ESOLAR-1648 General Instrumentation r2

7/27/2019 ESOLAR-1648 General Instrumentation r2

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Specification Number: ES-1648Revision Number: 2

TABLE OF CONTENTS

Paragraph Page

1.0 Scope 1

2.0 Codes and Standards 1

3.0 Deviations and Discrepancies 2

4.0 Instrument Identification 2

5.0 Controllers 2

6.0 Transmitters 3

7.0 Primary Elements 5

8.0 Recorders 7

9.0 Indicators (Gauges) 8

10.0 Switches 9

11.0 Instrument Installation 10

12.0 Control Valves 13

13.0 Control Valve Installation 15

14.0 Actuated Block Valves 17

15.0 Relief Valves 18

16.0 Alarms and Trips 19

17.0 Safety 20

18.0 Instrument Panel Board 21

19.0 Analyzers 21


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20.0 Instrument Air 22

21.0 Drawings, Data Sheets and Calculations 23

22.0 Inspection 24

ES-1648 ii


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ES-1648 1

GENERAL INSTRUMENT SPECIFICATION

1.0 SCOPE

This specification describes application guidelines and selection criteria for control and/ormeasurement instrumentation required in an industrial process plant. Instrument suppliers,plant designers and installation contractors must adhere to this specification. It covers fieldmounted TRANSMITTERS, local and remote panel mounted INDICATORS, RECORDERS,CONTROLLERS, SWITCHES, PRIMARY ELEMENTS, CONTROL VALVES, RELIEFVALVES, AND ANNUNCIATORS. It does not cover DISTRIBUTED CONTROL SYSTEMS,PRINTERS OR DATA ACQUISITION SYSTEMS.

Instrumentation associated with specific engineered items, such as BOILERS, STEAMTURBINES, CONDENSERS, and DEAERATORS may be specified with these items andtheir criteria for selection will be based on the manufacturer's standards with Solarsapproval.

2.0 CODES AND STANDARDS

Instrument shall conform in design basis, material and performance to the latest edition ofthe listed standards including addenda and revisions or supplements. These codes andstandards shall be considered a part of this specification.

2.1 Instrument Society of America (ISA)

ISA-S5.1 "Instrumentation Symbols and Identification" ISA-S20 Specification Forms for Process Measurement and Control

Instruments Primary Elements and Control Valves

2.2 American Society of Mechanical Engineers (ASME)

Section I "Boiler and Pressure Vessel Code, Power Boilers

Section VIII "Boiler and Pressure Vessel Code, Unfired Vessels

2.3 American National Standards Institute (ANSI)

B16.25 "Butt Welding Ends" B16.34 "Steel Valves" B16.5 "Steel Flanges" B31.1 "Power Piping" B31.3 "Chemical Plant and Petroleum Refinery Piping" B31.8 "Gas Transmission and Distribution Piping Systems" B40.1 "Gauges, Pressure and Vacuum, Indicating Dial Type"


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2.4 National Society of Corrosion Engineers (NACE)

MR-01-75 Sulfide Stress Cracking Resistant Metallic Materials forOilfield Equipment

2.5 American Petroleum Institute (API)

RP-14C "Analysis, Design, Installation and Testing of Basic SurfaceSafety Systems on Offshore Production Platforms"

RP-520 Parts I & II, "Design and Installation of Pressure RelievingSystems in Refineries"

RP-550 Parts I - IV, "Installation of Refinery Instruments and ControlSystems"

2.6 American Gas Association (AGA)

Rpt. No. 3 "Orifice Metering of Natural Gas"

2.7 Solar Standard Specifications (ES)

ES-1645 "Design of Process and Utility Piping Systems" ES-1647 "General Electrical Specification" ES-1649 "Instrument Calibration and Checkout"

3.0 DEVIATIONS AND DISCREPANCIES

Proposed deviations from this specification and proposed resolution of discrepanciesbetween the specifications, standards, codes, drawings and other documents shall bereferred to Solar for approval, and the result shall be expressed in writing.

4.0 INSTRUMENT IDENTIFICATION

The instrumentation identifiers, symbols, and the numbering system used shall conform toISA Standards. Numbering system shall be sequential 2, 3, or 4 digit numbers.

5.0 CONTROLLERS

Instrument controllers for variables requiring constant attention for normal operation,shutdown or during a plant fault condition shall preferably be located on a control panel.

The controller shall normally indicate the measured variable, set point and controller output.Controller operational modes may be ON-OFF, Proportional only, Proportional plus Integral(Reset) or Proportional-Integral plus Derivative (Rate).


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5.1 Pneumatic Controllers will normally be "flapper/nozzle" (fixed/variable orifice) typeand will be operated with clean dry air or gas. Dewpoint of supply medium shall beas a minimum 20

oF below the lowest ambient temperature for the area recorded

during the preceding 10 years.

5.1.1 Local Mounting such as pressure controllers yoke mounted to control valvesand liquid level controllers integral mounted to displacer/torque tubes areacceptable. Installations with excessive vibration should be avoided.

5.1.2 Remote Mounted controller process sense lines shall be a minimumdiameter of 1/2 inch and shall have a slope of 1 to 10 when connected in ahorizontal run. Slope should be downward to controller for liquid filledprocess lines and upward to controller for gas filled process lines. If the gasservice slope cannot be achieved, condensate pots with isolation and drainvalves may be used.

5.2 Electronic Controllers may be either analog or digital type controllers. Themicroprocessor based digital controller is preferred for complex control loops. Thesingle loop application that utilizes analog input and output signals is best suited forthe analog controller. Normal analog input or output signals shall be either 4 to 20mA or 1 to 5 Vdc. The digital controller shall also accept and output discrete signalsas well as the analog signals. Normal power supply shall be 24 Vdc.

