qdr-gcs-esj-spc-1000 reva

OWNER PMC

OIL & GAS DEVELOPMENT COMPANY LTDQADIRPUR COMPRESSION PROJECT

CONTRACTOR

Document Title:

GENERAL SPECIFICATION FOR DESIGN, FABRICATION AND INSTALLATION OF

INSTRUMENTS

Date: 15-Jan-07 Document No: QDR-GCS-ESJ-SPC-1000 Rev: A Class: 2 Sheet 1 of 29

GENERAL SPECIFICATION FOR

DESIGN, FABRICATION AND INSTALLATION

OF INSTRUMENTS

A Issued For Review 15-Jan-07 LY QBP LSH

Rev Description Date Prepared Checked Approved Client

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TABLE OF CONTENTS

1 INTRODUCTION...........................................................................................................................4

1.1 Scope...................................................................................................................................................... 4

1.2 Abbreviations and Definitions.................................................................................................................. 4

2 CODES AND STANDARDS.........................................................................................................5

3 REFERENCED DOCUMENTS......................................................................................................5

4 ENVIRONMENTAL CONDITIONS................................................................................................6

5 GENERAL.....................................................................................................................................6

5.1 Detailed Design Requirements................................................................................................................6

5.2 Contractor and Fabricators Inspection....................................................................................................9

6 DESIGN AND MATERIALS..........................................................................................................9

6.1 General.................................................................................................................................................... 9

6.2 Units of Measurement and Scales.........................................................................................................12

6.3 Equipment Tagging and Marking...........................................................................................................12

6.4 Temperature Instruments...................................................................................................................... 13

6.5 Pressure Instruments............................................................................................................................ 14

6.6 Flow Instruments................................................................................................................................... 15

6.7 Level Instruments.................................................................................................................................. 16

6.8 Control Valves....................................................................................................................................... 17

6.9 Safety Valves........................................................................................................................................ 18

6.10 Rupture Discs........................................................................................................................................ 18

6.11 Motorised Valves................................................................................................................................... 19

6.12 Utilities................................................................................................................................................... 19

6.13 Station Control Systems (SCS).............................................................................................................19

6.14 Programmable Logic Controller (PLC)...................................................................................................19

6.15 Earthing................................................................................................................................................. 19

6.16 Alarms, Switches, and Interlocks...........................................................................................................20

7 SYSTEM INSTALLATION..........................................................................................................20

7.1 Panels................................................................................................................................................... 20

7.2 Local Control Panels............................................................................................................................. 22

7.3 Control Centers..................................................................................................................................... 23

7.4 Electronic Transmission........................................................................................................................ 23

7.5 Noise Conditioners................................................................................................................................ 25

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7.6 Uninterruptible Power Systems (UPS)...................................................................................................26

8 INSTRUMENT AIR SYSTEM......................................................................................................26

9 DOCUMENTATION.....................................................................................................................27

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1 INTRODUCTION

The Oil & Gas Development Company Limited (OGDCL) is operator of Qadirpur Gas Field,

situated in Sindh Province in Central Indus Basin.

COMPANY plans to install a new Gas Turbine Driven Compressor Station at the existing Qadirpur

Gas Treatment Plant and to extend the gas gathering system to enhance the raw gas production

and maintain a high production plateau.

This specification is part of the detailed design dossier describing the technical requirements.

1.1 Scope

The purpose of this document is to define the general requirements for instrumentation and control

system. Any deviation from this Specification must be approved by COMPANY. A revision bar

indicates all changes made to this Revision.

1.2 Abbreviations and Definitions

COMPANY Oil & Gas Development COMPANY Limited (OGDCL)

EPCC/LSTK Engineering, Procurement, Construction, Precommissioning, Commissioning and 6 Month of Operation / Lump Sum Turn Key

CONTRACTOR China Petroleum Engineering Construction Co. (CPECC), Carrying Out the EPCC/LSTK Works for the Project

SUB-CONTRACTOR A party which manufactures and/or supplies equipment, technical documents/drawings and services to perform the duties specified by the COMPANY/CONTRACTOR

PROJECT Qadirpur Compression Project

The word shall is a verbal form used to indicate requirements to be strictly followed in order to

conform to this specification and from which no deviation is permitted, unless accepted by all

involved parties.

The word should is a verbal form used to indicate that among several possibilities one is

recommended as particularly suitable, without mentioning or excluding others, or that a certain

course of action is preferred but not necessarily required.

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The word may is a verbal form used to indicate a course of action permissible within the limits of

this specification.

The word can is a verbal form used for statements of possibility and capability, whether material,

physical or casual.

SCS – Station Control System

HMI – Human Machine Interface

ESD – Emergency Shut Down

USD – Unit Shut Down

2 CODES AND STANDARDS

The following codes, regulation and standards of the latest editions SHALL be used where

applicable. Where any conflict exists between the referenced codes or standards, the most

stringent of the codes or standards SHALL prevail.

