You are on page 1of 51

O

OWNER :

LORDEGAN UTILITY
U
AN
ND OFFSIT
TE
DETAIL
L ENGINEE
ERING

Lordega
an
UREA FERTILIIZER CO. (PUBLIC STOCK)
P
Project No.:

D
DOC. NO.: 1333-ESS-00-IN-002

CO
OVER SHEET
T

P
Page 1 of 51

Project No.: 1333


1

Rev. 0

DOCUME
ENT TITLE:

In
nstrum
ment Genera
G
al
Engiineerin
ng Spe
ecifica
ation

The docu
ument is co
ompletely ad
dapt from the original document Nu
umber 2103-ESS-00-IN--005, REV.1,
ISSUED DATE 23.06
6.2009

25.06.2015

FOR AP
PPROVAL

D.G. LI

L.L.. LIU

T.Y. HU

REV.

DATE

DESC
CRIPTION

DES
S.

CHKD.

AP
PPR.

Page 1 off 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

Hampa Energy
Engineering & Design Company

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

Rev.

2103

PROJECT No:.

REVISION INDEX SHEET

REV.
PAGE

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

45
46
47
48
49
50
51

REV.
PAGE

REV
.
PAGE

Page 2 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.
1
SCOPE

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

CODES AND STANDARDS

BASIC PRINCIPLES

3.1

GENERAL

3.2

SYMBOL AND IDENTIFICATION

3.3

UNITS OF MEASUREMENT

10

3.4

SCALE AND CHARTS

10

3.5

SELECTION OF RANGES

10

3.6

INSTRUMENT MATERIAL

12

3.7

ELECTRICAL AREA CLASSIFICATION & WEATHER PROTECTION

13

3.8

ENVIRONMENTAL CONDITION

14

3.9

INSTRUMENT ELECTRICITY SUPPLY

14

3.10

INSTRUMENT GROUNDING

15

3.11

INSTRUMENT AIR SUPPLY

15

3.12

SIGNAL TRANSMITION

16

3.13

INSTRUMENT CONNECTION

16

3.14

FAILURE REQUIREMENT

19

3.15

PAINTING

19

3.16

MARKING

19

3.17

CERTIFICATION

19

CONTROL & EMERGENCY SHUTDOWN SYSTEM

20

4.1

GENERAL

20

4.2

FIELDBUS CONTROL SYSTEM

21

4.3

EMERGENCY SHUTDOWN SYSTEM

24

4.4

PLC

25

4.5

INTERFACING WITH OTHER SYSTEMS

32

4.6

CRITICAL MACHINES INSTRUMENTATION

32

Page 3 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

4.7

PROVISSION OF INSTRUMENT ON PACKAGE UNITS

33

4.8

CABINETS AND PANELS

34

FIELD INSTRUMENT

36

5.1

GENERAL

36

5.2

TRANSMITTERS

36

5.3

FLOW INSTRUMENTS

37

5.4

LEVEL INSTRUMENTS

39

5.5

PRESSURE INSTRUMENT

41

5.6

TEMPERATURE INSTRUMENT

41

5.7

PROCESS ANALYZER

43

5.8

CONTROL VALVES

44

5.9

SAFETY RELEIFE VALVE

47

INSTALLATION

47

6.1

INSTRUMENT LOCATION

47

6.2

CABLING

48

6.3

INSTRUMENT IMPULSE LINES

50

6.4

INSTRUMENT HEATING

50

6.5

INSTRUMENT AIR LINES

50

GUALITY ASSURANCE & INSPECTION PROCEDURE

51

7.1

QUALITY ASSURANCE

51

7.2

INSPECTION PROCEDURE

51

7.3

INSPECTION & TEST ITEMS

51

Page 4 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

PROJECT No:.

Rev.

1. SCOPE
This Specification covers the basic requirements for the design of control and instrumentation systems
necessary for monitoring, control and safety of Ammonia and Urea Plant in LORDEGAN province,
Iran.
In case there is any conflict between the requirements in this specification and the specific
requirements of licensers or packaged unit vendors, the specific requirements by licensers or
packaged unit vendors shall be considered superseding this specification.

2. CODES AND STANDARDS


The following publications shall form a part of this Specification. Unless otherwise specified herein,
the design shall conform to the latest edition at effective date of the contract.
Instrument Process Connection

ANSI B31.3
ANSI B16.5
ANSI B1.20.1
AWS D1.1-2000
ANSI B46.1

process piping
pipe flanges and flanged fittings
pipe thread
American welding society for steel structure and instrument
welding
flange face and finishing

ASME 16.20

metallic gaskets for pipe flanges

ASME B16.47seriesB

large diameter steel flanges

Material

ASTM
ANSI B31.3
NACE MR 01-75

material specification
process piping
in sour service

Welding

ASME Boiler
ANSI B31.3
AWS D1.0

and pressure vessel code, section IX latest edition


process piping
structural steel

Relief Valves

ASME
ASME
API Std2000
API
API RP 520
API RP 526
API RP 527

unfired pressure vessel code, section VIII division I parts UG-125


through UG-136 and division 2, part AR
boiler and pressure vessel code, P-269 through P-290
venting atmospheric and low-pressure storage tank
guide for tank venting
design and Installation of pressure relieving system
Part I and Part II
dimensions of flanged relief valves
valve leakage limits

Differential Pressure Flow Measuring Elements

ISO 5167
ISO/TR 15377,1998

Measurement of Fluid Flow by Means of Pressure Differential


Devices
Measurement of Fluid Flow In Closed Conduits
Page 5 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

Hampa Energy
Engineering & Design Company

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

PROJECT No:.

Rev.

Flow Measurement (For Liquid Hydrocarbons)

API 2545
ISO 2714
ISO 2715
ISO 6551

Method of Gauging Petroleum and Petroleum Products


Liquid Hydrocarbons- Volumetric Measurement by Displacement
Meter Systems other than Dispensing Pumps
Liquid Hydrocarbons- Volumetric Measurement by Turbine
Meter Systems
Petroleum Liquid and Gases- Fidelity and Security of Dynamic
Measurement Cabled Transmission of Electric and/or Electronic
Data

Electrical

Cenelec-50014 to 50020 and 50039


IEC 60529
API 505
IEC 60079
BS 5308
ISA RP 60.8
IEC 60947-5-1

for explosion protection


ingress protection (IP Code)
hazardous area classification
electrical installation and wiring
instrumentation cables (IEC 61158 for FF cables)
electrical guide for control centers
switch contacts ratings

Control Valve Dimensions

ISA S75.08.01
ISA S75.04
NAMUR

face to face dimension for flanged control valve body


face to face dimension for flangeless control valves
proximity switches mounting and solenoid valve connection

Thermocouples/RTD

IEC 60584
IEC 60751

thermocouples
RTD

Instruments and Control Systems

API RP 551
API RP 552
API RP 553
API RP 554
API RP 555

Process Measurement Instrumentation


Transmission Systems
Refinery Control Valves
Process Instrumentation and Control
Process Analyzers

Instrument Symbols

ISA S5.1
ISA S5.3

conventional Instrumentation
distributed control and shared display

Logic Diagrams and Programs

IEC 1131
IEC 848

programmable controller
preparation of function charts for control system

Alarm Sequences

ISA S18.1

annunciator sequences and specifications

Instrument Sizing

ISA S75.01
IEC 534-8-3
ISO 5167/BS 1042
ASME VIII / API 520

control valves
control valve noise calculation
differential pressure type instruments
safety valves
Page 6 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

PROJECT No:.

Rev.

Control Valves

API 598/ANSI B16.37


ANSI B16.104/FCI 70-2
ISA S75.08.01/ANSI B16.10
ISA S75.02

hydrostatic testing
for seat leakage
face to face and end to end dimensions of valves
control valves capacity test

Steel Casting

MSS SP-55

FCS/PLC/ESD
IEC 61158
IEC 61131

quality assurance standards for valves, flanges and


fitting steel casting
Digital Data Communication, Part 2
Programmable Controllers

Safety

IEC 61508
IEC 61285
DIN V 19250

instrumented safety
explosion protecting of analyzer rooms
only for ESD and F&G system

Ethernet

IEEE 802.3 (TCP/IP)


Machines Monitoring System

API 670

Machinery Protection Systems

Boiler Instrumentation

NFPA 85.02
Batch Process Control

ISA 88

batch control
Computer Operating System

MS Windows Base (Latest Version)


Openness

OPC DA 2.0 and A and E1.0


Related Engineering Specifications

Engineering Specification for Piping Materials


Owners standard, IPS(Iranian Petroleum Standard), for cases not covered by above standard.

Page 7 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

Project No.:
TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

PROJECT No:.

BASIC PRINCIPLES

3.1

GENERAL

LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-005

Rev.

Measurement and control system shall generally be implemented by a state of the art Fieldbus
Control System based on FOUNDATION Fieldbus technology.
The safety protection system other than safety valves and locally mounted initiating devices
shall be incorporated in the Programmable Logic Controllers (PLC).
All design and engineering documents shall be written in English.

3.2

SYMBOL AND IDENTIFICATION

3.2.1

Instrument Tag Numbering Structure


Project instrument tag number designation standards listed below shall be consulted in the
following precedence :
P& ID Diagram Legend
Instrument Society Of America
ISA S 75.1
Instrument Society Of America
ISA S 75.3
Basic binary logic symbols
IEC 61131.

3.2.2

Project Instrument Component Identification


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

3.2.2.1 Cabinet Identification System


The cabinet shall be identified according to its service
FCS
PLC
MMS
BMS
IC
MC
PDC

Fieldbus Control System


Programmable Logic Controller
Machine Monitoring System
Burner Management System
Instrument Cabinets
Marshalling Cabinets
Power Distribution Cabinet

3.2.2.2 Junction Box Identification System:


Junction Boxes shall be identified according to the Unit where they are installed.
J.B. numbering to be as follows:
JB

XX

XX

XX

ab

e
Page 8 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

PROJECT No:.

Rev.

a: Represents the type of signals from IS or NIS point of view. I for IS and N for
NIS.
b: Represent the type of cables as follows:
I:
Miliampere
K:
Thermocouple K type
E:
Thermocouple E type
J:
Thermocouple J type
S:
Thermocouple S type
T:
Thermocouple T type
D:
Discrete
V:
Solenoid
R:
RTD
P:
Power
X:
Proximity switch
Z:
Special
HW: Data High Way
H1: FF H1 Hub
HSE: HSE Hub
L:
Serial Link
c: Represent the unit key number.
d: Represent the sequential number beginning from 001
e: Represent the destination of cable as follows:
E:
N:
S:

For ESD JB
For N ESD JB
For Safety JB

3.2.2.3 Multi-Core Cable Identification System


Multi-core cables shall be identified according to the junction box numbering.

3.2.2.4 Single Cable Identification System


Single cables shall be identified according to the instrument tag number.
Suffix for loops with more than one instrument with the same function (e.g. split range valves
A anB) to be added where necessary.