6.0 TRANSMITTERS

2 Notes1. Instrument piping or stainless steel tubing may be used to connect process

medium to be measured to the transmitter. Minimum diameter shall be 3/8inch, 1/2 inch for flow measurements, with length not to exceed 50 feet.Piping shall be in accordance with project piping specifications. 3/8 inchO.D. tubing shall have minimum wall thickness of 0.035 inch, 1/2 inch O.D.tubing shall have minimum wall thickness of 0.049 inch.

2. Filled instrument tubing such as chemical seal tubing and temperaturecapillary should not exceed 25 feet.

3. Effort should be made to minimize the use of lagging, tracing and similarancillary materials and techniques.

4. In general, transmitters shall be for 2" pipe stand mounting.

5. Transmitter wetted parts shall be stainless steel unless otherwise dictatedby the composition of the measured fluid.

6.1 Pneumatic Transmitters


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Notes1. Output signal of 3 to 15 psi or 6 to 30 psi shall be proportional to

process variable.

2. Transmitters will normally be non-indicating unless specificallyrequested to be indicating.

6.1.1 Temperature Transmitters will usually be flapper/nozzle type that providepneumatic output proportional to temperature range as flapper is positionedby temperature change.

6.1.2 Pressure Transmitters may be motion balance type or force balance. Theforce balance type is preferred.

6.1.3 Flow Transmitters shall be differential pressure type. Differential elementmay be either the force balance type or dual bellows type.

For turndown requirements greater than 3 to 1 dual transmitters may beused for increased accuracy at low flows.

6.1.4 Level Transmitters shall be the displacer-torque tube actuated type up to a48" range. For larger ranges, differential pressure type shall be used.

6.2 Electronic Transmitters

Notes1. Output signal of 4 to 20 mA dc shall be proportional to process

variable. Transmitters shall not be the smart type unless specificallyrequested to be smart.

2. Output meter shall be provided whenever indicating transmitter isspecified. Indication shall be 0 to 100% linear except for flowapplications. 0 to 10 square root will be used for flow.

3. Input/Output terminals and electronic boards will be isolated from eachother in separate compartments to allow access to the terminal

connections without exposing electronics.

4. Continuously adjustable zero and span adjustments shall be externalbut covered.

5. Electronics enclosure shall be weatherproof, NEMA 4X as a minimum.In hazardous locations, the enclosure shall be suitable for the areaclassification and shall be clearly labeled to that effect.

6.2.1 Temperature Transmitters shall provide an RFI-insensitive 4 to 20 mA dc


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output for either RTD or thermocouple inputs. Thermocouple models will besupplied with electrical isolation to allow for grounding of input signals.

Accuracy shall be +/- 0.25% of calibrated span for RTD's. Thermocoupleaccuracy shall be +/- 0.25% of calibrated span or 0.02 millivolts, whicheveris greater.

6.2.2 Pressure Transmitters shall be capable of full zero suppression andelevation. They shall have adjustable damping and a range turndown of atleast 5 to 1. The output signal shall be 4 to 20 mA dc linear with theprocess. Accuracy shall be +/- 0.25% of calibrated span. Operatingtemperature range shall be -20

oF to +180

oF with overpressure limit of 2000

psig for ranges up to 1000 psig and 4500 psig for ranges to 3000 psig.

Absolute pressure transmitters shall have an overpressure limit of 2000 psigwith a maximum zero suppression of 500% of calibrated span.

6.2.3 Flow Transmitters shall normally be differential pressure type with up to600% elevation and 500% suppression. All differential pressure flowtransmitters shall be supplied complete with 3 or 5 valve manifold.

Other types such as magnetic, positive displacement and turbine meters willbe considered.

6.2.4 Level Transmitters shall be the displacer-torque tube actuated type up to a48" range. For larger ranges, differential pressure type shall be used.

Other types, such as capacitance probes, thermal dispersion probes andultrasonic types will be considered.


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7.0 PRIMARY ELEMENTS

7.1 Temperature Elements

Notes1. Thermowells MUST be used except for surface temperature

measurement or for very rapid response time. Connections shall be inaccordance with the governing piping specification. When flanges areused, normal size will be 1-1/2 inches. Screwed connections may beeither 3/4 or 1 inch NPT in accordance with the piping specification.

2. Thermowells shall be stainless steel unless otherwise dictated by thecomposition of the measured fluid.

7.1.1 Liquid or Gas expansion filled systems shall not be used where fill (ifleakage occurs) may adversely affect process stream or react with theatmosphere.

Provide metallic-armored capillary of a material unaffected by theatmosphere. Maximum length shall be 25 feet.

7.1.2 Resistance Elements (RTD's) shall be used for maximum accuracy attemperatures below 400F. Do not use if high vibration is present.

3 or 4 wire systems may be used. RTD's shall conform to InternationalResistance vs. Temperature Standard - 100 ohms at 0C.

7.1.3 Thermocouples shall be used for temperatures above 400F and wherehigh vibration will be encountered. ISA thermocouple types J, K, E and Tmay be used, however, Type K, Chromel-Alumel, should normally be used.

7.1.4 Both RTD's and Thermocouples shall be supplied assembled with aterminal housing and terminal strip. Terminal housing shall be weatherproofand suitable for the area classification.

7.2 Pressure Elements

Notes1. Use damping devices where pressure pulsations will adversely affect

the instrument.

2. Use Pigtail Siphons to protect element from high temperatureprocesses (up to 1000F).

3. For corrosive process fluids, element materials are to be certified to


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NACE MR-01-75. If not available, diaphragm seals with filled systemsshall be used.