API American Petroleum Industry Standards

EN European Standard

CE Declaration of Conformity to European Standards

ISA Instrument Society of America

DIN Deutsche Industrie Normen (German Industrial Standard)

IEC International Electro-technical Commission

3 REFERENCED DOCUMENTS

QDR-GCS-ESJ-SPC-1001 Specification for Station Control System

QDR-GCS-ESJ-SPC-1006 Specification for Instrument Cable

QDR-GCS-ESJ-SPC-1008 Specification for Fire & Gas Detection, Inert Gas Extinguishing

Specification

QDR-GCS-ESJ-SPC-1009 Specification for Machine Monitoring System

QDR-GCS-ESJ-REP-1000 Instrumentation and Control Philosophy

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QDR-GCS-ESJ-SPC-1004 Specification for Programmable Logic Controller

QDR-GCS-ESJ-SPC-1005 Specification for Cabinets

QDR-GCS-ESJ-DRG-1001 Control System Block Drawing

QDR-GCS-ESC-DRG-1005 Trench System, Ditches and Crossing Typical Details

QDR-GCS-ESE-DRG-7500 Area Classification Plan

QDR-GCS-ENG-REP-1003 Tag Numbering System

4 ENVIRONMENTAL CONDITIONS

- Temperature Max 50 °C (122 °F)

Min 3 °C (17 °F)

- Absolute max/min recorded Max/Min 53 / -1.1 C

- Average Monthly Relative Humidity Max 77%

Min 20%

- Max/Min Barometric Pressure 1010.5 / 985.7 mbar

5 GENERAL

Where deviations occur between the documents, the order of preference is as follows:

1) Data (or specification) Sheets

2) Instrument Design Basis

3) COMPANY Engineering Standard

COMPANY will provide an approved SUBCONTRACTOR’s list which SHALL be used exclusively.

The production places of the SUBCONTRACTOR’s SHALL be in the European Union (EU), other

production places SHALL be approved by COMPANY.

All "package equipment" is to have the same type and quality of instruments and documentation

as the rest of the facility. Frequent quality control inspections will be required by COMPANY.

Functional Acceptance Test will be witnessed by COMPANY before "approval to ship" is granted.

5.1 Detailed Design Requirements

The following items SHALL be furnished for approval by COMPANY, as a minimum:

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1) Individual loop diagrams showing all interconnecting wiring and tubing SHALL be provided.

Controller and control valve action SHALL be included. Loop drawings SHALL be provided by

the engineering CONTRACTOR for all instrument loops appearing on P&ID or control and

instruments diagrams. ISA standard S5, Instrument Loop Diagram, or approved substitutes

SHALL be used. In the case of "interlocking instrument" or a "shutdown sequence”, Functional

Logic Diagrams SHALL be provided.

2) Functional logic diagrams SHALL use Boolean logic. Alarm and shutdown logic diagrams SHALL

note trip points.

3) Bid specifications are required for instruments, SCS, analyzers, cabinets, fire and gas systems,

package equipment control systems.

The following items SHALL be furnished for review by COMPANY:

1) Data sheets for all instrumentation and analyzers using the COMPANY numbering system. Data

sheets for each instrument furnished on "package equipment”. COMPANY SHALL approve the

form of the data sheet. Acceptable forms are only the COMPANY forms, or an approved equal.

Electronic data bases may be provided in approved database / software on an approved media.

2) Location plan views showing instruments, junction boxes, local panels, and analyzer houses.

3) Conduit and cable schedules and routing plans.

4) Termination and wiring diagrams of junction boxes and marshalling cabinets.

5) Control panel layout and design, including centralized and local.

6) Control house design and floor plan, showing location of all consoles, racks, and associated

equipment.

7) Rack design with input and output arrangement.

8) Composite drawings of any special systems such as gas turbine controls and compressor

controls.

9) Orifice calculations, control valve calculations.

10) Copies of all purchase requisitions issued for instrumentation.

11) Piping drawings showing all in-line mounted instruments unless a model is available for review

before the piping drawings are made.

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12) All vessel drawings or models that show location of all nozzles, connections, ladders and

platforms related to instrument locations and connections.

13) SUBCONTRACTOR drawings including those for Station Control System, turbine compressor

unit control system and other packages.

Any detailed design involving a Unit Emergency Shut Down System (USD) SHALL be the

responsibility of the assigned SUBCONTRACTOR.

SUBCONTRACTOR's certified drawings, instruction manuals, and recommended spare parts lists for

all instrumentation shall be provided. The spare parts lists are needed in time to get delivery before

startup. This item SHALL be included in the master schedule for distribution six months prior to

mechanical completion.

As-built drawings are generally required for the following:

1) Instrument Index,

2) Data Sheets,

3) Orifice Calculations,

4) Loop Diagrams,

5) Conduit and Cable Schedules,

6) Junction Box Termination Details,

7) Panel Layouts,

8) Alarm and Shutdown List,

9) Symbolic Logic Diagrams with narrative, and all special systems.

When specified by COMPANY, all the above documentation SHALL be compiled and issued in bound

volumes separate from other manuals and issued according to the time schedule. Unless otherwise

specified by COMPANY, all documentation/drawings written by the CONTRACTOR SHALL be

provided in approved electronic format on approved media. All documents as hardcopy SHALL be in

a reproducible quality.

It should be notified to COMPANY of alternative measurement and control devices that could result in

lower cost or improved reliability. When alternatives are proposed, COMPANY SHALL approve all

changes.

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5.2 Contractor and Fabricators Inspection

All systems as well as instrumentation on package equipment SHALL be subject to inspection by

COMPANY. A quality assurance plan SHALL be developed, itemizing those systems or packages

to be inspected in the shop. Frequent quality control inspections may be required by COMPANY.

The SUB-CONTRACTOR SHALL advise COMPANY four weeks before functional test and

checkout.

6 DESIGN AND MATERIALS

6.1 General

1) All instrument and construction materials SHALL be new and unused.

2) Separate process connections SHALL be used for all instruments. All instruments in the

field area have to be mounted in suitable protective shelters and fixed on mounting racks.