3.2.2.5 Cable Drum Coding and Numbering


Cable drum shall be coded and numbered in accordance with the following:
I
a

XX
b

XXX
c
Page 9 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

a: I (as Instrument)
b: Cable codes as specified in cable MTO codes.
c: sequential NO. beginning from 001

3.3

UNIT OF MEASUREMENT
The following units of measurement shall be applied to the complete project. Unless otherwise
specified, the unit based on the SI shall be used.
- Flow,
- Level
- Pressure,

liquid (volume)
gas
steam
gauge
absolute
vacuum
differential

- Temperature
- Other unit
density
viscosity
rotation
velocity
power
voltage
current
concentration
conductivity
weight
sound

m3/h
see Note below)
Nm3/h, Nl/h (at 0 C, 1.013 barA)
see Note below)
kg/h, t/h
%, mm
barG, mbarG
barA, mbarA
-barG, -mbarG
bar, mbar,mmH2O
C
kg/m3
cP
rpm
m/s
kW
V, kV
A, kA
mol%, ppm
S/m
kg
dBA

Note) In case flow transmitter provides mass flow measurement, like coriolis type, kg/h is used
instead.

3.4

SCALE AND CHARTS


Scales for panel mounted indicators:
Pressure and temperature indicators shall be direct reading. Flow indicators shall be direct
reading, or 0 to 10 square roots depending on the application. Level indications shall be direct
reading, or 0 to 100 % uniform depending on the application.

3.5
3.5.1

SELECTION OF RANGES
General
Unless otherwise specified, the instrument ranges shall be selected such that the normal
operation value is normally between 50% and 75% of the range. The maximum value should
be less than 90% of the range in general.

Page 10 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

For flow measurement by means of pressure differential devices, the maximum range should
be selected so that the normal operation value represents between 60 % and 80%.
The minimum flow should not be less than 33% of the range.
For level measurement, normal level should be positioned at 50% of the range.

3.5.2

Standard Range
As far as practical, the following standard range shall be used:
D/P Transmitter for Flow:

500 mmH2O
750 mmH2O
1000 mmH2O
1250 mmH2O

2500 mmH2O(preferred range)


5000 mmH2O
6250 mmH2O
10000 mmH2O

Displacers:

357 mm(14)
813 mm(32)

1219 mm(48)
Others on special application

D/P Transmitter for Level

As required,

Gauge Glass

Manufacturers standard ranges, however, the center to


center of nozzles should be in accordance with #8 glasses.

Level Switch

356 mm (center to center of nozzles)

Temperature Gauge/Switch

-30 to 50 C
-50 to 50 C
0 to 60 C
0 to 100 C

Temperature Transmitter

Manufacturers standard ranges

Pressure Gauge

-1 to 0 bar (g)
-1 to 1.5 bar (g)
0 to 1.0 bar (g)
0 to 1.6 bar (g)
0 to 2.5 bar (g)
0 to 4.0 bar (g)
0 to 6.0 bar (g)

0 to 10 bar (g)
0 to 16 bar (g)
0 to 25 bar (g)
0 to 40 bar (g)
0 to 60 bar (g)
0 t o 100 bar (g)

Draft Gauges

-10 mbar to 0 mbar


-20 mbar to 0 mbar
-40 mbar to 0 mbar

-3 mbar to 3 mbar
-1 mbar to 10 mbar
-50 mbar to 50 mbar

Pressure Transmitter/ Switch

As required

0 to 160 C
0 to 200 C
0 to 300 C
0 to 400 C

Page 11 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

PROJECT No:.

Rev.

3.5.3 Accuracy
3.5.3.1 Instrument accuracy shall conform to the following table.
TABLE 1.3
INSTRUMENT
Orifice plates and venturi tubes> 50%
measuring range
Local Digital Indicator
D.P. Transmitter
Pressure Transmitter
P.D Flowmeter for fiscal services
P.D Flowmeter
Turbine Flowmeter
Turbine Flowmeter for fiscal services
Annubar
Rotameters
Rotameters with PTFE lining
Rotameter for purging
Mass Flowmeter
Electromagnetic Flowmeter
Displacer type Level Transmitter
Radar Level Instrument
Thermocouple
Resistance Temperature Detector
Pressure Gauge
Bimetallic Thermometer
Temperature Transmitters
I/P Transducers
A/D or D/A Converters
Liquid Expansion Thermometer
Electric indicators
Flanged Pressure Gauge

ACCURACY
1.5% FS
1 digit
0.1% FS
0.1% FS
0.15% FS
0. 25% FS
0.25% FS
0.15% FS
1% FS
1.6% at 100% flow
2.5% at 100% flow
4% at 100% flow
0.2 % mv
1 % FS
0.5 % FS
1 mm
IEC-60584
IEC751 (Class A)
1% FS (Flanged 2.5%)
1% FS
0.1 % FS
0.6% FS
0.2% FS
1% FS
0.2% FS
1.6% FS

3.6

INSTRUMENT MATERIAL

3.6.1

Standard generally applicable to the material of different parts of instruments is ASTM.

3.6.2

Wetted parts of all instruments including sensing elements shall be minimum Stainless
Steels 316 and in sour services shall be in accordance with NACE MR 01-75 except where
the process condition requires other materials.

3.6.3

Movement (linkages, etc.) for instruments shall be stainless steel.

3.6.4

The material of components that come into contact with process fluid shall be selected to be
resistant to stress resulting from pressure, temperature, corrosion, etc. and shall further be
Page 12 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

compatible with the piping material with regard to welding or other methods of connection/
joint.
3.6.5

Electronic printed circuit boards shall be troplicalized and coated with suitable material
against corrosive or conductive dust wherever required.

3.6.6

due to the presence of Ammonia vapors in the surroundings atmosphere, the use of copper
& copper alloys is not allowed.

3.7

ELETRICAL AREA CLASSIFICATION & WEATHER PROTECTION

3.7.1 Hazardous Area Classification


Classification of hazardous area shall be defined in accordance with API 500, while zone
definition shall be based on IEC 60079.

3.7.2 Type of Protection


All electrical or electronic instrumentation equipment shall conform to electrical area
classifications. The type of protection for electrical or electronic instruments or devices for use
in hazardous area shall be as follows:
Equipment
General Instruments
Thermocouples/RTD
Switches
Valve Positioners
Lamps
Solenoid Valves
Local Panels
Junction Boxes

Zone 0
EEx ia
EEx ia
EEx ia
EEx ia
Shall not install
Shall not install
Shall not install
Shall not install

Zone 1
EEx i
EEx i
EEx i
EEx i
EEx d
EEx i
EEx d or EEx p
EEx e

Zone 2
EEx i
EEx i
EEx i
EEx i
EEx d
EEx i
EEx d or EEx p
EEx e

In case EExi apparatus is not available in the manufacturers standard products, type EExd can
be used as an alternative for Zone 1 and 2 installations.
Gas group and ignition level (temp class) will be in accordance with area classification
(according to CENELEC)

3.7.3 Weather Protection:


3.7.3.1 Applicable codes to Weather protection of the instruments are as follows:
- IEC-60529

Degrees of protection provided by enclosures (IP code)

3.7.3..2 All equipments shall be furnished with all necessary weather and antifreeze protection to
prevent damage due to climate or from the plant atmosphere. (if required).
3.7.3.3 Field instruments shall be damp and dust proof, with the minimum type of protection being
IP65.

Page 13 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

3.8

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

ENVIRONMENTAL CONDITIONS
All field instruments shall be suitable for operation in the following environmental conditions.
The environmental conditions at the job site are as below:
Ambient temperature:

Minimum Recorded temperature:

-27c

Maximum Recorded temperature:

+44c

Maximum temperature for Equipment


exposed to sunlight:

+80c

Humidity Design:

71%

Barometric pressure:

Use 840 mbar for design.

Plant elevation:

Plant is located at 1840m above sea level.

Valve and accessories shall be suitably constructed and coated to withstand these
conditions without affecting its operation.
The minimum degree of protection for enclosures containing electronic components shall be
IP 65 or equivalent, otherwise suitable measures shall be provided.
All field instruments such as transmitters and control valves shall be both operable and
storable in minimum ambient temperature up to maximum ambient temperature according to
site condition.
Protection/heating box shall be supplied as far as required and sunshade for field instruments
shall be considered if instruments are under direct sunlight.

3.9

INSTRUMENT ELECTRICITY SUPPLY


The instrumentation power shall be distributed from a main power distribution board (PDB),
which is installed in the Control Auxiliary Room.
Primary electrical powers fed to the PDB shall be connected to the Uninterrupted Power
Supply (UPS) system and supply voltage is as follows.
-

AC 110 V 5%, 50 Hz 1%, single phase


Battery Back-up time: 30 min.

The UPS shall be used to supply all instruments and control system, except analyzer oven
heaters.
24 VDC to supply instruments and to implement the logic of the alarm and shut down system
shall be generated by using DC power supplies fed at 110 V 50Hz from above mentioned
UPS. Said DC power supplies shall be furnished in general by manufacturer of
FCS/PLC/ESD systems.
Page 14 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Power supply inside FCS, PLC and ESD systems shall be designed with back up redundancy
i.e. in the case of one power supply failure, the associated consumers shall automatically be
fed from another stand by power supply.
The instrument electrical power supply distributed shall consist of a cabinet with automatic
breakers that shall be installed in the auxiliary room. Each system shall be supplied by an
automatic breaker. In addition each instrument shall be protected by a fuse or integral
electronic current limiter.
20% of installed spare breakers and fuses shall be provided for future expansion.
For signals and systems a dedicated clean earth to be provided.

3.10

INSTRUMENT GROUNDING
The equipment energized with the voltage > 50 VAC or 120 VDC shall be provided with earth
grounding protection. Grounding resistance shall normally be of following:
- Safety ground:
five (5) ohms or less
- System ground:
one (1) ohms or less
- IS ground:
one (1) ohms or less
Metallic frames of cabinets, panels, consoles, junction boxes and cable wire armors shall be
connected to the safety ground. Instrument ground is provided for earthling of digital systems,
such as DCS and PLC based systems, and the Manufacturers recommendation on the
arrangement of grounding shall be followed. Screens of instrumentation cables shall be
connected to intrinsic safety ground for IS cables and to safety ground for Non-IS cables.
A tinned copper safety ground bus bar shall be mounted inside the cabinet or panel and
connected to the frames. Conducting parts such as doors, etc., which is not permanently
connected to safety ground, shall be connected to the frame of cabinets or panels with a
flexible ground straps. Separate tinned copper ground bus bars shall be provided with clear
demarcation in each cabinet or panel for instrument ground and IS ground. Instrument ground
bus bar and IS ground bus bar shall be isolated from the safety ground.

3.11

INSTRUMENT AIR SUPPLY


The conditions of instrument air supply source shall be as follows.
- Pressure,
minimum
5.0 bar (g)
normal
7.0 bar (g)
design
10.5 bar (g)
(Note: Minimum air supply pressure for actuator sizing is 4.0 barg)
- Temperature, normal
design
- Dew point
- Oil/dust

amb.
85 C
-37 C (at 7.5 barG.)
free

All instrument consumers, pneumatic instruments or devices, shall have an air filter regulator
set with a small size output gauge at the air supply connection.
Page 15 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

3.12 SIGNAL TRANSMISSION


3.12.1 Fieldbus Signal Transmission
FOUNDATION Fieldbus shall be used for transmission of measuring inputs and control outputs
depending on the availability of Fieldbus compatible instruments, which will be determined at
the beginning of detail design stage.

3.12.2 Electric Analog Signal Transmission


Standard 2 wire 4 to 20 mA DC signals with HART protocol shall be applied for measuring
inputs and control outputs of conventional analog instruments.
Conventional analog instruments shall be used for safety protection systems (ESD, Gas
Detection) , instrument of packages and for the applications where no Fieldbus compatible
instrument is available.

3.12.3 Discrete Signal Transmission


Discrete signals shall be used for status and alarm indication which contact is basically
potential free and closing on normal operation conditions except for proximity switch signals
which contact is closing when magnetic sensor is detecting steel (end of travel).