2 7.2.1 Bourdon Tubes shall normally be used with indicators. They may also beused in pneumatic pressure controllers. The tube material shall be selectedbased on the process fluid.

7.2.2 Bellows elements will normally be used for pressures below 15 psig and aremandatory for pressures below 30 inches of water column.

7.2.3 Other elements may be considered when deemed to be more suitable fortransmission service.

7.3 Flow Elements

Notes1. Locate an indicating flowmeter for a locally and manually controlled

stream within 6 feet of the valve so that it can be seen from the valve.

2. For corrosive process fluids, element materials are to be certified toNACE MR-01-75.

7.3.1 Differential Pressure. Normally square edged concentric orifice assemblieswith flange taps shall be used. Raised face weld neck orifice flanges shallbe used unless specified otherwise in the governing piping specification.Where possible, use a Beta Ratio of 0.7 to determine upstream anddownstream straight pipe runs in accordance with AGA Standards.

Orifice plate calculations shall normally be based on 100 inches of watercolumn pressure drop with a Beta ratio between 0.25 and 0.75.

Corner Taps, Venturies, Nozzles and Annubars will also be consideredwhere they are superior to flange taps.

7.3.2 Positive Displacement meters shall normally be used for liquid service whentotalized flow is required. Materials of construction shall be dictated by

process fluid requirements.


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7.3.3 Turbine meters will be considered for applications requiring attention tolinearity, range, resolution, long life, and signal generation (Liquid Service).

7.3.4 Magnetic Flow Meters will also be considered for all the above reasons andare preferred on Feedwater, Condensate and Cooling tower make up waterapplications requiring transmitter output signals.

7.4 Level Elements

Notes1. Chamber (Cage) and body materials to be equal in quality to or better

than the vessel material.

2. Trim material to be stainless steel or better quality alloy.

3. Where process fluid temperatures exceed 400F use air finextensions.

4. Provide a drain valve not less than 1/2 inch in size at the bottom of theinstrument.

7.4.1 Displacement type shall normally be with external cage for use on liquidservice in closed vessel with level range less than 48 inches. Instrumenthead to be rotatable with respect to vessel.

Cage connection shall normally be side and side with minimum connectionsize of 1-1/2 inch NPT. Flanges will be used when required by the vesselspecifications. Use 2 inch connections for 900# ANSI cages and above.Flange rating shall be in accordance with the piping specifications.

7.4.2 Internal displacement type will be considered for special circumstances -e.g., extreme temperatures, viscous or corrosive liquids, or where excessiveboiling may occur in external cage.

7.4.3 Float (Mechanical) type may be used on open sumps or vented tanks whensufficient leverage can be obtained to insure positive action.

7.4.4 Differential Pressure will be considered for any suitable application in anyrange available. Refer to Pressure and Flow Primary Elements.


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8.0 RECORDERS

Notes1. Charts shall be 0 to 10 square root for differential type flow and direct

reading for all other variables.

2. Multipoint temperature recorders shall have 12-inch strip charts. A width of4 inches is preferred for other variables.

3. A 30-day supply of charts shall be supplied along with one ink set for eachrecording instrument.

8.1 Mechanical - locally mounted recorders shall be equipped with 24-hour circularcharts on an 8-day spring wound chart drive with a combination hub for either 7-dayor 24-hour rotation.

8.2 Electronic - board mounted recorders shall be strip charts with electric chart drives.Ink path may be either vertical or horizontal. Chart width of 4 inches with no morethan 3 pens is preferred.

9.0 INDICATORS (GAUGES)

Notes1. Pressure Gauges shall be made in accordance with ANSI B40.1 (Gauges,

Pressure and Vacuum, Indicating Dial Type-elastic element).

2. Minimum scale size, length or diameter, shall be 4-1/2 inches. Differentialpressure may use 2-1/2 inches. Where digital meters are used, 3-1/2inches x 1-1/2 inches shall be the minimum requirement.

3. Range shall be selected so that the maximum continually operating processcondition shall fall within the middle 33% of the range.

4. Overrange protection shall be included if system pressure can exceed

maximum range of gauge.

9.1 Temperature Indicators

9.1.1 Direct Mounted shall have bimetallic element with silicone dampening forminimum pointer vibration. Dial face shall be fully adjustable to provide360 rotation and 180 angle viewing. 5-inch dial is preferred however,3-inch will be considered. Accuracy shall be 1% full scale or better.

9.1.2 Remote mounted shall have filled (liquid or gas) element and capillary.


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Capillary shall be stainless steel with stainless steel armor and shall notexceed 25 feet. Dial case shall be weatherproof with adjustable pointer.4-1/2 inch dial with accuracy of 1% full scale.

9.2 Pressure Indicators

9.2.1 Pressure gauge case shall have solid front and be designed for liquid fill forhigh vibration applications. Process connection shall be 1/2 inch NPT -bottom connection for local mounting and rear connection for panelmounting.

9.2.2 Pressure gauges shall be installed with block valves on process connectionand shall have means of venting pressure when closed off. Gaugesinstalled on nearby pressure instruments may use a common processconnecting point but require individual block and bleed valves at theinstrument.

9.2.3 Differential pressure indicators may be either the bellows or piston type.Overpressure protection shall be equal to the maximum allowable workingpressure of the body.

9.3 Level Indicators

9.3.1 Tank Gauges - Atmospheric product storage, small process and utility tanksshall normally use float type gauges with an external target (locate target atground level).

9.3.2 Gauge Glasses shall be used on process pressure vessels to cover the fulloperating range of level, including the spans of level controllers and levelalarm switches.