Mounting and connection has to be performed in accordance with the typical hook-ups and

the requirements of the instrument SUBCONTRACTOR and have to take care for safe and

disturbance free operation of the instruments.

3) Stainless steel SHALL be the standard material of construction for all pressure elements and

wetted surfaces unless otherwise specified or approved. All process connecting piping

SHALL be 12 mm stainless steel tubing unless otherwise specified or approved. Tubing and

fittings SHALL meet the requirements of “General Specification Instrument Installation”.

4) All instruments SHALL be permanently tagged by the SUBCONTRACTOR or

CONTRACTOR with a screwed metal tag bearing the tag number and service.

Thermocouple assemblies, pressure gauges, etc., SHALL be tagged also, however, their tag

may be attached with stainless steel wire. Instruments installed in individual housing SHALL

also have an engraved stainless steel nameplate on the outside of the housing showing both

tag number and descriptor of service.

5) Instruments SHALL not be mounted on handrails or vibrating equipment or vibrating lines.

This applies also to pressure gauges on pumps having high frequency vibration.

6) Cables in hazardous areas SHALL be sealed using flameproof barrier glands.

7) Cable glands for incoming cables SHALL be supplied complete with any necessary locknuts,

washers, shrouds and earth tags.

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8) Shutdown devices SHALL be completely separated from other sensing devices. All shutdown

systems SHALL have a final checkout by mechanically actuating the primary sensing device.

9) Standardization of instrument SHALL be implemented, as it will result in a smaller variety of

items to be purchased, installed and maintained. The standardization SHALL cover, as a

minimum the instrument selection (e.g. sizes, materials, SUBCONTRACTORs etc),

instrument installation and hook-ups (e.g. sizes, connections, tubing and fittings etc.),

instrument cables and junction box (e.g. types, sizes etc.).

10) Instruments shall be manufactured to survive the environmental conditions and meet the

hazardous area requirements. Equipment designed for use in the field area, should be

protected from direct sunlight and ambient temperature higher than manufacturer’s

maximum recommended temperature.

11) It is preferable for the use of instruments which are less susceptible to failures and have the

capability to carry out an automatic functional test.

12) It is preferable for the use of SMART/intelligent instruments, which have remote accessibility

and can provide, and document, useful information for maintenance and operation (e.g. zero

point calibration, range calibration, remote diagnostic, etc.).

13) Specialized instruments which may require a specialist to be flown in for servicing and

maintenance should allow quick and easy replacement.

14) Shutdown and interlock logic shall be provided according the General Specification Emer-

gency Shut Down System.

15) Generally all field instrumentation SHALL be certified “Exd” flameproof, or “Exe” increased

safety. Where the instrumentation cannot achieve the stated degrees of protection an “Exia”

or “Exib” SHALL be applied.

16) All outdoor instrumentation cabinets, housings, devises etc. are to be protected to IP65 as

minimum.

17) Package equipment is to have the same type and quality of instruments as the rest of the

facility.

18) All engineering details pertaining to control systems on package equipment SHALL be made

available for review by COMPANY before the design is finalized.

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19) All recorders SHALL be mounted on the main control panel or console. Local controllers

SHALL be the indicating type, except displacement level controllers, and SHALL be limited

to simple applications requiring infrequent set point changes such as seasonal changes.

Self-contained regulators SHALL also be limited to simple applications and where operator

attention is not required.

20) All field instruments and control valves SHALL be within working reach of a man standing at

grade or on a permanent platform. Preferred mounting height is 1.3 meters to the centerline

of instruments.

21) All gauge glasses and indicating dials SHALL be oriented to be readable by a man standing

at grade or on a permanent platform.

22) Individual filter regulators SHALL be furnished for the air supply to each pneumatic in-

strument, except those on panels.

23) Dedicated junction boxes shall be provided for electrical supply cables. Signal cables SHALL

be taken to separate boxes. Colour coding SHALL be used to differentiate all signal junction

boxes from power junction boxes.

24) Separate junction boxes shall be provided for each of the following groups of cables:

Cables carrying non-intrinsically safe digital signals

Cables carrying intrinsically safe digital signals

Cables carrying non-intrinsically safe analog signals

Cables carrying intrinsically safe analog signals

25) Cable carrying different characteristic signals SHALL be segregated in cable runs and

SHALL be connected to dedicated junction boxes, for example on/off switch signals and 4 to

20 mA DC signals. All junction boxes SHALL be labelled with JB numbers. All junction boxes

SHALL be installed to allow adequate room for the loops of bottom entry off-skid cables. All

junction boxes SHALL be provided with glands and shrouds for the off-skids cable.

26) Tubing and cableways to control valves and instruments SHALL be routed in the field so as

to avoid obstructing walkways or ladders and prevent damage from personnel traffic.

27) Electronic systems are preferred to pneumatic. Generally, only local field loops will be

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pneumatic.

28) Provision SHALL be made to paint all steel instrument supports and mounting brackets for

corrosion protection. Aluminum supports and brackets or hot-dipped galvanized steel can be

used as a substitute for painting.

29) All instruments SHALL be RFI immune. Manufacturers SHALL test their equipment per

SAMA Standard, PMC 33.1. All instruments SHALL be affected by no more than 1% of span

when exposed to field strength of 10 volts per meter (Class 2) with a frequency range of 50-

500 MHz (band b and c).

6.2 Units of Measurement and Scales

The units and scales both in Imperial Unit System and IS System shall be applied for the project

as listed below.