3.12.4 Pulse Signal Transmission


Pulse trains where applied shall be directly proportional to the measured variable with
magnitude and frequency as per vendor standard.

3.12.5 Pneumatic Signal Transmission


Standard range for pneumatic signal transmission shall be 0.2 to 1.0 bar (g).
Pneumatic signal transmission shall be applied only for positioner.

3.13

INSTRUMENT CONNECTION

3.13.1 In-Line Instruments Process Connection


Unless otherwise specified, process connection of inline instruments shall be flanged in
accordance with the relevant Piping Materials Specifications.

3.13.2 Process Connection Of General Instruments


Process connection of instruments except for in-line instruments shall generally be in
accordance with the following table.
The flanged connections shall conform to ANSI B16.5. and according to Specification for
Piping Materials. Standard connection of instrument shall be 1/2 NPT female as per ANSI
B1.20.1.

Page 16 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

The first isolation valves may be provided with screwed connection at instrument side instead
of flanged end so that screwed instrument fitting can be directly mounted on the valves.
Diversity of make in instruments shall be avoided and care shall be taken to limit the
sensor/capsule types without sacrificing the process measurement quality.

Type of Instruments

Piping
block
valve
Size

Equipment/
pipe
connection

Instrument
connection
of block
valve/ Nipple

Final
Connection
for
Instrument

Notes

) Part 1: Connection on equipment


) Pressure and Differential Pressure
) Pressure gauge

) 1 1/2"
nozzle

3/4"

3/4" NPTM

1/2" NPTF

(1)

) Diaphragm gauge

) 2" nozzle

2"

2" flanged

(2)

3/4"

3/4" NPTM

1/2" NPTF

(1)

) Pressure transmitter

1 1/2"
nozzle

) Flanged pressure
transmitter

) 2" nozzle

2"

2" flanged

2" flanged

(2)

) Diaphragm sealed
pressure transmitter

) 2" nozzle

2"

2" flanged

(2)

) 1 1/2"
nozzle

1 1/2"
flanged

) Level indicator (Level


Gauge)

) 1 1/2"
nozzle

1 1/2"

1 1/2"
flanged

1 1/2"
flanged

) Level switch (External


float and side mounted)

) 1 1/2"
nozzle

1 1/2"

1 1/2"
flanged

1 1/2"
flanged

3/4"

3/4" NPTF

1/2" NPTM

(1)

) Temperature
) Thermowell
) Level

) DP level transmitter

1 1/2"
nozzle

) Diaphragm sealed level


transmitter (Drum,
Vessel, Tower)

) 2" nozzle

2"

2" flanged

(2)

) Diaphragm sealed level


transmitter (Storage
Tank)

) 3" nozzle

3"

3" flanged

(2)

Page 17 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

) Displacer level
transmitter (External)

2" nozzle

) Level transmitter
(Internal float and
displacer)

) 4" nozzle

2"

2" flanged

Rev.

2" flanged
4" flanged

) Part 2: Connection on piping


) Pressure and Differential Pressure
) Pressure gauge

) 3/4" nozzle

3/4"

3/4" NPTM

1/2" NPTF

(1)

) Diaphragm gauge

) 2" nozzle

2"

2" flanged

(2)

3/4" nozzle

3/4"

3/4" NPTM

1/2" NPTF

(1)

) DP transmitter for orifice


flange

) 1/2" nozzle

1/2"

1/2" NPTM

1/2" NPTF

(1)

) Flanged pressure
transmitter

) 2" nozzle

2"

2" flanged

2" flanged

(2)

2" nozzle

2"

2" flanged

(2)

) Pressure transmitter

) Diaphragm sealed
pressure transmitter
) Orifice tap

) 1/2" NPT

1/2"

1/2" NPTM

1/2" NPTF

) Analyzer tap-Liquid
(Probe Type)

) 1 1/2"
nozzle

3/4"
flanged

3/4"
flanged

) Analyzer tap-Gas
(Sample Type)

1 1/2"
nozzle

3/4"

3/4" NPTM

3/4" NPTF

) Annubar flow element

1 1/2"
nozzle

1 1/2"
flanged

1 1/2"
flanged

) 1 1/2"
nozzle

1 1/2"
flanged

(1)

) Temperature
) Thermowell

Notes:
1) Manifolds/isolating valves connections shall be 1/2NPTF and/or 3/4NPTF at both sides.
2) Instrument accuracy could require 3 and upper connection (If required)

Page 18 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

3.13.3 Air Connection


Instrument air supply and pneumatic signal connections on instruments shall normally be 1/4
NPTF. Instrument air supply connections on control valves shall be 1/4 or 1/2 NPTF
depending on the application and air demands.
Instrument pneumatic signal connections on instruments and control valves shall normally be
1/4 NPTF.

3.13.4 Electric Connection


Cable entry to instruments shall normally be M20 (M = ISO Metric Fine Screw Threads, Pitch
1.5) fitted with compression gland for PVC/SWA/PVC type cables. The size of cable entry to
junction boxes, field panels, etc. shall normally be selected from the series; M20, M25, M32,
M40, M50, M63 and M75.
Flying lead connections for instruments shall be avoided, proper terminals enclosed in the
instruments housing shall be furnished.

3.14

FAILURE REQUIREMENTS
All instruments shall be considered for fail to safe action upon loss of instrument air or
electrical power. Control valves with spring-loaded actuators are recommended to take
actions of air fail to open or close, otherwise double acting cylinder with volume tank and
accessories may be used.
The input contacts to alarm, interlock and emergency shutdown system shall be close (make
contact) during normal operation and open on alarm or trip. The solenoids shall be energized
during normal operation and de-energized to trip.

3.15

PAINTING
Painting procedure for instrumentation equipment and materials shall be as per Summary of
Paint Specification (2103-ESS-00-QC-810) unless otherwise specified on Requisition for RAL
colors .

3.16

MARKING
All instrumentation equipment shall be provided with permanent identification of the
instrument tag number and other specifications as per detail engineering. Nameplates for
field-mounted instruments shall be stainless steel.
Terminal strips shall be furnished with the terminal makers. Wire markers shall be installed on
the wires inside panels and junction boxes at their termination point. Cable markers shall be
installed to identify field cables inside panels and junction boxes.

3.17

CERTIFICATION
Shop inspection, mill test and other QC certification shall be provided in accordance with Shop
Inspection Requirement (SIR).

Page 19 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

3.17.1 Material Certification


The pressure containing part of in-line instruments shall be provided with material certification
in accordance with the requirements stipulated in Piping Material Specification.
The materials of wetted part in sour services shall generally be selected and treated in
accordance with the recommendation of NACE MR 01-75.
Due to the presence of Ammonia vapors in the surrounding atmosphere, the use of copper or
copper alloys is not allowed.

3.17.2 Ex-proof Certification


All electrical or electronic instruments or devices for use in hazardous areas shall be certified
and approved for the installation location by an internationally recognized authority:
-

Comite Europeaen de normalization Electrotechnique (CENELEC)

Europe

British Approval Service for Electrical Equipment in


Flammable Atmosphere (BASSEFA)

UK

Centro Elettrotecnica Sperimentale Italiano (CESI)

Italy

Physikalische Technische Bundesanstalt (PTB)

FRG

Technical Recommendation of the Reserch Institute


of Industrial Safety Japan (RIIS)

Japan

Laboratoire Central des Industries Electriques (LCIE)

France

Factory Mutual (FM)


Underwriters Laboratories (UL)

USA
USA

CONTROL AND EMERGENCY SHUTDOWN SYSTEM

4.1
4.1.1

GENERAL
Overall System Configuration
The plant control system consists of Basic Process Control System (BPCS; hereinafter called
FCS), Emergency Shutdown System (ESD) and other subsystems, such as rotating machine
controls, packaged equipment controls, etc.
FCS shall be established on the Distributed Control System (DCS) along with FOUNDATION
Fieldbus technology.
The H1 Fieldbus with Fieldbus devices to the extent available shall be used for process
interface except for ESD applications. Packaged control system shall be vendors standard
system, preferably PLC based.
ESD shall be performed by a QMR/TMR type Programmable Logic Controller (PLC) certified
by TUV for use in safety related system as per requirements categories of AK6 according to
DIN V 19250 (equivalent to SIL3 according to IEC-61508).
Page 20 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Besides FCS and ESD system, control sub-systems for 3rd parties equipment/units may be a
part of the plant control system and those control systems will be as per the vendors
standard design.
The system shall have redundancy of CPU and I/O.
Redundancy for fault tolerance shall not decrease system safety and reliability. It shall be
possible to change the fault components, in line, without plant shutdown and system
degradation.
ESD shall meet IEC-61508 and/or IEC-61511 requirements.
ESD primary elements shall be normally close (open for shutdown) and final elements
normally energized (de-energized for shut down).
Prototypes are not acceptable, 2 years operation on similar application are required.
Besides FCS and ESD systems sub-system controls for 3rd parties equipment/unit may be a
part of the plant control system and those control systems will be as per vendors standard
design.
The electromagnetic relays, specially for use in the field, shall be hermetically sealed
enclosure type.
The relays shall be provided with surge protection internally or externally and with LED
indicator, if possible.
Interposing relays shall be provided for signal isolation between MCC and control room that
shall be located in electrical cabinets.

4.2

FIELDBUS CONTROL SYSTEM (FCS)

4.2.1

Function
FCS shall be designed to perform regulatory control, sequence/ logic control and data
acquisition/alarm detection.
FCS shall be capable of performing following functions:
-

Control and monitoring of process conditions


Presentation of alarm status
Logging of events and alarms
Historical data storage
Report generation
Trend indication
Self diagnostic of the system
Capability of interfacing with management information systems
Capability of monitoring and control of other systems
Loop detail/tuning displays

4.2.1.1 Asset Management:


The system shall be provided with instrument maintenance management system for
FOUNDATION Fieldbus and Smart instruments

Page 21 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

4.2.1.2 MIS Connectivity


Further to above functional requirements, the system shall be capable for connection with
Ethernet computer network with TCP/ IP protocol for management information system ( MIS).
To meet the MIS program requirements selected FCS data shall be available.

4.2.2

Redundancy
In general, FCS and system is provided with redundancy in the following equipment subject to
manufacturers availability:
-

Cabinet mount controllers


H1 Fieldbus interface card
Power supply
I/O buses and data highways
Communication modules
Operator stations
Interface modules/gateways
All field bus I/O cards and also, non-field bus I/O cards for analog closed loop.

If the operator workstations are functionally identical and operating with the same application
programs and the database, it regards as redundancy is effectively provided.
QMR PLC shall mean quadruple modular redundant PLC which has two CPU cards and each
CPU card is provided with two CPUs or Triple modular redundant type except for the purpose
of annunciation on auxiliary consoles, for which non-redundant or simplex discrete output
cards may be utilized.
Dual-redundant communications between FCS and could be based on Ethernet TCP/IP as
well as MODBUS plus RTU protocol based on RS-485 physical link shall be provided for
interfacing between FCS and major subsystem such as PLC. While simplex system may be
used for communication with other subsystems based on modbus, Ethernet TCP/IP, and etc.