9.3.3 Gauge glass column shall not exceed 48 inches. For greater lengths usemultiple units.

9.3.4 Use transparent type gauge glasses (double glass) for service in which alevel may not be readily distinguishable such as interface fluids surfaces,

fluids of high viscosity or solid content.

9.3.5 Use reflex glasses if pressure exceeds 25 psig or the vessel temperature isoutside the range of 0-100C. Use illuminators for interface surfaces only.Provide a frost shield if vessel temperature is less than 0C.

9.3.6 Gauge body materials shall be equal in quality to or better than the vesselmaterial. The use of ductile iron covers shall be avoided.

9.3.7 Gauge cock body material shall match gauge body material. Trim shall


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normally be stainless steel with renewable seats and ball checks. Gaugecock vessel connections shall normally be female, 3/4 inch NPT.

10.0 SWITCHES

Notes1. Switch enclosures shall be weatherproof and explosion proof unless

otherwise specified.

2. Switch mechanisms shall be snap-acting and hermetically sealed in an inertgas or epoxy encapsulated. Conventional switch mechanisms shall beconsidered. Mercury switches shall be avoided.

3. Switches shall always be either single-pole-double-throw (SPDT) ordouble-pole-double-throw (DPDT). When available, double-pole-double-throw shall be used.

4. Switch contacts shall be rated for 0.5 A at 24 Vdc as a minimum.

5. Dual set point switches in the same housing may not be used.

6. As much as possible, switches shall have their set-point located in themiddle third of their calibrated range. All shall have a means for fieldcalibration adjustment.

10.1 Temperature switches shall normally have vapor pressure thermal elements. Theyshall be supplied with thermowells (see 5.1 Note 1).

10.2 Pressure switch elements and pressure port materials shall be determined by theapplication and operating pressure. Elements may be Diaphragm, Piston, Bellows,Bourdon Tube or Belleville spring types.

10.3 Flow switches will normally be vane actuated (field adjustable), Thermal Dispersion(field adjustable) or Rate of Flow Magnetic Type (factory adjusted). All types will beconsidered and selection based on application.

10.4 Level switches

10.4.1 Switches shall be externally mounted, displacer or float operated. For highvibration applications, displacer types are preferred.

10.4.2 Switch connections shall normally be 1 inch, installed with 1 inch pipe,isolation valves and fill tee with plug. Connection type shall be inaccordance with the governing vessel specification.


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10.4.3 Internal floats may be used in services where they can be removed formaintenance without a major shutdown, where performance is superior, orwhere physical limitations require their use.

11.0 INSTRUMENT INSTALLATION

Notes1. All instruments and related measuring elements shall be installed such that

they are easily accessible from floors, platforms or walkways.

2. All instruments shall be installed such that they are not subject to excessivevibration and/or exposed to high temperature.

3. No sense line shall slope less than 1 in 10 in a horizontal run. When theprocess is liquid the slope is to be to the instrument. When the process isvapor the slope is to be to the process pipe or vessel.

4. The piping configuration shall be arranged so that gas and liquid blocks(pockets) will not occur.

5. Condensate pots with drain valves shall be provided where condensationmay occur.

6. A blow-down facility with drain valve shall be provided where sedimentationmay occur. The minimum valve size shall be 1/8".

7. Plugged tees shall be provided for rotting out where solid deposition mayoccur.

8. For piping where condensate will exist during plant operation, filling teesand drains at the lowest points shall be provided. Where the highestinstrument process piping points are higher than the process connection,vents shall be provided.

9. A transmitter shall be located as closely as possible to its process

connection having proper regard to maintenance access. Particularattention shall be paid to making the instrument process piping as short aspossible for viscous fluids. Transmitters shall not be mounted on thepipeline. For each transmitter local isolation must be provided at thetransmitter if the process isolation (root) valve cannot be reached whilestanding at the transmitter. Pressure transmitters and gauges shall beprovided with vent valves after the isolation valve for zero checking.

10. Sealing liquids may be used to isolate instrument parts from the processstream if other techniques of protection and connection are not reasonable


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or practicable.

11. All instrument lines shall be properly supported.

11.1 Instrument Connections

The preferred size of instrument process connection shall be as indicated in therelevant instrument details. Where possible instrument process connections shallmeet the requirements of the appropriate piping specification.

11.2 Instrument Process Piping

11.2.1 Instrument process connections shall not be less than 1/2 inch. Whenconnections to other sizes are required, i.e., 1/4 inch connections toinstrument manifolds, appropriate and compatible fittings shall be used.

11.2.2 The pipe wall thickness shall be sized for the application and in accordancewith the relevant piping standard.

2 11.2.3 3/8 inch O.D. x .035 inch wall thickness stainless steel tubing and approvedcompression fittings will be generally used for all impulse lines unlessprocess conditions dictate otherwise. (Where required 1/2 inch O.D. x .049inch minimum wall thickness stainless steel tubing will be used.) Tubingshall be fully annealed per ASTM-A-269.

11.2.4 For high temperature or pressure and where screwed or flanged fittings arenot permitted in the process piping the instrument piping shall meet theprocess piping specifications up to and including the first block valve.

11.2.5 Piping and fittings materials shall be in accordance with the project pipingspecifications.

11.2.6 Isolation (Root) Valves: Shall be a minimum size of 1/2 inch with aminimum port size of 1/8 inch. Valves shall be located at the processconnection and be capable of being closed even though they remain openfor long periods. If the isolation valve is inaccessible or if the instrument

process piping must be longer than 15 feet, then a second isolation valveshall be installed at the instrument.