Vapour flow

Pipe diameter

Heat Duty

Specific Heat

Heat Transfer

Temperature

Length

Mass

Time

Pressure

ft3/h, MMscfd

in

MMBtu/h

kJ/kg

Btu/hft°F

°F

km, m, mm

lb

s, h, d, a

psig, psia

Mass Flow

Volume Flow

Molar Flow

Density

Viscosity

Voltage

Current

Power

Rotation

Noise

lb/h

bpd/gpm

kmol/s

lb/ft3

cP, cS

V

A

kW, MW

rpm

dB(A)

6.3 Equipment Tagging and Marking

Identification labels SHALL be provided for each motor, panel, power supply or control device,

cables and other components.

The information SHALL be stamped or engraved on a stainless steel plate permanently affixed to

the equipment. The nameplate SHALL provide at least the following information:

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1) Tag number

2) Manufacturer's name, model and serial number of the instrument

3) Energy supply (electrical or pneumatic)

4) Measuring range

5) Material grade(s) used, in particular for bodies and plugs of control valves, transmitter

bodies, etc.

6) Method of protection with certification number for certified equipment.

Further requirements are detailed in related “Specifications” for particular instruments.

All terminals and disconnect able terminations with wiring > 0,75 mm2 SHALL be provided with

closed-type numbered designation sleeves on the wiring.

All permanently installed cables SHALL be identified by using permanent, durable labels including

unique and clear cable numbers. The cable SHALL be marked at both ends and at intervals of

50m.

The cable numbering shall be taking into consideration according with QPR-ESJ-SPC-5300.

6.4 Temperature Instruments

1) All thermometers, thermocouples, and temperature switches SHALL be installed in wells.

Wells with an insertion length of 300 mm or less SHALL be of drilled bar stock. Wells over

300 mm SHALL require approval by COMPANY. Wells SHALL be of 316 stainless steel

unless otherwise approved by COMPANY. Tapered wells are required in vibrating service.

Extension necks are not needed on flanged wells. In general flanged wells SHALL be used.

The flange SHALL be 1 ½ inch with minimum rating of 300# and facing according the piping

class. Well depth SHALL be engraved or stamped on a tag attached to the head of the well.

2) Bimetal dial thermometers of the adjustable angle type are acceptable for local indication.

Fully compensated filled systems with remote dials SHALL be used where required for

readability or protection from vibration.

3) Resistance thermometer SHALL be 3 wire and 4 wire Pt 100 type ANSI/ISA MC 96.1 Class

A. The maximum temperatures for which the Platinum resistance thermometers are allowed

to be used is 500°C.

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4) Thermocouple extension wire material SHALL match the thermocouple.

5) All temperature instruments SHALL include a provision for thermocouple burn-out indication.

6) Temperature measurements SHALL have up scale at a burn out.

7) Thermo wells SHALL be assessed for vibration resonance effect (wake frequency

calculations using ASME PTC 16.3).

8) Dial size SHALL be 100 mm (4") nominal and instruments will be ”every angle” head type.

6.5 Pressure Instruments

1) All process pressure connections SHALL be 12 mm OD x 1.5 mm NPT or instrument flange.

2) Two valve manifolds SHALL be provided for all pressure transmitters, switches and gauges.

3) Remote pressure measurements should be provided with pressure transducers with unified

analogue output signal 4 to 20 mA and/or digital. Basic transducer error should be less than

0.5% of set measuring range. Instability of static transducer characteristic should not exceed

0.25% of maximal measuring range.

4) Pressure elements measuring a steady normal operating pressure should not exceed 75% of

their maximum range. Pressure elements measuring a fluctuating pressure should not

normally be operated beyond 60% of their maximum range.

5) Pressure gauges SHALL comply with Instrument Specification Pressure.

6) All local pressure/temperature gauges used in pulsation and vibration conditions are to be

glycol filled and where necessay, pulsation damperners should be adopted. If visibility is not

possible at operator level then these instruments shall be provided with liquid filled

capillaries for remote mounting.

7) There SHALL be a pressure gauge on the discharge of all pumps, and it SHALL be visible

from the location of the discharge block valve.

8) Local pressure controllers SHALL have weatherproof cases with adjustable reset and

adjustable proportional band.

9) All compressed air regulators SHALL be installed with a pressure gauge. Air sets on the

pneumatic supply tubes to instruments SHALL have supply and output gauges.

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10) A differential pressure transducer SHALL be connected to the process through a 5-way valve

block which allows to connect it to calibrating-pressure source by calibration and equalize

the pressure in +/- chambers.

11) Pressure gauges SHALL conform to ANSI B40.1 grade A, accuracy 1 % of full range.

12) For pressure instruments the standard ranges should be specified also approved attached

factory test certificates.

6.6 Flow Instruments

1) Square-edged, concentric-type orifice plates and prefabricated meter runs with weld neck

orifice flanges SHALL normally be specified. These meter runs, including an orifice

calculation, SHALL be furnished by an approved SUB-CONTRACTOR. Minimum meter run

lengths SHALL be sized according to API 551 or AGA 351 at a d/D ratio of 0.7. Meter runs

SHALL normally be between 2 and 12 inches in diameter.

2) Orifice plates in horizontal meter runs on saturated steam and vapours near their dew point

SHALL have drain holes. Where this is upstream of steam turbines, a drain valve SHALL be

provided also just upstream of the plate.

3) Orifice plates SHALL not be in the line during pre-start-up flushing or hydraulic testing.