4.2.3

System Components
FCS shall consist of following functional elements:
-

Human-machine interface complete with LCDs , keyboards with mouse (or track ball)
Fieldbus configuration devices
Controller modules
Input and output processor modules including I/O cards and remote I/O link
Fieldbus network (H1) interface modules
Serial communication devices
System printers
Auxiliary instruments such as IS barriers, proximity amplifiers, relays, etc.
Control Panels supplied by Vendors (Installed in Control room or Locally mounted)

Human Machine Interface (HMI) of FCS shall be a Windows-NT based PC with OPC
openness and consist of a standard 21-inch color LCD.
Printers shall be provided for printing alarm/events and reports respectively.
The system shall include an engineering workstation with a printer.
Controllers shall be sized to provide adequate performance for users application.
Page 22 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

Project No.:
TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-005

Rev.

After FAT minimum of 20% installed spare in all respects (per type of hardware/software
items) shall be available for future addition/modifications. In addition 10% free space shall
also be considered for cabinets.

4.2.4

Marshalling Cabinets
Marshaling cabinets shall be provided for interfacing between field instruments and I/O
subsystem and equip with field cable termination strips, intrinsic safety barriers, proximity
amplifiers and Field Termination Assembly (FTA) to allow crosspatch wiring.
Cabling between the marshaling cabinets and I/O subsystem shall be performed using prefabricated plug-in cables. The marshalling cabinets shall be completely independent and
separate for FCS and ESD.
Intrinsic safety barriers, where applicable, may be an integral type with FTA.
The barriers shall be galvanic isolation type and suitable for use of HART or FF
communication instruments.

4.2.5

Alarming
In addition to standard FCS alarm functions, FCS shall be provided with hardwired alarms on
conventional consoles for important ESD alarms.
Annunciators shall be microprocessor-based type and the alarm sequence shall be
configurable and comply with ISA S18.1. Sequence F3A shall be selected for first out and 1A
for others. An audible alarm device shall also be provided. Annunciator windows shall be
white with color filters according to their function as follows.
-

4.2.6

General alarms and status indications


Shutdown
Alarms in first-out sequence groups

white
Red
Amber

Package Equipment Control and Monitoring


Package vendor equipment/facilities units shall be provided with independent control panels.
These panels will be supplied by package vendors and installed in instrument equipment
room, in general.
The packages local control system shall be implemented by a state of the art high grade
PLC.
Electronic instruments equipping the package, such as reformer, compressors, etc., shall be
SMART type with HART protocol on 4-20 mA.
The manufacturer shall be subject to purchasers approval.
The control system shall be connected to FCS be means of MODBUS RTU protocol based on
RS-485, allowing the data reading of the process and diagnostic information of the package
instrumentation and their inclusion in the Asset Management System.
Selected important information such as key operational process parameters, facility fault
alarms and shut down alarms shall be repeated to FCS through redundant serial interface, for
Page 23 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

major process packages.


Above applies to all packages and, more in detail:
- Steam turbine governor system
- Centrifugal compressors vibration monitoring system
- Centrifugal compressors over speed shutdown system
Further, dedicated controllers shall be furnished to compressor anti-surge controls unless
compressors vendor can guaranty that anti-surge controls can be implemented in PLC.
Package control system could include the package ESD functions.
The PLC for ESD, that could be integrated with control function, shall have the characteristics
of plant ESD.
I/O redundancy will be decided by package vendor.
Every micro processor based equipment must have the possibility for verification/
configuration of software application.
At site, for commissioning, start of, operation, maintenance PC (s) shall be used for this
purpose.
The PC (s) shall have all required software/licenses.
During detail engineering phase and depending of selected package, manufacturers shall be
defined the type/quantity of PC (s).
.

4.3

EMERGENCY SHUTDOWN SYSTEM

4.3.1

Function
ESD system shall operate independently from the FCS and be provided to prevent plant
hazardous conditions.
The system shall be provided with adequate diagnostic feature to enable fault detections and
be provided with on-line repair capability.
ESD shall be connected to FCS through dual redundant serial communication devices, and
key process parameters as well as ESD system hardware information shall be represented
on FCS/HMI.
ESD system, comprising sensor subsystem, logic subsystem and final element subsystem,
shall be designed to satisfy the required safety availability of target Safety Integrity Level (SIL)
3 which will be determined by the safety life cycle analysis according to IEC-61508 and IEC61511.

4.3.2

System Components
The logic function of ESD system shall be performed by PLC, which consists of the following
equipment in general:
-

PLC system comprises of Central Processors and I/O Subsystem


A PC for PLC engineering along with a printer
A PC for sequence event recording along with a printer

The PLC engineering workstation software shall be compliant with IEC61131-3 and provided
with access security protection in order to eliminate an adverse affect on the safety integrity of
the system.
Page 24 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

4.3.3 Redundancy
In general, ESD system shall be fully redundant, providing redundancy in the following
equipment subject to manufacturers availability:
-Control Processor Units (CPUs)
-Communication modules and links
-Power supply
-I/O buses and data high ways.
-I/O cards
-Interface modules / Gate ways to FCS
All the input and output cards of ESD system shall be in redundant configuration except for the
purpose of annunciation of auxiliary consoles, alarms for which non-redundant or simplex
discrete output cards may be utilized.
Dual-redundant communications between FCS and ESD could be based on Ethernet TCP/IP
as well as MODBUS RTU protocol based on RS-485 physical link provided for interfacing
between ESD and FCS for alarms and high importance signals involved in process control and
logics.

4.3.4

Sequence Of Event Recording


A personal computer along with a black & white LaserJet printer shall be supplied for sequence
of event recording (SER). SER may be an integral function of ESD-PLC and to log ESD
related sequence of events with time stamping. The time stamp shall be generated in ESDPLC and it will be synchronized with DCS clocks.

4.3.5

Override
1) Process Override :

Process override switches shall be shown on P&ID and shall be considered in case
normal conditions may cause a shutdown during start-up operations. Process override
shall act only on input signals and be initiated by key-operated switches mounted on
console or software key through work-stations. Process override shall be announced by a
constant flashing lamp where active.
Alarm function shall not be bypassed by process override switch.
2) Maintenance Override:

Maintenance override shall be considered in order to enable maintenance work safely


during operation. Maintenance override (MOS) shall be applied for all ESD initiators and
to be configured in ESD PLC Logics via ESD engineering workstation.

4.4

PLC

4.4.1 System Design Basis


The PLC shall have TV approval according to IEC-61508 with the following requirements:
Page 25 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

- Redundant CPU.
- Redundant bus system.
- Redundant power supplies.
- Redundant communication modules and link.
- On-line loading of software (Online configuration possibility)
- On-line changing of modules (CPUs or I/Os)
NOTE: For BMS,SIL3 approval & I/O redundancy is required too.
The PLC system shall interface directly with the following devices, but not limited to:
INPUTS:
- Analogue transmitters (4-20 mA) smart type supporting HART protocol (Transmitter
configuration/check can be done with Hand Held Communicator not with ESD EWS)
- Field contacts (Voltage free contacts, ESD 24VDC powered)
- Proximity switches
- Pushbuttons/key switches
OUTPUTS:
- Solenoid valves
- Digital outputs (1SPDT voltage free contacts)
- Contact from/to local panels
- Motor Control Center and switchgear devices
- Contact from/to package Units
Note (*): contact rating for SPDT contact shall be specified by purchaser depending on
required application (MCC, Package, etc)
DATA LINKS:
- Redundant Bi-directional communication to FCS, shall be realized with MODBUS PLUS
RTU RS-485, while hardware connection shall be used for any input/output to ESD
system.
All I/O signals from and to hazardous area will be provided with suitable EExi protection
measures and intrinsically galvanic isolators are in vendors scope of supply. I/O signals
between. Active barriers shall be plug-in type with the terminal block on base unit.
Input signals will be in the form of potential-free contacts or proximity switches or derived
separately from analog inputs by PLC software and shall not be built inside the software of
other systems.
24 VDC will drive the EExi solenoid valves. The PLC system will distribute this energy. In the
other word the system will supply power to field input devices in two wire technique and to
external actuating devices.

Page 26 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

For power supply distribution to barriers, etc. Miniature circuit breakers shall be used.
The system has a modular architecture which will make it possible to service parts or
components without changing the function of the remained part of the system.
The system logic shall be fail-safe, de-energized on alarm state. This implies that in the
normal conditions, closed input sensor switches shall keep the logic outputs active providing
a closed circuit for supplying electrical power to remote devices such as solenoid valves &
relays.
Software reliability shall be considered in order to reduce effects on the overall system
reliability.
For the visualization of status and signals on FCS workstations, PLC shall be linked to the
FCS via redundant interface bus, generally implemented with MODBUS PLUS RTU protocol
based on RS-485.
Master of the communication will be the FCS (PLC slave).
Analog signals shall not change by more than 0.5% span and digital signals shall not change
status under conditions given immediately above.
Vendor will be technically evaluated based on the following qualitative aspects:
- Minimizing the use of diverse software
- Utilizing high quality software
- Minimizing software modifications /updating
Each instrument/equipment, cabinet, panel included in vendors scope of supply shall have
its own individual name and tag plates. All name and tag plates shall be designed and
supplied by the vendor. English lettering shall be used.

4.4.2 System Hardware Requirements


The hardware shall be included in cabinets, completely wired & connected to plug sockets
and including:
- Intrinsically safe safety barriers for inputs from proximity probes (inductive) NAMUR, fail
safe, testable, with short circuit controlling, according to SIL 3.
- Fail safe safety barriers for inputs from mechanical contacts, testable according to SIL 3.
- Fail safe safety barriers for outputs to solenoid valves & motors testable, according to SIL
3.
- Fail safe safety barriers for field transmitter 4 20 mA output with HART protocol.
- Transmitter configuration/diagnostic shall be done with Hand Held Communicator.
- CPUs.
- Interface modules and communication cards.
- Power supplies.
Vendor shall avoid using I/O modules with built-in barriers.
System cables among PLC cabinets belong also to the delivery of the vendor.
Page 27 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

Project No.:
TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-005

Rev.

4.4.3 Processor
The processors are in charge of all PLC sequences and test facilities. They shall be
operating synchronously and in parallel.
Each processor shall consist of microprocessor, memory, test circuits (if any) and necessary
communication blocks.
The processors shall be provided with both internal and external watchdog timers, to check
the program execution.
The PLC shall also be provided with internal self-checking programs, to be executed
regularly as part of the normal startup/running sequence.
The system-operating program shall be resident on EPROM memory. The central processing
unit should contain the application program in non-volatile memory.
If the application program is kept in a battery backed up memory then:
- A minimum 48 HOURS battery backup shall be provided.
- It shall be possible to replace the battery while the system is operating without losing the
contents of the memory.
- Indication of low battery power shall be provided locally by LED and remote on system
status display.
The CPU shall continuously scan the control program stored in memory, along with the
status of all inputs and execute specified commands to appropriate outputs.
In the event of a PLC processor failure, all outputs shall be de-energized. A common PLC
malfunction alarm contact shall be made available for informing to FCS of a fault in the PLC
system.
The system shall comply with above requirements, and the logic solver shall be suitably
distributed to several units accordingly.
The system supplier shall provide calculation of program execution time based on the
estimated number of logic solvers and I/O points specified in this document.

4.4.3.1 CPU Hardware Security


Software password or key-lock shall be used for more level of security.
Each CPU shall provide sufficient loading capacity/memory for the initial configuration plus
30% excess for future expansion
4.4.3.2 CPU Status Indicators
The CPU shall continuously monitor its own status and indicate both normal operation and
Page 28 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

error conditions via LED status indicators on each CPU module faceplate.
Vendor shall provide reliability data for the watchdog and advise how he avoids its
malfunctioning due to common mode failure.
Monitoring hardware shall be kept as simple as possible.