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11.3 Pre-Testing

11.3.1 Generally, instruments shall be tested by the manufacturer before shipmentand calibrated at job site.

11.3.2 Electronic equipment shall be powered up for at least 1 hour prior to test.

11.4 Accessibility and Visibility

11.4.1 All dials and scales of field-mounted instruments shall be easily read fromgrade level or platform level.

11.4.2 All Instruments shall be located to allow ready maintenance access.

11.4.3 Permanent platforms and ladders shall be provided for access to elevatedinstruments except pressure gauges, dial thermometers and thermocouplesor RTD's.

11.5 Instrument Protection

11.5.1 Instruments shall be installed in a position where mechanical damage isunlikely and the effects of vibrating equipment are minimized.

11.5.2 Instruments shall be installed so that corrosive effects of atmosphere (eitherfrom normal or abnormal plant operation) are eliminated by using suitableprotective coatings and seals, or a corrosive proof enclosure. Also weatherprotection shall be provided by selection of weatherproof instrumentation orby provision of a weatherproof enclosure.

11.5.3 Instrument panels and cabinets in exposed conditions shall be provided withoverhead shelter extended to keep wind-swept rain from the instruments.

11.6 Mounting and Identification

11.6.1 Instruments mounted on any local instrument panel shall be flush mounted.

Those separately mounted in other locations may be surface, yoke orbracket mounted.

11.6.2 A permanent nameplate or stainless steel tag shall be provided for eachinstrument.


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11.6.3 Local panel-mounted instrument locations shall be labelled at the front andrear of the panel.

11.6.4 Nameplate and legend plate wording shall be horizontal.

11.6.5 All vendor installed instrument connections (pneumatic and electric) shall beidentified at all tubing and cabling ends. Tag numbers shall be inaccordance with the installation drawings.

12.0 CONTROL VALVES

12.1 Sizing and Characterizing

12.1.1 Control valve body sizes generally shall not be less than 1 inch. Inaccordance with the piping specifications, bastard sizes shall be avoided.

12.1.2 Control valves shall be sized to operate at no more than 65-75% openunder maximum design flow rates and process conditions.

12.1.3 Calculations shall be made for the range of anticipated plant operationalrates and process conditions as specified on the Process Flow Diagrams(PFD's).

12.1.4 The characteristic of a valve shall be selected to be most suitable for thecontrol system and plant and process conditions.

12.1.5 Special care shall be taken to consider the possibility of cavitating and/orflashing service when sizing valves for liquid applications.

12.2 Valve Type

12.2.1 Generally, globe valves with cage guided trims shall be used. For liquidservice, characterized plug globe valves may be used. Other types ofvalves may be used if their application is superior to those of globe valves.

12.2.2 Butterfly valves should be considered for flows requiring a Cv of 300 ormore.

12.2.3 Angle valves should be considered for such arduous services as highpressure drop (300 psi or more), flashing liquid, slurry, anticipated ice andhydrate service.

12.2.4 Diaphragm or pinch valves should be considered for slurry and corrosivefluid.


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12.3 End Connections - Valve body end connections shall conform to the valve and pipingspecifications. Exception may be made relative to weld end connections if plantand/or process operating conditions dictate that flange or screwed connectionsshould be used.

12.4 Bonnets and Bellows Seals - Shall be selected based on the valve manufacturersrecommendations for the specified service.

12.5 Materials for Construction

12.5.1 Generally the body material shall be equal in quality or better than thematerial in the contiguous piping. However, cast iron may be considered forcommon fluids at low temperatures and pressures (between 0C and150C and between atmospheric pressure and 125 psig), or in a servicewhere cast iron is best suited.

12.5.2 The valve trim and other wetted parts (except the valve body) shall bestainless steel unless this is unsuitable for the fluid or the processconditions, then a suitable compatible material shall be selected. Trims forvalves in corrosive services shall be in accordance with NACE MR-01-75requirements.

12.5.3 When wear is likely to be excessive, stellate trim or the manufacturer'sequivalent hardened trim shall be used.

12.6 Actuators

12.6.1 The power of an actuator shall not be less than required to seat the valveagainst the maximum shut off pressure. Unless otherwise specified,maximum shut off pressure shall be the maximum flange pressure rating.

12.6.2 Actuators shall normally be the Spring and Diaphragm type, with the pringdriving the valve to the fail safe position as specified on the data sheets.Piston type and double acting actuators will be considered.

2

12.6.3 Where available air supply pressure exceeds the maximum allowablepressure of the actuator, a pressure regulator (and relief valve) will beprovided.


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12.7 Positioners

Notes1. Electropneumatic positioners shall be used for electronic control

systems and pneumatic actuators. Electronics enclosure shall besuitable for the area classification.

2. A positioner bypass is not permitted where the valve operating rangeand the positioner input range are not compatible.

3. A positioner with a bypass and three gauges or booster relay shall beused under specified conditions.

12.7.1 Positioner with bypass shall be used in a control loop whose controllerrequires a proportional band setting of 500% or more.

12.7.2 Positioner with bypass shall be used for flashing service in whichvaporization of the fluid flowing through the valve is 10% by mass orgreater.

12.7.3 Positioner without bypass shall be used in split range service.

12.7.5 Positioner with or without bypass and three gauges or booster relay shall beused when valve is 6 inches or larger.

12.7.6 Positioners with bypass and three gauges shall be used with butterfly valvesand ball valves.

12.8 Control Valve By-Passes - Generally, a control valve shall not be provided with aby-pass valve except when Standards or Regulations specify the requirement.

When a by-pass valve is required, block valves of line size, shall be provided to allowthe by-pass valve to be operated with the control valve blocked from operation, andthe by-pass valve shall be sized for its specific duty (generally a globe valve one sizeless than the line valve).

12.9 Valve Position on Power Failure. Whether a valve shall travel to an open or shutposition, or remain unmoved on failure of the actuating medium shall be determinedfrom the process and safety requirements.