4) The ultrasonic flowmeter must be installed in accordance with the requirements defined in

the ultrasonic gas flowmeter reference, installation and operations manual. A typical system

comprises the following main assemblies:

Flowcomputer

Meter body

Transducers

Drive Unit (Main unit, and Base unit)

5) The ultrasonic gas flowmeter body is mounted in the gas pipeline. The transducers are fitted

directly onto the meter body. The drive unit is either mounted directly onto the meter body, or

in some instances remotely on a suitable stand. The drive unit houses eight (senior sonic) or

four (junior sonic) individual cables, with plugs to connect to the transducers. The drive unit

is used to operate the ultrasonic transducers and also to digitise and then process the

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received signals from the transducers. The drive unit normally communicates to a flow

computer using a RS 485 (RS 232 optional) communication link. The flow computer can be

used to send setup parameters and system constants to the drive unit. The drive unit

computes the flow velocity of the gas through the ultrasonic meter body from which the

actual volume flowrate can be determined. This information is then passed to the flow

computer through the communication link. The ultrasonic gas flowmeter shall be assembled

with data transfer facilities in both digital and analog signals for the Station Control System.

6) If a Turbine Flowmeter is used, it will be calibrated with natural gas of pressure and Reynolds

index close to the operational values.

7) Unless otherwise specified by COMPANY custody transfer meters of liquids for above 20 cSt

viscosity application can be positive displacement meters.

8) Turbine meters, positive displacement flowmeter, magnetic flowmeter SHALL comply with

Instrument Specification Flow.

9) Electromagnetic flow meters may be used for measuring the flow of conductive liquids.

10) For flow instruments the standard ranges should be specified also approved attached factory

test certificates.

6.7 Level Instruments

1) Each level instrument SHALL be mounted on a dedicated vessel connection. Displacers,

floats, gauge glasses, alarms, shutdowns, etc., SHALL have separate vessel connections.

Pipe size, connection, and material for bridles SHALL comply with General Specification

Instrument Installation.

2) Gauge glasses SHALL meet the requirements of Instrument Specification Level.

3) Gauge glasses SHALL be used in services only up to 75% of their manufacturer's rating and

not to exceed 16 barg. Above 16 barg, metal tube gauges SHALL be used.

4) Gauge glasses SHALL be visible from the associated level instrument (e.g. Level Trans-

mitter) and the visible length SHALL cover or exceed the span of the level instrument, the

visible portion will overlap at least 50 mm.

5) Differential pressure type level instruments SHALL be used where the level range is greater

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than 2134 mm (84”). Differential type level transmitters SHALL be provided with a zero

elevation/suppression adjustment.

6) Removable stilling tubes SHALL be provided for all internal displacers to prevent damage to

the displacer and faulty operation of the instrument.

7) Level chambers and displacers SHALL have drain discharge piping and a vent hole on the

top.

8) Level switches SHALL be vibration type or other suitable and reliable types and will be used

for critical (high-high) alarm actuation and/or shut down system, whenever transmitters are

used to measure the level.

9) For pressure instruments the standard ranges should be specified also approved attached

factory test certificates.

6.8 Control Valves

1) Control Valves SHALL conforms to Instrument Specification Control Elements.

2) Split body and loose flange design valves SHALL not be used.

3) Valve body material SHALL be in accordance with the line piping classification or better.

4) Carbon steel and stainless steel flanged globe and ball valves SHALL have a minimum

pressure rating of 300 lbs.

5) Butterfly valves SHALL have ratings as per the pipe line specification.

6) The minimum size for control valves SHALL be 1 inch (25 mm). Where line size is less than

1 inch (25 mm) a line size valve may be considered provided materials and connections

comply with line specification requirements. Valve sizes 1.25, 2.5 and 5 inch (30, 60 and 125

mm) SHALL not be used. Control valves 1 inch (25 mm) and larger SHALL be flanged or

suitable for insertion between pipeline flanges.

7) Butterfly valves SHALL be heavy duty design with powerful (piston) operators to permit

precise positioning of vane. Butterfly valves will operate over 60° angular opening unless

valve design provides full 90° characteristic capability.

8) Actuators are to be sized to drive the valve to its closed position against the maximum

differential pressure, taking into account the design pressure of the line in which the valve is

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installed.

9) By-pass and split range valves SHALL be included with each positioner.

10) On-off service control valves SHALL be line size, with quick opening trim.

11) Adequate space SHALL be allowed for maintenance, and the valve SHALL be located for

convenient access. Butterfly valves SHALL not be installed close to fans or blowers.

12) By-pass where used SHALL be indicated on P&I Diagrams. When by-passes are not pro-

vided control valves SHALL be fitted with side-mounted hand wheels. Control valves which

operate under emergency plant conditions SHALL not be provided with either by-pass or

hand wheels unless specifically shown on the P&I Diagrams.

6.9 Safety Valves

1) Design of pressure relieving systems SHALL comply with the requirements of Instrument

Specification Safety Valves.

2) Safety relief valve orifice sizes SHALL be calculated on a pure ”area” requirement basis,

capacity adjustments required by code revisions or other applicable regulations SHALL be

covered within the valve selection procedure.

3) Safety valves for general process service SHALL be direct spring loaded with high lift

characteristics, flanged and composed of a with minimum carbon-steel body and stainless

trim.

4) Lifting levers SHALL be provided as required by the applicable code to allow the disc to be

lifted from the seat when the operating pressure is 75% of the seat pressure.