CPU Protection
Power line inputs to the CPU shall be protected against electrical transient.
The processors shall be mechanically and electrically isolated. Each shall provide protection
against overload current and line voltage spikes.
It shall be possible to remove any of the processors without disturbing the normal operation
of the overall system.
Upon re-installation of processor, it shall up-date its database automatically and ensures a
bump-less operation.
4.4.3.3 I/O Interface system
Binary inputs from hazardous areas are partly inductive contacts (fail-safe mode) and partly
mechanical contacts.
NOTE:
Vendor is requested to select proper barrier that shall meet the purchased solenoid valve
characteristics.
Digital input section shall be designed to receive input signals from field contacts that are
closed during normal conditions and will open on shutdown conditions as well as analog
input signal failure.
MCC output circuits shall be provided with protection against the switching of inductive loads
and protection against current overloads.
The I/O interface system shall connect all field -wiring signals to the safety system and shall
perform signal conversion, signal conditioning, and signal multiplexing features.
All I/O signals from and to hazardous areas shall be provided with suitable Ex. protection
measures; as signal segregation general rule, IS circuit and terminals/raceway shall be blue.
The I/O interface shall comply with the following requirements:
- The number of different types of I/O units should be minimized.
- The I/O cards will be replaceable with the system energized (on-line) without affecting the
function of the remainder of the system.
- All I/Os shall be galvanic and/or optically isolated and adequately fused or short circuit
proof/negative proof.
Page 29 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

- Indication shall be provided (by LED) on each module to show module status and power.
Input bypass facilities for each input should be provided to allow calibration, testing and
maintenance, they shall be enable via dedicated displays on the PLC engineering
workstations.
Activation of the said facilities shall be annunciated and logged at this workstation, and shall
not bypass output to signaling, VDU alarm display etc.

Digital Inputs
Some digital inputs will come from solid-state sensors (field contacts) acc. to DIN 19234
(NAMUR type). The input voltage shall be powered by PLC according to NAMUR operation
standard.
The operating voltage for digital inputs (contact inputs) shall be 24 VDC powered by the PLC.
Each digital input module shall be individually fused with blown fuse indication or shall be
designed to be current limit / short circuit proof.
Galvanic isolating safety barrier shall be provided where required.

Digital Outputs
Contact relay output modules shall be provided to achieve output signal isolation
Each discrete output point shall be individually fused rated at the same voltage as output
module or shall be designed to be current limit / short circuit proof. The fuses shall be placed
in location readily accessible for maintenance.
All output signals shall be hard wired. Signal level shall be energized for normal and deenergized for alarm and shut down conditions.
The system output shall be connected to electrical substation by hardwired connections with
suitable interposing relays that included in electrical department duty.
Isolation relays shall not be used for multiplication of PLC system inputs and outputs unless
they are specified to be essential for:
- Isolation of different input or output signals such as motor control circuits.
- Preventing the mixing of circuit voltage/currents.
Galvanic isolating safety barriers shall be provided where required.

Analog I/O
The PLC systems shall be capable of accepting both active and passive analog signals
directly through an input module.
Analog signals are 4-20 mA smart type supporting HART protocol.
Analog inputs/ outputs shall be powered by the PLC system.
Galvanic isolating safety barriers shall be provided where required.
Page 30 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

Ground Fault Detection Circuitry


A ground fault detection circuitry shall monitor floating electrical circuits in field wiring via an
alarm indicator, when resistance to earth fails.
4.4.3.4 Communication network
The only permitted software connection is for sending analog/ binary signals to the FCS.

FCS Interface
The PLC system shall be capable of synchronizing and Bi-directional communication with
MODBUS PLUS RTU RS-485 with plant control system.
The following parameter will be defined by package vendor and PURCHASER:
MODBUS device number (slave address)
Data flow range
Baud rate
: 19'200 preferable
Stop bit
: 1 preferable
Parity
: Even preferable
Data bits
: 8 preferable
Error checking
: CRC
Connection
: Four wire Multidrop
All communication ports shall permit connection and disconnection without interrupting
system operation of fail-safe system.
The data communication system shall be fully redundant.
The vendor shall provide complete electrical and mechanical specifications, plus
manufacturer and model number for cable and fittings of the data communication system.
Data communication between FCS and PLC shall have the following characteristics:
- Redundant data bus and MODBUS interface.
- Detailed diagnostic information.
- Signal transmission with time controlled event recording.
- Transmission of data by TV certified communication protocol to avoid errors.
- Bus transmission time Safe time of process plant.
- During Loading of a new or changed software, no influence of data transmission between
PLC and FCS.

4.4.3.5 Power Supply


Redundant power 110 VAC 5%, 50 Hz 1% from UPS will be supplied via PDP located in
CAR by Purchaser.
System power supplies shall have galvanic isolation between input and output voltage, over
voltage protection, current limiting.
Page 31 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

A dedicated redundant power supply unit, included in the scope of supply, shall be used to
feed power to racks of the system.
The vendor has to provide all the equipment necessary to generate the different voltage
levels needed by the PLC system. These power and distribution systems shall be full
redundant.
The vendor shall indicate the power consumption of the system (auxiliary and control room)
as well as the heat dissipation for each cabinet and engineering console.
Power supply unit status shall be indicated on its faceplate and shall be remotely
communicated via alarm contacts and software.
The system shall be designed to ensure that no incorrect command is given to the field
devices upon power on or power restore to the CPU or I/O modules.

4.5
4.5.1

INTERFACING WITH OTHER SYSTEMS


Communication
The PLANTs will consist of several PROCESS UNITs/UNIT which must operate together in
complete harmony.
In instrumentation and control systems, a complete communication harmony must be
accomplished by FOUNDATION FIELDBUS, HART, MODBUS PLUS, MODBUS if Modbus
Plus is not commercially available, and TCP/IP protocols.

4.5.2

FCS Interconnection with MCC


FCS interconnection with MCC shall be provided via remote I/O system.
The remote I/O cabinet shall be in similar design with other FCS cabinets and installed in the
electric sub-station(S/S).
A serial communication with MODBUS RTU protocol shall be provided between FCS and PDC.

4.5.3

Ethernet Interface
An Ethernet interface with TCP/IP protocol shall be provided to link the FCS to the OWNER
PLANTS area network/ internet as an IT infrastructure for a totally computerized PLANTS.

4.5.4

Host Interoperability Support Test (HIST)


Host Interoperability Support Test (HIST) certificate shall be considered as a preference.

4.6

CRITICAL MACHINES INSTRUMENTATION


Critical machines shall mean centrifugal compressors, expanders and large size of the
following machines:
Fan, blowers, pumps, turbines, electrical motors, generators etc.
Page 32 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

4.6.1

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Centrifugal Compressors Anti-surge


Anti-surge for each compressor shall be comprised of:
Performance monitoring
Anti-surge control
Anti-surge control valves at field
Flow element (venture)
Flow transmitter

4.6.2

Control Cabinet(s)
Critical machine(s) shall have cabinets(s) complete with:
Woodward* digital governor(or equivalent) suitable for HP and LP valves actuators control
and turbine over-speed protection with dual speed probe arrangement.

Bently Nevada* system(or equivalent) for vibration, axial displacement and bearing
temperature monitor both for drive and driven machine including a common PC and
expert and predictive machine condition monitoring software.

Annunciator (lamps box) for compressor ESD. Alarms first out feature shall be provided.

4.7

Over-speed shut down protection system (Jaguet or equivalent), dual speed probe
arrangement.

If these vendors products are not commercially available, the equivalent products of other
approved vendors shall be provided with OWNER approval.

PROVISION OF INSTRUMENTS ON PACKAGE UNITS


Where package units with Owners prior approval are furnished then instruments, PLC etc shall
be of the same make and type (as far as possible) as the rest of the process units/ unit of the
plants. Deviations are subject to mutual agreement.
The packaged unit control systems design and documentation shall be harmonized with that of
the rest of the process units/ units of the plants.
Package control system shall be preferably PLC based system.
Major subsystems shall be linked to the FCS via redundant interface and bus, generally with
FF or OPC, MODBUS PLUS, Ethernet TCP/IP protocol, MODBUS RTU protocol based on RS485 physical link.
The packages that need to be started locally shall have the provision to be monitored and
controlled from the central control room after start up (single operation centre).

Page 33 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

4.8
4.8.1

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

CABINETS AND PANELS


Design of Cabinets and Panels
The cabinets and panel shall be fully prefabricated at the factory. All system hardware,
instruments and components provided with the cabinet and panel shall be installed and wired.
No fieldwork shall be allowed inside the cabinet or panel except the tie-in cable termination.
After FAT minimum of 20% installed spare in all respects shall be available for future
additions/modifications, and 10% free spare shall also be considered for cabinets.
1) Control room cabinets:

The cabinets shall be freestanding in the form of box, provided with dual access doors
(front and rear).
The design of cabinets, i.e. dimension, color, etc., shall be unified as much as possible.
The side panels shall be removable type and any equipment including cable entries,
ventilation openings, etc., shall not be installed on side panels. The application of swing
out frames shall be avoided wherever possible.
Cable entry shall be in the bottom. Bottom plates shall be removable for cable entries.
Sufficient space shall be provided for accommodating and terminating cables. Properly
designed cable clamps and cable support rails shall be provided in order to prevent
undue force on terminations. The cabinet shall be lockable and the each lock shall be
identical for all cabinets.
The cabinets shall be provided with natural ventilation by means of filtered louvers.
Forced ventilation system fitted with dust filters and with extraction fans mounted on the
top of cabinet may be required due to the amount of heat generation. Dust filters shall be
of the replaceable or cleanable type, and this maintenance can be done without disturbing
the cabinet functions.
Interior lighting shall be provided and each section of panel shall have 230V, 50HZ socket
for maintenance activities.
The cabinets shall be fitted with 4 numbers of removable eyebolts for lifting purposes of
each cabinet. The blinds shall be provided to seal the holes after removal of eyebolts.
Anchor bolt holes shall be provided at bottom of the cabinets. The anchor bolts, nuts and
washers shall be furnished with the cabinets.
Temperature measuring system shall be provided in order to generate an alarm signal, in
case the temperature exceeds the sets value.
2) Field panels:

The field panels shall be designed to provide adequate instrument display and to protect
instruments from the specified environmental conditions.
The panels shall be lockable and a freestanding type.
The panel shall be designed suitable for installation in a specified environment as well as
electrical area classification.

Page 34 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

The panels located in hazardous area shall be Eex-d or of pressurized apparatus (like
EEXp).
The panel shall be provided with a canopy with lighting and also lighting inside the
panels, if required. The framework shall be made of structural shapes with lifting lugs for
handling.
Provisions against instrument heat dissipation shall be considered.
Cable entry shall be in the bottom or side. Cable entry plates shall be adequately
designed for mounting cable glands. Sufficient freely space shall be provided for
accommodating and terminating cables.