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12.10 Control Valve Noise

Notes1. If a control valve may pass fluid at or near sonic velocity, or if

cavitation or flashing may occur at the valve, or if the valve situation isdesigned for flashing service, then its operational noise level shall becalculated.

2. If the predicted noise level is greater than 85 dbA measured 1 meterfrom the valve, then preventative or corrective or restraining measuresshall be taken to insure that ambient noise developed by the valveoperation shall be no greater than allowable by local codes and shallcause no mechanical damage to the valve.

3. If in-line items are installed as a corrective or restraining measure thenthe design of the control valve situation shall account for the presenceof such items over the full operating range of the plant.

13.0 CONTROL VALVE INSTALLATION

13.1 Orientation and Location

13.1.1 Where possible, for each control valve, space shall be allowed for the futureinstallation of a line size control valve.

13.1.2 When allowed by the process configuration, a level controller and its controlvalve shall be located at the same operating level and in sight of the levelindicator.

13.1.3 Generally a by-pass valve, if required, shall be installed in the samehorizontal plane as its control valve.

13.1.4 Valve should be installed so that stem is vertical (unless valve is designedfor rotating shaft).

13.1.5 Valve should be located where maintenance access and valve removal willnot be hindered, preferable on ground or operating level.

13.1.6 Valve should be fitted with a flexible, extendable gland cover whereexcessive dust build-up around stem may occur from external sources.

13.1.7 Generally, in flashing service, the valve shall be installed close to the downstream end of the pipe.


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13.2 Drains, Traps and Pressure Tappings

13.2.1 Drains installed at control valves shall be furnished with 1/2 inch ball valveswhich shall be stopped with plugs.

13.2.2 For a single-seated valve which opens on failure of the actuating medium, adrain between the control valve and the upstream block valve (if they exist)shall be installed.

13.2.3 For a single-seated valve which closes on failure of the actuating medium, adrain on each side of the control valve between it and the block valves (ifthey exists) shall be installed.

13.2.4 For a double-seated valve irrespective of the final position of the valve onfailure of the actuating medium, a drain between the control valve andupstream block valve (if it exists) shall be provided.

13.2.5 For control valves without block and by-pass valves, low-point drainage onlyof the lines shall be provided.

13.2.6 For control valves installed with steam traps, the trap should be connectedto the line up stream of the control valve so it will drain the line whether thecontrol valve or a by-pass valve is in service.

13.2.7 Pressure taps for a pressure regulating valve shall be located in a straightrun of piping not less than ten pipe diameters upstream or downstream ofthe valve whichever is required by the valve service. If the pipe line ishorizontal, the taps shall be made on its upper surface.


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14.0 ACTUATED BLOCK VALVES

14.1 Valve Types

14.1.1 Generally, ball valves rated for tight shut-off service shall be used. FireSafe ball valves shall be in accordance with the applicable pipingspecification.

14.1.2 Ball valves may be the trunnion mounted or floating ball type in accordancewith the applicable piping specification.

14.2 Valve Size

14.2.1 In all cases, the valve size shall be equal to the size of the contiguouspiping.

14.2.2 In general, trim size shall equal the full bore size of the valve. Reduced sizetrims will be considered as long as pressure drop across the valve does notadversely affect the process.

14.3 End Connections - Shall be flanged and conform to the valve and pipingspecifications. Weld end connections will be considered.

14.4 Materials for Construction

14.4.1 Generally the body material shall be equal in quality or better than thematerial in the contiguous piping. However, alloy materials may beconsidered for extremely corrosive services.

14.4.2 The valve trim and other wetted parts (except the valve body) shall bestainless steel or nickel plated carbon steel unless this is unsuitable for thefluid or the process conditions, then a suitable compatible material shall beselected. Trims for valves in corrosive services shall be in accordance withNACE MR-01-75 requirements.

14.5 Actuators

14.5.1 In general, block valve actuators shall be the spring fail, pneumatic scotch-yoke piston type. Double-acting pistons, electric motor, spring anddiaphragm and other actuator designs may be used for special applications,but the control logic must be fail safe.

14.5.2 Pneumatic rack and pinion actuators may be used for valves 2 inches andsmaller.


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14.5.3 Actuators shall be sized in accordance with the manufacturer'srecommendation using a 1.25 safety factor. Unless otherwise specified,maximum shut off pressure for actuator sizing shall be the maximum flangepressure rating.

14.5.4 Actuators shall be sized based on 80 psig minimum instrument air pressure.

14.5.5 Actuator design shall prevent the entry of water, dirt and dust during normaloperating conditions. Actuator shall be capable of operating in a corrosiveatmosphere.

14.6 Control Accessories - Valves shall be equipped with control accessories which willallow for the remote electrical control and monitoring of the valves. Electricalcomponents in hazardous locations shall be suitable for the area classification.

14.6.1 Solenoids shall be the three-way type with cadmium plated valve bodies.Stainless steel bodies shall be considered. Coil shall be potted andnormally operating at 24 Vdc. Bolting shall be stainless steel.

14.6.2 Valve actuators shall be supplied with pressure regulator, output gauge andrelief valve if normal operating pressure exceeds maximum actuatoroperating pressure. Supply pressure will normally be 100 psig.

14.6.3 Position switches will be provided for remote position monitoring. Switcheswill generally be single-pole-double-throw, hermetically sealed or epoxyencapsulated, and mounted in an enclosure with terminal strip and localposition indicator.

14.6.4 Speed controls shall be provided. Actuation speed for valves 2 inches andsmaller shall be 2 seconds or less. Actuation speed for larger valves shallbe 1 second per inch of valve bore.

