instruments/Equipment

• Functional test for 100% of the instrument/equipment supplied

• 5 Point calibration checks of instruments at random for 20%

• Hydrotest/Pneumatic pressure test where applicable

• Flange facing and finish check at random for 20%

• Thermocouple and RTD sensor 3-point calibration check at random for 20%




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• Hydrotest of thermowells as per ANSI B 16.5 for 100%

• Bore concentricity test report on all thermowell welding joints shall be submitted for review

• 100% radiography test report for all thermowells shall be submitted for review

• 100% radiograph test reports shall be submitted for review on all casting valve/equipment bodies for rating above 600#. Radiograph to be performed in areas as mentioned in relevant standards. In the absence of any requirement in the standards, minimum 3 areas of high stress concentration shall be radiographed

• 100% of all safety/relief valves shall be checked for pop-up test.

• 20% of all safety/relief valves shall be checked for seat tightness.

• 25% of all tubes and fittings shall be hydrotested to confirm to the design pressure requirements.

• 20% of all instruments, tubing and valves shall be leak tested to verify bubble tight seat leakage.

10.3 Inspection and Testing at Fabrication Yard/Offshore

All instruments/equipment shall be tested for general operability before installation at site.

All pressure gauges, temperature gauges, electronic transmitters and switches shall be re-calibrated before installation. The above equipment supplied as part of the package equipment shall also be calibrated at site.

For the electronic transmitters, if a 2 year warranty against drift in zero and span is available, then recalibration is not necessary.

All safety relief valves (including package equipment) shall be checked and tested. Within a short time period prior to start-up (to be agreed upon with COMPANY), all the safety and relief valves shall be tested to the coldtest set pressure indicated by the manufacturer. CONTRACTOR shall supply a proper test bench to perform these tests unless the safety/relief valves may be tested in place by use of block and bleed valves.

Control valve electro-pneumatic positioner shall be calibrated in place while performing the loop checking.

All impulse lines shall be hydrotested. Leak test in pneumatic tubing shall be performed by using dry clean air.

Inspection, testing/Calibration and loop checking shall be carried out in accordance with pre-arranged programme to ensure systematic and complete installation and pre commissioning of the instrumentation equipment.

CONTRACTOR shall develop and submit to COMPANY for approval all check lists, function record form, calibration sheets, procedure, instructions etc. to ensure sufficient and effective coverage of inspection, testing, calibration and pre–commissioning.

11.0 DRAWINGS AND DOCUMENTS Documentation shall be provided for design information, installation, start-up, commissioning and maintenance of all instrumentation equipment.

Following are the minimum drawings and documents to be furnished by the CONTRACTOR/VENDOR for review by COMPANY.

• VENDOR’s final technical offer and technical clarifications

• CONTRACTOR’S purchase order (technical portion)

• VENDOR’s master list for all drawings and documents

• Detailed bill of materials




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• Instrument Datasheets

• Calculation sheets (Sizing, noise level, Frequency, etc)

• Dimensional drawings

• Wiring Drawings

• Painting Specification

• Inspection and Test plan

• Test Procedures (Functional test, Hydrotest, Leak test, NDE test etc)

• Test Certificates

• Calibration certificates

• Hazardous area certification

• Ingress protection certification

• Material Certificates

• Internal test reports

• Factory inspection and testing reports

• Recommendation for storage prior and during erection

• Start-up and commissioning spare list

• Recommended spare list for 2 years normal operation

• Installation, startup and commissioning manuals

• VENDOR data book (VDB) – Binders containing all VENDOR documents

10. 1014-bktng-in-sp-0006_rev 0

Documents

instrument general requirement

valves general requirements

instrument installation

instrument air

flow instrument

level instrument

temperature instrument

pressure instrument