5) Safety valves SHALL be set to open at the pressure stated on the P&ID. Where variable

back pressure exceeds 10% of the set pressure balanced, bellows seal type valves will be

used.

6.10 Rupture Discs

1) Rupture discs SHALL be reverse buckling narrow face capsule type complete with holders to

fit inside the ID of the bolt circle of standard flanges. Jacking bolts SHALL be supplied for

disc sizes 2" (50 mm) and larger.

2) Where a rupture disc is installed upstream of a safety valve an excess flow valve must be

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installed downstream of the disc to prevent any back pressure on the disc in the event of

disc seepage insufficient to burst the disc, and 50 mm (2") diameter pressure gauge

provided to detect leakage or rupture.

3) Inconel discs SHALL be used for temperatures above 100 °C, where possible.

6.11 Motorised Valves

Motorised valves SHALL be in two or three way design, complete with actuator, manual

handwheel and protected three-phase 230/400 V, 50 Hz.

6.12 Utilities

The following electrical power supply and instrument air supply SHALL be provided to the

appropriate instruments for design purposes.

The Voltage Levels for instruments SHALL be as follows:

1) 230 VAC, 50 Hz (single phase) (e.g. in system cabinets etc,)

2) 24 VDC (for solenoid valves)

3) 24 VDC (for transmitters etc.)

6.13 Station Control Systems (SCS)

1) Station Control Systems SHALL meets the requirements of the Specification for Station

Control System.

2) Electronic transmitters associated with the SCS SHALL derive their 24V DC supply from

within the SCS.

3) The instrument supply distribution SHALL be by fused distribution boards.

6.14 Programmable Logic Controller (PLC)

Programmable controller applications for shutdown and protective instrumentation SHALL comply

with Specification Emergency Shut Down System.

6.15 Earthing

The following earthing systems SHALL be provided when applicable:

1) Instrument System Earth (Clean Earth) for signal earth’s, screens, etc.

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2) Control Cabinet Earth (Dirty Earth) for mechanical continuity and personnel safety.

3) Barrier Device Earth for barrier system earth requirements (where intrinsically safe zener

barrier devices are included).

Cable screens SHALL be earthed at one location only, and this will generally be at the control

room terminal location area.

The Barrier Device earth SHALL be insulated from the Control Panel Earth and run separately to

the instrument system earth electrodes.

For Instrument System and Barrier Device earthing the total earth loop impedance on any circuit

SHALL be 1 Ohm or less.

6.16 Alarms, Switches, and Interlocks

1) Protective instrumentation SHALL meet the requirements of Instrument Specification

Emergency Shut Down System.

2) Switches for alarms and interlock systems SHALL be used for on-off application only. The

design of the switches SHALL be suitable and approved to meet the electrical area

classification.

3) Flow switches for direct operation by process fluids SHALL be of paddle type. Flow

transmitters with external switch function may also be used.

4) Level switches for direct operation by process fluids SHALL preferably be of the pack less

type (i.e. torsion rod, diaphragm or magnetic coupled). Unless otherwise specified, internal

trim SHALL be 316 stainless steel.

5) First out sequence SHALL be used for solid state annunciators.

6) Power supply voltage SHALL be 230 V AC 50 Hz.

7 SYSTEM INSTALLATION

7.1 Panels

1) Control Room Panels SHALL be built by an approved control panel manufacturer. The panel

SHALL be built, tested and delivered to the site ready for operation. Field work SHALL

consist of loop checking of the external wiring, installation of separately packaged

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instruments, and the connection of external utilities.

2) The following information, drawings and literature SHALL be furnished to the panel

manufacturer:

Ambient temperature and relative humidity ranges.

Hazardous area classification.

Detailed panel cut-out information.

Panel clearances to surrounding equipment.

Any required physical layout for the panel front and the inside of the panel.

Any required wiring details.

Any required diagrams for pneumatic instrumentation and process connections.

Any required ladder diagrams for relay logic systems.

3) The panel and all equipment within it SHALL be suitable for the area classification.

4) All materials not supplied by COMPANY shall be purchased and procided. All materials

SHALL comply with COMPANY requirements. A bill of material SHALL be submitted to

COMPANY for approval prior to construction.

5) Panels SHALL be self supporting, and have adequate stiffener bars to prevent distortion.

Removable lifting eye-bolts SHALL be provided on the top of the panel capable of

supporting the panel without distortion.

6) The panel SHALL have adequate mounting holes and provisions for anchoring to the

foundation.

7) All terminal strips SHALL have each terminal clearly identified. All wires SHALL be labelled

on each end.

8) Tubing SHALL be installed and connections made to instruments so that each instrument is

accessible for removal, maintenance, adjustment, or repair without removal or distortion of

tubing and/or equipment.

9) All instruments SHALL be installed so that they are easily accessible for maintenance and

inspection.

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10) All panel instruments SHALL be permanently identified. All panel instrument locations SHALL

be identified on the face of the panel with a plastic name plate. Name plate colours SHALL

be approved by COMPANY. The name plate SHALL show the tag. The name plate SHALL

not be mounted on the removable cover of the instrument. Each instrument mounted in the

back of the panel and terminal strips SHALL be identified with similar nameplates showing

the tag numbers. The use of ‘masking tape’ for temporary identification is strictly Prohibited;

Only electrical insulation tape is acceptably for temporary panel identification.

11) The panel manufacturer SHALL perform the following tests prior to final inspection:

Wiring point to point continuity check.

Process and pneumatic leak checks.