2 14.6.5 All tubing shall be 316 stainless steel, sized for the above outlined speedrequirements. Minimum wall thickness shall be 0.035" for 3/8 inch O.D. andbelow and 0.049 inch for 1/2 inch O.D. Company approved fittings shall be

316 stainless steel.


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15.0 RELIEF (SAFETY) VALVES

15.1 Valve Types

15.1.1 Relief valves are characterized by their opening in proportion to theincrease in pressure over the setpoint.

15.1.2 Safety valves are characterized by their rapid opening or "pop" action at theset point.

15.1.3 Spring loaded valves may be the conventional or balanced type. Balancedvalves shall be designed to minimize the effects of back pressure on thevalve characteristic.

15.1.4 Pilot operated relief valves shall be the preferred type for gas applications orwhere premium seat tightness is required.

15.2 Codes - Valves shall be stamped with ASME Boiler and Pressure Vessel Code,Section VIII or Section I. The capacities must be certified by the National Board ofBoiler and Pressure Vessel Inspectors for air or saturated steam service and/orcapacities for gas service.They shall be designed to meet API Standard 526 for seat tightness and API RP 520for installation.

15.3 Guidelines

15.3.1 Valves shall be sized to protect vessels and piping for maximum throughput(blocked flow), fire exposure or thermal expansion, whichever is greater.Sizing shall be in accordance with API RP 520 using the valvemanufacturer's coefficient of discharge.

15.3.2 Valves shall be sized and installed to protect both sides of exchangersagainst overpressure due to liquid expansion, vaporization, tube failure orleakage and fire.

15.3.3 Relief set point shall be no higher than the design pressure (MAWP) of the

weakest element protected, except as may be permitted by the ASMECodes.

15.3.4 Bonnets for spring operated valves shall normally be the closed type.Exposed spring bonnets shall be as required by the ASME Codes.

15.3.5 Generally, flanged connections shall be provided on all relief valves 1 inchand larger. Screwed connections may be provided on thermal relief valves,1 inch and smaller.


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15.3.8 Pilot operated relief valves for blocked flow (full flow) applications shall bethe modulating type.

15.3.7 Pilot operated relief valves shall be supplied complete with backflowpreventers and field test connections.

15.4 Materials of Construction will generally follow manufacturer's standards for the givenservice except where there is a conflict with the pipe specifications. The pipespecifications will rule. When required trim shall be supplied in accordance withNACE MR-01-75.

16.0 ALARMS AND TRIPS (SHUTDOWNS)

Notes1. Trip system fault detection devices shall be physically and electrically

separate from alarm and operating systems.

2. Alarm and trip system shall be basically 24 Vdc operated. Other powersystems may be considered in certain circumstances.

3. Sensing circuits shall be normally energized, i.e., the circuit shall open tocause an alarm or trip.

16.1 Alarm Annunciation System

16.1.1 Local audible and visual alarms shall be annunciator type. Individual typealarm units may be used for remote locations or where hazard requirementsso dictate. All alarms shall be both visible and audible.

16.1.2 Sequence shall be ISA-1 with First Out Sequence (FOS) Option.

16.1.3 An acknowledge reset button and lamp test switch shall be provided oneach annunciator cabinet.

16.1.4 Legend window displays shall be readable when the alarm light is off.

16.1.5 Annunciator shall be provided with at least 10% pre-wired or on line sparecapacity.

16.2 Trip (Shutdown) System

16.2.1 All safeguarding functions shall normally be derived via a PLC System withFail Safe features.

The input/output organization of various safety systems by the PLC shall bemodularly arranged to provide easy maintainability.


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16.2.2 In a system in which voltages other than 24 Vdc occur, e.g., because anelectric motor must be tripped, a relay which isolates one voltage circuitfrom the other shall be provided.

A relay or other equipment with an impressed voltage greater than 32 voltsdc shall be located in a box or housing which physically isolates it from the24 volt dc circuit area and from electrical interference from other sources.The box or housing shall be prominently labelled with the high voltage in it.

16.2.3 In a High Integrity protective system sensing will be in triplicate with eachsending its digital signal to the PLC logic which in turn will produce a digitaloutput if two of the three digital input signals exceed the trip limit value.

17.0 SAFETY

The safety of operators and the operating plant and its systems, considered as a whole,shall be the prime safety goal.

17.1 Safe Condition - A safe condition is a state in which no unreasonable hazard ispresented to a plant operator, plant or process.

17.2 Fail-Safe Condition - A fail-safe condition is one in which a system remains in a safecondition after occurrence of process or plant faults or on failure of electric power,instrument air or other source of energy.

18.0 INSTRUMENT PANEL BOARDS

18.1 Local Control Panels - Site-mounted control panels shall be used for specificpurposes, e.g. start up or compressor control or to centralize a number of siteinstruments. The panels shall be adequately protected from the environment andaccidental damage.

18.2 Control Room Panels - Panels shall be located so that the face is prominent foroperator inspection and attention. Rear access for maintenance is preferred,

however, front access will be considered.

18.2.1 Where possible, instruments shall be grouped in a process sequence fromleft to right. Alarms shall be located above process-relatedinstrumentation.

18.2.2 Instrumentation requiring close observation shall be between 28 inches and72 inches from floor level. Miniature instruments for operator use orrequiring manual operation shall be located between 36 inches and 72inches from floor level.


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18.2.3 The minimum spacing between instruments shall be the instrumentmanufacturer's standard.

18.2.4 Terminals with an impressed voltage above 32 volts D.C. or any A.C. voltageshall be fully shielded and labelled, noting voltage.

19.0 ANALYZERS

The term analyzers shall include equipment for the measurement of composition ofsubstances and the measurement of chemical and physical properties, e.g. turbidity,density, caloric value, conductivity, and pH.