4.8.2

Internal Panel Wiring


All wiring runs inside the panel shall be laid in the Polyvinyl Chloride (PVC) close-slotted
ducting with a cover.
Proper segregation among power lines, IS signal lines and non-IS signal lines shall be made.
The ducting color of IS signal lines shall be light blue. Wiring between terminals shall be
continuous runs and shall not be spliced.
All wires inside the panel shall be PVC insulated wire as a minimum. The conductor shall be
stranded, plain annealed copper. The copper conductor shall be of circular cross-section and
minimum cross-sectional area of conductor shall be 0.5 mm2 for signal wiring runs and 1.5
mm2 for power / grounding wiring runs.
Wiring carrying signals susceptible to electrical interference shall be adequately screened and
the conductors shall be uniformly twisted together to form a pair or a triad. The wiring shall be
appropriately identified by means of colored insulation as follows.
-

AC Phase (P):
AC Neutral (N):
DC +24 V:
DC Return:
Ground/earth:
Thermocouple:

brown
blue
red
black
green/yellow strip or green
as per IEC 60584, Part 3

4.8.3 Field Wiring


Single per cables shall be used to connect field-mounted instruments to local junction boxes.
Single cables shall be armored type laid on galvanized carbon steel/aluminum pipes with open
ends or on closed cable trays.
In order not to damage the cable, a plastic annular cap shall cover the pipe end.
Multi-pair cables shall be used to connect above said junction boxes to the control room.
Multi-pair cables shall be armored type and shall run overhead in closed cable trays supported
on the pipe racks.
Following different types of cables shall run in separated cable trays or to be separated by
metallic walls:
-Intrinsically safe signals
-Non-intrinsically safe signals
-Instrument power supply cables
Page 35 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

The cables for 4-20 mA signal shall be of the following types:


-Single pair: 1.5 mm2 stranded copper conductor with pair shield.
-Multi-pair: 0.75 mm2 stranded copper conductor with overall shield.
A 20% installed spare cores/pairs/triples accordingly shall be considered for cables and
terminals.
Cable trays and accessories shall be hot dip galvanized.

4.8.4

Panel Controllers And Receivers


All the panel controllers and receivers shall be of electronic miniature type. The indicating
controllers shall indicate the input signal, set point and output signal, and be furnished with
balance-less, bump-less automatic-manual transfer system and changeable control action,
direct or reverse.

FIELD INSTRUMENTS

5.1

GENERAL
This section intends to describe general requirements and selection criteria of field instruments
and the detailed technical requirements of each instrument shall be referred to the respective
specifications sheets.

5.2

TRANSMITTERS
All transmitters shall be FOUNDATION Fieldbus compatible with relevant conformity and
ITK4.0 interoperability test certificates(latest revision), otherwise smart type with HART
protocol shall be used for transmission to control room.
The transmitters shall generally be provided with integral indicators. Differential pressure
transmitters, except for transmitters furnished with diaphragm seals, shall be provided with
close-coupled 3/5 way valve manifold as required by application.
All process wetted parts of pressure transmitters and differential pressure transmitters including
manifolds shall be type 316 stainless steel or better. Other materials shall be used as required
by the process conditions.
Transmitters shall be furnished with test terminals and bypass diode to facilitate field testing
without disconnection/ connection of a field mounted signal indicator, either integral with or
remote from the transmitter. Transmitters shall be reverse polarity protected.
The sensing element of the transmitters shall be of direct sensing, sealed capsule type
(diffused silicon strain gauge, capacitance sensing etc).
All explosionproof transmitters shall be furnished complete with flameproof cable glands.
Transmitters enclosure shall be IP-65 minimum.
Electronic Receiver Gauges
Electronic receiver gauges with digital indication shall be provided for remote indicating from
transmitters mounted inaccessible locations.
Page 36 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

The receiver instrument shall have big display and easily configurable with engineering value
and/or percentage indications.
The electrical execution shall be Eexia and the enclosure protection shall be IP-65
The instrument shall be capable of receiving foundation fieldbus signals.
Transmitters discrepancy alarm
For special critical control loops and readings, a dual transmitter configuration, reading the
same process point, is foreseen.
When indicated in P&ID, a discrepancy alarm for those transmitters shall be foreseen.
The measurements coming from transmitters are compared and an alarm is generated when
the difference between the measurements is higher than 5%. Purpose of the alarm is to advise
the operator about measurements derive, and to take corrective action.

5.3

FLOW INSTRUMENTS

5.3.1 General
The flow measuring devices shall preferably be square edge concentric plates for line size 2
and larger. Where line size is 1-1/2 and smaller, variable area flow meters or integral type
orifice flow meter may be selected. Other type of flow measuring devices as described below
may be considered depending on process parameters, accuracy and range-ability points of
view.

5.3.2 Differential Pressure Producers


The design of orifice plates, nozzles and Venturi tubes shall conform to ISO 5167.
1) Orifice plates and orifice flanges:

Square edge concentric orifice plates with flange tapping shall normally be applied to line
size 2 through 24 and 1D-1/2D tapping shall be applied to line size 28 and larger.
Quarter circle or conical entrance orifice plates may be selected where a square edge
orifice is not suitable due to process conditions.
The design of orifice flanges shall conform to ANSI B16.36.
The minimum rating of flanges shall be 300#, otherwise the flange rating and material
shall be as per piping class.
The flanges shall be provided with flange taps connection. The pressure tap size shall be
indicated on data sheets, usually shall be 1/2".
The flanges shall be provided with jack screw bolts for easy orifice installation and
maintenance.
For flanges with ring joint finish it is required the supply of ring joint plate holder.
For orifice plates, metering range shall be selected such that normal flow rate produces a
differential pressure of approximately 70% of the design value (preferably 2500 mm H2O
Orifice plates shall be type 316 stainless steel or better. Other materials shall be used as
required by the process conditions. Orifice plates shall be provided with tab handle, which
is welded on the orifice plate and engraved with following information on the upstream of
the tab handle.
- UPSTREAM or UP
- Instrument tag number
Page 37 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103
PROJECT No:.
- Orifice diameter
- NPS (Nominal Pipe Size) and ANSI flange class
- Material of the orifice plate

Rev.

2) Venturis and Flow nozzles:

Venturis and flow nozzles may be selected where system requires low-pressure drops.
3) Pitot tubes:

The pitot tube should be an averaging pressure type, and may be selected for clean
fluids, low pressure loss and large quantity measurement.

5.3.3

Variable Area Flow Meters

5.3.3.1 Metal tube flow meters may be used as local indicators or transmitters where measurement
with low accuracy is accepted. Use of glass tube flow meters shall be limited to the service
where the temperature is 120 C and below; the pressure is 8 barG and under.
5.3.3.2 Variable area flowmeters shall be selected such that process minimum and maximum flow
to be between 10% and 95% of the measuring range offered by the instrument and normal
flow rate shall be between 60%-80% of capacity.
5.3.3.3 Variable area flow meters shall be of metal tube type (normally S.S.316)
5.3.3.4 Glass tube type meters may be used for the following services:
a)

Air, water and inert gas at pressure below 3 barg.

b)

Analyzer sampling line and all other similar services.

5.3.3.5 Purge Rotameter shall be supplied complete with the needle valve.
5.3.3.6 Metal tube type meters shall have magnetic coupling mechanism for float position detection.
5.3.3.7 Process connections of meters shall be bottom-top. (Exception: Instrument service,
Analyzer)
5.3.3.8 Rotameters shall always be mounted in vertical positions and in such a way that strain or
stress caused by the weight of the unsupported lines or by thermal expansion is kept to a
minimum.
5.3.3.9 Connection shall be flange type in principle. But threaded connection may also be used for
1/2 line sizes and below.
5.3.3.10

5.3.4

Sight glasses may be used only for lubricating oil, sealing and cooling water.

Vortex Meter
Vortex meter may be considered for clean liquids, gasses and steam measuring application
with higher turndown ratio.
Page 38 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

5.3.5

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Turbine Meters and Positive Displacement Type Flow Meters

5.3.5.1 Where coriolis type is not applicable due to process conditions, turbine or positive
displacement type may be considered for custody transfer flow measurement.
5.3.5.2 All turbine meters shall be designed to cover maximum operating flow rate considering the
turn down ratio.
5.3.5.3 Strainers with the suitable mesh size, material and rating shall be installed preceding each
meter.

5.3.6

Ultra-Sonic Type Flow Meters


Ultra-sonic flow meter may be considered for the flow meter on large bore piping such as flare
gas measurement.

5.3.7

Flow Meters For Feed And Product Flow Measurement


FEED and PRODUCT from/to battery limit and PRODUCT flow to main storage tanks shall be
measured by coriolis or ultrasonic type mass flow meter whichever is technically more
appropriate with OWNERs APPROVAL.

5.4
5.4.1

LEVEL INSTRUMENTS
General
The differential pressure transmitters shall generally be used for liquid level measurement. The
displacer type level transmitters should be considered for the application where the ranges are
narrow for accurate measurement by differential pressure transmitter, liquid interface is to be
measured, or the displacer type is specified by Licensor. Other level measuring devices, such
as capacitance type, ultra sonic type, or nuclear type, etc. may be considered depending on
process conditions.
Level instruments rating shall follow pipe/vessel pressure rating.
The connection to vessels shall be flanged side-side mounted.

5.4.2

Displacer Type Transmitters


External chamber (cage) displacer type transmitters shall normally be used.
Extensions should be considered for the service temperature above 200 C and below 0 C.
The electronic shall be installed on rotating head.
The external chambers shall normally be provided with a NPS 3/4" drain valve and a 1/2 NPT
vent blind plug.
In case internal displacer type is used, a stilling well should be considered for preventing
turbulences.

Page 39 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

5.4.3

Project No.:
TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-005

Rev.

Remote Seals
Remote diaphragm seal type differential pressure transmitters may be considered for
measurement of viscous fluids, fluids containing solids, highly corrosive fluids and the service
where temperature changes influence the fluid properties.
Remote diaphragm seal type differential pressure transmitters may be selected in lieu of
displacer type transmitters.

5.4.4

Level Switches
External chamber with float type or displacer type level switches may be considered for alarm
and shutdown purposes.
The external chambers shall normally be provided with NPS 3/4" drain valve.
Extensions should be considered for the service above 200C and below 0 C.
The switch shall be SPDT snap acting hermetically sealed type or proximity type. Current rating
shall be 1A @ 24 VDC suitable for intrinsically safe circuit.

5.4.5

Gauge Glasses
Gauge glasses shall be armored type and cover the operating ranges of all associated level
instruments. The reflex gauge glasses shall be used on all clean service applications, whereas
the transparent gauge glasses shall be used for following services with protective shield of
glasses as required:
- fluids containing acid and caustic
- fluids containing dirty (dark colored) liquids
- high pressure steam applications
- liquid-liquid interface services
Tubular gauge glasses shall not be used in general.
In services where internal lining is required or fluid is toxic, use of magnetic gauges may be
considered.
For cold services where temperature below 0C can be reached, a non-frosting gauge will be
used.
Gauge glasses shall normally be provided with standard angle gauge valves containing ball
checks, a 3/4 drain valve and a 1/2 NPT blind vent plug. The gauge glasses shall normally be
hooked-up top-bottom. The connections to vessels shall normally be 1 1/2 flanged and sideside mounted.
Visible length of one (1) gauge glass shall not exceed 2000 mm.
Where multiple gauges are required to cover the ranges required, visible area of each gauge
shall overlap 30 mm minimum.
When illuminators required, they shall be designed to give a proper diffusion of light over the
entire length of level gauge.
The illuminator shall have the electrical execution Eexd.

5.4.6

Tank Gauges
Tank gauges shall be of radar type with 1 mm accuracy.
The gauges shall be furnished with a tank side indicator for local reading at ground level.