Operational action checks of all switches to ensure compliance with drawings.

12) Control panels SHALL include "as built" documentation with the following information:

Detailed structural and panel cut-out drawings.

Front and rear panel arrangement drawing showing equipment locations.

Wiring details for power, auxiliary circuits, and instrument wiring.

Piping diagrams for pneumatic instrumentation, and process connections.

Dimensional details, connection diagrams, and instruction manuals for all

instrumentation.

Function diagrams for any logic systems.

Inter-connection wiring diagrams showing all terminal connections between the panel

and external instrumentation, equipment, and other panels.

13) The panel may be shop inspected by the COMPANY during and after final completion. The

SUB-CONTRACTOR SHALL notify COMPANY four weeks in advance of when the panel will

be available for final inspection. The panel fabricator SHALL make available as required,

power, analogue signal sources, pneumatic signal sources, jumpers, meters, and

measurement devices, and a technician to assist in the functional check out and inspection

of the panel.

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14) All shelves mounted or delicate instruments SHALL be removed from the panel and packed

for separate shipment.

15) Unless otherwise specified by COMPANY, control panels SHALL not be used when a

Distributed Control System is available.

7.2 Local Control Panels

1) The design and fabrication of local control panels SHALL also conform to Section 7.1 of this

Specification. All instrumentation SHALL comply with all other sections of this specification.

2) All doors SHALL be gasketed, have a 3-point latching system with a key locking handle, and

have stainless steel hinges and hardware.

3) Sheet metal pockets for holding drawing and documents SHALL be provided on the inside of

the panel door.

4) Field tubing terminations and electrical conduits on local panels SHALL enter the side of the

panel. Low point drip legs and drains SHALL be added to all conduits just before entering

the panel. Connection between the field and panel tubing SHALL be made by means of a

brass bulkhead and tube fittings.

5) Sheet metal pockets SHALL be stainless steel. Panels for outdoor service SHALL meet IP 65

classification. Casketed hinged covers with safety glass or acrylic front, and key lock latch

SHALL be provided for all flush mounted instrumentation that would not meet IP 65 or that

would permit air leakage through the front of the panel.

7.3 Control Centers

1) The control room area within the Operation and Control Building is the area from where the

Compressor Station SHALL be monitored and controlled.

2) The cabinets SHALL be positioned within this area to provide front access.

3) All incoming cables SHALL enter the instrument room via cable transits below grade, the

floor SHALL be computer type with a void below.

4) The location and method of entry into the control building for field cables SHALL be

approved.

5) The Trunk Radio Communication system SHALL be located in the Control Room.

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6) Control rooms SHALL comply with General Specification Distributed Control System.

7.4 Electronic Transmission

1) Instrument DC signal wire and thermocouple extension wire SHALL comply with General

Specification Instrument Installation.

2) Insulation suitable for high temperature SHALL be used where ambient temperatures exceed

60°C.

3) Where overhead cable runs are used, the junction box centerline SHALL be located 1400

mm above grade or platform with top of box not to exceed 2000 mm. Entry into junction

boxes SHALL be made in the bottom of the box.

4) Separate cable, conduit, and junction boxes SHALL be used for the different applications,

such as DC control wiring, DC alarm wiring, and thermocouple wiring.

5) All instrument cables SHALL be meggered both before and after pulling for shorts and/or

grounds with results recorded. Megger voltage SHALL be 1000V. Instruments SHALL not be

connected until after meggering.

6) Tubular clamp type sectional terminal blocks SHALL be used throughout the complete

system. The terminals SHALL be mounted on a raised base. Junction boxes SHALL be

sized to allow 150 mm spacing of terminal strips and a minimum of 150 mm clearance

between walls and terminal strips and a 150 mm box depth.

7) Junction box location SHALL be approved. All junction points SHALL be permanently

identified with loop number. Splices are not allowed. The boxes SHALL be numbered and

tagged with engraved stainless steel nameplates.

8) All wiring within junction boxes SHALL include 20% spares. Spares SHALL be labelled and

terminated at terminal blocks.

9) Incoming and outgoing thermocouple, control, and other instrument transmission wires

SHALL not be terminated at the same side of terminals in junction boxes.

10) Signal wires at all instruments SHALL be identified according to positive or negative lead.

Where black and white pairs are used, black is positive (+) and white is negative (-). In

addition, all wires SHALL be labelled as to loop number and wire number, using permanent

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heat-shrink type labels or acceptable sleeve-type labels.

11) Two independent sources of power SHALL supply the instruments. The 230 VAC circuits to

the instrument panels SHALL be supplied from a separate distribution panel and SHALL

serve only instruments and alarm circuits. This distribution panel SHALL have 16 amp

protection devices. Approximately 20% spare circuits SHALL be provided. Each SCS rack,

console and operating station SHALL have a separate branch circuit. Each panel section or

multi-loop DC power supply SHALL have a separate circuit.

12) Instruments SHALL not be bracketed directly off process lines except where specified.

13) Transmitters SHALL be mounted on 2” pipe stands where practical.

14) Pressure transmitters may be line mounted supported from process lines, to keep impulse

line short.

15) Service conditions and licensers requirements SHALL also be considered for deciding close

or remote coupling. Instrument support brackets SHALL not be welded to process piping.

16) All electronic and electrical equipment SHALL be suitable for area classification in which it is

installed and SHALL be in accordance with current standards and must be certified by

national certifying authorities for operation in classified area and gas group.

17) Wherever possible instruments SHALL be located so that they are protected from damage by

passing or falling objects.