19.1 Selection Guidelines

19.1.1 The type and make shall have a record of reliable service.

19.1.2 Accuracy and response time of analyzer system shall meet processrequirements.

19.1.3 The analyzer system shall be designed to facilitate maintenance andcalibration. System shall include a facility for calibration checking insite.

19.1.4 For hazardous areas, the analyzer system and its installation shall meetstatutory requirements.

19.2 Sampling System

If a suitable in-line or immersion type analyzer head is not available for anapplication, then a sampling system shall be provided. This system should includebut is not limited to the following features:

19.2.1 Designed to provide minimum sampling lags.

19.2.2 Use stainless steel or better for the sample pipe and tubing.

19.2.3 Provide a facility for purging sample tubing.

19.2.4 Provide for sample return to process where possible. When possible, pumpoutlets and inlets should be used for sample delivery.

19.2.5 Analyzer vent gas or bypass flow shall normally be disposed or sent to flare.


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19.2.6 Insertion type probes shall be used. Isolation and by-pass valves shall beprovided around analyzer heads which are installed within the plantpiping system.

20.0 INSTRUMENT AIR

20.1 Air Supply Quality - Dewpoint of air shall be as a minimum 20F below the lowestambient temperature for the area recorded during the preceding 10 years.

20.2 Air Supply Capacity - The capacity of the instrument air supply system shall begreater than 55 times the number of connected flapper/nozzle mechanismsexpressed as ft

3/hr at STD 60F, 14.7 psig. A pneumatically actuated control valve

shall be considered as one flapper/nozzle mechanism for this calculation.

20.3 Air Supply Piping - Air distribution piping shall be galvanized carbon steel or stainlesssteal and shall conform to the appropriate piping specification for instrument air.

20.4 Air Supply to Instruments - Each instrument shall have its own air isolation valve.Each site-mounted instrument shall have its own supply filter/regulator.

In a local panel there shall be an air supply filtering and pressure regulating systemcomprised of two sets of equipment (two filter/regulators in parallel). Each shall becapable of supplying the dynamic needs of the instrument air users connected to itand having block valves enabling it to be isolated for maintenance with the other is inservice. Pressure gauges shall be located upstream and downstream of thisfilter/regulator system.

2 20.5 Pneumatic Tubing - Pneumatic tubing for air supply headers and betweeninstruments shall be 1/4 inch O.D. with 0.35 inch wall as a minimum. Stainless steeltubing and fittings shall be standard. Other materials may be selected for non-corrosive environments.

20.6 Air Pressure Alarm - A low pressure alarm shall be provided for the plant air supplymain.


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21.0 DRAWINGS, DATA SHEETS AND CALCULATIONS

As part of a "Request To Quote" package all or part of these items may be supplied to thebidder or the bidder may be required to furnish all or part of these items as part of theirproposal. The proposed instrumentation scheme will be shown on a Piping and InstrumentDiagram and will be included with the RFQ.

21.1 Construction Drawings - The number and type of drawings required will bedetermined by the complexity and type of instrumentation to be furnished on theproject. Normally only those drawings which are required to insure a correctinstallation of the various instrument components will be required.

21.1.1 Instrument Index - Data shall include as a minimum the instrument tagnumber, a brief service description, flowsheet location, I/O address orcable number, specification number, purchase order number andcross reference drawing numbers for instruments, piping and electricaldrawings.

21.1.2 Instrument Plot Plan - Shows the general location of all local mountedinstruments requiring pneumatic or electrical connections, controlpanels, or other items as required.

21.1.3 Instrument Installation Details - Details shall show all commodity itemsrequired for proper instrument hookup and shall include a Bill ofMaterial. This drawing should also include the pneumatic schematic forsimple local controls and identify boundaries of discipline interface.

21.1.4 Pneumatic Schematics - These may be required for complex control loopssuch as emergency shutdown or compressor control panels. Theyshould show all components in the loop to enable an understanding ofthe operation of the loop.

21.1.5 Electric Loop Diagrams - They shall be provided when interconnection isrequired between field controllers, transmitters etc. and control panelinstruments. The loop diagram shall identify the field device tagnumbers, field junction boxes, electrical cable number, rear of panel

terminal strips and panel instrument connection details.

21.1.6 Control Panel Layout and Details - Details should show pertinent informationto allow for approval of instrument arrangement and to be suitable forfabrication.


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21.1.7 Cause and Effect Analysis - A matrix drawing shall list all field and panelmounted devices that sense or initiate an alarm or shutdown signalalong one margin with a description of the resulting action along across referenced margin. Normal control switching is not required onthis drawing.

21.1.8 Safety Analysis Function Evaluation Chart (SAFE) - A matrix drawing shall listall process components and their associated safety devices asrequired by API RP 14C.

21.1.9 Miscellaneous Drawings - Certain additional drawings may be required whenother drawings do not provide sufficient information to insure correctinstallation or are specifically requested.

21.2 Data Sheets - These will be required for all instruments and will include supplier'sdata. Data sheets will conform to the Instrument Society of America S20 format.They are to be completed and supplied by the design engineer.

21.3 Calculations - Calculations to determine size, capacity and characteristics shall berequired for primary elements, such as restriction orifice, and final elements, such ascontrol valve sizing and noise.

22.0 INSPECTION

The responsibility for inspection to compliance with the applicable codes and standards ofthis specification rests with the supplier. However, Solar reserves the right to inspect, orhave its authorized representative inspect work in progress at the supplier's facility or at anyof his suppliers facilities to assure that materials and workmanship are in accordance withthis specification.

ESOLAR-1648 General Instrumentation r2

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Transcript of ESOLAR-1648 General Instrumentation r2