Page 40 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

5.5

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

PRESSURE INSTRUMENTS

5.5.1 Pressure Gauges


5.5.1.1Bourdon tube type pressure gauges with nominal dial size of 100 mm (4) shall generally be
used. All process-wetted parts shall be type 316 stainless steel or better. Other materials shall
be used as required by the process conditions.
The gauges shall be provided with pulsation damper or be a glycerin -filled system in case
vibration and pulsation is anticipated.
5.5.1.2 Diaphragm, bellows or capsule type pressure gauges may be used for the low pressure
service. Diaphragms are normally more durable and repeatable and consequently are
preferable to bellows for low ranges.
5.5.1.3 Pressure ranges will be such that the normal pressure will be in the middle third of the span.
Gauge ranges shall normally be specified for not less than 1.2 times the relief valve setting.
Special cases, such as vacuum unit, will be considered individually.
5.5.1.4 Pressure elements shall have an over range protection of at least 1.3 times the maximum
range of the instrument. Elements in vacuum service shall be capable of withstanding full
vacuum regardless of range, without shifting calibrations.
5.5.1.5 Whenever more than 120% over range is predicted, external over range protection shall be
provided.
5.5.1.6 Blow-out device shall be fitted for all gauges. Gauges measuring absolute pressure shall
have compensation for barometric pressure changes.
5.5.1.7 Syphon shall be provided on hot water or steam services, when operating temperature
exceeds 120C.
5.5.1.8 Pressure gauges dial shall be white laminated with black numbers and marking.
5.5.1.9 Movements shall be stainless steel.

5.5.2 Pressure Switches


Element of pressure switches shall be minimum 316 stainless steel and diaphragm seal type is
preferable.
The switch shall be SPDT snap acting hermetically sealed type or proximity type.
Unless specified, the switches may have fixed reset band, and set points should be adjustable
over the ranges.

5.6
5.6.1

TEMPERATURE INSTRUMENTS
General
Temperature signal transmission shall be by RTD or T/C plus temperature transmitter to FCS.

Page 41 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

RTD, PT100 shall be used for normal operation temperature below 500 C. Where the
measurement range exceeds 500 C and up to 1260 C, thermocouples type K
(nickel/chromium-nickel) shall be used, and where the measurement range exceeds 1260 C,
thermocouples type R (platinum-13% rhodium/platinum) shall be used.
The thermo elements shall generally be completed with head mounted transmitters except for
not accessible thermometers with the exception that the thermo elements are connected to
Machine Monitoring System.
Bimetallic thermometers shall generally be used wherever local temperature indication up to
500C is required. For temperatures above 500C liquid or gas expansion type thermometer
shall be provided.
Bimetallic temperature switches shall not be used for important process alarm and shutdown
applications.

5.6.2

Platinum Resistance Temperature Detector


The platinum resistance temperature detector shall have a nominal resistance at 0 C of 100
ohms in accordance with IEC 60751. The connection shall be performed using 3-wire method.
The stainless steel sheathed and mineral (usually magnesium oxide) insulated elements shall
normally be used. The sheath diameter shall be 6.4 mm, in general.

5.6.3

Thermocouples
The thermocouples shall be designed in accordance with IEC 60584, Part 1 and 2.
The tolerances shall be class 2 as per IEC 60584, Part 2.
The stainless steel sheathed and mineral (usually magnesium oxide) insulated thermocouples
shall normally be used. The sheath diameter shall be 6.0 mm in general, and measuring
junction shall normally be ungrounded (electrically isolated from the sheath).

5.6.4

Thermoelement Assemblies
Thermoelement shall normally be provided as an assembly consisting of a thermoelement, a
connection head and a thermowell. The entry to thermowell shall normally be 1/2 NPTF. The
connection head extension length shall normally be 150 mm. The element shall firmly contact
the bottom of well or tube.

5.6.5

Dial Thermometers
Dial thermometers shall be of the bimetallic type with adjustable dial or filled thermal system
type. The thermometers shall be provided with a thermowell. The entry to thermowell shall be
1/2 NPTF.
The nominal dial size shall be 150 mm.
Operating temperature of temperature indicators shall be between 50% and 75% of full
scale.
Thermometers of the filled capillary type shall be used, where bimetallic type might be
damaged by the mechanical vibration.
Temperature gauges dial shall be white laminated with black numbers and marking.
Movements shall be stainless steel.
Page 42 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

5.6.6

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

Thermowells
Thermowells shall normally be drilled bar stock and tapered. The material of the well shall be
type 316 stainless steel, as minimum. Other materials may be used as required by the process
conditions. The process connection shall normally be 1 flanged, except that welded
connection may be used for mounting on pipe with pressure rating of 1500# and above.
The insertion length shall normally be as follows:
-

Flanged thermowell on piping


Welded thermowell on piping
Flanged thermowell on vessels

: 250 mm
: 150 mm
: 400 mm

The design of the wells shall be verified by means of stress analysis, resulting from stream
velocity condition. The wake frequency shall not exceed 66 % of the thermowell natural
frequency.
Empty thermowell (test wells) shall be provided with a blind plug and chain.
Thermowell stress calculation shall be as per ANSI/ASME PTC 19.3

5.7
5.7.1

PROCESS ANALYZERS
General
The process analyzer shall consist of analyzer sample conditioning systems and calibration
systems including test gas bottles as required for proper calibration.
Where possible the analyzers shall be direct on line type and provided with auto calibration
facilities.
Where is possible or convenient, serial communication to FCS shall be provided.

5.7.2

Sample Conditioning
Sample conditioning system shall comprise of all the components necessary to extract a
representative sample and to have the sample suitable for the measurement in the analyzers.
The design of total sample conditioning system that includes sample probes, sample tap
primary conditionings, sample transportation lines, etc., shall be designed for each specific
application.
All material of sample conditioning system components in contact with the process sample
shall be 316 stainless steel unless a special material is required for the process conditions.
Sampling system time lag calculation shall be done when process required a predefined
analysis time.

5.7.3

Analyzer Housing
Analyzers shall preferably be installed in protective cabinets, with air conditioning system, or
either in open or closed shelters. Following selected vendor requirements for max. working
temperature.

Page 43 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

5.7.4

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Protective Cabinets
Where appropriate, the analyzer may be installed in a purged cabinet or enclosure in order to
comply with the required area classification. In this case, the power supply shall be
automatically switched off on loss of purged air flow or pressure inside the enclosure.
A manual reset shall be considered in case of power/ purged air failure.

5.7.5

Shelters
The shelter shall be provided with sufficient maintenance spaces. Closed shelters shall be
ventilated, air-conditioned and pressurized enclosure, which shall be provided with
safeguarding system designed in accordance with IEC 60079-16.

5.7.6

Fire and Gas Monitoring System (F&G)


A fire and gas monitoring system (F&G) shall be provided to detect the leakage of flammable
and toxic gases from potential gas leakage sources. Flammable gas detector may be of infrared or catalytic combustion type and the toxic gas detector will be of the type suitable for the
detective gases. Alarms shall be transferred to FCS via serial communication or hardwired
interface as per control philosophy.
Dedicated graphic pages, on FCS, will show the plant layout with detectors location. Operator
will use the graphic pages to define location of activated detector.

5.8
5.8.1

CONTROL VALVES
Selection of Valve Types
The following valve types shall be used for throttling applications:
-

Globe type valves with standard and angle type bodies


Eccentric spherical plug valve
Segmental ball valve
Butterfly valve

The globe type valve shall be used for throttling service in general, however, the butterfly valve
may be used for control and on-off valves if it is provided with sufficient performance against
required range of control applications.
Ball valves may be used for on-off applications.
Where internal lining of control valves is required for protection against corrosion or erosion,
the valve types may be as follows.
-

5.8.2

Diaphragm valve (often called Saunders valve)


Butterfly valve
Plug valve
Ball valve

Sizing
The control valves shall be sized such that approximately 80% of rated Cv at maximum flow
and never less than 20% opening for the minimum flow shall be achieved. The sizing shall be
carried out based on ISA S75.01 and the Manufacturers standard equations.
Page 44 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

5.8.3

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Noise
Maximum allowable noise level shall be 85 dBA measured at 1 meter downstream of the valve
and at 1 meter away from the downstream pipe at normal operating condition except for
emergency depressurizing and short period steam-venting applications. Vendor shall take into
account any noise attenuating devices as source treatment, path treatment is subject to
purchase approval.

5.8.4

Body Construction
For the pipeline larger than 2, the control valve body size shall normally be equal to or larger
than half of inlet pipeline size. For lines below 2, the control valve body size shall normally be
equal to the pipeline size. The body size shall normally be selected from 1/2, 3/4, 1, 1-1/2, 2, 3,
4, 6, 8, 10, 12, and larger.
Flanged end connections shall generally be selected. The flange rating shall be in accordance
with the piping specification. The flangeless insertion type body (wafer/lug type) may be used
for butterfly type and eccentric rotary disk type control valves.
- Threaded end connections, where specified, shall be as per ANSI.

- Carbon Steel (CS) material shall be ASTM A216 GR WCB/WCC.


- When used in sour fluid services, control valve materials and heat treatments shall be in
accordance with NACE MR-0175.

5.8.5

Bonnet Construction
Extended or Finned bonnets shall usually be required for the applications where normal
operating temperature of the controlled fluid exceeds 200 C (or another temperature as
specified by vendor).
The valve bonnet construction with Fin or Extended will be decided according to the
manufacturer standard practices.
Extension bonnets shall usually be required for the applications where normal operating
temperature of the controlled fluid is below 0 C (or another temperature as specified by
vendor).
The valve packing shall normally be PTFE based materials for the temperature up to 200 C,
and graphite based for the temperature above 200 C. The control valve packing glands shall
be of the bolted type.

5.8.6

Trim Construction
1) Materials:

Valve trim shall be type 316 stainless steel unless process conditions require a higher
grade or special material. Stellited stainless trim shall be used in all liquid and vapor
services where cavitations and or flashing exist, fluid containing solids, valve pressure
drops exceeding 10 bar, and services temperature above 350 C.
Other stellited applications shall be as per control valve vendor practice.
2) Flow characteristics:

An equal percentage characteristic shall normally be specified for all cases, with the
exceptions of valves on the following services, which linear characteristic shall be
selected.
Page 45 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.
-

Hampa Energy
Engineering & Design Company

Project No.:
TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

LORDEGAN
PETROCHEMICAL
COMPANY
DOC. NO.: 2103-ESS-00-IN-005

Rev.

Depressuring control
Minimum flow control of pumps or anti-surge control of compressors
Level control in gravity service
Split range control
Where two (2) valves are applied in parallel for increasing the rangeability
Control valves that are only operated via manual control station (HC)

3) Seat leakage:

Seat leakage shall be defined according to FCI 70-2.


The seat leakage of emergency shutoff valves shall be class V for gas services and class
IV for liquid services as a minimum.

5.8.7

Actuators
The actuators shall preferably be of spring opposed diaphragm type.
Actuator shall be sized to operate assuming differential pressure of maximum upstream
pressure and atmospheric pressure ( or vacuum conditions, if stated) of downstream or design
pressure indicated on data sheets.
The actuators shall usually be of pneumatic operating type and supply air pressure should be
limited to 5 barG, in general.
The actuators shall be equipped with a local travel indicator.
The control valves used for on-off applications shall have a maximum stroking time of 10
seconds unless other stroking times are required.
Actuator case material shall be carbon steel or equivalent material depends on purchase
approval.
The required force to stroke the valve, on a bench test shall be obtained by applying a 0.2-1.0
bar-g air signal to the diaphragm; if the vendors largest standard single diaphragm size does
not produce sufficient force with a 0.2-1.0 bar-g air signal then a signal of 0.4-2.0 bar-g shall be
used.
Other bench test sets may be applied if the above mentioned ones are not practical.