18) Local instruments with the exception of those on lines SHALL be mounted with the centre

line at approximately 1.4 m above the platform or floor in a position accessible for operation

and maintenance.

19) Handrails and removable flooring SHALL not be used for supporting instruments.

20) All electronic instrument enclosures, Marshalling cabinets and instrument housings with

electrical components SHALL be electrically grounded. Instrument enclosure ground and

cabinets frame ground SHALL be connected to the control centre ground bars.

21) If installation requires shutdown or partially depresurisation of any part of the pipeline or

pipeline station CONTRACTOR SHALL prepare detailed plan of works. The plan SHALL be

presented to Client and SHALL obtain Client’s approval. The plan SHALL be presented to

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Client at least 2 months prior to the planned actions.

22) All transmitters exposed to direct sunshine SHALL be equipped with sunshine canopies.

7.5 Noise Conditioners

Power/noise conditioners SHALL be provided for all field (where powered from the instrument

rack) control and interlock instruments, all control room instruments, and all rack and computing

instruments. Power/noise conditioners may be omitted where their function is performed by an

acceptable Uninterruptible Power System (UPS).

7.6 Uninterruptible Power Systems (UPS)

1) Uninterruptible Power Supply (UPS) SHALL be provided for all safety and shutdown

interlocks, analogue, and microprocessor-based distributed instrumentation.

2) The UPS SHALL be designed to provide continuous power without interruption or under-

voltage or over-voltage for a time period of not less than 60 minutes (SHALL be confirm by

Turbine SUB-CONTRACTOR).

3) Where an AC mains and auto change over facility is provided the delay on change over

SHALL not exceed 10 milliseconds.

4) The PCS, ESD and Fire & Gas Detection System SHALL all be fed from UPS.

8 INSTRUMENT AIR SYSTEM

1) Stainless Steel tubing SHALL be used for pneumatic transmission. Minimum size is 6 mm

OD.

2) Tubing runs consisting of four or more tubes SHALL be made by using bundled tubing.

3) Tube, tube fittings, and installation SHALL comply with General Specification for Instrument

Installation.

4) All tubing bundles SHALL be supported in channels or trays. Individual tubes or groups of

individual tubes SHALL be supported in conduit or angle iron. Wiring or attaching to a pipe

SHALL not be done.

5) Angle iron SHALL not be attached to a control valve or instrument by the valve/instrument

bolts.

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6) All tubing installations SHALL be leak-tested by using a bubbler systems and 2 bar in-

strument air. A leakage rate of more than 2 bubbles per minute is not acceptable and SHALL

be corrected.

7) Tube fittings SHALL be installed in strict accordance with the manufacturer's instructions.

8) Tubing SHALL be tested. Apply maximum signal input pressure to the process connection,

close the inlet valve and disconnect the pressure source. Observe the gauge on the signal

inlet and ensure that there is no fall off of pressure over a 3 minute period. Where leaks are

suspected, these SHALL be eliminated and the test repeated.

9) All tubing bends SHALL be made with benders.

10) Teflon tape SHALL not be used on pipe threads in instrument air or pneumatic signal service.

11) Any underground tubing for instrument service SHALL be in hot dip steel conduit and

protected with a minimum of three inches of red dyed concrete.

12) Each sub-header SHALL be fitted with a diameter pressure gauge.

13) Each air supply SHALL be marked at the sub-header with the tag number of the in-

strument/control valve it is feeding.

14) All field mounted, air consuming instruments SHALL have a combination of filter regulator

unit and an output pressure gauge. The output range of the filter regulator is to be chosen to

suit the item it is supplying.

15) All connections SHALL be made using stainless steel fittings.

16) Instruments SHALL be close coupled to the process to minimise mounting problems. Impulse

piping, etc. must be readily assessable for maintenance from grade or access platforms.

17) For instruments located remote from the process connection the impulse piping will slope at

least 10% between take-off and instrument.

18) All installations with process seals including those with condensate legs, pots etc., SHALL be

provided with fill connections.

9 DOCUMENTATION

System documents SHALL include PROJECT drawings, documents and SUB-CONTRACTOR

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documentation (hardwire, software, user manuals) according with the Contract agreement, and

SHALL be supplied for final approval to the COMPANY before completion of Factory Acceptance

Test and Site Acceptance Test:

Document list:

1) Overall hardware and software descriptions,

2) Technical description of each hardware item,

3) Hardware maintenance manual of each component in the system,

4) Installation check-out documentation for all the system components,

5) Certified mechanical drawing of all units (including weights),

6) Certified electrical connection diagrams showing all plugs, cable termination blocks and

equipment,

7) System overall earthing arrangement,

8) Heat dissipation,

9) Power balance,

10) Software manual,

11) CONTRACTOR general and other specific documentation related to the system (including

reliability figures),

12) Safety certification dossier. This dossier must contain copies of all certificates and other

document pertaining to the safety of the system. This dossier SHALL be submitted to

COMPANY prior to the commencement of the FAT.

13) System hardware diagnostic programs with user instructions,

14) Description and user instructions for the operating system and all other programs and

subprograms provided by others,

15) A write-up covering system reloads, restarts and any other system user function, including

procedure to add new features such as new algorithms (sufficient examples SHALL be

included),

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16) Test procedures,

17) Test Certificates and reports,

18) List of system and application software including the software back-up,

19) Purchasing records,

20) Preservation and storage procedure,

21) Installation procedure,

22) System black start procedure,

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