5.8.8

Accessories
1) Positioners :

Control valves for throttling applications shall normally be provided with a FF/P positioner
compatible with Fieldbus system. The positioner shall be furnished with small size supply
pressure and output pressure gauges, which indicate supply pressure and output
pressure to actuator and shall be easily convertible from direct to reverse acting.
All fitting and tubing for pneumatic lines shall be made of stainless steel.
Positioners shall be provided with internal or external by-passes.
The electrical execution shall be Eexi IIC T6.
2) Hand wheels:

Hand wheels shall be fitted only if indicated on P&IDs. The hand wheels may be side or
top mounted on the actuator. The hand wheels shall not be used as travel limit stops.
3) Solenoid valves:
Page 46 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

Three (3)-way direct operated, stainless steel body and internal solenoid valves shall
normally be used. The coils shall be suitable for DC 24 V and the insulation class shall be
class F as a minimum.
The electrical execution shall be Eexi IIC T6.
4) Limit switches:

Limit switches shall be proximity type and as per NAMUR standard and each switch box
shall be equipment with two cable entries M20.
5) Nameplates:

Each valve shall have a stainless steel label, securely attached, engraved with the
following information:
- Tag Number
- Vendors serial number
- Body size and material
- CV value (preferably) along with flange rating, trim size, material, characteristic and
valve action on air failure.
- Other information specified on material standard specification.
6)

5.9

Depending on applications, miscellaneous accessories, such as booster relays, quick


exhaust valves, lock-up valves, accumulators (air volume tanks), travel limit stops, etc.
shall be considered to maintain proper operation of the control valves.

SAFETY RELIEF VALVES


As a rule, spring-loaded valves shall be applied as much as possible. Pilot-operated valves
may be considered for clean service and for special applications. Balanced-bellows valves
shall be used in case variable backpressure exceeds 10% of the set pressure.
The valve shall be sized in accordance with ASME Section VIII or API RP 520, Part 1.
The valves shall generally conform to ASME Section VIII, API Std. 526 for materials of
construction and size of flanged valves, and API Std 527 for seat tightness.
The valve shall have flanged end connections.
The safety valves shall be provided with a plain lifting lever for steam and air services and with
packed lever for hot water (over 60 C) applications.
All valves shall be furnished with a threaded cap over the spring-adjusting screw.

6
6.1

INSTALLATION
INSTRUMENT LOCATIONS
The location of instruments, control valves, including junction boxes shall permit easy access
from grade, permanent platforms or stairways for operation, inspection and maintenance.
Locations shall also minimize the possibility of damage from passing or falling objects.

Page 47 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

6.2

CABLING

6.2.1

Routing

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

Multi-conductor cables may be used between instrument rack room and local junction boxes
(JB). All signals in one cable should be of the same magnitude and multi-conductor cables
should be provided with 20% spare cores. The multi-conductor cables shall run aboveground
and supported with closed cable duct or trays.
Instrument signal cable runs from the junction box to individual instruments in the field shall be
routed aboveground in closed trays, channels and open conduits, etc., as appropriate.
The trays and conduits shall be made of galvanized steel and be provided respectively for
intrinsic safety (IS) signals, non-IS signals, and power.
The following different type of cables shall run in separated cable tray or be separated by
metallic walls:
- Intrinsically safe signals.
- Signal cables not intrinsically safe.
- Instruments AC power supply cables.

6.2.2

Instrument Signal Cables


Instrument signal cables shall be polyvinyl chloride (PVC) insulated for NIS signal and
polyethylene(PE) insulated for IS signal, single steel wire armored and polyvinyl chloride (PVC)
outer-sheathed cables of rated voltages, 300/500 V, generally in accordance with BS 5308,
Part 2 and IPS-E-IN-190(1).
The conductors shall be stranded, plain annealed copper. The nominal cross-sectional area of
the conductors shall be 1.5 mm2 for single pair/triad and 0.75 mm2 for multi-pair/triad as a
minimum. The insulated conductors shall be twisted together to form a pair or a triad.
Overall collective screen (electrostatic shield), comprising laminated aluminum tapes and a
tinned copper drain wire, shall be applied for the cables which carry 4 to 20 mA signals and
with triad and overall shielded for platinum resistance thermometer signals. The insulated
conductors in a pair shall be identified by means of colored insulation in Black and White. The
insulated conductors in a triad shall be identified by means of colored insulation in Black, White
and Red.
The color of outer sheath shall normally be gray for NIS signal cables. Cables that form part of
IS circuits shall have a light blue outer sheath.
Specification of FF cable shall be individual and overall shield otherwise shall be selected
according to vendors recommendation.

6.2.3

Thermocouple Extension Cables


Thermocouple extension cables shall be polyvinyl chloride (PVC)/PE insulated, single steel
wire armored and polyvinyl chloride (PVC) outer sheathed cables of rated voltages, 300/500 V,
generally in accordance with BS 5308, Part 1 and IPS-E-IN-190(1).

Page 48 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

The conductors shall be stranded, and the materials shall meet the requirements of IEC 60584
Part 3. The tolerances for thermocouple extension wires shall be class 2 as per IEC 60584 Part
3. The nominal cross-sectional area of the conductors shall be 1.5 mm2 for single pair and 0.75
mm2 for multi-pair as a minimum. The insulated conductors shall be twisted together to form a
pair. Pair and overall collective screen (electrostatic shield), comprising laminated aluminum
tapes and a tinned copper drain wire, shall be applied.
The color-coding of insulated conductors in a pair shall comply with IEC 60538, Part 3.
The color of outer sheath shall be in compliance with IEC 60584, Part 3. Cables that form part
of IS circuits shall have a light blue marking by means of taping along the cable.

6.2.4

Instrument Power Supply (AC) Cables


Instrument power supply (AC) cables shall be polyvinyl chloride (PVC) insulated, single steel
wire armored and PVC outer sheathed cables of rated voltages, 600/1000 V, generally in
accordance with IEC 60502.
The conductors shall be stranded, plain annealed copper. The nominal cross-sectional area of
conductors shall be 2.5 mm2 as a minimum. The core of cables shall be identified by means of
colored insulation in brown and blue.

6.2.5

Instrument Grounding Cables


Instrument grounding cables shall be single-core polyvinyl chloride (PVC) insulated and nonsheathed cables of rated voltages, 450/750 V, generally in accordance with IEC 60227, Part 3.
The conductors shall be stranded, plain annealed copper. The color of insulation shall be green
or green/yellow stripe.

6.2.6

Field Junction Boxes


Single-pair or single-triad cables shall generally be terminated at junction boxes, from which
the signals are carried via multi-pair or multi-triad cables to the field mounted panel or the
control system in the control building.
The junction boxes shall be of reinforced polyester, stainless steel sheet or aluminum casting,
provided with increased safety type enclosure.
Terminal strips shall be modular construction and provided with 20% spare terminals. Electrical
contacts shall be of the tubular screw pressure plate type with all live parts recessed into the
insulation block.
A junction box shall contain only signals of the same class. The signal class is categorized as
follows:
(1) H1 field bus cable
(2) DC power
(3) AC power
(4) 4-20mA non IS signals (if any)
(5) 4-20 mA IS signals
(6) Digital I/O non IS signals
(7) Digital I/O IS signals, including solenoid valves
(8) RTD, position, vibration and speed
(9) Thermocouples
(10) RS-485 based serial communication, including converters and repeaters( if any)
Page 49 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION

Hampa Energy
Engineering & Design Company

PROJECT No:.

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

2103

DOC. NO.: 2103-ESS-00-IN-005

Rev.

Junction boxes for fieldbus foundation signals shall be of FF approved type.

6.2.7

Cable Glands
Cable glands shall be applied at all places where cables enter the enclosures of instruments,
junction boxes and panels in the field.
Flameproof type cable glands shall be used for EExd apparatus.
The material of cable glands shall be metallic.

6.3

INSTRUMENT IMPULSE LINES


Process connections of instruments shall generally be of NPTF 1/2.
Instrument impulse lines downstream of the process tap block valve shall generally consist of
type 316 stainless steel, 1/2 outside diameter (OD), 0.049 wall thickness tubing and type 316
stainless steel compression fittings. The fittings shall be double ferrule type. All instrument
impulse lines shall have facilities integral multi-valve manifold for venting or draining..
Other materials shall be used as required for the process conditions.

6.4

INSTRUMEN T HEATING
Steam heating system shall be provided where impulse lines or instruments require heating.
If steam tracing is required ,Steam heating lines shall consist of 3/8 outside diameter (OD) and
0.035 wall thickness stainless steel tubing with stainless steel compression fittings. Instrument
heating system shall be independent from that for pipeline heating.
Instrument heating should be provided as per P&ID.

6.5
6.5.1

INSTRUMENT AIR LINES


Instrument Air Supply Lines
The sub distribution branch headers shall be made by means of galvanized carbon steel pipes
and threaded fitting. Sub-distribution branch headers shall be sized as indicated below:
-

1/2 inch for up to 5 users


3/4 inch for up to 10 users
1 inch for up to 15 users
1-1/2 inch for up to 20 users

Each pneumatic user shall be provided with 1/4 stainless steel valve and one air filter regulator
with pressure gauge (pressure gauge in case of control valves shall be installed on the
positioner). On/Off ball valves will be equipped with filter only.
Pneumatic connections shall be executed by 1/4 OD, 0.028 thickness stainless steel tubing
and compression fittings The fittings shall be double ferrule type.
Instrument air headers shall be provided with sufficient number of spare isolation valves for
future connections.

Page 50 of 51

CONTRACTOR:

DETAIL ENGINEER :

OWNER

LORDEGAN
AMMONIA & UREA
PROJECT
HAMPA
ENGINEERING
CORPORATION
PROJECT No:.

6.5.2

Hampa Energy
Engineering & Design Company

LORDEGAN
PETROCHEMICAL
COMPANY
Project No.:

TITLE

INSTRUMENT GENERAL
ENGINEERING SPECIFICATION

DOC. NO.: 2103-ESS-00-IN-005

2103

Rev.

Pneumatic Signal Lines


1/4 OD, 0.028 thickness stainless steel tubing and compression fittings shall be used for
pneumatic control and signal transmission lines.

7
7.1

QUALITY ASSURANCE AND INSPECTION PROCEDURES


QUALITY ASSURANCE
Quality assurance plan shall be provided before start of manufacturing.
The quality assurance plan shall generally cover the following aspects:
- Quality assurance organization with indication of key personnel responsible for quality
assurance
- Accountability of the quality assurance personnel
- Quality control process for welding, heat-treatment, non-destructive test, etc.,
- Procedure for test and calibration
- Quality audit and maintenance procedure

7.2

INSPECTION PROCEDURE
Inspection and test of instrumentation equipment at Manufacturers factory shall be conducted
as per the manufacturers standard procedures for test and calibration subject to Owner/
Purchaser review and approvals.
Manufacturers inspection and test records including relevant certificates of calibrations,
conformity of materials, type of protections, etc., shall be ready for Owners and Purchasers
review by the time of witness inspection at Manufacturers factory.
Inspection percentage shall be referred to SHOP INSPECTION REQUIREMENT (SIR form).
The Purchaser may take waiver of complete or part of the inspection case by case for each
applicable purchase order or equipment.

7.3

INSPECTION AND TEST ITEMS


The standard inspection and test items at manufacturers shop shall be referred to SHOP
INSPECTION REQUIREMENT (SIR) form.

Page 51 of 51

You might also like